Kisssoft Release 2020 User Manual
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Mohamad HamediKisssoft Release 2020 User Manual
Uploaded by
Mohamad HamediKISSsoft
Release 2020
User Manual
Sharing Knowledge
Table of Contents
I General ................................................................. 44
1 Installing KISSsoft ...................................................................... 45
1.1 Basic installation ......................................................................................................................45
1.2 Downloading a license file .......................................................................................................45
1.3 Licensing ..................................................................................................................................46
1.3.1 Test version .....................................................................................................................46
1.3.2 Student version................................................................................................................46
1.3.3 Single user version with dongle (protection key) .............................................................47
1.3.4 Single user version with license code..............................................................................47
1.3.5 Network version with dongle (protection key) ..................................................................47
1.3.6 Network version with a license code ...............................................................................48
2 Setting Up KISSsoft .................................................................... 49
2.1 Directory structure....................................................................................................................49
2.2 Language settings....................................................................................................................49
2.3 Systems of units.......................................................................................................................50
2.4 Defining your own template files ..............................................................................................50
2.5 Rights .......................................................................................................................................50
2.6 Global settings - KISS.ini .........................................................................................................51
2.6.1 Definitions in [PATH] .......................................................................................................51
2.6.2 Definitions in [SETUP] .....................................................................................................52
2.6.3 Definitions in [REPORT] ..................................................................................................54
2.6.4 Definitions in [GRAPHICS] ..............................................................................................55
2.6.5 Definitions in [LICENSE]..................................................................................................55
2.6.6 Definitions in [CADEXPORT] ...........................................................................................56
2.6.7 Definitions in [INTERFACES] ..........................................................................................56
2.6.8 Definitions in [SOLIDEDGE] ............................................................................................57
2.6.9 Definitions in [SOLIDWORKS].........................................................................................57
2.6.10 Definitions in [INVENTOR] ............................................................................................57
2.6.11 Definitions in [CATIA] ....................................................................................................57
2.6.12 Definitions in [PROENGINEER] ....................................................................................58
2.6.13 Definitions in [HICAD] ....................................................................................................58
2.6.14 Definitions in [VIDEOENCODING] ................................................................................59
2.7 User-defined settings ...............................................................................................................60
2.7.1 Configuration tool ............................................................................................................60
2.8 Rules ........................................................................................................................................63
3 Running KISSsoft ....................................................................... 66
3.1 Start parameters ......................................................................................................................66
3.2 Disconnect license from the network .......................................................................................66
4 Elements of the KISSsoft User Interface ..................................... 68
4.1 Menus, context menus and the tool bar ...................................................................................68
4.2 Docking window .......................................................................................................................69
4.2.1 The module tree ..............................................................................................................70
4.2.2 The project tree ...............................................................................................................70
4.2.3 The Results window ........................................................................................................71
4.2.4 The Messages window ....................................................................................................71
4.2.5 The info window...............................................................................................................71
4.2.6 Manual and Search .........................................................................................................71
4.3 Graphics window......................................................................................................................72
4.3.1 Tool bar and context menu ..............................................................................................72
4.3.2 Comment field .................................................................................................................74
4.3.3 Context menu ..................................................................................................................74
4.3.4 Properties ........................................................................................................................75
4.3.5 Toothing...........................................................................................................................76
4.4 Main input area ........................................................................................................................77
4.4.1 Report Viewer ..................................................................................................................78
4.4.2 Helptext Viewer ...............................................................................................................78
4.5 Tooltips and status bar.............................................................................................................78
5 KISSsoft Calculation Modules..................................................... 79
5.1 Standard and special tabs .......................................................................................................79
5.2 Input elements .........................................................................................................................79
5.2.1 Value input fields .............................................................................................................80
5.2.2 Formula entry and angle input .........................................................................................80
5.2.3 Unit switch .......................................................................................................................81
5.2.4 Tables ..............................................................................................................................81
5.3 Calculating and generating a report .........................................................................................81
5.4 Messages.................................................................................................................................82
6 Project Management .................................................................. 83
6.1 Generating, opening and closing projects ...............................................................................83
6.2 Adding and deleting files ..........................................................................................................84
6.3 The active working project .......................................................................................................84
6.4 Storage locations .....................................................................................................................84
6.5 Project properties .....................................................................................................................84
7 Dynamic User Interface .............................................................. 85
7.1 Modified tabs and dialogs supplied with the system ................................................................85
7.2 Adding additional tabs and dialogs ..........................................................................................85
7.3 Formatting ................................................................................................................................86
7.3.1 Elements..........................................................................................................................86
7.3.2 Columns ..........................................................................................................................87
7.3.3 Groups .............................................................................................................................87
7.3.4 Tabs.................................................................................................................................88
7.3.5 Attributes .........................................................................................................................88
7.3.6 Comments .......................................................................................................................90
7.3.7 Special elements .............................................................................................................90
8 Results and Reports ................................................................... 91
8.1 Results of a calculation ............................................................................................................91
8.1.1 Add your own texts in the results window........................................................................91
8.2 Calculation reports ...................................................................................................................91
8.3 Drawing data ............................................................................................................................92
8.4 Report settings .........................................................................................................................92
8.4.1 General ............................................................................................................................92
8.4.2 Page layout......................................................................................................................92
8.4.3 Header and footer ............................................................................................................93
8.4.4 Start and end block..........................................................................................................93
8.5 Report templates......................................................................................................................94
8.5.1 Storage locations and descriptions..................................................................................94
8.5.2 Scope of a report .............................................................................................................96
8.5.3 Formatting .......................................................................................................................96
9 Database Tool and External Tables .......................................... 104
9.1 Viewing database entries .......................................................................................................105
9.2 Managing database entries ...................................................................................................107
9.2.1 Creating a database entry .............................................................................................107
9.2.2 Deleting a database entry..............................................................................................108
9.2.3 Restoring a database entry ...........................................................................................108
9.3 Import and export data from the database tool ......................................................................108
9.4 External tables .......................................................................................................................109
9.4.1 Functions tables ............................................................................................................110
9.4.2 Range tables .................................................................................................................112
9.4.3 List tables ......................................................................................................................113
9.4.4 List of key words used ...................................................................................................115
9.5 Description of database tables...............................................................................................116
9.5.1 Center distance tolerances ............................................................................................116
9.5.2 Machining allowance for cylindrical gear .......................................................................116
9.5.3 Reference profiles .........................................................................................................116
9.5.4 Compression springs standard ......................................................................................116
9.5.5 Hobbing cutter selection ................................................................................................117
9.5.6 Basic material Glued and Soldered joints......................................................................117
9.5.7 Manufacturing process for bevel and hypoid gears .......................................................117
9.5.8 V-belt standard ..............................................................................................................117
9.5.9 Spline Standard .............................................................................................................118
9.5.10 Chain profiles ISO 606 ................................................................................................118
9.5.11 Adhesives ....................................................................................................................118
9.5.12 Modifications................................................................................................................118
9.5.13 Load spectra ................................................................................................................118
9.5.14 Solders ........................................................................................................................119
9.5.15 Surface roughness of shafts and shaft-hub connections.............................................119
9.5.16 Key standard ...............................................................................................................120
9.5.17 Polygon standard.........................................................................................................120
9.5.18 Woodruff key standard ................................................................................................120
9.5.19 Bolts/pins .....................................................................................................................120
9.5.20 Lubricants ....................................................................................................................120
9.5.21 Bolts: Tightening factor ................................................................................................122
9.5.22 Bolts: Bore ...................................................................................................................122
9.5.23 Bolts: Strength grade ...................................................................................................122
9.5.24 Bolts: Nut strength grade .............................................................................................123
9.5.25 Bolts: Coefficients of friction classes ...........................................................................123
9.5.26 Bolts: Thread type .......................................................................................................123
9.5.27 Bolts: Nuts ...................................................................................................................124
9.5.28 Bolts: Type...................................................................................................................124
9.5.29 Bolts: Washer ..............................................................................................................124
9.5.30 Selection of pinion type cutters....................................................................................124
9.5.31 Disc spring standard ....................................................................................................124
9.5.32 Tolerances standard ....................................................................................................124
9.5.33 Beam profiles...............................................................................................................125
9.5.34 Multi-Spline standard ...................................................................................................125
9.5.35 Materials ......................................................................................................................125
9.5.36 Material of gears ..........................................................................................................129
9.5.37 Rolling bearings ...........................................................................................................130
9.5.38 Rolling bearing tolerance .............................................................................................140
9.5.39 Rolling bearing fit (tolerance) classes..........................................................................141
9.5.40 Tooth thickness tolerances ..........................................................................................141
9.5.41 Toothed belt standard..................................................................................................141
10 Description of the Public Interface .......................................... 143
10.1 Interfaces between calculation programs and CAD - Overview...........................................143
10.1.1 Efficient interfaces .......................................................................................................143
10.1.2 Open interfaces concept in KISSsoft ...........................................................................144
10.2 Defining input and output .....................................................................................................145
10.2.1 Preamble .....................................................................................................................145
10.2.2 Requirements placed on the third party program ........................................................146
10.2.3 Used files .....................................................................................................................147
10.2.4 Temporary files ............................................................................................................147
10.2.5 Explicitly reading (importing) and generating data ......................................................148
10.3 Example: Interference fit calculation ....................................................................................148
10.4 Geometry data .....................................................................................................................150
10.5 COM interface ......................................................................................................................150
10.5.1 Registering the server .................................................................................................150
10.5.2 Server functionality ......................................................................................................150
10.5.3 Example of a call from Excel .......................................................................................153
11 3D Interfaces .......................................................................... 158
11.1 Overview of the available CAD interfaces and their functionality ........................................158
11.2 Generation of 3D gears........................................................................................................159
11.3 Generating 3D shafts ...........................................................................................................159
11.4 Viewer with neutral format interface.....................................................................................160
11.4.1 Parasolid Export of 3D Shafts .....................................................................................160
11.4.2 Face gear: 3D geometry ..............................................................................................160
11.4.3 Bevel gear: generating a 3D model .............................................................................161
11.4.4 Worm wheel: generating a 3D model ..........................................................................162
11.4.5 General information about 3D modeling in Parasolid ..................................................162
11.5 3D interface to SolidWorks ..................................................................................................163
11.5.1 Gear teeth if existing shaft data is present ..................................................................163
11.5.2 Integrate the KISSsoft Add-in (menu options in CAD).................................................163
11.5.3 Add-in functions (calls) ................................................................................................164
11.6 3D interface to Solid Edge ...................................................................................................166
11.6.1 Changing the parameter for generation.......................................................................166
11.6.2 Gear teeth if existing shaft data is present ..................................................................166
11.6.3 Integrate the KISSsoft Add-in (menu options in CAD).................................................167
11.6.4 Add-in functions (calls) ................................................................................................168
11.6.5 Opening the calculation file for the created gear .........................................................168
11.6.6 Simplified gear view.....................................................................................................168
11.7 3D interface to Autodesk Inventor .......................................................................................169
11.7.1 Gear teeth if existing shaft data is present ..................................................................169
11.7.2 Integrate the KISSsoft Add-in (menu options in CAD).................................................170
11.7.3 Add-in functions (calls) ................................................................................................171
11.7.4 Opening the calculation file for the created gear .........................................................171
11.8 3D interface to Siemens NX:................................................................................................171
11.8.1 Integrate the KISSsoft Add-in (menu options in CAD).................................................172
11.8.2 Calling KISSsoft from the Add-in .................................................................................174
11.9 3D interface to Creo Parametric (ProEngineer) ...................................................................176
11.9.1 Integrating the KISSsoft Add-in ...................................................................................177
11.9.2 Cutting gear teeth on an existing shaft ........................................................................179
11.9.3 Modifying the selected 3D model ................................................................................179
11.9.4 Modifying the teeth on an existing shaft ......................................................................180
11.9.5 Changing base settings in the interface ......................................................................180
11.9.6 Saving the files to the PTC Windchill working directory ..............................................181
11.10 3D interface to CATIA ........................................................................................................181
12 Answers to Frequently Asked Questions ................................ 182
12.1 Changing the output of angles in reports .............................................................................182
12.2 Inputting materials for gear calculations in the database .....................................................182
12.3 How can I test the software?................................................................................................183
12.4 What licenses are available? ...............................................................................................183
12.5 Add your own texts in the results window ............................................................................183
12.6 Restoring a previous stage in the calculation ......................................................................184
II KISSdesign ........................................................ 185
13 User interface ......................................................................... 186
13.1 Shaft view in the model tree structure..................................................................................186
13.2 Calculation view in the model tree structure ........................................................................186
13.3 Element Box.........................................................................................................................187
13.4 Sketcher ...............................................................................................................................187
13.5 3D Viewer ............................................................................................................................188
13.6 Kinematics ...........................................................................................................................188
13.7 Ratio.....................................................................................................................................188
13.8 Module specific settings .......................................................................................................188
13.9 Group modeling ...................................................................................................................190
14 Modeling ................................................................................. 191
14.1 Creating a model with the Element Box ...............................................................................191
14.2 Creating a model with the Sketcher .....................................................................................192
14.3 Creating a model with groups ..............................................................................................192
15 Special Calculations ............................................................... 193
15.1 Modal analysis .....................................................................................................................193
15.2 Campbell diagram ................................................................................................................193
15.3 Forced response ..................................................................................................................194
III Gears ............................................................... 195
16 Introduction............................................................................. 196
16.1 Underlying principles of calculation......................................................................................196
17 Cylindrical gears ..................................................................... 198
17.1 Basic data ............................................................................................................................199
17.1.1 Hand of gear for gear teeth .........................................................................................199
17.1.2 Normal module ............................................................................................................199
17.1.3 Pressure angle at normal section ................................................................................200
17.1.4 Helix angle at reference circle .....................................................................................200
17.1.5 Center distance ...........................................................................................................201
17.1.6 Number of teeth ...........................................................................................................201
17.1.7 Facewidth ....................................................................................................................201
17.1.8 Profile shift coefficient..................................................................................................202
17.1.9 Tooth thickness modification factor .............................................................................205
17.1.10 Quality .......................................................................................................................205
17.1.11 Geometry details .......................................................................................................207
17.1.12 Material and lubrication .............................................................................................208
17.2 Load .....................................................................................................................................213
17.2.1 Calculation methods ....................................................................................................213
17.2.2 Service life ...................................................................................................................223
17.2.3 Reliability .....................................................................................................................226
17.2.4 Application factor .........................................................................................................228
17.2.5 Power, torque and speed ............................................................................................229
17.2.6 Strength details............................................................................................................229
17.2.7 Strength details (AGMA)..............................................................................................242
17.2.8 Define load spectrum...................................................................................................243
17.3 Factors .................................................................................................................................246
17.3.1 Transverse coefficient .................................................................................................246
17.3.2 Dynamic factor.............................................................................................................246
17.3.3 Mesh load factor ..........................................................................................................246
17.3.4 Alternating bending factor............................................................................................247
17.3.5 Load spectrum with alternating torque ........................................................................249
17.3.6 Face load factor ...........................................................................................................251
17.3.7 Taking into account shaft bending (face load factor and contact analysis) .................270
17.3.8 Z-Y factors and the technology factor..........................................................................272
17.3.9 General calculation procedure for KHbeta as specified in ISO 6336-1, Annex E........274
17.4 Reference profile..................................................................................................................275
17.4.1 Configuration ...............................................................................................................275
17.4.2 Pre-machining and grinding allowance........................................................................284
17.4.3 Tip alteration ................................................................................................................285
17.5 Manufacture .........................................................................................................................285
17.5.1 Details about the grinding process ..............................................................................285
17.5.2 Power skiving ..............................................................................................................286
17.6 Tolerances ...........................................................................................................................287
17.6.1 Tooth thickness tolerance............................................................................................288
17.6.2 Tip diameter allowances ..............................................................................................289
17.6.3 Root diameter allowances ...........................................................................................290
17.6.4 Center distance tolerances ..........................................................................................290
17.6.5 Settings........................................................................................................................290
17.7 Modifications ........................................................................................................................291
17.7.1 Type of modification ....................................................................................................291
17.7.2 Individual modifications per tooth ................................................................................292
17.7.3 Profile modifications ....................................................................................................293
17.7.4 Tooth trace modifications ............................................................................................301
17.7.5 Sizing modifications .....................................................................................................308
17.7.6 Notes about profile modification ..................................................................................311
17.7.7 Using diamond dressing wheels and grinding worms .................................................311
17.8 Tooth form............................................................................................................................314
17.8.1 Context menu ..............................................................................................................315
17.8.2 Operations ...................................................................................................................316
17.9 Asymmetric gears ................................................................................................................335
17.10 Contact analysis.................................................................................................................336
17.10.1 Theory of contact analysis .........................................................................................339
17.10.2 Asymmetrical gear teeth in the contact analysis .......................................................340
17.10.3 Discretized model ......................................................................................................340
17.10.4 Reduced stiffness on the side edges.........................................................................341
17.10.5 Contact analysis model for planetary systems ..........................................................342
17.10.6 Meshing position for contact analysis ........................................................................342
17.11 Gear pump .........................................................................................................................343
17.12 Operating backlash ............................................................................................................345
17.12.1 Temperatures ............................................................................................................347
17.12.2 Relative water absorption during swelling .................................................................347
17.12.3 Coefficient of thermal expansion for housing ............................................................348
17.12.4 Take into account the bending of the shafts and width modifications .......................348
17.12.5 Tooth deformation .....................................................................................................348
17.13 Master gear ........................................................................................................................348
17.14 AGMA 925 .........................................................................................................................349
17.15 Root stress FEM ................................................................................................................350
17.16 Rough sizing ......................................................................................................................351
17.17 Fine sizing ..........................................................................................................................355
17.17.1 Necessary entries in the input window ......................................................................355
17.17.2 Conditions I................................................................................................................356
17.17.3 Conditions II...............................................................................................................357
17.17.4 Conditions III..............................................................................................................357
17.17.5 Results.......................................................................................................................360
17.17.6 Graphics ....................................................................................................................361
17.17.7 Geometry fine sizing for 3 gears................................................................................362
17.17.8 Geometry-Fine Sizing for 4 gears..............................................................................362
17.17.9 Additional strength calculation of all variants.............................................................363
17.18 Sizing modifications ...........................................................................................................363
17.18.1 Conditions I/II.............................................................................................................364
17.18.2 Results.......................................................................................................................364
17.18.3 Graphic I ....................................................................................................................365
17.18.4 Graphic II ...................................................................................................................365
17.18.5 Report ........................................................................................................................366
17.19 Measurement grid ..............................................................................................................366
17.20 Settings ..............................................................................................................................367
17.20.1 General ......................................................................................................................368
17.20.2 Plastic ........................................................................................................................371
17.20.3 Planets.......................................................................................................................373
17.20.4 Sizings .......................................................................................................................373
17.20.5 Calculations ...............................................................................................................374
17.20.6 Required safeties.......................................................................................................378
17.20.7 Contact analysis/face load factor...............................................................................379
17.20.8 Contact analysis ........................................................................................................379
17.20.9 Summary ...................................................................................................................382
17.20.10 Diagrams .................................................................................................................382
17.20.11 Generate a 3D model ..............................................................................................383
17.21 Tooth thickness ..................................................................................................................385
17.22 Tooth form export...............................................................................................................385
18 Bevel and Hypoid Gears ......................................................... 387
18.1 Underlying principles of calculation......................................................................................387
18.1.1 General ........................................................................................................................387
18.1.2 Overview of the bevel gear manufacturing process and the terminology used in it ....387
18.1.3 Calculation according to Klingelnberg, Gleason and Oerlikon ....................................388
18.2 Basic data ............................................................................................................................389
18.2.1 Type.............................................................................................................................389
18.2.2 Mean normal module ...................................................................................................392
18.2.3 Pitch diameter gear 2 ..................................................................................................392
18.2.4 Pressure angle at normal section ................................................................................392
18.2.5 Pressure angle driving/driven flank: Hypoid gears ......................................................392
18.2.6 Spiral and helix angle ..................................................................................................394
18.2.7 Addendum angle and root angle .................................................................................395
18.2.8 Angle modifications .....................................................................................................397
18.2.9 Number of teeth ...........................................................................................................397
18.2.10 Facewidth ..................................................................................................................397
18.2.11 Profile shift coefficient................................................................................................397
18.2.12 Tooth thickness modification factor ...........................................................................398
18.2.13 Quality .......................................................................................................................398
18.2.14 Shaft angle ................................................................................................................398
18.2.15 Offset .........................................................................................................................398
18.2.16 Geometry details .......................................................................................................399
18.3 Process ................................................................................................................................401
18.3.1 Manufacturing process ................................................................................................401
18.3.2 Manufacture type .........................................................................................................402
18.3.3 Cutter radius ................................................................................................................402
18.3.4 Number of blade groups ..............................................................................................402
18.4 Load .....................................................................................................................................402
18.4.1 Methods used for strength calculation .........................................................................402
18.4.2 Driving gear and working flank gear 1 .........................................................................405
18.4.3 Power, torque and speed ............................................................................................406
18.4.4 Required service life ....................................................................................................406
18.4.5 Application factor .........................................................................................................407
18.4.6 Strength details............................................................................................................407
18.5 Reference profile..................................................................................................................408
18.5.1 Default values for tip clearance ...................................................................................408
18.5.2 Default values for addendum coefficients....................................................................409
18.6 Contact analysis...................................................................................................................409
18.7 Modifications ........................................................................................................................409
18.8 Factors .................................................................................................................................412
18.8.1 Bearing application factor ............................................................................................412
18.8.2 Dynamic factor.............................................................................................................413
18.8.3 Bevel gear factor at flank and root...............................................................................414
18.9 Rough sizing ........................................................................................................................414
18.9.1 Facewidth ratio ............................................................................................................414
18.9.2 Module ratio .................................................................................................................415
18.10 Fine sizing ..........................................................................................................................415
18.10.1 Required entries in the standard tabs........................................................................415
18.10.2 Conditions I................................................................................................................416
18.10.3 Conditions II...............................................................................................................416
18.10.4 Conditions III..............................................................................................................417
18.10.5 Results.......................................................................................................................420
18.10.6 Graphics ....................................................................................................................420
18.11 Torque measurement.........................................................................................................420
18.11.1 Grid and spread .........................................................................................................422
18.11.2 Multiplier ....................................................................................................................422
18.11.3 Torque curve .............................................................................................................422
18.11.4 Calculation .................................................................................................................423
18.11.5 Notes .........................................................................................................................425
18.12 Measurement grid ..............................................................................................................426
18.13 Topological modifications...................................................................................................426
18.14 Notes about calculations according to the Klingelnberg standard .....................................426
18.14.1 Bevel gears with cyclo-palloid® gear teeth ...............................................................426
18.14.2 Hypoid gears with cyclo-palloid gear teeth ................................................................427
18.14.3 Bevel gears with palloid gear teeth............................................................................427
18.14.4 Minimum safeties.......................................................................................................428
18.14.5 Surface roughness at tooth root ................................................................................428
18.14.6 Manufacturing quality for bevel gears........................................................................429
18.14.7 Characteristic number ...............................................................................................429
18.15 Settings ..............................................................................................................................430
18.15.1 General ......................................................................................................................430
18.15.2 Calculations ...............................................................................................................430
18.15.3 Differential gears .......................................................................................................430
18.15.4 Helpful information about the Generation of 3D model tab .......................................431
18.15.5 Contact analysis ........................................................................................................431
19 Face gears ............................................................................. 434
19.1 Underlying principles of calculation......................................................................................434
19.2 Basic data ............................................................................................................................437
19.2.1 Normal module ............................................................................................................437
19.2.2 Pressure angle at normal section ................................................................................439
19.2.3 Helix angle at reference circle .....................................................................................439
19.2.4 Axial offset ...................................................................................................................440
19.2.5 Profile shift coefficient..................................................................................................440
19.2.6 Quality .........................................................................................................................441
19.2.7 Geometry details .........................................................................................................442
19.2.8 Material and lubrication ...............................................................................................443
19.3 Load .....................................................................................................................................443
19.3.1 Methods used for strength calculation .........................................................................443
19.3.2 Service life ...................................................................................................................445
19.3.3 Power, torque and speed ............................................................................................448
19.3.4 Application factor .........................................................................................................448
19.3.5 Strength details............................................................................................................449
19.4 Factors .................................................................................................................................452
19.4.1 Face load factor ...........................................................................................................452
19.5 Modifications ........................................................................................................................452
19.5.1 Addendum reduction ...................................................................................................453
19.5.2 Type of modification ....................................................................................................453
19.6 Settings ................................................................................................................................453
19.6.1 General ........................................................................................................................453
19.6.2 Sizings .........................................................................................................................454
19.7 Notes on face gear calculation.............................................................................................454
19.7.1 Dimensioning ...............................................................................................................454
19.7.2 Pinion - Face gear with Z1 > Z2 ..................................................................................455
20 Worms with enveloping worm wheels ..................................... 456
20.1 Underlying principles of calculation......................................................................................456
20.2 Basic data ............................................................................................................................458
20.2.1 Axial/transverse module ..............................................................................................458
20.2.2 Pressure angle at normal section ................................................................................458
20.2.3 Lead angle at reference diameter................................................................................458
20.2.4 Center distance ...........................................................................................................459
20.2.5 Number of teeth ...........................................................................................................459
20.2.6 Facewidth ....................................................................................................................459
20.2.7 Profile shift coefficient..................................................................................................459
20.2.8 Tooth thickness modification factor .............................................................................460
20.2.9 Quality for worm gear units..........................................................................................460
20.2.10 Geometry details .......................................................................................................461
20.2.11 Material and lubrication .............................................................................................462
20.3 Load .....................................................................................................................................463
20.3.1 Methods used for strength calculation .........................................................................463
20.3.2 Service life ...................................................................................................................464
20.3.3 Application factor .........................................................................................................464
20.3.4 Permissible decrease in quality ...................................................................................464
20.3.5 Power, torque and speed ............................................................................................464
20.3.6 Strength details............................................................................................................464
20.4 Tolerances ...........................................................................................................................467
20.5 Settings ................................................................................................................................467
20.5.1 General ........................................................................................................................467
20.5.2 Reference gearing .......................................................................................................468
20.5.3 Sizings .........................................................................................................................468
20.5.4 Calculations .................................................................................................................469
20.5.5 Required safeties.........................................................................................................470
21 Crossed helical gears, precision mechanics worms and crossed
helical gear with rack ................................................................... 472
21.1 Underlying principles of calculation......................................................................................473
21.2 Basic data ............................................................................................................................473
21.2.1 Normal module ............................................................................................................473
21.2.2 Pressure angle at normal section ................................................................................473
21.2.3 Helix angle reference circle gear 1 ..............................................................................473
21.2.4 Center distance ...........................................................................................................474
21.2.5 Facewidth ....................................................................................................................474
21.2.6 Profile shift coefficient..................................................................................................474
21.2.7 Quality .........................................................................................................................474
21.2.8 Geometry details .........................................................................................................475
21.2.9 Material and lubrication ...............................................................................................476
21.2.10 Load...........................................................................................................................476
21.3 Settings ................................................................................................................................488
21.4 Notes....................................................................................................................................489
21.4.1 Checking the contact pattern .......................................................................................489
21.5 Crossed helical gear with rack .............................................................................................490
22 Beveloid Gears ....................................................................... 491
22.1 Underlying principles of calculation......................................................................................491
22.2 Basic data ............................................................................................................................492
22.2.1 Normal module ............................................................................................................492
22.2.2 Normal pressure angle ................................................................................................492
22.2.3 Helix angle ...................................................................................................................492
22.2.4 Shaft angle ..................................................................................................................492
22.2.5 Number of teeth ...........................................................................................................493
22.2.6 Width ...........................................................................................................................493
22.2.7 Cone angle ..................................................................................................................493
22.2.8 Profile shift coefficient (center) ....................................................................................493
22.2.9 Quality .........................................................................................................................493
22.2.10 Material and lubrication .............................................................................................493
22.3 Reference profile..................................................................................................................493
22.4 Modifications ........................................................................................................................494
22.5 Factors .................................................................................................................................494
22.6 Dimensioning .......................................................................................................................494
22.7 Manufacturing Data and Working Data ................................................................................494
23 Non-Circular Gears ................................................................. 496
23.1 Input data .............................................................................................................................496
23.1.1 Geometry .....................................................................................................................496
23.1.2 Tolerances ...................................................................................................................498
23.1.3 Reference profile .........................................................................................................498
23.2 Notes on how to operate KISSsoft .......................................................................................499
23.2.1 Angle error ...................................................................................................................499
23.2.2 Checking the meshing .................................................................................................499
23.2.3 Improving the tooth form..............................................................................................500
23.2.4 Accuracy of the tooth form...........................................................................................500
23.2.5 Exporting individual teeth ............................................................................................501
23.2.6 Report ..........................................................................................................................502
23.2.7 Temporary files ............................................................................................................502
24 Report Menu ........................................................................... 504
24.1 Drawing data ........................................................................................................................504
24.2 Manufacturing tolerances.....................................................................................................504
24.3 Summary..............................................................................................................................504
24.4 Service life ...........................................................................................................................504
24.5 Sizing of torque ....................................................................................................................504
24.6 Proposal for the hardening depth EHT ................................................................................505
25 Graphics Menu ....................................................................... 506
25.1 AGMA 925 ...........................................................................................................................509
25.1.1 Lubricant film thickness and specific oil film thickness ................................................509
25.2 Geometry 2D........................................................................................................................510
25.2.1 Gear tooth forms..........................................................................................................510
25.2.2 Gear tool ......................................................................................................................511
25.2.3 Manufacturing a gear...................................................................................................511
25.2.4 Meshing .......................................................................................................................511
25.2.5 Profile and tooth trace diagram ...................................................................................512
25.2.6 Drawing .......................................................................................................................515
25.2.7 Assembly .....................................................................................................................515
25.2.8 Manufacturing drawing ................................................................................................515
25.3 Geometry 3D........................................................................................................................518
25.3.1 Tooth system ...............................................................................................................518
25.3.2 Tooth form ...................................................................................................................519
25.4 Evaluation ............................................................................................................................519
25.4.1 Specific sliding .............................................................................................................519
25.4.2 Contact temperature ....................................................................................................519
25.4.3 Flash temperature .......................................................................................................519
25.4.4 Surface layer shear stress ...........................................................................................519
25.4.5 Suggested hardening depth ........................................................................................520
25.4.6 Theoretical contact stiffness ........................................................................................520
25.4.7 S-N curve (Woehler lines) for material ........................................................................521
25.4.8 Safety factor curves .....................................................................................................521
25.4.9 Oil viscosity..................................................................................................................521
25.4.10 Gap analysis ..............................................................................................................521
25.4.11 face load distribution..................................................................................................521
25.4.12 Backlash calculation from tooth form.........................................................................522
25.4.13 Tooth flank fracture....................................................................................................522
25.4.14 Sliding velocity (face gear) ........................................................................................522
25.4.15 Contact line (face gear) .............................................................................................522
25.4.16 Stress curve (face gear) ............................................................................................522
25.4.17 Scuffing and sliding velocity (face gear) ....................................................................522
25.5 Contact analysis...................................................................................................................523
25.5.1 Axis alignment .............................................................................................................524
25.5.2 Transmission error.......................................................................................................524
25.5.3 Transmission error acceleration ..................................................................................524
25.5.4 Amplitude of transmission error ...................................................................................526
25.5.5 Normal force curve ......................................................................................................526
Normal force distribution .................................................................................................527
25.5.6 Torque curve ...............................................................................................................527
Single contact stiffness ....................................................................................................527
25.5.7 Stiffness curve .............................................................................................................527
25.5.8 Amplitude spectrum of the contact stiffness ................................................................528
25.5.9 Bearing force curve and direction of the bearing forces ..............................................528
25.5.10 Kinematics .................................................................................................................529
25.5.11 Specific sliding ...........................................................................................................529
25.5.12 Power loss .................................................................................................................529
25.5.13 Heat development .....................................................................................................529
25.5.14 Stress curve...............................................................................................................529
25.5.15 Flash temperature .....................................................................................................530
25.5.16 Micropitting (frosting) .................................................................................................530
25.5.17 Wear ..........................................................................................................................532
25.6 Gear pump ...........................................................................................................................534
25.7 3D export .............................................................................................................................534
25.8 Settings ................................................................................................................................534
25.9 Graphics list .........................................................................................................................534
26 Answers to Frequently Asked Questions ................................ 535
26.1 Answers concerning geometry calculation...........................................................................535
26.1.1 Precision engineering ..................................................................................................535
26.1.2 Deep tooth forms or cylindrical gears with a high transverse contact ratio .................535
26.1.3 Pairing an external gear to an inside gear that has a slightly different number of teeth
................................................................................................................................................536
26.1.4 Undercut or insufficient effective involute ....................................................................536
26.1.5 Tooth thickness at tip...................................................................................................536
26.1.6 Special toothing ...........................................................................................................537
26.1.7 Calculating cylindrical gears manufactured using tools specified in DIN 3972 ............537
26.1.8 Composites as defined in DIN 58405 ..........................................................................538
26.1.9 Automatic change of reference profiles .......................................................................538
26.1.10 Non-identical (mirrored symmetry) tooth flanks .........................................................539
26.1.11 Internal teeth - differences in the reference profile if you select different configurations
................................................................................................................................................539
26.1.12 Effect of profile modifications.....................................................................................540
26.1.13 Number of teeth with common multiples ...................................................................541
26.1.14 Allowances for racks..................................................................................................542
26.2 Answers to questions about strength calculation .................................................................542
26.2.1 Differences between different gear calculation programs ...........................................542
26.2.2 Difference between cylindrical gear calculation according to ISO 6336 or DIN 3990 .543
26.2.3 Calculation using Methods B or C (DIN 3990, 3991)...................................................543
26.2.4 Required safeties for cylindrical gear units ..................................................................543
26.2.5 Insufficient safety against scuffing ...............................................................................544
26.2.6 Material hardening factor (for strengthening an unhardened gear) .............................545
26.2.7 Defining the load stage scuffing (oil specification).......................................................545
26.2.8 The effect of the face load factor KHß for the tooth trace deviation fma is due to a
manufacturing error. ...............................................................................................................545
26.2.9 Load spectrum with alternating torque ........................................................................546
26.2.10 Strength calculation with several meshings on one gear ..........................................547
26.2.11 Bevel gears: – Determine permitted overloads .........................................................550
26.2.12 Taking shot peening data into account when calculating gear strength ....................550
26.2.13 Calculation according to AGMA 421.06 (High Speed Gears) ....................................551
26.2.14 Comparison of an FEM calculation with the crossed helical gear calculation ...........551
26.2.15 Determine the equivalent torque (for load spectra) ...................................................552
26.2.16 Check changes in safeties if the center distance changes ........................................552
26.2.17 Warning: "Notch parameter qs …. outside RANGE (1.0 to 8.0) ..." ...........................553
26.2.18 Tooth root stresses in the contact analysis and stress according to FEM – is there a
difference? ..............................................................................................................................553
26.3 Abbreviations used in gear calculation ................................................................................554
IV Shafts and Bearings ......................................... 561
27 Defining Shafts ....................................................................... 562
27.1 Input window ........................................................................................................................563
27.1.1 Shaft editor ..................................................................................................................563
27.1.2 Element Tree ...............................................................................................................564
27.1.3 Element List .................................................................................................................564
27.1.4 Element Editor .............................................................................................................564
27.2 Element overview.................................................................................................................564
27.2.1 The shaft element ........................................................................................................564
27.2.2 Outer contour...............................................................................................................569
27.2.3 Inner contour ...............................................................................................................574
27.2.4 Forces..........................................................................................................................574
27.2.5 Bearings ......................................................................................................................580
27.2.6 Connection elements ...................................................................................................584
27.2.7 Cross sections .............................................................................................................584
27.3 Basic data ............................................................................................................................585
27.3.1 Position of shaft axis in space .....................................................................................585
27.3.2 Number of eigenfrequencies .......................................................................................586
27.3.3 Number of buckling cases ...........................................................................................586
27.3.4 Speed ..........................................................................................................................586
27.3.5 Direction of rotation .....................................................................................................587
27.3.6 Reference temperature................................................................................................587
27.3.7 Housing temperature ...................................................................................................588
27.3.8 Lubricant temperature .................................................................................................588
27.3.9 Load spectra ................................................................................................................589
27.3.10 Gears .........................................................................................................................589
27.3.11 Rolling bearings .........................................................................................................590
27.3.12 Tolerance field ...........................................................................................................591
27.3.13 Modified rating life according ISO 281.......................................................................593
27.3.14 Consider weight .........................................................................................................593
27.3.15 Consider gyroscopic effect ........................................................................................593
27.3.16 Housing material........................................................................................................593
27.3.17 Lubrication .................................................................................................................594
27.3.18 Contamination ...........................................................................................................594
27.4 Module specific settings .......................................................................................................594
27.4.1 Non-linear shaft ...........................................................................................................594
27.4.2 Consider deformation due to shearing and shear correction factor.............................595
27.4.3 Activating offset of the load application center point ...................................................595
27.4.4 Using the 2013 solver ..................................................................................................595
27.4.5 Saving temporary results in CSV format with .tmp file extension ................................596
27.4.6 Standard radius at shoulders.......................................................................................596
27.4.7 Node density................................................................................................................596
27.4.8 Iterative calculation of load distribution........................................................................597
27.4.9 Input different numbers of load cycles for bending and torsion (for limited life
calculations)............................................................................................................................597
27.4.10 Save user defined bearings in calculation file ...........................................................597
27.4.11 Read user-defined rolling bearings from calculation file ............................................597
27.4.12 Entering contamination in each bearing separately...................................................598
27.4.13 Axial clearance ..........................................................................................................598
27.4.14 Failure probability ......................................................................................................598
27.4.15 Required service life ..................................................................................................598
27.4.16 Maximum life modification factor ...............................................................................598
27.4.17 Display critical bearings .............................................................................................598
27.4.18 Housing surface roughness .......................................................................................599
27.4.19 Calculation method for friction ...................................................................................599
27.4.20 Grease lifetime ..........................................................................................................599
27.4.21 Oil level ......................................................................................................................600
27.4.22 Type of oil lubrication.................................................................................................600
27.4.23 Moment of friction, seals............................................................................................600
27.4.24 Bearing manufacturer ................................................................................................601
27.4.25 Show coordinates system..........................................................................................601
27.4.26 Show automatic dimensioning ...................................................................................601
27.4.27 Equivalent stress for sizings ......................................................................................601
27.4.28 Maximum deflection for sizings .................................................................................601
28 Calculating Shafts................................................................... 602
28.1 Deflection and bearing forces, distribution of force and torque ...........................................602
28.1.1 Calculating force on bearings with a contact angle .....................................................604
28.2 Eigenfrequencies .................................................................................................................605
28.2.1 Bending critical speed .................................................................................................606
28.2.2 Torsion critical speed...................................................................................................606
28.3 Buckling ...............................................................................................................................606
28.4 Rough sizing of shafts..........................................................................................................606
28.5 Strength ...............................................................................................................................607
28.5.1 Calculation method ......................................................................................................608
28.5.2 Type of calculation.......................................................................................................612
28.5.3 Rating life.....................................................................................................................614
28.5.4 Strength parameters according to Hänchen and Decker ............................................614
28.5.5 Strength parameters according to FKM.......................................................................615
28.5.6 Strength parameters according to DIN ........................................................................617
28.5.7 Strength parameters according to AGMA....................................................................622
28.5.8 Stress ..........................................................................................................................624
28.5.9 Stress ratio ..................................................................................................................624
28.5.10 Load factor for static analysis ....................................................................................625
28.5.11 Load factor endurance calculation.............................................................................625
28.5.12 Cross sections ...........................................................................................................626
28.5.13 Sizing .........................................................................................................................626
28.5.14 Cross-section types ...................................................................................................627
28.5.15 General entries ..........................................................................................................633
28.5.16 Thermally safe operating speed ................................................................................633
28.6 Tooth trace modification.......................................................................................................633
28.7 Campbell diagram ................................................................................................................635
28.8 Forced vibrations .................................................................................................................636
28.8.1 Calculation procedure..................................................................................................636
28.8.2 Results.........................................................................................................................636
29 Rolling Bearings (Classic Analysis) ........................................ 637
29.1 Selecting the type of rolling bearing .....................................................................................637
29.1.1 Properties of the most important bearing types ...........................................................637
29.1.2 Comparing types .........................................................................................................639
29.1.3 Hybrid bearings ...........................................................................................................642
29.2 Load capacity of rolling bearings .........................................................................................642
29.2.1 Dynamic load capacity.................................................................................................642
29.2.2 Static load capacity......................................................................................................643
29.2.3 Rolling bearing calculation with internal geometry ......................................................643
29.3 Thermally safe operating speed...........................................................................................644
29.3.1 Thermal reference speed ............................................................................................644
29.3.2 Process for calculating thermally safe operating speed (DIN 732-2) ..........................646
29.4 Moment of friction ................................................................................................................647
29.4.1 Calculation according to SKF Catalog 1994 ................................................................647
29.4.2 Calculation according to SKF Catalog 2018 ................................................................649
29.4.3 Calculation according to Schaeffler 2017 (INA, FAG) .................................................651
29.5 Grease lifetime .....................................................................................................................652
29.5.1 Calculation according to Schaeffler 2018 (INA, FAG) .................................................652
29.5.2 Calculation according to SKF Catalog 2018 ................................................................653
29.6 Maximum Speeds ................................................................................................................653
29.7 Rating life .............................................................................................................................654
29.7.1 Modified rating life calculation according to the Supplement to DIN ISO 281 (2007) ..654
29.7.2 Rating life calculation with load spectra.......................................................................654
29.8 Failure probability.................................................................................................................656
29.9 Bearing with radial and/or axial force ...................................................................................656
29.10 Calculating axial forces on bearings in face-to-face or back-to-back arrangements .........656
29.11 Oil level and lubrication type ..............................................................................................657
30 Rolling Bearings (Internal Geometry) ...................................... 659
30.1 Bearing data tab...................................................................................................................659
30.1.1 File interface ................................................................................................................659
30.1.2 Bearing data ................................................................................................................660
30.2 Rating (load) tab ..................................................................................................................663
30.2.1 Rating (load) ................................................................................................................663
30.2.2 Modified rating life calculation in accordance with ISO 281 ........................................664
30.3 Tab Elastic Rings .................................................................................................................664
30.3.1 Basic data ....................................................................................................................664
30.3.2 Details..........................................................................................................................666
30.4 Graphics...............................................................................................................................667
30.5 Fine sizing ............................................................................................................................668
31 Hydrodynamic Plain Journal Bearings .................................... 669
31.1 Calculation methods ............................................................................................................669
31.2 Module specific entries ........................................................................................................670
31.3 Coefficients of thermal expansion ........................................................................................670
31.4 Average surface pressure ....................................................................................................671
31.5 Geometries according to DIN 31657 ...................................................................................671
31.6 Stiffness ...............................................................................................................................674
31.7 Lubrication arrangement ......................................................................................................674
31.8 Heat transfer coefficient .......................................................................................................676
31.9 Heat transfer surface ...........................................................................................................676
31.10 Oil temperatures ................................................................................................................677
31.11 Mixture factor .....................................................................................................................677
31.12 Sizing the bearing clearance..............................................................................................677
31.13 Sommerfeld number ..........................................................................................................678
31.14 Bearing width .....................................................................................................................679
31.15 Permissible lubricant film thickness ...................................................................................679
32 Hydrodynamic Plain Thrust Bearings ...................................... 680
32.1 Calculation ...........................................................................................................................681
32.2 Sizings .................................................................................................................................682
32.3 Calculation of volume-specific heat .....................................................................................683
32.4 Limiting values in the calculation .........................................................................................683
33 Answers to Frequently Asked Questions ................................ 684
33.1 Intersecting notch effects .....................................................................................................684
33.2 Notch effects on hollow shafts .............................................................................................684
33.2.1 Notches on the outer contour ......................................................................................684
33.2.2 Notches on the inner contour ......................................................................................685
33.3 Fatigue Limits for New Materials..........................................................................................685
33.4 Taking double helical gearings into account in the shaft calculation ...................................686
V Connections ....................................................... 687
34 Cylindrical Interference Fit ...................................................... 688
34.1 Inputting Tolerances ............................................................................................................690
34.2 Coefficients of friction...........................................................................................................691
34.3 Variable external diameter of the hub ..................................................................................693
34.4 Convert external pressure with multiple interference fit .......................................................693
34.5 Materials ..............................................................................................................................695
34.6 Settings ................................................................................................................................696
34.7 Sizings .................................................................................................................................697
35 Conical Interference Fit........................................................... 699
35.1 Calculation ...........................................................................................................................701
35.2 Application factor .................................................................................................................702
35.3 Axial spanning with nut ........................................................................................................702
35.4 Variable external diameter of the hub ..................................................................................703
35.5 Conicity ................................................................................................................................704
35.6 Materials ..............................................................................................................................705
35.7 Settings ................................................................................................................................706
35.8 Sizings .................................................................................................................................706
36 Clamped Connections ............................................................ 708
36.1 Calculations .........................................................................................................................708
36.2 Sizings .................................................................................................................................710
36.3 Settings ................................................................................................................................711
36.4 Materials ..............................................................................................................................712
37 Keys ....................................................................................... 713
37.1 Main window ........................................................................................................................713
37.1.1 Additional inputs for DIN 6892 Method B ....................................................................715
37.2 Application factor .................................................................................................................717
37.3 Contact coefficient ...............................................................................................................718
37.4 Own inputs ...........................................................................................................................719
37.5 Permissible pressure ...........................................................................................................719
37.6 Materials ..............................................................................................................................719
37.7 Settings ................................................................................................................................719
37.8 Sizings .................................................................................................................................720
38 Straight-sided splines ............................................................. 721
38.1 Standard profiles ..................................................................................................................721
38.2 Application factor .................................................................................................................722
38.3 Torque curve/Number of changes of load direction .............................................................723
38.4 Occurring contact stress ......................................................................................................723
38.5 Length factor ........................................................................................................................723
38.6 Share factor .........................................................................................................................724
38.7 Permissible pressure ...........................................................................................................724
38.8 Materials ..............................................................................................................................725
38.9 Settings ................................................................................................................................725
38.10 Sizings ...............................................................................................................................726
39 Splines (Strength) ................................................................... 727
39.1 Standard profiles ..................................................................................................................727
39.2 Application factor .................................................................................................................728
39.3 Torque curve/Number of changes of load direction .............................................................729
39.4 Occurring contact stress ......................................................................................................729
39.5 Length factor ........................................................................................................................729
39.6 Share factor .........................................................................................................................730
39.7 Permissible pressure ...........................................................................................................731
39.8 Materials ..............................................................................................................................732
39.9 Settings ................................................................................................................................732
39.10 Sizings ...............................................................................................................................732
40 Splines (Geometry and Strength) ........................................... 733
40.1 Underlying principles of calculation......................................................................................733
40.1.1 General ........................................................................................................................733
40.1.2 Calculation of spline connections as described in DIN 5480 with diameter centering.733
40.1.3 Calculating spline connections according to DIN 5480 with flank centering................734
40.2 Basic data ............................................................................................................................735
40.2.1 Geometry standards ....................................................................................................735
40.2.2 Normal module ............................................................................................................736
40.2.3 Pressure angle at normal section an ...........................................................................736
40.2.4 Number of teeth ...........................................................................................................736
40.2.5 Profile shift coefficient..................................................................................................736
40.2.6 Quality and tolerances .................................................................................................737
40.2.7 Niemann geometry data ..............................................................................................738
40.2.8 Geometry details .........................................................................................................739
40.2.9 Define details of strength .............................................................................................739
40.2.10 Materials ....................................................................................................................743
40.3 Tolerances ...........................................................................................................................743
40.3.1 Tooth thickness tolerance............................................................................................743
40.3.2 Effective/Actual ............................................................................................................745
40.3.3 Shaft/hub: diameter of ball/pin .....................................................................................745
40.4 Gauges ................................................................................................................................745
40.5 Tooth form............................................................................................................................746
41 Polygons................................................................................. 748
41.1 Standard profiles ..................................................................................................................748
41.2 Application factor .................................................................................................................749
41.3 Torque curve/Number of changes of load direction .............................................................749
41.4 Occurring contact stress ......................................................................................................749
41.5 Permissible pressure ...........................................................................................................751
41.6 Materials ..............................................................................................................................752
41.7 Settings ................................................................................................................................752
41.8 Sizings .................................................................................................................................752
41.9 Graphics...............................................................................................................................753
42 Woodruff Keys ........................................................................ 754
42.1 Standard profiles ..................................................................................................................754
42.2 Application factor .................................................................................................................755
42.3 Torque curve/Number of changes of load direction .............................................................755
42.4 Occurring contact stress ......................................................................................................756
42.5 Length factor ........................................................................................................................756
42.6 Share factor .........................................................................................................................757
42.7 Permissible pressure ...........................................................................................................757
42.8 Materials ..............................................................................................................................758
42.9 Settings ................................................................................................................................758
42.10 Sizings ...............................................................................................................................758
43 Bolts and Pins......................................................................... 760
43.1 Influence factors...................................................................................................................761
43.2 Materials ..............................................................................................................................762
43.3 Settings ................................................................................................................................763
43.4 Permitted values ..................................................................................................................763
43.5 Sizings .................................................................................................................................764
44 Bolts ....................................................................................... 765
44.1 Special features in KISSsoft ................................................................................................765
44.2 Inputs for Basic data ............................................................................................................766
44.2.1 Operating data .............................................................................................................766
44.2.2 Bolt data ......................................................................................................................776
44.2.3 Type of bolted joint ......................................................................................................778
44.2.4 Washers ......................................................................................................................779
44.2.5 Extension sleeves without external forces...................................................................779
44.2.6 Tightening technique ...................................................................................................779
44.3 Data input for clamped parts ................................................................................................780
44.3.1 Geometry of clamped parts (connecting solids) ..........................................................780
44.3.2 Distances for eccentric load/clamping .........................................................................782
44.3.3 Load application ..........................................................................................................782
44.4 Constraints data ...................................................................................................................783
44.4.1 Technical Explanations................................................................................................784
44.4.2 Coefficients of friction ..................................................................................................785
44.4.3 Rotation-angle controlled tightening ............................................................................786
44.5 Stripping strength .................................................................................................................787
44.6 Settings ................................................................................................................................787
45 Welded Joints ......................................................................... 790
45.1 Welded joints .......................................................................................................................790
45.2 Seam length .........................................................................................................................791
45.3 Welded seam equivalent stress ...........................................................................................791
45.4 Weld seam boundary stress ................................................................................................791
45.5 Part safety coefficient...........................................................................................................792
45.6 Boundary safety coefficient ..................................................................................................792
45.7 Materials ..............................................................................................................................792
46 Glued and Soldered Joints ..................................................... 793
46.1 Basic materials.....................................................................................................................794
46.2 Module specific settings .......................................................................................................794
46.3 Sizings .................................................................................................................................794
47 Snap Rings ............................................................................. 795
47.1 Basic data ............................................................................................................................795
47.2 Automatic calculation of load factor q ..................................................................................796
47.3 Automatic calculation of the dishing angle ψ .......................................................................797
47.4 Module specific settings .......................................................................................................797
48 Hirth coupling ......................................................................... 798
48.1 Basic data ............................................................................................................................798
48.2 Module specific settings .......................................................................................................798
49 Answers to Frequently Asked Questions ................................ 799
49.1 Adding new bolt types to the database ................................................................................799
49.1.1 Extending an existing bolt series .................................................................................799
49.1.2 Creating a new bolt type ..............................................................................................800
VI Springs ............................................................. 801
50 Compression Springs ............................................................. 802
50.1 Strength values ....................................................................................................................802
50.2 Shear stress values .............................................................................................................803
50.3 Bearings coefficient..............................................................................................................803
50.4 Materials ..............................................................................................................................804
50.5 Tolerances ...........................................................................................................................804
50.6 Relaxation ............................................................................................................................805
50.7 Drawing data ........................................................................................................................805
50.8 Sizing ...................................................................................................................................805
51 Tension springs ...................................................................... 807
51.1 Strength values ....................................................................................................................807
51.2 Shear stress values .............................................................................................................808
51.3 Manufacturing type ..............................................................................................................808
51.4 Eyes screen .........................................................................................................................809
51.5 Materials ..............................................................................................................................810
51.6 Settings ................................................................................................................................811
51.7 Tolerances ...........................................................................................................................811
51.8 Relaxation ............................................................................................................................811
51.9 Drawing data ........................................................................................................................812
51.10 Sizing .................................................................................................................................812
52 Leg Springs ............................................................................ 813
52.1 Strength values ....................................................................................................................814
52.2 Bending stress values ..........................................................................................................814
52.3 Spring design .......................................................................................................................814
52.4 Assumptions made for the calculation .................................................................................815
52.5 Materials ..............................................................................................................................815
52.6 Tolerances ...........................................................................................................................815
52.7 Drawing data ........................................................................................................................816
52.8 Sizing ...................................................................................................................................816
53 Disc Springs ........................................................................... 817
53.1 Strength values ....................................................................................................................817
53.2 Stress values .......................................................................................................................818
53.3 Materials ..............................................................................................................................819
53.4 Layout number .....................................................................................................................819
53.5 Limit dimensions ..................................................................................................................819
54 Torsion-Bar Springs ................................................................ 820
54.1 Tip forms ..............................................................................................................................820
54.2 Strength values ....................................................................................................................821
54.3 Shear stress .........................................................................................................................821
54.4 Limiting values .....................................................................................................................822
54.5 Sizing ...................................................................................................................................822
VII Belts and chain drives ..................................... 823
55 V-belts .................................................................................... 824
55.1 V-belts data ..........................................................................................................................825
55.2 V-belt standards ...................................................................................................................825
55.3 Configuring tensioning pulleys .............................................................................................826
55.4 Application factor F1 ............................................................................................................826
55.5 Center distance ....................................................................................................................826
55.6 Belt length ............................................................................................................................827
55.7 Effective number of V-belts ..................................................................................................827
55.8 Tensioning pulley diameter ..................................................................................................827
55.9 Position of tensioning pulley (x/y) ........................................................................................827
55.10 Inspecting V-belts ..............................................................................................................827
56 Toothed Belt ........................................................................... 828
56.1 Technical notes (toothed belts) ............................................................................................828
56.2 Toothed belt standard ..........................................................................................................830
56.3 Possible sizings/suggestions ...............................................................................................831
56.4 Configuring tensioning pulleys .............................................................................................831
56.5 Application factor and summand for operational behavior ...................................................832
56.6 Center distance ....................................................................................................................832
56.7 Belt length and number of teeth on belt ...............................................................................832
56.8 Effective belt width ...............................................................................................................833
56.9 Tensioning pulley tooth number ...........................................................................................833
56.10 Position of the tensioning pulley x/y ...................................................................................834
57 Chain Drives ........................................................................... 835
57.1 Sizings .................................................................................................................................835
57.2 Tensioning pulleys ...............................................................................................................836
57.3 Standard ..............................................................................................................................836
57.4 Chain type ............................................................................................................................836
57.5 Number of strands ...............................................................................................................836
57.6 Application factor .................................................................................................................836
57.7 Speed/number of teeth/ratio ................................................................................................837
57.8 Configuration........................................................................................................................837
57.9 Center distance ....................................................................................................................838
57.10 Polygon effect ....................................................................................................................838
57.11 Number of links ..................................................................................................................839
57.12 Sprocket geometry .............................................................................................................839
VIII Automotive ..................................................... 841
58 Synchronization ...................................................................... 842
58.1 Geometry .............................................................................................................................842
58.2 Operating data .....................................................................................................................843
59 Friction couplings.................................................................... 844
59.1 Calculation ...........................................................................................................................845
59.2 Definition of spring forces ....................................................................................................848
59.3 Definition of the coefficients of sliding friction and velocities ...............................................849
59.4 Graphics...............................................................................................................................849
59.5 Settings ................................................................................................................................849
IX Various ............................................................. 851
60 Tolerance Calculation ............................................................. 852
61 Proof of strength with local stresses ....................................... 853
61.1 General ................................................................................................................................853
61.1.1 Software functionality ..................................................................................................853
61.1.2 Areas of application for the FKM Guideline .................................................................853
61.2 Background ..........................................................................................................................854
61.2.1 The FKM Guideline: Rechnerischer Festigkeitsnachweis für Maschinenbauteile .......854
61.2.2 Usefulness of the service life calculation .....................................................................855
61.3 Implementation in KISSsoft..................................................................................................857
61.3.1 Main screen .................................................................................................................857
61.3.2 Stress cases ................................................................................................................859
61.3.3 S-N curve (Woehler lines) ...........................................................................................860
61.3.4 Number of load cycles .................................................................................................860
61.3.5 Temperature ................................................................................................................860
61.3.6 Temperature duration ..................................................................................................860
61.3.7 Protective layer thickness, Aluminum, section 4.3.4, Figure 4.3.4 ..............................860
61.3.8 Stress ratios.................................................................................................................860
61.3.9 Spectra ........................................................................................................................861
61.3.10 Surface factor KV, section 4.3.3, Table 4.3.7 ............................................................862
61.4 Materials ..............................................................................................................................862
61.4.1 Surface roughness ......................................................................................................862
61.5 Settings ................................................................................................................................863
61.5.1 General settings ..........................................................................................................863
61.5.2 Required safeties.........................................................................................................865
61.6 Estimation of the endurance limit for surface-treated parts (section 5.5).............................866
62 Hertzian Pressure ................................................................... 868
62.1 Settings ................................................................................................................................870
63 Hardness Conversion ............................................................. 871
64 Linear Drive Train ................................................................... 873
64.1 Calculation ...........................................................................................................................874
64.2 Sizings .................................................................................................................................878
64.3 Settings ................................................................................................................................879
64.4 Materials ..............................................................................................................................879
65 Deformation of the Gear Body ................................................ 881
65.1 Calculation procedure ..........................................................................................................881
65.2 Results .................................................................................................................................882
66 Plastics Manager .................................................................... 883
66.1 Gear test results...................................................................................................................884
66.1.1 Case I, test results for unchanged test gears ..............................................................884
66.1.2 Case II. Test results with different gear geometry .......................................................885
66.2 Additional settings in the "Test data" tab .............................................................................885
66.3 Module specific settings .......................................................................................................887
66.4 Extrapolation of the calculated permissible root and/or flank stresses ................................888
66.5 Other calculation options .....................................................................................................889
66.6 Writing material data to the KISSsoft database ...................................................................889
66.7 Graphics...............................................................................................................................889
66.8 Importing material files from M-Base ...................................................................................890
X KISSsys ............................................................. 891
67 KISSsys: Calculation Systems ................................................ 892
67.1 General ................................................................................................................................892
67.1.1 Structure of KISSsys ...................................................................................................892
67.1.2 Ways in which KISSsys can be used ..........................................................................892
67.1.3 The user interface........................................................................................................893
67.2 Creating Models in KISSsys ................................................................................................897
67.2.1 Classic method ............................................................................................................897
67.2.2 Element Assistant ........................................................................................................897
67.2.3 System Assistant .........................................................................................................897
67.2.4 Setup with icon ............................................................................................................898
67.2.5 Creating and modifying tables .....................................................................................898
67.2.6 Adding variables to tables ...........................................................................................898
67.2.7 Individual names for elements .....................................................................................899
67.3 Extended functionality for developers ..................................................................................900
67.3.1 Properties dialog..........................................................................................................900
67.3.2 Table view ...................................................................................................................902
67.4 The following elements are available ...................................................................................903
67.4.1 Variables......................................................................................................................903
67.4.2 Calculation elements ...................................................................................................904
67.4.3 Elements for shafts ......................................................................................................906
67.4.4 Connection elements ...................................................................................................906
67.4.5 Displaying elements in a 3D graphic ...........................................................................908
67.4.6 System settings ...........................................................................................................908
67.5 Programming in the Interpreter ............................................................................................908
67.5.1 Expressions in variables ..............................................................................................908
67.5.2 Functions .....................................................................................................................910
67.5.3 Important service functions..........................................................................................913
67.5.4 Variable dialogs ...........................................................................................................913
67.5.5 Defining 2D graphics ...................................................................................................922
67.6 Specific functions .................................................................................................................925
67.6.1 Load spectrum calculation ...........................................................................................925
67.6.2 Efficiency Calculation ..................................................................................................926
67.6.3 Taking into account housing deformation in static KISSsys calculations ....................926
67.6.4 Modal analysis of shaft systems ..................................................................................929
67.6.5 Campbell diagram for shaft systems ...........................................................................930
67.6.6 Analysis of unbalance response of shaft systems .......................................................931
XI Bibliography and Index ..................................... 933
68 Bibliography ............................................................................ 934
I
General
Chapter 1 - 12
I Installing KISSsoft 45
1 Installing KISSsoft
1.1 Basic installation
After you have inserted the KISSsoft CD in the appropriate disk drive, the setup program starts
automatically. If it does not, you can run the setup.exe file directly in the CD root directory by double-
clicking on it.
The setup program guides you through the installation process step by step. All you need to do is
select an installation folder and the required language for the installation. If you change the default
installation folder, it is advisable to include the version descriptor as part of the directory name of the
new installation folder (e.g. C:/Programs/KISSsoft xx-20xx).
At the end of installation, we recommend that you install the latest Service Pack (patch). Download
the latest patch from our website. You can choose between an installation program (.exe) and zipped
files (.zip). The installation program automatically copies the necessary files after you specify which
installation folder it is to use. However, not all companies permit .exe files to be downloaded. If not,
you must unpack the ZIP file and manually copy the files it contains into your installation folder. Any
files that are already present must be overwritten by the ones contained in the patch.
Once you have installed KISSsoft, you will need a license for it (see chapter 1.3, Licensing). If
KISSsoft is not licensed, it will only run as a demo version.
► Note:
If you are installing KISSsoft on a server, we recommend that you perform the installation from a
client (workstation computer). This means that all the necessary directory entries will automatically
be added to the KISS.ini file (see chapter 2.6.1, Definitions in [PATH]) correctly. Otherwise, you will
have to change these directory entries from the local drive name (e.g. C:/...) to the appropriate share
name in the network, later, manually, using an editor.
1.2 Downloading a license file
1. Go to our website www.KISSsoft.ch and open the Service/Support page. There, you will find a
link to the "customer zone". Click on the link. You will see the Customer Zone web page. In that
page, on the top right-hand side, enter your license number in the License Number field, and
click on "Open".
2. A login window will open, in which you enter your license number, and also your download
password, again. If you do not have this password, please get in touch with your commercial
I Installing KISSsoft 46
contact representative or contact KISSsoft directly by email at [email protected] or on phone
number +41 55 254 20 53.
3. You are now in your personal download area. Save the lizenzxxxx.lic file in your KISSsoft
installation's license directory.
► Note:
It may be that your personal download area contains license files for different versions of KISSsoft.
Please make sure you select the correct license file for the system version you have just installed.
1.3 Licensing
After you have completed the KISSsoft installation (see chapter 1.1, Basic installation), you must
license the software either by downloading a license file or activating the program's license. Please
read the relevant section for your license type.
1.3.1 Test version
1. If you run KISSsoft from the client (workstation computer), the user account for the test version
will become active.
2. Select License tool in the Extras menu, and then click on the Activate license tab.
3. Activating the license online: If your computer has Internet access, and you have received an
online code from us, enter this code under the Activate Test or Student version option and
then click on the Activate license tab.
4. Activating the license directly: Under the Activate test version by phone option, you see a
question code. Call the telephone number you see there and tell us this code. We will then give
you the appropriate answer code. Input this in the appropriate field, and then click on the
Activate license tab.
1.3.2 Student version
1. Copy your license file (which you will usually be given by the place you are studying for your
qualification) to your License directory (see chapter 2.6.2, Definitions in [SETUP]).
2. Select License tool in the Extras menu, and then click on the Activate license tab.
3. To input your online code (which you will usually be given by the place you are studying for your
qualification), select the Activate test or student version (online code required) option and
then click on Activate license.
I Installing KISSsoft 47
1.3.3 Single user version with dongle (protection key)
1. Copy your license file (see chapter 1.2, Downloading a license file) to your License directory
(see chapter 2.6.2, Definitions in [SETUP]))
2. Now, simply plug in the dongle supplied with the system.
► Note
The single user version of KISSsoft can also be installed on a central server. Local clients
(workstation computers) can then run the software directly from this server. Please note that, in this
case, the dongle must always be plugged into the particular client on which you want to use
KISSsoft.
1.3.4 Single user version with license code
1. Start KISSsoft from the client (workstation computer) for which the software is to be licensed.
2. Select License tool in the Extras menu, and then click on the Activate license tab.
3. Enter your contact data under the Request license file option and click on Send to send your
computer-specific access data directly to us. Alternatively, you can first save this access data in
a file and then send us this file by email.
4. You will receive an email as soon as we have created your license file.
5. Download your License file (see chapter 1.2, Downloading a license file) and copy it to your
License directory (see chapter 2.6.2, Definitions in [SETUP]).
1.3.5 Network version with dongle (protection key)
For the network version with dongle a server program has to be installed in addition to the licensing
of the KISSsoft installation.
1.3.5.1 Installation on the server
1. Copy the KISSsoft dongle/MxNet installation directory onto a server.
2. Start MxNet32 on the server. You will see a dongle icon in the task bar.
3. Double-click this icon to start the user interface.
4. Now enter Application: KISSsoft and any file with the file extension .mx as the server file. The
clients must have both read and write access to this file. Now click New Entry to add this entry.
5. Then click the Active Users button to check who is using KISSsoft. You can also reactivate a
license that has already been used.
I Installing KISSsoft 48
1.3.5.2 Licensing the KISSsoft system
1. Copy your license file (see chapter 1.2, Downloading a license file) to your License directory
(see chapter 2.6.2, Definitions in [SETUP]).
2. Complete the necessary details in the "ServerFile: serverfilepath" line after the checksum line in
the license file. The "serverfilepath" is the path to the server file that is defined in the server
program.
► Note
The KISSsoft installation will also run if the client is not connected to the network and if the dongle is
inserted in the client instead of in the server. You can also "check out" the license if you remove the
dongle.
1.3.6 Network version with a license code
1. Start KISSsoft from a client (workstation computer).
2. Select License tool in the Extras menu and go to the General tab.
3. Select an access directory on a server. Please note: If you change this, you will need a new
license.
4. Open the Activate license tab.
5. Enter your contact data under the Request license file option and click on Send to send your
computer-specific access data directly to us. Alternatively, you can first save this access data in
a file and then send us this file by email.
6. You will receive an email as soon as we have created your license file.
7. Download your License file (see chapter 1.2, Downloading a license file) and copy it to your
License directory (see chapter 2.6.1, Definitions in [PATH]).
I Setting Up KISSsoft 49
2 Setting Up KISSsoft
2.1 Directory structure
If there are several users, it is advisable to store shared data (databases, user-defined report
templates and standard files) on a server. This ensures that, if there are changes and upgrades, all
users will be able to work with one uniform set of data. To set this up, put the UDB, EXT and
TEMPLATE directories on a server that can be accessed by all users, and then set the
corresponding variables, UDBDIR, EXTDIR and TEMPLATEDIR, in the KISS.ini (see chapter 2.6.1,
Definitions in [PATH]) file.
In contrast, if there are several users, the temporary directories should be defined locally on their
workstations. Otherwise, the interim results generated for individual users might overwrite each
other. For each installation, KISSsoft uses the temporary user directory set in the operating system.
The CADDIR and TEMPDIR variables can, however, be tailored in the KISS.ini (see chapter 2.6.1,
Definitions in [PATH]) file.
If you want to open or save a calculation file or report, KISSsoft displays your own personal user
directory as the first choice storage location. This saves you frequent searches in the directories on
your system. You can define this user directory via the USERDIR variable in the KISS.ini (see
chapter 2.6.1, Definitions in [PATH]) file. The user directory will be ignored if you have selected an
Active working project (see chapter 6.3, The active working project). In this case, KISSsoft offers you
the project directory as the first choice storage location.
2.2 Language settings
KISSsoft is available in eight languages: English, Chinese, French, German, Italian, Portuguese,
Russian and Spanish. When you select a language, the program differentiates between the language
used for the user interface and the language used for the reports. This makes it possible to operate
KISSsoft in one language and simultaneously display reports in a different language. Messages will
be displayed either in the same language as the user interface or as the reports.
In the program, select Extras > Language to change between the languages available in your
licence. To make global language settings, you need to edit the KISS.ini (see chapter 2.6.2,
Definitions in [SETUP]) file. The user can change the language used for reports by selecting Report
> Settings.
I Setting Up KISSsoft 50
2.3 Systems of units
KISSsoft recognizes two systems of units: the metric system and the US Customary Units system.
For global settings, you need to edit the KISS.ini (see chapter 2.6.2, Definitions in [SETUP]) file. You
can also quickly toggle between systems of units in the program by selecting Extras > System of
units. In addition to changing the system of units, it is possible to switch the unit used for a particular
value input field (see chapter 5.2.1, Value input fields).
2.4 Defining your own template files
Anyone who frequently carries out the same, or at least similar, calculations has to repeatedly select
or enter the same values in selection lists and value input fields. Thanks to template files, KISSsoft
makes it much easier to do this. For each calculation module, there is an internal default setting for
all values. If, however, you have defined your own template file, this template file will be used when
you open a calculation module or load a new file.
To define a template file, you open a new file in the appropriate calculation module and enter your
default settings. Click on File > Save as template to transfer your values to the template file. All
template files will be saved in the directory that has been defined as TEMPLATEDIR (see chapter
2.6.1, Definitions in [PATH]).
Project-specific template files can also be created. To define special standards for a project (see
chapter 6, Project Management), select this project in the Project Tree (see chapter 4.2.2, The
project tree) and open its properties by selecting Project > Properties. There, select Use own
templates for this project and specify a directory for the template files. To define the template files,
first select this project as the active working project (see chapter 6.3, The active working project).
2.5 Rights
You can restrict the rights for selected areas of KISSsoft for some users.
Right Implementation
Change general settings Write-protect the KISS.ini: (see chapter 2.6, Global
settings - KISS.ini) file
Change or add data to databases Write-protect databases (files of the type .udb), and the
DAT and EXT/DAT directories (write rights for UDBDIR
(see chapter 2.6.1, Definitions in [PATH]) should be
retained).
Change report templates Write protect RPT, EXT/RPT and EXT/RPU directories
Change template files Write protect the TEMPLATE directory
I Setting Up KISSsoft 51
2.6 Global settings - KISS.ini
Global settings for KISSsoft are defined in the KISS.ini file, which is located directly in the installation
folder. Most of these settings can also be defined directly in the software and are then saved to the
KISS.ini file.
2.6.1 Definitions in [PATH]
Variable name Description Note
KISSDIR=<INIDIR> The KISSsoft installation folder
path is generally defined with the
INIDIR variable.
HELPDIR Directory for user manual and
help figures
DATADIR Directory for .dat files Attention: You should not carry out any
upgrades or make any changes in this
directory. Save your own files in the DAT
subdirectory in the EXTDIR directory.
RPTDIR Directory for report templates Attention: You should not carry out any
(*.rpt) upgrades or make any changes in this
directory. Save your own files in the RPT
subdirectory in the EXTDIR directory.
USERDIR Default directory for opening and
saving
<CADDIR> Default directory for CAD export Should be located locally on a
workstation.
%TEMP% sets the temporary directory to
the operating system default.
TMPDIR Directory for temporary files Should be located locally on a
workstation.
%TEMP% sets the temporary directory to
the operating system default.
UDBDIR Directory for user-defined If several users are using the system, we
databases (*.udb) recommend you store the databases on a
server to ensure data uniformity if there
are changes and upgrades.
KDBDIR Directory for KISSsoft's KISSsoft datasets containing data that
databases (*.kdb) cannot be modified.
I Setting Up KISSsoft 52
EXTDIR Directory for user-defined report If there are several users, it is advisable to
templates and additional DAT store this directory on a server.
files
TEMPLATEDIR Directory for template files If there are several users, it is advisable to
(STANDARD.*). store this directory on a server.
LICDIR Directory for the license files You can install this directory on a server
so that all users can access the new
license files.
2.1 table: Table of variables used in the PATH environment
► Note
You should have write permission for the directories set in these variables: TMPDIR, CADDIR,
USRDIR and UDBDIR.
Depending on in the configuration, you might not have write permission in these directories: C:\
Program files\ KISSsoft directory name or C:\ Programs\ KISSsoft directory name. Any files you
create are then diverted to the operating system's internal directories. In this case, select directories
with write permission.
The UDBDIR, TMPDIR, CADDIR, USERDIR and EXTDIR directories can also be defined in the
"Directories" tab, in the "Program settings" dialog (Extras > Settings).
You can also use JAVADIR to define the path to the java.exe here. You need this file if you want to
use Code_Aster (FEM) to calculate the deformation of planet carriers due to torsion.
2.6.2 Definitions in [SETUP]
Variable name Description Values
USCUSTOMARYUNITS Sets the system of units 0: metric, 1: US customary
units
MATERIALSSTANDARD Specifies the standard 0: DIN, 1: BS, 2: AISI, 3:
according to which the UNI, 4: AFNOR, 5: JIS, 6:
materials are defined CN
(configuration tool)
REPORTLANGUAGE Sets the language in which 0: German, 1: English, 2:
reports are displayed French, 3: Italian, 4:
Spanish, 5: Russian, 6:
Portuguese, 7: Chinese,
11: English with US
Customary Units
SHOWCALCTIME Displays the amount of time 0: No, 1: Yes
taken to perform a calculation
I Setting Up KISSsoft 53
SHOWPROGRESSBAR Shows the progress bar for 0: No, 1: Yes
time-intensive calculations
DISPLAYLANGUAGE Sets the language in which the 0: German, 1: English, 2:
user interface is displayed French, 3: Italian, 4:
Spanish, 5: Russian, 6:
Portuguese, 7: Chinese
DISPLAYFONTSIZE Sets the font size in KISSsoft 0: System size or else the
(FONT) direct font size
MESSAGESINREPORTLANGUAGE Sets the language in which 0: as interface, 1: as
messages are displayed reports
MESSAGESSHOWSTATE Defines which messages are to 0: all, 1: Information only in
be displayed in a message box. message window, 2:
Information and warnings
only in message window
EDITOR Path to the external editor
USEEXTERNALEDITOR Defines whether the external 0: No, 1: Yes
editor is to be used.
DATEFORMAT Date format, e.g.
DD.MM.YYYY
TIMEFORMAT Time format, e.g. hh.mm.ss
ENABLENETWORKING Defines whether the 0: No, 1: Yes
network/Internet can be
accessed (for example, to
display product news).
CHECKFORUPDATES Defines whether the system is 0: No, 1: Yes
to search for updates when the
program starts.
USETEMPORARYDATABASE Defines whether the databases 0: No, 1: Yes
are to be copied to a temporary
directory when the program
starts
RECENTFILESCOUNT Set number of most recently
used files in the File menu
displayed.
FORCEEXCLUSIVEOPEN Defines whether files can only 0: No, 1: Yes
be opened exclusively.
CALCONOPEN Defines whether calculations 0: No, 1: Yes, 2: no if
are to be performed on a file KISSsoft is started from
immediately, when it is loaded. KISSsys, otherwise yes
I Setting Up KISSsoft 54
CALCINTERFACEOUT Defines whether temporary 0: No, 1: Yes
reports for manufacturing data
are to be written during a
calculation.
ENABLEUSERSETTINGS Defines whether the settings in 0: No, 1: Yes
kiss.ini can be overwritten by
local settings.
USEFILEEXPLORER Defines whether the Explorer is 0: No, 1: Yes
to be displayed in the "View"
menu list. This process will
slow down KISSsoft
considerably.
USEHIGHDPIICONS Use scaled icons for high- 0: No, 1: Yes
resolution screens.
2.2 table: Table of variables used in the SETUP environment
2.6.3 Definitions in [REPORT]
Variable name Description
SIZE A number, 0-9, that specifies the scope of the report.
INCLUDEWARNINGS 0/1: Warnings are contained in the report
FONTSIZE Number that sets the font size in the report.
PAPERFORMAT Paper format: A3, A4, A5, Letter, Legal
PAPERORIENTATION 0/1: Portrait/Landscape
PAPERMARGINLEFT Distance from the left-hand page margin [mm].
PAPERMARGINRIGHT Distance from the right-hand page margin [mm].
PAPERMARGINTOP Distance from the top page margin [mm].
PAPERMARGINBOTTOM Distance from the bottom page margin [mm].
COMPARE 0/1: Adds date/time to the report in comparison mode.
SAVEFORMAT 0-4: RTF, PDF, DOC, DOCX, TXT
LOGO Sets the picture file displayed in the header and footer.
HEADER Contains the header usage definition.
USEHEADERFORALLPAGES 0/1: header only on first page/on all pages
FOOTER Contains the footer usage definition.
USEFOOTERFORALLPAGES 0/1: footer only on first page/on all pages
I Setting Up KISSsoft 55
0: Reports can be edited and saved as editable text
documents
READONLY
1: Reports cannot be edited and can only be exported as PDF
documents
0: The zoom factor is reset to 100% when you open a new
report.
KEEPZOOMFACTOR
1: The zoom factor is retained when you open a new report.
0: The scroll position is reset when you open a new report.
KEEPSCROLLPOSITION
1: The scroll position is retained when you open a new report.
false: When you open a file with KISSedit, it is displayed in full
screen mode.
SPLITONOPEN
true: When you open a file with KISSedit, it is displayed in split
view.
Table 2.3: Table of variables used in the REPORT environment
2.6.4 Definitions in [GRAPHICS]
Variable name Description
BACKGROUND 0: black, 15: white (for more information, see Graphics > Settings)
2.4 table: Table of variables used in the GRAPHICS environment
2.6.5 Definitions in [LICENSE]
Variable name Description
LOGGING Number used to configure the logging of license usage.
0: no log file
1: Log in, Log out, No license, Used and Missing rights
2: Log in, Log out, No license
3: Log in, Log out, No license, Missing rights
In network versions, the user's uptime is also displayed in minutes when
they log out.
LICENSELOGFILE .log file for generating reports of license usage.
I Setting Up KISSsoft 56
TIMEOUT Time [min] until an unused floating license is activated on the network
again.
2.5 table: Table of variables used in the LICENSE environment
2.6.6 Definitions in [CADEXPORT]
Variable name Description
USEDXFHEADER 0/1: Use DXF header for DXF export.
DXFVERSION 0/1: Version 12/15
INPUTLAYER Name of the layer for import.
OUTPUTLAYER Name of the layer for export.
DXFPOLYLINE 0/1/2: Use polygonal course, lines or points for the export.
2.6 table: Table of variables used in the CADEXPORT environment
2.6.7 Definitions in [INTERFACES]
Variable name Description
DEFAULT Name of the CAD system:
Solid Edge
SolidWorks
Inventor
CATIA
Creo
HiCAD
GEAREXPORT3D Displays the CAD system name in lists (see DEFAULT).
SYMMETRIC 0/1: Full tooth space/half tooth space mirrored (symmetrical)
(default = 0)
SAVEFILENAME 0/1: Saves the entire file contents/Saves only the file name and
the path.
(Default = 1)
MESSAGECADVERSION 0/1: You see a message/no message if the CAD version is no
longer supported by the interface.
(Default = 1)
2.7 table: Table of variables used in the INTERFACES environment
I Setting Up KISSsoft 57
2.6.8 Definitions in [SOLIDEDGE]
Variable name Description
LIBRARY Interface dll (kSoftSolidEdge.dll) directory
SIMPLIFIEDPRESENTATION 0/1: Set the variable to 1 to also generate a simplified gear
SMARTPATTERN 0/1: Fastpattern/Smartpattern
APPROXIMATION 1/2/3/4: Polygonal course (supported)/Arcs of circle
(supported)/Quadratic splines (supported)/Cubic splines
(default)
USERPARTTEMPLATE Template file directory (e.g. C:\Template\metric.par) or just the
template file name (e.g. metric.par): the path is then taken from
the settings in Solid Edge
Table 2.8: Table of variables used in the SOLIDEDGE environment
2.6.9 Definitions in [SOLIDWORKS]
Variable name Description
LIBRARY Interface dll (kSoftSolidWorks.dll) directory
SIMPLIFIEDPRESENTATIONNAME Setting this variable generates a simplified gear with this
name
APPROXIMATION 1/2/3/4: Polygonal course (supported)/Arcs of circle
(supported)/Quadratic splines (supported)/Cubic splines
(default)
2.9 table: Table of variables used in the SOLIDWORKS environment
2.6.10 Definitions in [INVENTOR]
Variable name Description
LIBRARY Interface dll (kSoftInventor.dll) directory
APPROXIMATION 1/2/3/4: Polygonal course (supported)/Arcs of circle
(supported)/Quadratic splines (supported)/Cubic splines
(default)
2.10 table: Table of variables used in the INVENTOR environment
2.6.11 Definitions in [CATIA]
Variable name Description
LIBRARY Interface dll (kSoftCatia.dll) directory
I Setting Up KISSsoft 58
LIBRARYSWMS Directory containing the interface manufacturer's .dll file
LANGUAGEFILE Directory containing the interface manufacturer's .ini file
DEBUG Interface manufacturer's variable
DEBUGPATH Interface manufacturer's variable
HELPFILE Interface manufacturer's variable
LASTSETTING_CONSTRUCTION Interface manufacturer's variable
LASTSETTING_GEARNAME Interface manufacturer's variable
LASTSETTING_PRODUCTIONINFO Interface manufacturer's variable
LASTSETTING_CALCINFO Interface manufacturer's variable
LASTSETTING_FLAGINFO Interface manufacturer's variable
APPROXIMATION 1/2/3/4: Polygonal course (not supported)/Arcs of circle
(not supported)/Quadratic splines (default)/Cubic splines
(not supported)
2.11 table: Table of variables used in the CATIA environment
2.6.12 Definitions in [PROENGINEER]
The ProEngineer interface has an individual subsection/menu for each version (for example, Wildfire
5, 32bit). However, the definitions in "kiss.ini" are the same in every 3D interface to Creo Parametric
(ProEngineer) chapters.
Variable name Description
LIBRARY Interface dll directory (kSoftProEngineer.dll)
INTERFACECOMMAND Directory containing the interface manufacturer's .exe file
USCUSTOMARYUNITS 0/1: System of units used in the metric or US Customary Units model
APPROXIMATION 1/2/3/4: Polygonal course (not supported)/Arcs of circle
(default)/Quadratic splines (not supported)/Cubic splines (not
supported)
2.12 table: Table of variables used in the PROENGINEER environment
2.6.13 Definitions in [HICAD]
Variable name Description
LIBRARY Interface dll directory (kSoftHiCAD.dll)
I Setting Up KISSsoft 59
APPROXIMATION 1/2/3/4: Polygonal course (not supported)/Arcs of circle
(default)/Quadratic splines (not supported)/Cubic splines (not
supported)
2.13 table: Table of variables used in the HICAD environment
2.6.14 Definitions in [VIDEOENCODING]
Variable name Description Values
Specifies the video codec which is to be used
to encode videos.
0: H.264, 1: H.265
CODEC
(default = 0)
Not all operating systems support all possible
values.
Specifies whether hardware video encoding is 0: No, 1: Yes (default =
HARDWAREENCODING
to be used, if available. 1)
0: CBR (fixed bitrate)
1: Unconstrained VBR
(variable bitrate without
maximum)
Specifies the encoding mode. In some
circumstances, a different mode will be used if 2: Constrained VBR
MODE the hardware, operating system or selected (variable bitrate with
codec do not support the initially selected maximum)
mode.
3: Quality level (target
quality, without
specifying the bitrate)
(Default = 3)
0: Use the current width
of the graphic in the
Specifies the video width. The width can be
Graphics window
either defined automatically or fixed.
WIDTH
1-32767: Use this width
However, very small or very large values may
(in pixels)
cause the video recording to fail.
(Default = 0)
Specifies the video height. The height can be
0: Use the current
either defined automatically or fixed.
height of the graphic in
HEIGHT
the Graphics window
However, very small or very large values may
cause the video recording to fail.
I Setting Up KISSsoft 60
Variable name Description Values
1-32767: Use this height
(in pixels)
(Default = 0)
Specifies the quality level to be used if
MODE=3 is set.
0-51: The quality level
QUALITY #
to be used (default = 24)
Not all codecs or operating systems support
all possible values.
The video's target bitrate in bit/s.
0: The bitrate is
If MODE=0, this specifies the video's constant calculated automatically
bitrate. using the Kush gauge
AVGBITRATE
If MODE=1/2, this specifies the video's Other values: The
average bitrate. bitrate to be used
However, very small or very large values may (Default = 0)
cause the video recording to fail.
The video's maximum bitrate in bit/s, if
MODE=2. 0: The bitrate is
calculated automatically
MAXBITRATE This value should be greater than using the Kush gauge
AVGBITRATE. However, very small or very Other values: The
large values may cause the video recording to bitrate to be used
fail.
Specifies the number of images per second in
the recorded video.
Recommended values:
FPS
30 or 60 (default = 30)
However, very small or very large values may
cause the video recording to fail.
2.7 User-defined settings
User-defined settings can be reset via Extras > Configuration tool.
2.7.1 Configuration tool
In the General tab, you can select the older version's "kdb" database directory (prior to 03-2017.
After that, it is called "udb".) by selecting the Update database option. Click "Run" to transfer the
I Setting Up KISSsoft 61
datasets you defined yourself in the older version to the current version, to ensure these datasets are
available in the current version.
Click Update external data to select the older version's "ext" directory. This then automatically
copies the "dat", "rpt" and "rpu" subdirectories to the current release.
Click Update settings to transfer your personal settings from the previous version to the current
release.
Select Connect file extensions to link all the KISSsoft files with the current version so that you can
double-click on any file to open it in the current release.
Figure 2.1: General tab in the Configuration tool window
In the Materials tab, you can specify the standard with which the material descriptions in the
database are to comply.
I Setting Up KISSsoft 62
Figure 2.2: Materials tab in the Configuration tool window
In the Settings tab, you can delete the user-defined settings (divided into groups). This reloads the
default values.
I Setting Up KISSsoft 63
Figure 2.3: Settings tab in the Configuration tool window
2.8 Rules
Rules are used to ensure that in-house guidelines for the ranges of validity of parameters are applied
and complied with. This typically concerns the maximum and minimum limits of input values,
calculated values and the relationships between these values i.e. length/width ratios, length/diameter
relationships or even the relationship between the module and the center distance.
These rules are defined by being stored in a module.rls file, where module stands for the calculation
module's in-house label, e.g. Z012 for cylindrical gear pairs.
These rules are subdivided into those that must be fulfilled before the calculation is performed and
those that must be checked afterwards. If a rule is infringed, the appropriate messages can be
displayed. In the case of rules that must be checked before the calculation, variables can also be set
to constant or calculated values.
The following statements are possible:
I Setting Up KISSsoft 64
precalc: marks the beginning of the rules that must be checked before a calculation is performed.
postcalc: marks the beginning of the rules that must be checked after a calculation.
assert(Condition): The condition is ensured. In this case, the condition usually represents a
comparison in which both the right-hand and left-hand side of the comparison can also be calculated.
action msg Message: If the condition of the previous assert has not been fulfilled, the message is
output. Here the message can include variables, in the same way as report templates.
action set Assignment: If the condition of the previous assert has not been fulfilled, the assignment
is performed. The assigned value can be a constant, or can be calculated from variables, in the same
way as for the report templates.
Defining an assignment is only really useful in the precalc section because changing the contents of
variables after the calculation merely leads to inconsistent results and has no other effects.
Here is an example file for a helical gear calculation:
precalc
assert (ZR[0].x.nul < 1)
action msg "Profilverschiebung Rad 1 zu gross, Ist {ZR[0].x.nul}, Maximum
1. Wird auf 1 gesetzt."
action set ZR[0].x.nul = 1
assert (ZR[1].x.nul < 1)
action msg "Profilverschiebung Rad 2 zu gross, Ist {ZR[1].x.nul}, Maximum
1. Wird auf 1 gesetzt."
action set ZR[1].x.nul = 1
postcalc
assert ((ZP[0].a/ZS.Geo.mn) < 200)
action msg "Center distance too big for module (a={ZP[0].a}, mn={ZS.Geo.mn},
a/mn={ZP[0].a/ZS.Geo.mn})."
Explanations:
The "precalc" statement opens the section of the rules that must be executed before the calculation.
The first "assert" statement checks whether the nominal profile shift of gear 1 is less than 1.0.
I Setting Up KISSsoft 65
If this "assert" is not fulfilled, the "action msg" statement outputs the message that the profile shift is
too big, displays the current value and tells you that the profile shift has been set to 1.0.
The "action set" then sets the profile shift to 1.0.
The second "assert" statement checks the same values for gear 2.
The "postcalc" statement signifies the end of the set of rules to be executed before the calculation
and opens the section containing the rules that are to be checked after the calculation. The example
shows a definition of an "assert" statement. This checks the ratio between the center distance to the
module. If the rule is infringed, the "action msg" statement triggers a message to the user. However,
there is no point in changing one of these two values after the calculation, and this is why the "action
set" statement is not present here.
Permitted operators and functions in the formulae (see chapter 8.5.3.3, Calculation variables).
The file containing the rules is stored in the template directory (TEMPLATEDIR, usually the
"template" (see chapter 2.1, Directory structure) subdirectory). As the template directory can also be
project-specific, you can also define project-specific rules.
I Running KISSsoft 66
3 Running KISSsoft
3.1 Start parameters
You can run KISSsoft from the input prompt with the following start parameters:
Parameter Description
INI=directory The KISS.ini (see chapter 2.6, Global settings - KISS.ini) file will be
loaded from the specified location. You can transfer a file name, with
its directory path, or only a directory name.
START=module The specified calculation module will be started. The module
descriptor is, for example, M040 for bolt calculation or Z012 for
cylindrical gear pair calculation.
LOAD=file name The calculation module belonging to the file is started and the file is
loaded. If the supplied file name does not include a path, the system
looks for the file in the User directory (see chapter 2.6.1, Definitions
in [PATH]).
LANGUAGE=number KISSsoft starts with the language specified for the interface and
reports. (0: German, 1: English, 2: French, 3: Italian, 4: Spanish, 5:
Russian, 6: Portuguese, 7: Chinese, 11: English with US Customary
Units)
DEBUG=file name A log file containing debug information will be written. It can be very
helpful for error-tracking. It is advisable to define the file name with a
complete path, so that you can find the log file easily later.
File name The calculation module belonging to the file is started and the file is
loaded. This also provides a way to associate KISSsoft with the
appropriate file name extensions in Windows.
3.2 Disconnect license from the network
If KISSsoft has not been properly shut down, users may remain registered if a network version is in
use. This may lead to licenses being blocked even though some users are no longer working with
KISSsoft. You can disconnect a license from the network by selecting the required license (the user
and start time are also displayed). To do so, select the Extras > License tool option in the Network
tab. The system then also deletes the appropriate cookie file and activates the blocked license on the
network again.
I Running KISSsoft 67
Unused licenses will be activated after a certain time, as soon as the next user logs on. This time-
span can be predefined via the TIMEOUT (see chapter 2.6.5, Definitions in [LICENSE]) variable in
the KISS.ini (see chapter 2.6, Global settings - KISS.ini) file.
► Note
A user who has been disconnected from KISSsoft can no longer carry out calculations in the current
session. The user must restart KISSsoft. However, they can still save data.
I Elements of the KISSsoft User Interface 68
4 Elements of the KISSsoft User Interface
KISSsoft is a Windows-compliant software application. Regular Windows users will recognize user
interface elements, such as the menus and context menus, docking window, dialogs, tooltips and
status bar, from other applications. Because the internationally valid Windows Style Guides are
applied during development, Windows users will quickly become familiar with how to use KISSsoft.
Figure 4.1: KISSsoft's user interface
4.1 Menus, context menus and the tool bar
In the File main menu, you can open and save calculation files, and send them as e-mail
attachments, restore previous calculation stages, view file properties and exit KISSsoft. Click File >
Save as template to retain user-defined default values (see chapter 2.4, Defining your own template
files).
You can use the KISSsoft Project Management (see chapter 6, Project Management) functionality
from both the Project main menu and the Project Tree (see chapter 4.2.2, The project tree). You can
open, close and activate projects, insert files into a project, or delete them, and also view project
properties.
I Elements of the KISSsoft User Interface 69
Each individual docking window (see chapter 4.2, Docking window) in the user interface can be
hidden or displayed in the View main menu. If you are in the report or helptext viewer, select View >
Input window to return to the calculation module input dialog.
In the Calculation main menu, you can run the current calculation (see chapter 5, KISSsoft
Calculation Modules), add more calculations to the calculation module as default tabs or special tabs
and call subcalculations as dialogs. Select Calculation > Settings to change the Module specific
settings.
In the Report main menu you will find actions for generating and opening a report. The system
always generates a report for the current calculation. Click Report > Drawing data to display
drawing data (see chapter 8.3, Drawing data) for the element currently selected in the Report Viewer
(see chapter 4.4.1, Report Viewer). Click Report > Settings to change the report's font size, page
margins and scope. The options for saving, sending and printing are only active if a report is open.
You can open and close the Graphics window (see chapter 4.3, Graphics window) of a calculation
module in the Graphics main menu. Select 3D export to access KISSsoft's CAD interfaces. Select
Graphics > Settings to choose the CAD system into which you want to export the selected element.
In the Extras menu, you will find the license tool, the configuration tool and the database tool. In this
main menu, you can start the Windows calculator and change the language (see chapter 2.2,
Language settings) and system of units (see chapter 2.3, Systems of units). In Extras > Settings,
you can change general program settings such as the formats for time and date values.
In accordance with Windows conventions, at the end of the menu bar you will find the Help icon,
which you can use to navigate in the KISSsoft manual. In Help > Info you will find information on the
program version and on the support provided by KISSsoft.
In addition to the main menu, KISSsoft uses context menus in many locations. Context menus give
you access to actions for a particular area or element of the software. Normally, you click the right-
hand mouse button to display context menus.
The tool bar gives you faster access to actions from the menus that are used particularly frequently.
You should also read the tool tips: they display information about the actions in the tool bar and also
the more detailed explanations in the status bar (see chapter 4.5, Tooltips and status bar).
► Note
The Calculation, Report and Graphics main menus are only active if a calculation module is open.
The actions available in these menus may vary depending on the current calculation module.
4.2 Docking window
Beside the menu bar, tool bar and status bar, the docking windows are important elements in the
KISSsoft user interface. Docking windows are windows that can either be moved freely on the
I Elements of the KISSsoft User Interface 70
desktop, like a dialog, or can be docked on the program pages in any arrangement that suits you.
Several docking windows can be placed on top of each other and be displayed as tabs.
You can release a docking window by double-clicking in its title bar. To move a docking window, click
the left-hand mouse button in the title bar and move the mouse while holding down the mouse
button. If you move the mouse close to the edge of the main window, a new position for the docking
window will be displayed. Release the mouse button to position the docking window. Docking
windows can be displayed and hidden via the View (see chapter 4.1, Menus, context menus and the
tool bar)menu.
4.2.1 The module tree
The module tree shows all KISSsoft calculation modules in an easy to understand and logically
structured list. Any calculation modules for which you have not purchased a license are grayed out.
To open a module, double-click on it with the left mouse button. The current calculation module will
be shown in bold.
Figure 4.2: KISSsoft calculation modules
4.2.2 The project tree
The Project Tree gives you an overview of the open projects, and the files belonging to these
projects, and highlights the active working project (see chapter 6.3, The active working project) in
I Elements of the KISSsoft User Interface 71
bold. You use project management functions (see chapter 6, Project Management) via the Project
menu or from a context menu (see chapter 4.1, Menus, context menus and the tool bar).
4.2.3 The Results window
The KISSsoft results window displays the results of the last calculation.
Figure 4.3: The KISSsoft results window
4.2.4 The Messages window
The messages window displays all information messages, warnings and errors. Generally, all
additional messages are not only displayed, but also appear in a message box. You can change the
way information and warnings are displayed in a message box by selecting Extras > Settings.
4.2.5 The info window
The Info window displays information that is displayed when you click on an Info button (see chapter
5.2.1, Value input fields) in the calculation module. You zoom and print the information via a context
menu (see chapter 4.1, Menus, context menus and the tool bar).
4.2.6 Manual and Search
The manual's Table of Contents and search function are also available as docking windows. When
you select an entry, by double-clicking on it, the Helptext viewer (see chapter 4.4.2, Helptext Viewer)
opens and the relevant section in the manual is displayed.
I Elements of the KISSsoft User Interface 72
4.3 Graphics window
In KISSsoft, you can open as many graphics windows as you need at the same time and arrange
them in the same way as the other docking windows (see chapter 4.2, Docking window). This means
you can see all the graphics and diagrams you require for your calculations at a glance. To make
working with graphics more effective, you can use the tool bar (see chapter 4.3.1, Tool bar and
context menu), the Comment field, the context menu (see chapter 4.3.3, Context menu) and the
Properties (see chapter 4.3.4, Properties).
Figure 4.4: Components of the graphics window
4.3.1 Tool bar and context menu
Use the selection list in the tool bar to switch from one graphic to another in a group. You will also
see various icons for saving, printing and locking a graphic, as well as functions for highlighting and
graying out its properties.
Save graphic as
This saves the graphic as a DXF, IGES or other image or text format, with the name you enter here.
I Elements of the KISSsoft User Interface 73
Saving diagrams in a DXF file usually creates a conflict between the diagram axis units and the unit
used in the DXF file. For this reason, when you save a diagram, the program opens a dialog in which
you can specify the drawing area to which the diagram is to be projected, in the file.
Print graphic
Prints the current section of the graphic. The information underneath the graphic is defined by the
graph*.rpt report templates (see chapter 8.5).
Lock
This is useful for comparing two calculation results. In this way, you can, for example, generate a
Specific sliding graphic for a toothing scenario, lock this graphic and then, after having changed the
gear parameters, open a new graphics window that shows the new calculation results. The locked
window will no longer be updated.
(a) Locked window (b) Window with new calculation results
4.1 table: Figure: Locking graphics windows
When you lock a graphics window, a dialog will open, in which you can enter a title for the window,
which will make it easier for you when you are comparing different graphics.
I Elements of the KISSsoft User Interface 74
Figure 4.5: Dialog window for inputting the window title
Properties
This opens a list with the Properties (see chapter 4.3.4, Properties) of the current graphic in the same
window.
Video recording
Starts recording a video of the 3D graphic. All of the graphic's animations and movements are
recorded when video recording is enabled. Click again to stop recording. You can then either save or
delete the video file.
The size of the graphic cannot be changed while video recording is active.
4.3.2 Comment field
In the Comment information is displayed about the graphic. You can change the Comment to suit
your needs and it is included in the print output.
4.3.3 Context menu
Here, use the left-hand mouse button to select, move, zoom and measure elements in a graphic. You
can permanently select which action is to be performed in the context menu. You can access this
more quickly by using these combinations: Move: Shift, Zoom: Ctrl and Measure: You can select
multiple single items by pressing the Alt key while holding down the left-hand mouse button.
Other actions in the context menu are: Zoom In (plus), Zoom out (minus) and Fit window (Pos1 or
Home). Use the direction keys to move the current section of the graphic.
I Elements of the KISSsoft User Interface 75
4.3.4 Properties
In Properties, you can display or hide elements in a graphic and change its colors and line styles.
You can make different modifications, depending on the graphic: for diagrams and such like, you can
modify the value ranges and units to match the axes, or, for a meshing, you can change the center
distance.
Figure 4.6: Graphic properties
If the properties are displayed, you will see three other icons in the tool bar. You use them to store
curves in a graphic as text, or in the graphic itself.
Save curve as text
Stores the coordinates of the curve selected in Properties in a text file. This makes it
easy to transfer curves to, for example, an Excel file.
Save curve
Stores the curve selected in Properties in the graphic. This function is ideal for
comparing the graphical outputs of a calculation while you change its parameters.
I Elements of the KISSsoft User Interface 76
Delete memory
Deletes the curve from the memory.
Figure 4.7: Graphics with saved and different curves
4.3.5 Toothing
If you select Toothing, additional icons are displayed for generating the gear pair and creating the
flanks when you open the Geometry graphics window.
Rotate to the left
Generates the gear pair to the left.
Key combination: Ctrl + left direction key
Rotate to the right
Generates the gear pair to the right.
Key combination: Ctrl + right direction key
I Elements of the KISSsoft User Interface 77
Rotate one gear independently to the left
One gear remains static while the other is rotated to the left. The profiles overlap.
Key combination: Alt + left direction key
Rotate one gear independently to the right
One gear remains static while the other is rotated to the right. The profiles overlap.
Key combination: Alt + right direction key
Make flank contact left
The gears are rotated until the flanks of both gears touch on the left.
Make flank contact right
The gears are rotated until the flanks of both gears touch on the right.
► Note:
If you press and hold down a button, to rotate it, the gears rotate continuously (movie).
► Note:
Click Properties (see chapter 4.3.4, Properties) to specify the number of rotation steps for the
rotation. The number of rotation steps here refers to the pitch.
4.4 Main input area
The main input area shows a calculation module's input window. In addition, it is used to display the
internal report viewer or the internal help viewer.
I Elements of the KISSsoft User Interface 78
4.4.1 Report Viewer
When you generate a report in KISSsoft, the report viewer opens in the main input area, the entries
in the Report menu are activated and the report viewer tool bar is displayed. The report viewer is a
text editor that supports the usual functions for saving and printing a text file. In KISSsoft, you can
save reports in portable document format (.pdf), in Microsoft Word format (.doc) or as ANSII text
(.txt).
The report viewer's other functions are Undo/Redo, Copy, Cut and Paste, and Search, with the usual
shortcuts. You can zoom in on the view and edit the report later on by changing the font size, bold,
italics and underlining style. To change the general appearance of the report, select Report >
Settings.
4.4.2 Helptext Viewer
The KISSsoft manual is displayed in the Helptext viewer in HTML format. To open the manual, select
something in the Table of Contents or the Search function. If you press function key F1, the system
displays more information about where the cursor is currently located in KISSsoft.
4.5 Tooltips and status bar
Whenever it is useful, tool tips are provided in KISSsoft, to give you additional information about
program elements. Tooltips appear automatically if you slowly move the mouse over a program
element.
If you position the mouse over a particular menu option, the system will display detailed information
on all actions available in that menu, in the left-hand area of the Status bar. If the mouse is
positioned over a selection list, the currently selected list entry will be displayed in the status bar.
This is especially helpful if the display is restricted by the width of the selection list.
In the right-hand area of the status bar, the system will display the current status of the calculation.
The flag is set to CONSISTENT if the results are current. INCONSISTENT shows that a new
calculation needs to be carried out.
I KISSsoft Calculation Modules 79
5 KISSsoft Calculation Modules
5.1 Standard and special tabs
The input window for most calculation modules is subdivided into different tabs. This ensures that
inputs are separated logically. The system does not automatically display all the existing tabs for
more complex calculations, such as for a cylindrical gear pair. When you open a new calculation, you
only see the tabs that contain the absolutely necessary inputs (e.g. for a cylindrical gear pair this
would be the Basic data, Reference profile, Manufacturing and Tolerances tabs). In the
Calculation menu, you can add more tabs if needed (e.g. for a cylindrical gear pair, you would need
to add the Modifications tab if you wanted to modify the gears).
KISSsoft calculation modules use two types of tabs: Standard tabs and special tabs (see Figure 5.1).
Figure 5.1: Standard and special tabs
If a standard tab (e.g. Basic data) is active when the calculation is run, then the standard calculation
will be executed and the results of this standard calculation will be displayed in the Results window
(see chapter 4.2.3, The Results window). When a report is generated, the default report is created.
Special tabs are marked with the icon. If this type of special tab is active when the calculation is
run, then a special calculation will be executed in addition to the standard calculation, (e.g. for a
cylindrical gear pair, the calculation of the path of contact under load). The results of this additional
calculation will then be displayed in the Results window, and when you generate reports you will get
a report containing the results the additional calculation.
5.2 Input elements
All KISSsoft calculation modules use the same input elements for input. These input elements are
described in more detail in the sections that follow.
I KISSsoft Calculation Modules 80
5.2.1 Value input fields
In general, a value input field always includes the variable label, a formula character, the edit field
and a unit. If the edit field is grayed out, this variable cannot be predefined. Instead it will be
determined during the calculation. One or more of the following buttons can follow a value input field:
You can retain a value by selecting the Check button
You can set a radio button to specify which values in a group should be calculated and
which should be retained
Click the sizing button to calculate the value using calculation methods
Click the convert button to calculate the value using conversion formulae
Click the Plus button to display additional data for a value
Click the Info button to display information in the Info (see chapter 4.2.5, The info
window) window.
5.2.2 Formula entry and angle input
In some cases it is advisable to use a small auxiliary calculation to determine a value. Right-click in a
value input field's edit field (see chapter 5.2.1, Value input fields) to open a formula editor. In it, you
can enter a formula, which must be one of the four basic calculation types: +, -, * and /. Additionally,
you can use all the functions that are supported by the report generator (see Table 8.2). Confirm the
formula by pressing Enter. The system will evaluate the formula. The formula itself will be lost: if you
return to the formula entry dialog, the calculated value will be shown there instead of the formula.
In value input fields (see chapter 5.2.1, Value input fields) that display an angle, a dialog in which you
can input degrees, minutes and seconds will be displayed instead of the formula editor.
I KISSsoft Calculation Modules 81
5.2.3 Unit switch
In KISSsoft, you can switch all the units in the value input fields (see chapter 5.2.1, Value input fields)
and in the tables (see chapter 5.2.1, Value input fields). To do this, right-click on a unit. This opens a
context menu in which you see all the possible units for the value. If you select a different unit from
the one that is currently in use, KISSsoft converts the current value in the value input field to the new
unit.
To switch between metric and US customary units globally, select Extras > Systems of units.
5.2.4 Tables
In some modules, data is displayed or entered in a table. You select a row by double-clicking, just
like when you select a field for input. For tables, additional information is often displayed in a tooltip
(see chapter 4.5, Tooltips and status bar). In general, the following buttons come after tables so that
you can input data:
Click the Add button to add a row to the table.
Click the Remove button to delete the selected row from the table
Click the Clear button to delete all entries in the table
5.3 Calculating and generating a report
Click Run to perform the current calculation. In addition, the tool bar and the F5 function key give you
quick, convenient access to this action. Here, please note that a calculation module can have other
special calculations in addition to the standard calculation. These special calculations are only
executed if the appropriate special tab (see chapter 5.1, Standard and special tabs) is active.
Select Report > Generate to generate a report about the current calculation. Also note the
differentiation here between the default report and the reports about the special calculations in the
special tabs (see chapter 5.1, Standard and special tabs).
The status of a calculation is consistent if it could be performed without error. As soon as you change
data in the input window, the calculation becomes inconsistent, which means the results of the
calculation in the Results window and the graphics no longer match the data in the interface. The
I KISSsoft Calculation Modules 82
current status of the calculation is displayed in the status bar (see chapter 4.5, Tooltips and status
bar).
5.4 Messages
A calculation sends different types of messages to the input window: information, warnings and
errors. Information and warnings should always be taken note of to ensure accurate results. If an
error has occurred, the calculation is interrupted.
Normally, all the messages are displayed in a message box and in the Messages window (see
chapter 4.2.4, The Messages window). You can change the way information and warnings are
displayed in a message box by selecting Extras > Settings, and clicking on the Messages tab.
I Project Management 83
6 Project Management
KISSsoft has its own project management system, which you can use to organize your calculation
files and external files. The most important area in the project management system is the KISSsoft
Project Tree (see chapter 4.2.2, The project tree). In it, you can see which projects are currently open
or active, and you can see all the information about the files that belong to the individual projects.
Figure 6.1: The KISSsoft project tree
6.1 Generating, opening and closing projects
Select Project > New ... to create a new project. A dialog opens in which you enter the name of the
project, the project directory, descriptions and comments, and also the directory for the template files
(see chapter 2.4, Defining your own template files) that are to be used. The newly created project is
inserted into the Project Tree and defined as the Active working project (see chapter 5.2.3, Unit
switch).
If you open an existing project (Project > Open...) this will also be inserted into the project tree and
defined as the Active working project (see chapter 6.3, The active working project).
I Project Management 84
You close a project by selecting it and then selecting Project > Close. You will also find this action in
the context menu (see chapter 4.1, Menus, context menus and the tool bar) in the Project Tree. The
project will still be retained, and you can open it again at any time.
6.2 Adding and deleting files
Files can be added and deleted either via the Project properties (see chapter 6.5, Project properties)
or the context menu (see chapter 4.1, Menus, context menus and the tool bar). As well as calculation
files from KISSsoft, you can insert any external files in a project.
6.3 The active working project
The project tree shows all the open projects. It is not absolutely necessary to define an active
working project. If you have defined an active working project, it is highlighted in bold. You can also
set a project as an active working project by selecting Project > Set as working project or by
activating it via the context menu. If you select Project > Work without project, this deactivates the
active working project.
The current calculation file does not have to belong to the active working project.
6.4 Storage locations
Files that belong to a particular project do not have to be stored in that project's directory. This
means files can belong to several projects at the same time. However, if you have defined an active
working project (see chapter 6.3, The active working project), KISSsoft will prompt you with its project
directory as the first choice storage location whenever you want to open or save a calculation file or a
report. If you are working without a project, the system will display your personal user directory (see
chapter 2.6.1, Definitions in [PATH]) as a default storage location.
6.5 Project properties
To display the project properties for the selected project, either select Project > Properties, or use
the Project Tree's context menu (see chapter 4.1, Menus, context menus and the tool bar).
I Dynamic User Interface 85
7 Dynamic User Interface
The KISSsoft interface is defined by its editable text files (descriptive data). The elements it contains
are fixed components of the software. However, any user can decide how these elements are divided
up and arranged. Frequently used entries can be given priority in the tabs and dialog and less
commonly used entries can be either hidden or write-protected. KISSsoft can therefore easily be
adapted to suit the requirements of individual users.
7.1 Modified tabs and dialogs supplied with the
system
The description files for the tabs and dialogs supplied with the system are stored in the kui (kisssoft
user interface) directory. These files should never, under any circumstances, be modified by the
user. This is because interface upgrades, which are supplied with a patch, always overwrite any user
modifications. To modify the interface to suit your own requirements, copy the appropriate description
file to the ext/kui directory and change it there. KISSsoft evaluates the files in this directory first. The
description files are assigned to the appropriate calculation module by their file name and the file
extension .kui. This is why the file name must not be changed.
7.2 Adding additional tabs and dialogs
The description files for additional tabs and dialogs are stored in the ext/dui (dynamic user interface)
directory. KISSsoft evaluates the files in this directory every time a module is started. You can give
these files any name you want, although the file extension must always be *.dui.
The <module> tag tells KISSsoft which calculation module the description file was defined for. This
entry is mandatory for tabs. The titles of the tabs or dialogs are defined by the <title> tab. The tag
can contain either an actual text or the ID (number) of a text from the KISSsoft Glossary
(wpoolUi_.txt).
Use the <before> tag to define the position of the additional tabs. If you do not see the <before>
tag, the additional tab is placed after the standard system tabs. An additional tab can also be used to
replace a standard tab. To exclude a tab, set the <exclude> tag.
Example of an additional tab:
<KISSsoft filetype="userinterface">
<module>Z012</module>
<title>My own title</title>
I Dynamic User Interface 86
<before>Z012_Tolerances</before>
<exclude>Z012_BasicData</exclude>
<element>a</element>
<element>Q</element>
</KISSsoft>
An additional tab is always displayed. Set the <permanent> tag to define that the tab can be enabled
via the "Calculations" menu.
<permanent>false</permanent>
Additional tabs always work in the same way as the standard tabs supplied with the system. Insert
the <calculation>, <report> and <results> tags to represent the behavior of a special tab.
The <calculation> tag executes a COM function. All the functions that are available via the COM
interface are also available here. The name of the corresponding template is set for the report and
the results (see chapter 8, Results and Reports).
Use the <setup> tag to assign a COM function to additional dialogs. This function is executed when
those dialogs run.
Examples of additional description files can be requested from KISSsoft AG.
7.3 Formatting
7.3.1 Elements
Set the <element>element name</element> to add an element. The elements in the description file
appear in the same sequence as they appear in the interface.
The following element types are available:
Value input fields For entering whole number values or floating values
Selection lists (drop-down For selecting list entries, database entries, materials, lubricants or
lists) load spectra
Checkboxes For selecting/deselecting calculation options
Titles and texts For structuring the interface
I Dynamic User Interface 87
Click on kui in the Help directory to display lists of available elements.
7.3.2 Columns
Set the <column> tag to add a column. The columns in the description file appear in the same
sequence as they appear in the interface. You will not usually need more than two columns.
Example of a two-column layout:
<column>
<element>Element1</element>
<element>Element2</element>
</column>
<column>
<element>Element3</element>
<element>Element4</element>
</column>
7.3.3 Groups
Set the <group> tag to add a group. The groups in the description file appear in the same sequence
as they appear in the interface. Groups can also contain columns. Groups cannot be nested.
Set the <title> tag to define a group's title. The tag can contain either an actual text or the ID
(number) of a text from the KISSsoft Glossary (wpoolUi_.txt).
Example of a group:
<group>
<title>145</title>
<element>Element1</element>
I Dynamic User Interface 88
<element>Element2</element>
</group>
7.3.4 Tabs
Dialogs can also have tabs. Set the <tab> tag to add a tab. The tabs in the description file appear in
the same sequence as they appear in the dialog. Each tab includes elements that are arranged in
groups or columns. Sub-tabs are not supported in the tabs in a calculation module.
Set the <title> tag to define the title of a tab. The tag can contain either an actual text or the ID
(number) of a text from the KISSsoft Glossary (wpoolUi_.txt).
7.3.5 Attributes
The following attributes can be set for an element:
Attribute Value Description Usage
de, en, fr, it, es, Actual text or the ID Overwrites the element's label for a element,
pt, ru (all: (number) of a text in the language. Use this option to create title
obsolete!) KISSsoft Glossary company-specific or regional glossaries.
(wpoolUi_.txt)
prompt ID (number) of a text in Overwrites the element's label. Use this element
the KISSsoft Glossary option to create company-specific or
(wpoolUi_.txt) regional glossaries.
showPrompt false The label is not displayed. element
(type
selection
list)
ignoreTitle true The group is displayed without a label. group
dynamic true The label is determined using a function. title
readOnly true Set this attribute to write-protect the element
associated element. Use this option to
predefine values (see "Defining your own
default files" in the manual) and prevent
other users from changing them.
decimals 2 The set unit of decimal places is then element
used as the default in the interface. (value
input type)
I Dynamic User Interface 89
unit DEGREE, The set unit is then used as the default in element
MILLIMETER, INCH, the interface.
etc.
index 1, 2, 3, etc. Elements with multiple entries are element
reduced to a fixed index.
count 1, 2, 3, etc. Sets the number to be used for elements element
with multiple entries.
Function, for example,
GetGearCount
visibleCondition Function, for example, If this attribute is set, the associated element,
IsOwnInput element is only displayed if this function group, tab
returns "true".
shrink true The element can be narrower than its element
contents. (type
selection
list)
layout table The table fills the entire range (including element
label, formula symbol, unit). (type
table)
joinLayout off The group or tab is not linked to the group, tab
automatic layout.
alignment left, right, center The input elements are left-justified, right- element,
justified, or centered. text,
button
hSpacer skip The automatic horizontal placeholder is group
not set.
vSpacer skip The automatic vertical placeholder is not dlg, tab,
set. column
geometry 1000x450, etc. The dialog is displayed in the predefined dlg
size.
editButton no The element is not provided with an element
EditButton, even if one is present (a
Checkbox or RadioButton is not
displayed).
Function e.g. The element is not provided with an
IsOwnInput EditButton if the function is not fulfilled,
even if this button is present.
dummy The element is given a placeholder.
I Dynamic User Interface 90
button KUI file The element is provided with a button element
that displays a dialog as defined in the
KUI file.
Table 7.1: <element attribute1="wert" attribute2="wert">Name</element>
7.3.6 Comments
Comments in a description file are a useful way of explaining how the file is structured. Comments
start with //.
<title>32</title> // Basic data
7.3.7 Special elements
7.3.7.1 Separator
A (horizontal) separator can be added like this
<line></line>
7.3.7.2 Text
To insert a (horizontal) text:
<text>975</text> // ID (number) of a text in the KISSsoft glossary (wpoolUi_.txt)
<text>My own text</text> // actual text
I Results and Reports 91
8 Results and Reports
8.1 Results of a calculation
KISSsoft displays the results of a calculation in the Results window (see chapter 4.2.3, The Results
window). If no results are displayed, an error has occurred during the calculation. If this happens, a
system message appears in a message box to alert you to the error. An indicator in the status bar
(see chapter 4.5, Tooltips and status bar) shows whether the results are consistent, i.e. whether the
results match up with the data in the user interface.
8.1.1 Add your own texts in the results window
To enable this, define a new file in the KISSsoft installation folder in "…\ext\.rpt\". This file must then
be named using this convention: "Modulname + result.RPT" (e.g. for a cylindrical gear pair
Z012result.RPT).
Then define the new parameters or values that are to be added. These values then also appear at
the end of the "Results" window.
The syntax corresponds exactly to the entries for the report templates.
8.2 Calculation reports
Select Report > Generate to generate reports about your calculations. In addition, the tool bar and
the F6 function key give you quick, convenient access to this action. The report contents depend on
which tab is currently active (see chapter 5.1, Standard and special tabs). The Length (see chapter
8.5.2, Scope of a report) and Appearance (see chapter 8.5.3, Formatting) of standard reports can be
influenced by user-defined report templates (see chapter 8.5, Report templates).
A calculation module can contain further reports which you can access via the Report menu.
Reports are usually displayed in the KISSsoft Report Viewer (see chapter 4.4.1, Report Viewer).
Important: The report is not saved when you return from the report viewer to the input window. To
make it permanently available, you must save it with a new name!
► Note
In general, a report should only be created if the calculation is consistent (see chapter 5.3,
Calculating and generating a report). If this is not the case, you can still generate the report, but the
status of the calculation will then be noted in the report.
I Results and Reports 92
► Note
When you generate a standard report, the system generates a report file with the module's label as
its file name. The file is saved in the directory defined as the TEMPDIR (see chapter 2.6, Global
settings - KISS.ini) in the KISS.ini file (see chapter 2.6.1, Definitions in [PATH]).
8.3 Drawing data
Depending on the calculation module, you can select Report > Drawing data to generate a report
which can be used to output drawings.
8.4 Report settings
Select the Report >Settings menu option to tailor the automatic generation of reports. All the
settings can also be defined globally in the KISS.ini (see chapter 2.6.3, Definitions in [REPORT]) file.
8.4.1 General
Here you define the scope of the report (see chapter 8.5.2, Scope of a report) and whether warnings
from the calculation are to be included in it. You can also set the font size, language and the
standard format used to save reports.
The report can be viewed in two different modes: "overwrite" or "compare".
If a report is generated, and a previous report is still open, the data will be updated. The cursor in the
editor will remain in the same line it was in before this. This feature will help you analyze specific
values using different inputs.
In the report settings, change the report mode to "compare" if you need to compare two or more
reports at a time. This mode can only by set if you are using KISSedit as the editor. You can also
synchronize the reports and scroll through them all at the same time.
You can also set these report settings directly in the KISS.ini file.
8.4.2 Page layout
Here you can define the paper size and the page margins used to generate reports automatically.
I Results and Reports 93
8.4.3 Header and footer
In KISSsoft, reports are usually generated with headers and footers. You can define your own header
and footer lines. There are a number of placeholders available for this.
Placeholder Description
%logo Picture file
%date Dated
%time Time
%pn Number of pages
%pc Number of pages
%t Tab
The %logo placeholder uses the selected graphics file to integrate a user-defined logo (company
label). The date and time are output in accordance with the details specified under Extras >
Settings.
8.4.4 Start and end block
Reports in KISSsoft are usually generated with a start block and an end block. You can define these
start and end blocks yourself. The start and end blocks are defined in template files which are stored
in the rpt directory in the installation folder.
Language Start block file End block file
German kissd.rpt kissfd.rpt
English kisse.rpt kissfe.rpt
French kissf.rpt kissff.rpt
Italian kissi.rpt kissfi.rpt
Spanish kisss.rpt kissfs.rpt
Russian kissr.rpt kissfr.rpt
Portuguese kissp.rpt kissfp.rpt
Chinese kissc.rpt kissfc.rpt
Commands that can be used in these templates and what they mean:
Command Description
I Results and Reports 94
DATE Date (select "Extras > Settings" and then set your preferred output
format.)
TIME Time (select "Extras > Settings" and then set your preferred output
format.)
PROJECT Project name
PROJECTDESCRIPTION Description of the project
FILENAME/DESCRIPTION File name
FILENAME.EXT File name with extension (e.g. "Example1.Z12")
FILEPATH Path with file name (e.g. "C:\Temp\GearPair.Z12")
DESCRIPTION Description of the file
COMMENT Comment for the file
CUSTOMER Customer name as defined in the project
USER User name (Windows user name)
RELEASE Version number (e.g. "04-2010")
COMPANY Company name (as defined in the license file)
NLINES Number of lines in the report
IMPERIALUNITS Whether US customary units are specified for IF statements
METRICUNITS Whether metric units are specified for IF statements
PROJECTUSED Whether projects are used for IF statements
8.5 Report templates
For each calculation module, KISSsoft provides report templates to define the form and content of
the reports. You can use these supplied templates as the basis for generating user-defined templates
for producing reports that meet your requirements. However, you must ensure the Formatting (see
chapter 8.5.3, Formatting) and Storage locations (see chapter 8.5.1, Storage locations and
descriptions) remain the same.
8.5.1 Storage locations and descriptions
The report templates supplied by KISSsoft are stored in the directory that has been set as RPTDIR
(see chapter 2.6, Global settings - KISS.ini) in the KISS.ini (see chapter 2.6.1, Definitions in [PATH])
file. If RPTDIR (see chapter 2.6.1, Definitions in [PATH]) was not defined in KISS.ini (see chapter
2.6, Global settings - KISS.ini), you will find the templates in the installation folder under rpt. It is
essential that user-defined report templates are stored in the RPT subdirectory, in the EXTDIR (see
chapter 2.6.1, Definitions in [PATH]) directory. This is the only way to prevent your templates from
I Results and Reports 95
being overwritten if a patch is installed. When the system generates a report, it uses the user-defined
template from the EXTDIR directory, if present. Otherwise it uses the template from the RPTDIR to
create the report.
The report template labels have this structure: MMMMlsz.rptIt is made up of:
MMMM Module descriptor e.g. M040
l For historical reasons, always = l
s Language of the report s = d, e, f, i, s or a
z For historical reasons, always = 0
.rpt File type
► Examples
Bolt calculation:
M040LD0.RPT Bolt calculation, German printout
M040USER.RPT Default printout via the interface,
results in the M040USER.OUT file
Cylindrical gear calculation:
Z012LD0.RPT Cylindrical gear pair, German printout
Z012USER.RPT Default printout via the interface,
results in the Z012USER.OUT file
Z10GEAR1.RPT Output via interface, contains only data
for gear 1, results in file Z10GEAR1.OUT
Z10GEAR2.RPT Output via interface, contains only data
for gear 2, results in file Z10GEAR2.OUT
Z011LD0.RPT Single gear, German printout
Z013LD0.RPT Rack, German printout
Z014LD0.RPT Planetary gear, German printout
Z015LD0.RPT 3 gears, German printout
Z016LD0.RPT 4 gears, German printout
Spring calculation:
F10SPRING.RPT Default printout for drawing data results in the F10SPRING.OUT
file
English printout:
M040LE0.RPT Bolt calculation, English printout
I Results and Reports 96
American printout:
M040LA0.RPT Bolt calculation, American printout
8.5.2 Scope of a report
To preset the scope or length of a report, on a scale of 1 to 9, select the Report > Settings menu
option. 9 will produce a complete report, and 1 will produce a short report. In the report template, you
see a number between 1 and 9 at the beginning of every row. This number works together with the
setting described above to determine whether or not the row is to be read.
Example: If you entered 5 (medium) as the report length, all the lines in the report template that start
with 1, 2, 3, 4 or 5 are read. Rows with 6, 7, 8 and 9 will be not read.
8.5.3 Formatting
Both the report template and the report generated from this are text files that are created with the
Microsoft Windows font. You should always edit text in MS Windows, otherwise accented characters
such as ä, ö, ü, as well as some special characters, may be represented incorrectly.
The following statements and key words are defined in the report format:
▪ Texts that are to be output
▪ Comments that are not to be output
▪ Descriptions and formatting of calculation variables
▪ Limited branchings (IF ELSE END)
▪ Iterations (FOR-loops)
8.5.3.1 Text formatting features
You can use these text formatting features in RPT:
Description Start End
Underline <UL> </UL>
Cross out <STRIKE> </STRIKE>
Grease <BF> </BF>
Italic <IT> </IT>
Superscript <SUPER> </SUPER>
Subscript <SUB> </SUB>
I Results and Reports 97
Font size <FONTSIZE=xx>
Enlarge font size <INCFONTSIZE> </INCFONTSIZE>
Reduce font size <DECFONTSIZE> </DECFONTSIZE>
Page break <NEWPAGE>
Line break <BR>
Text color red <RED> <BLACK>
Text color green <GREEN> <BLACK>
Text color blue <BLUE> <BLACK>
Http link or e-mail address <LINK=destination> </LINK>
Blank space <SPACE>
Insert figure <IMAGE=name,WIDTH=xx,HEIGHT=yy>
Insert image <INCLUDEGRAPHIC=name,WIDTH=xx,HEIGHT=yy>
Adding a report template <EXECUTE=name.rpt>
8.5.3.2 Comments
Comment lines begin with //. Comments are ignored when a report is created.
► Example
// Hier habe ich am 13.12.95 die Protokollvorlage geändert, hm
Aussendurchmesser mm : %10.2f {sheave[0].da}
In this case, only the second line will be output.
8.5.3.3 Calculation variables
You cannot define your own variables (apart from the number variables used for FOR loops (see
chapter 8.5.3.5, FOR loop), which you (as the user) specify, and which can output a value.
Placeholder
Use placeholders to specify the file type and formatting for a variable:
▪ %i stands for a whole number
▪ %f stands for a floating point number
I Results and Reports 98
▪ %ν1.ν2f stands for a formatted floating point number with ν1 places in total (including prefix
operator and decimal separator) and ν2 decimal places
▪ %s stands for a left-justified character string (text)
▪ %ns stands for a right-justified character string in a n- number field (n is a whole number).
The data types must match the definition in the program. The value is returned in exactly the place
where the placeholder is positioned. The syntax of the formatting corresponds to the C/C++standard.
► Examples
▪ %10.2f returns a right-justified 10-digit floating point number, with 2 decimal places.
▪ %ireturns an unformatted whole number in exactly this location.
▪ %30s stands for a right-justified character string in a field that is 30 characters long (if the
number 30 is omitted, the characters will be left justified).
► Counter-examples
▪ %8.2i is an invalid formatting because a whole number has no decimal places.
▪ %10f2 outputs a right-justified 10-digit floating point number. However, the 2 decimal places are
ignored and output as text 2. The default setting is to output floating point numbers to 6 decimal
places.
Variables
The variable to be displayed must stand after the placeholder in the same row. The variable is
identified by being enclosed in curly brackets. If these brackets are left out, the variable name will be
displayed as normal text.
Important: It is essential that the number of placeholders exactly matches the number of pairs of
brackets {}.
► Example
%f {sheave[0].d} is the value of the variable sheave[0].d at the point %f as a floating point number with
6 decimal places.
Basic calculation types - output of changed variables
You can output changed variables in the report. They can be multiplied or divided with a coefficient.
You can also add or subtract a number. This functionality is also available in the arguments of IF- or
FORinstructions (see below).
Value of the variable multiplied %3.2f {Var*2.0}
I Results and Reports 99
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}
The two Degree and Gear functions are also available for converting variables to degrees or radians:
Angle %3.2f {grad(angle)}
Variables can also be directly linked with each other, e.g. in the form {sheave[0].d- sheave[1].d}. More
than two numbers can be linked. Numbers that have sign operators must be enclosed in brackets, for
example {ZR[0].NL*(1e-6)}.
The available functions are listed in Table 8.2.
Function Meaning
sin(angle) sine of angle in the radian measure
cos(angle) cosine of angle in the radian measure
tan(angle) tangent of angle in the radian measure
asin(val) arcsine of val, returns radian measure
acos(val) arccosine of val, returns radian measure
atan(val) arctangent of val, returns radian measure
abs(val) |val|
exp(val) eval
log(val) Return value x in ex = val
log10(val) Return value x in 10x = val
sqr(val) Return value val2
sqrt(val) Return value
int(val) Whole number of val
pow(x;y) Return value xy
sgn(val)
Return value
sgn2(val)
Return value
grad(angle) Converting from the radian measure to degrees
rad(angle) Converting from degrees to radian measure
I Results and Reports 100
mm_in(val) Return value val/25.4
celsius_f(val)
Return value val + 32
min(ν1; ...; ν5) The return value is the minimum of v1,...,ν5
max(ν1; ...; ν5) The return value is the maximum of v1,...,ν5
and(ν1; ν2) binary and function
or(ν1; ν2) binary or function
xor(ν1; ν2) binary exclusive or function
AND(ν1; ...; ν5) logical and function
OR(ν1; ...,ν5) logical or function
NOT(val)
Return value
LESS(ν1; ν2)
Return value
EQUAL(ν1; ν2)
Return value
GREATER(ν1; ν2)
Return value
ROUND(x;n) Rounds off x to n places
strlen(str) Length of character string
strcmp(str1;str2) Compare character string
Return value:
1 if str1 = str2
0 otherwise
8.1 table: Functions available for calculations in the report
8.5.3.4 Condition query IF ELSE END
The condition query or branching enables you to output certain values and texts only if a particular
condition has been fulfilled. The following conditions are supported:
Combination of characters Meaning
= equal
I Results and Reports 101
≥ greater than or equal
≤ less than or equal
≠ unequal
< smaller
> larger
Table 8.2:
This condition is entered as follows:
IF (condition) {Var}
Case 1
ELSE
Case 2
END;
► Example
IF (%i=0) {Zst.kXmnFlag}
Addendum modified no
ELSE
Addendum modified yes
END;
If the Zst.kXmnFlag variable is 0, the first text is output. If not, the second text is output. There can be
any number of rows between IF, ELSE and END . For each branching opened with IF you must use
ENDto close it again (do not forget the semicolon after END ). The key word ELSE is optional. It
reverses the condition. Branchings can be nested within each other up to a depth of 9.
► EXAMPLE OF A SIMPLE BRANCHING
IF (%i=1) {ZP[0].Fuss.ZFFmeth}
Calculation of tooth form coefficients according to method: B
END;
If the ZP[0].Fuss.ZFFmeth variable is 1, the text is output. If not, no text is output.
► EXAMPLE OF ENCAPSULATED BRANCHINGS
IF (%f ≤ 2.7) {z092k.vp}
Regular manual lubrication (Text1 )
ELSE
IF (%f<12) {z092k.vp}
I Results and Reports 102
Lubrication with drop dispenser (2 to 6 drops per minute) (Text 2)
ELSE
IF (%f<34) {z092k.vp}
Lubrication with oil bath lubrication (Text 3)
ELSE
Lubrication with circulation system lubrication (Text4)
END;
END;
END;
If the z092k.vp less than or equal to 2.7: text 1 is output. Otherwise you are prompted to confirm that
z092k.vp less than 12. If yes, text 2 is output. Otherwise you are prompted to confirm that z092k.vp
less than 34. If yes, text 3 is output, otherwise text 4 is output.
8.5.3.5 FOR loop
In KISSsoft you can also use FORloops in the report generator. A numerical variable will be
incremented (or decremented) within a FOR loop. You can use constructs that are nested down to 10
levels.
This loop is specified as follows:
FOR varname=%i TO %i BY %i DO {initial value}{final value} {step}
// access to variable with #varname or $varname
...
END FOR;
▪ Instead of %i or %f you can also use fixed figures (static FORloop):
FOR varname=0 TO 10 BY 1 DO
...
END FOR;
▪ or a mixture:
FOR varname=5 TO %i BY -1 DO {final value}
...
END FOR;
I Results and Reports 103
▪ Each FORloop must end with the statement END FOR; (including semicolon). Each defined
numerical variable (varname) within the loop can be addressed with the statement #varname .
▪ The increment can also be selected as a negative value (for example -1). However, it must
never be 0. You must always specify the intervals.
▪ The #varnamestatement can be used to define a variable. For example:
▪ Number of teeth: %3.2f {ZR[#varname].z}
▪ The $varnamestatement can be used to output the variable value as a letter. The value 0
corresponds to A, 1 corresponds to B etc. For example:
FOR quer=0 TO 3 BY 1 DO
Cross section $quer-$quer: %8.2f {Qu[#quer].sStatisch}
END FOR;
► EXAMPLE OF A SIMPLE LOOP
FOR i=0 TO 10 BY 1 DO
Run number #i $i
END FOR;
Results in the following output:
Run number 0 A
Run number 1 B
Run number 2 C
Run number 3 D
Run number 4 E
Run number 5 F
Run number 6 G
Run number 7 H
Run number 8 I
Run number 9 J
Run number 10 K
The numerical variable can be used anywhere within the loop, even for arrays.
I Database Tool and External Tables 104
9 Database Tool and External Tables
In addition to the unique data you input for calculations, you may also encounter recurring data such
as a material's characteristics. KISSsoft will store these characteristics in databases. You view and
change them with the database tool, whose use will be explained in the following sections. Tables
form the elements of the databases and are contained in your program package as editable ASCII
files. The External tables (see chapter 9.4, External tables) section deals with the setting up and
handling of external tables (also called "look-up tables).
In KISSsoft there are four databases:
KMAT - Materials
M000 - Shaft-Hub Connection and Bolts
W000 - Shafts and Bearings
Z000 - Gears
This table (see Table 9.1) uses the M000 database as an example to show how data is organized in
KISSsoft. As shown there, the F040NORM and M090MAT tables belong to the group of shaft-hub
connections.
KMAT
M000
W000
Z000
(a) Databases
9.1 table: Table: How data is organized in KISSsoft (1 of 2)
KMAT
F040NORM
M000 ...
M090MAT
W000
I Database Tool and External Tables 105
Z000
(b) tables
9.2 table: Table: How data is organized in KISSsoft (2 of 2)
Up to now, the following tables have been created in the databases: Center distance tolerances,
Reference profiles, Bore standard, Thread type bolt, Production process for hypoid bevel gears,
Manufacturing process for bevel gears, V-belt standard, Spline standard, Chain type DIN 8154,
Chain type DIN 8187, Chain type DIN 8188, Glue materials, Load spectra, Soldering materials, Key
standard, Polygon standard, Woodruff key standard, Lubricants, Bolt type, Washer standard, Multi-
spline standard, Rolling bearing, Materials for glued and soldered joint, Material, Tooth thickness
tolerances, Toothed belt standard.
9.1 Viewing database entries
To open the database, select the Extras > Database tool menu option, as shown in (Figure 9.5, ).
A dialog window appears with the question whether you want to open the database with write
authorization ( ). If you click on Yes, you can edit the database entries, otherwise they are write
protected. If you select No, the actual database tool window ( ) opens, but in read-only mode.
There, you can select a table from a list that is assigned to a particular database. The row of a table
contains the values that set the parameters for the database entry. The columns contain the
parameters for the database entries, i.e. values for the yield point of different materials. This section
describes how to edit database entries. You can also display table entries by selecting a row in the
database tool window and then confirming this by clicking Display ( ). The Display entry window
opens with a structured display of the value amount from a table row ( ).
I Database Tool and External Tables 106
Figure 9.1: Accessing database entries
► Note:
With the KISSsoft database tool you can change the databases and expand them with your own
entries. The data stored in the databases are in a sense "sensitive", so that incorrectly entered
values can have consequences that are initially imperceptible, yet eventually far-reaching and
serious. For this reason, when you open the database you are asked whether the access should
have write authorization. If you answer this question with "No"", you can view the data in the tables
but not change it.
If you want to make absolutely sure that the databases remain unchanged, you can write protect their
corresponding files (*.udb). Any attempt to open a table with write authorization results in an error
message and the table will normally be opened in write protected mode. To change a file's write
I Database Tool and External Tables 107
protection attribute, right-click on the file in Windows® Explorer, and then click on Properties. Click
in the Properties dialog field, on the General tab, and then click the Write-protected checkbox. If
you want to make changes to a write protected file, first either deselect the Write-protected
checkbox or save the file with a different name.
9.2 Managing database entries
If you want to change one of your own entries in a table in the database, you must work in write
authorization mode. To do so, click Yes in the 5ba0bcdba6a56 dialog window. In the list that you see
next, ( ) select the required table by double-clicking on the appropriate row or single-clicking on the
Editbutton at the bottom right of the window, after you have selected the row. The database tool
window now shows a list of the table entries ( ) and a row of new buttons is displayed on the
bottom left in the window:
Moves the selected item up one row
Moves the selected item down one row
Moves the selected item to the start of the list
Moves the selected item to the end of the list
Adds a new item to the list
Moves the selected item into the list of hidden datasets.
Select the Filter drop-down menu option on the top right of the window to choose between displaying
active datasets, hidden datasets, or both. Active datasets can be used within the calculation
modules, hidden ones cannot.
9.2.1 Creating a database entry
If you click on the button without having selected a row, the Display entry window ( ) opens
and the input fields in it are empty. Only the Name field contains the entry _NEW, which normally
identifies the new table entry. After you have transferred the necessary data, confirm your entries by
clicking on OK and then Savein the database tool window. The new entry is assigned an
identification number (ID) ≥ 20000 and is then transferred into the list of active datasets. Click the
Edit button to change entries with an ID of ≥ 20000.
Click the button after having selected a row, the Display entry window opens and contains
predefined values in the input fields according to the table entry. The suffix _NEW will automatically
be attached to the name, in order to differentiate it from the original dataset. In all remaining steps,
you then proceed as described above.
Example: Creating a database entry
Let's assume you want to add a new spring material to the KMAT.F000 table. As described in the
procedure, you would select the F000 table from the KMAT database. Click on the button in it, to
I Database Tool and External Tables 108
add a new entry/new row to the table, and then transfer the new data into the input fields in the
Display entry window. However, as only a few parameters can be freely selected there, the next
question is, where can the other values such as the yield point and Young's modulus be changed?
The reply is: in the base material input fields, i.e. in table KMAT.KISS. You must always specify a
base material before you can introduce a new spring material. If this is not present, you must first
define it in the KMAT.KISS table and then make the missing entries in KMAT.F000.
► Note
All material-specific tables such as KMAT.F000 or KMAT.Z080 - with the exception of KMAT.KLUB -
have a checkbox beside the Base material drop-down menu. If you have marked the checkbox,
you have the option of selecting an alternative base material in the associated drop-down list-menu.
If the checkbox is empty, access to the menu of the base materials is blocked. This option helps
prevent unwanted changes when the base material is being assigned.
9.2.2 Deleting a database entry
Datasets in KISSsoft will never be deleted. It is only possible to move entries with an ID ≥ 20000 into
the table in which hidden datasets are stored. Select the corresponding entry by single clicking on it
in the window and then click on the button. The selected row will be copied into the range that
contains the hidden datasets and is removed from the list of active datasets. To access the table of
inactive datasets, select the Display only hidden datasets option in the Filter drop-down list menu
in the top right of the database tool window.
9.2.3 Restoring a database entry
In the hidden datasets table, select the appropriate row with a single mouse click and then click on
the button. The entry will be copied into the table of active datasets and then removed from the
inactive datasets range.
9.3 Import and export data from the database tool
The datasets from every table in the database tool can be exported to a file or imported from a file.
These datasets can be imported or exported as a single dataset or imported from a list of datasets.
To import a list of datasets, first save it in a file, preferably an Excel spreadsheet with the extension
".csv". The entries in the spreadsheet columns should match the database table columns.
The software can also interpret lists that are saved as text files with the ".txt" extension. List entries
should be separated by a "comma" or a "semicolon". Which separator is used depends on your
operating system configuration.
▪ Import a dataset from a file with the extension ".kds".
▪ Export the selected dataset to a file with the extension ".kds".
I Database Tool and External Tables 109
▪ Import a list of datasets from a file with the extension ".csv".
► Important notes:
1. Only "user-defined datasets" (ID >= 20000) can be exported or imported.
2. An existing "user-defined dataset" can be overwritten if you are processing individual datasets.
3. The names of the columns in the ".kds" files is case-sensitive and must exactly match the
names in the database tool. You could export a dataset to verify the column names.
4. A new ID will automatically be assigned to every dataset if an entire list is imported or exported.
9.4 External tables
KISSsoft uses external tables, also called look-up tables, to handle larger data volumes. One or more
output values from these external tables are assigned to one or more input values (see Figure 9.2).
Figure 9.2: Principle of functionality of external tables
The output data that is assigned to the input data are contained in the table.
The external tables are stored in the /KISSsoft installation directory/dat. If a new table name is
entered in a database, a file with the same name and the file extension .dat must also be created
manually.
Because tables are located externally, KISSsoft can only determine how many of them there are
during program execution. The user directly benefits from the fact that they can generate their own
files with data tables, in a similar way to the files supplied by KISSsoft. The tables are readable ASCII
files and can therefore be edited and expanded by the user. It would, for example, be possible to use
an internal standard as an alternative to the ISO base tolerances.
Figure (see Figure 9.3) shows the three table types used by KISSsoft in one diagram:
I Database Tool and External Tables 110
Figure 9.3: Types of external tables
A table always has the following structure, no matter what type it is:
:TABLE type variable or label
table header
DATA
data
END
Use the :TABLE command to mark the external table as an external table. You must use one of the
following designations for the Type argument:
FUNCTION Functions tables
RANGE Range tables
LIST List tables
► Note
You can mark blanks in tables with *, - or blank spaces. Note here that no space characters can be
used if they are followed by more values. KISSsoft interprets blank space as value separators.
The structure of the table header and the body data, which is dependent on the type, is described
with example applications in the following sections.
9.4.1 Functions tables
Functions tables are tables that expect one or two input values (1D or 2D table) and which return
exactly one corresponding value.
► Example 1D table
The angle coefficient (factor) is determined on the basis of a specified (angle). For example: if the
input value angle = 45 supplies an output value of factor = 0.35.
I Database Tool and External Tables 111
-- table type: Functions table; output variable: factor
:TABLE FUNCTION factor
-- INPUT X angle defines the input parameter angle;
-- interim values will be interpolated linearly
INPUT X angle TREAT LINEAR
-- Data content: 1st line: input values, 2nd line: output values
DATA
0 30 60 90 ...
0.1 0.25 .45 .078 ...
END
INPUT is a key word, i.e. a word that is reserved by the Table Interpreter, and is followed by an
argument X, which assigns a dimension to the angle input parameter. The key word TREAT, with
associated LINEAR argument, specifies that interim values are to be interpolated linearly. The output
value factor will determined using the value of the angle variable. The first row of data content in the
1D table (between DATA and END) corresponds to the input value angle, and the second row
corresponds to the output value. The data content in a 1D table is therefore always a (2 × n) matrix,
i.e. both rows must contain the same number of values.
► Example of a 2D table
The nominal power is defined on the basis of the speed and the sheave diameter. For example: if the
input values diameter = 60 and speed = 60 supply an output value power = 8.6.
-- table type: Functions table; output variable: power
:TABLE FUNCTION power
-- INPUT X diameter defines the input parameter diameter;
-- INPUT Y speed defines the input parameter speed;
-- interim values will be interpolated linearly in both dimensions
INPUT X angle TREAT LINEAR
INPUT Y Speed TREAT LINEAR
-- Data content: (see chapter 10.3, Example: Interference fit calculation)
DATA
50 100 200 300 ...
50 4 7 12 25 ...
I Database Tool and External Tables 112
75 12 25 30 35 ...
... ... ... ... ... ...
END
Here, the variable power is defined with the input variables INPUT X and INPUT Y. Interim values
running down the columns (Y) should be interpolated linearly. The same applies across the rows (X).
The first row in the table corresponds to the values of the INPUT X entry variables. The first column
corresponds to the values of the INPUT Y entry variables. The values placed at the points where the
entry values intersect are values which correspond to the output variables (see Figure 9.4).
Figure 9.4: Data schema of 2D tables
If would be possible to use this method to define an inverse table. Assuming that, in your XY belt
catalog, the table displaying power output shows the speed in the first row, and the diameter in the
first column, then there is no need for you to turn your table upside down. Instead, simply change the
assignment in the table header (i.e. replace X with Y).
9.4.2 Range tables
Range tables check whether a given value is moving within a defined range.
► Example
-- table type: range table; Name of the table: 'A'
:TABLE RANGE 'A'r
-- INPUT X drehzahl defines the drehzahl (speed) input parameter.
-- interim values will be interpolated logarithmically.
-- INPUT Y leistung defines the leistung (power) input parameter.
INPUT X drehzahl l TREAT LOG
INPUT Y leistung
I Database Tool and External Tables 113
-- Data content: 1st line: INPUT X, 2nd line: INPUT Y upper limit
-- 3rd line: INPUT Y lower limit
DATA
200 300 500 1000 4000
LOWER 1.5 2.0 3.0 10 20
UPPER 10 15 20 15 40
END
The two input variables are drehzahl (speed) and leistung (power). The output value represents the
decision about whether the power in dependency with the speed is moving within a defined range
and does not have to be declared. Interim values of the speed will be interpolated logarithmically.
The first row of the body data corresponds to values of the drehzahl (speed) variable. The other
rows correspond to values of the leistung (power) variable with LOWER as the lower, and UPPER
as the upper, limit. The input value of leistung (power) is compared with these limits and a report
sent to the program stating whether the leistung is located below, within, or above, the given range
A.
9.4.3 List tables
Several output values are defined in list tables that contain at least one input value. The sequence of
the input values is important if more than one input value is entered. The reading direction goes from
left to right and the first input value defines the range of the next input value, which in turn defines
that of the next one, etc. up to the last. All input values apart from the last one must match the entries
in the body data (TREAT DIRECT, (see chapter 9.4.4, List of key words used)).
► Example 1
If the following three input values are assumed:
g.d = 2.0; g.P = 0.8; s.l = 6
The output values would be in accordance with the code given below:
s.l = 7; s.k = 3; s.k = 4.5.
-- Table type: list table. Output variable: s.norm
:TABLE LIST s.norm
-- INPUT g.d defines the input parameter g.d;
-- INPUT g.P defines the input parameter g.P;
INPUT g.d
INPUT g.P
-- IN_OUT s.l defines s.l as phase variable
I Database Tool and External Tables 114
-- TREAT NEXT_BIGGER specified how interim values are handled
IN_OUT s.l TREAT NEXT_BIGGER
-- OUTPUT s.k, s.dk declares s.k and s.dk as output variables
OUTPUT s.k,s.dk
-- Data content: A (N × Nin) matrix
DATA
2.0 0.4 0
2.0 0.8 5 3 4.5
2.0 0.8 7 3 4.5 - relevant data row
2.0 0.8 10 3 4.8
END
In contrast to functions tables, s.norm in the first row of the code specifies the name of the external
table, and not the output variable. IN_OUT s.l declares a variable s.l, which is used both as an input
and output variable (phase variable). TREAT functions again as a key word for processing the
interim values: NEXT_BIGGER shows that input values are to be evaluated it they are not present in
the appropriate column in the body data. In the example, the input value s.l = 6 lies between the
values 5 and 7 and, in accordance with NEXT_BIGGER, will be promoted to the next bigger value.
OUTPUT s.k, s.dk declares not only s.l. but also the output values s.k and s.dk. The number of the
columns in the body data must at least correspond to the number of input variables and, at most,
correspond to the number of input variables + output variables, in this case: 3 < Nin > 5.
► Example 2
Two input values are used to determine the different measurements for a bolt: the bolt type, here
represented by the typ variable, and the bolt length, specified by l.
:TABLE LIST schraube.geometrie (meaning "bolt.geometry")
INPUT typ
INPUT l TREAT NEXT_SMALLER
OUTPUT M, dw, (s), e, bez, vorrat
DATA
...
12x2.5 20 12 14.57 23.78 5.75 ID 1 1
12x2.5 25 12 15.78 24.88 5.75 ID 2 1
...
I Database Tool and External Tables 115
END
This table is called schrauben.geometrie (meaning "bolts.geometry"). The sequence in the table
header defines the sequence within the columns. The first column therefore corresponds to the typ
variable, the second to the l variable, etc. The typ and l variables are used as inputs, where the
value for the typ variable must be present in the list. If an interim value is given for the l variable, the
row with the next smaller value will be interpreted as the result. Blanks are not permitted, i.e. in this
type table values must always be present. It may happen that individual variables are shown in
brackets in the output definition. This has the effect that the appropriate column is ignored, i.e. this
variable will not be specified.
► Note
Commented-out output definitions cannot be changed by the user.
9.4.4 List of key words used
-- The Interpreter ignores everything in a row that follows
this comment character.
DATA The data matrix is below this.
END Ends the input area of the external table.
INPUT [<dim>] <var> Input variable, with definition of the dimension if required.
IN_OUT <var 1>[, <var 2>, ...] List tables: Phase variables
LOWER Range tables: Lower limiting value.
OUTPUT <var 1>[, <var 2>, ...] Output value(s)
:TABLE <type> Defines the type of the external table.
TREAT DIRECT Interim values: none permitted. The values input in the
appropriate column/row must match those of the body
data.
TREAT NEXT_SMALLER Interim values: The next smallest value is assigned.
TREAT NEXT_BIGGER Interim values: The next highest value is assigned.
TREAT LINEAR Interim values: Linear interpolation.
TREAT LOG Interim values: Logarithmic interpolation.
UPPER Range tables: Upper limiting value.
I Database Tool and External Tables 116
9.5 Description of database tables
The individual database tables have very different structures. The next section describes these
database tables and their specific fields.
The Label field is displayed in every table, and is only described here. You must enter a unique
name for the dataset in this field. This name is then used to select the datasets in the program.
Note: Fields in which file names are to be entered have an auto-fill function. To perform this, the
software searches in the ..\dat and ..\ext\dat folders, and also in the current project directory.
9.5.1 Center distance tolerances
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables). The
tables used for center distance tolerances begin with K10-???.dat. The center distance
tolerances specified in ISO 286 are imported directly from the program code and not from a file.
9.5.2 Machining allowance for cylindrical gear
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables). The
tables for the cylindrical gear machining allowance begin with ZADDT-???.dat.
9.5.3 Reference profiles
You enter reference profile data directly in the database. However, each individual value depends on
the other.
▪ Description in accordance with ISO, the standard on which this is based
▪ Comment: Text field for your own use
▪ Data source: Text field for your own use
▪ Definable reference profile data: Dedendum coefficient h*fP, root radius coefficient ϱ*fP,
addendum coefficient h*aP, tip radius coefficient ϱ*aP, topping, protuberance height coefficient
h*prP, protuberance angle αprP, tip form height coefficient h*FaP, ramp angle αKP
9.5.4 Compression springs standard
You can store data from geometry standards for compression springs.
I Database Tool and External Tables 117
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables). The
tables for compression spring standards begin with f010-??.dat.
▪ Tolerance: tolerance data for the geometry standard
9.5.5 Hobbing cutter selection
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables). The
table for cutter data according to DIN 3972 is called Z000-BP.dat.
9.5.6 Basic material Glued and Soldered joints
▪ Tensile strength Rm: [N/mm2] Data about the material's tensile strength is required to calculate
glued and soldered joints.
9.5.7 Manufacturing process for bevel and hypoid gears
These values are only necessary for calculations using the Klingelnberg method. They correspond to
tables for machine types that use the Klingelnberg in-house standard.
▪ Values that must be defined: machine type, cutter tip cutter radius r0[mm], No. of blade groups
cutter z0, maximum machining distance MDmax[mm], minimum normal module mn,min[mm],
maximum normal module mn,max[mm]
9.5.8 V-belt standard
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for the V-belt standard begin with Z090-???.dat.
▪ Calculation method:
▪ 1) Narrow V-belts (Fenner)
▪ 2) Narrow V-belts/force belts
▪ 3) Conti belts
▪ More definitions: Maximum belt speed vmax[m/s], elasticity E: [N], weight per length q: [kg/m],
coefficient of friction μr
I Database Tool and External Tables 118
9.5.9 Spline Standard
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for spline standard norms begin with M02C-???.dat.
▪ Calculation method: the appropriate calculation method is selected for each spline.
9.5.10 Chain profiles ISO 606
▪ Values to be defined for this table: type, pitch p: [mm], number of strands ns, maximum roller
diameter d1[mm], maximum bolt diameter d2[mm], minimum width between inner plates
b1[mm], maximum width over inner link b2[mm], total width btot[mm], maximum inner plates
depth h2[mm], ratio tH/tS
9.5.11 Adhesives
▪ Comment: Text field for your own use.
▪ Definable values: Minimum and Maximum shear strength τB,min, τB,max [N/mm2].
9.5.12 Modifications
The different modifications applied to gears are defined as database classes. If a dataset is hidden in
the database, it will no longer appear in the modifications selection list.
Although you can add new datasets to the database, these will not be visible in the calculation
module.
9.5.13 Load spectra
All inputs (frequency, power, speed) must be defined in coefficients. The power and speed are given
as factors of the nominal power. In the calculations, the factor for torque (load factor/speed factor) is
used for forces and moments. You can either import load spectra from a file or enter them directly. If
you input this data directly, the number of load cases is defined by the number of lines you enter.
▪ Input: Specify whether the factors are for power or torque. This also applies if the load spectrum
is imported from a file.
▪ Link with file: This option is displayed if the load spectrum is set to "Own input". If the option is
displayed, load spectrum values can be imported from a selected file. The import can be
performed in two ways: If the flag is not set, the imported load spectrum values can be modified.
I Database Tool and External Tables 119
If the flag is set, the load spectrum values are automatically overwritten by the values in the
selected file, and cannot be modified.
▪ Own input of load spectra: You can input the load spectrum directly, or import it from a file.
▪ File name: Click the button to select a file from the directories. The file containing the load
spectrum must be a text file (.dat). You will find a sample load spectrum file called
"Example_DutyCycle.dat" in the "dat" directory. You should store load spectra you define
yourself in the "EXT/dat" directory to ensure they are always available even after a version
upgrade.
Example of a file used to input a load spectrum
▪ Frequency: H0 ... H19, the sum of these frequencies must be 1.
▪ Load factor (torque factor): P0 ... P19 0<Pn<,∞.
▪ Speed factor: N0 ... N19, 0<Nn<∞.
Load spectrum elements with negative power or speed are interpreted as a change from driving
to driven. This does not affect the root and flank strengths, but it does change the safety against
scuffing and against micropitting.
9.5.14 Solders
▪ Definable values: Minimum and Maximum shear strength τB,min, τB,max [N/mm2].
9.5.15 Surface roughness of shafts and shaft-hub connections
You can also input your own data for shaft-hub connections in the "Own Input" field. The Rz values
for the shafts are taken from the list.
▪ Comment: Text field for your own use.
I Database Tool and External Tables 120
▪ Definable values: Mean peak-to-valley roughness Rz [μm] and arithmetic mean roughness
value Ra[μm].
9.5.16 Key standard
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for key standards begin with M02A-???.dat.
9.5.17 Polygon standard
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for polygon standards begin with M02D-???.dat.
9.5.18 Woodruff key standard
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for Woodruff key standards begin with M02E-???.dat.
9.5.19 Bolts/pins
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for bolt/pin standards begin with M03A-???.dat.
9.5.20 Lubricants
▪ Comment, description as specified in ISO, data source: Text fields for your own use
▪ Additive for rolling bearings:
▪ Without additives: Lubricants without additives, or with those additives whose effectiveness
in rolling bearings has not been tested.
▪ With additives: Lubricants whose effectiveness has been tested in rolling bearings
▪ Oil/Grease: specify whether the lubricant is an oil or a grease.
▪ Kinematic viscosity at 40°C and at 100°C ν40,ν100 : [mm2/s]
▪ Lubricant base: Selection options:
▪ Mineral oil
▪ Polyglycol-based synthetic oil
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▪ Polyether-based synthetic oil
▪ Polyalphaolefin-based synthetic oil
▪ Ester-based synthetic oil
Polyalphaolefin: similar to mineral oil, easily mixable with mineral oil, some approved for use with
foodstuffs.
Esters: some approved for use with foodstuffs, some biodegradable.
▪ Scuffing test procedure: Selection options:
▪ No information about scuffing
▪ FZG Test A/8.3/90; ISO 14635-1 (normal)
▪ FZG Test A/16.6/90
▪ FZG Test A/16.6/120
▪ FZG Test A/16.6/140
▪ FZG Test A10/16.6R/120; ISO 14635-2
▪ Input of scuffing temperature
▪ FZG test A10/16.6R/90
▪ FZG test S-A10/16.6R/90
▪ Failure load stage scuffing FZG test: Input load stage scuffing as specified in the FZG test.
These values are required for gear calculations.
1= weakest stage; 12=best stage
Good gear lubricants all have a load stage scuffing value of 12.
▪ Scuffing temperature θs:You can also enter the scuffing temperature for the scuffing test
procedure.
▪ Micropitting process: Selection options
▪ No information available for load stage micropitting
▪ C-GF/8.3/90 (FZG)
▪ Load stage micropitting test: The best achievable load stage is 10.
▪ Densityϱ: [kg/dm3]
▪ Cone penetration at 25°C (grease) Pe: [0.1mm] This value is only required to calculate grease-
lubricated plain bearings.
▪ Soap proportion (grease) cs: [Vol%] This value is only required to calculate grease-lubricated
plain bearings.
▪ k coefficient, s coefficient (compression viscosity) k, s: Coefficient used to calculate
compression viscosity (AGMA 925):
I Database Tool and External Tables 122
If you do not know these values, you can input 0. The values are then taken from the standard
(AGMA 925-A03, Table 2).
▪ Lower/upper service temperature limitθmin, θmax : [°C]
9.5.21 Bolts: Tightening factor
▪ Tightening technique: Select "not yield point- or rotation-angle-controlled tightening" and "yield
point- or rotation-angle-controlled tightening"
▪ Minimum tightening factor αAmin: Minimum value, can be defined per tightening technique.
▪ Medium tightening factorαAmid: Medium value, can be defined per tightening technique.
▪ Maximum tightening factor αAmax: Maximum value, can be defined per tightening technique.
9.5.22 Bolts: Bore
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for bores begin with M04-???.dat.
▪ Unit in use: select whether the values in the file are to be read in mm or inches.
9.5.23 Bolts: Strength grade
▪ Comment: Text field for your own use.
▪ Definable values: Yield point Rp [N/mm2], tensile strength Rm [N/mm2], shearing strength ratio
ιb/Rm[-]
► Note:
The yield point and tensile strength for the lower diameter limit for strength classes 8.8 and SAE
J429 Grades 2 and 5 are always displayed in the database. If the diameter is greater than the
diameter limit, this is corrected in the program.
The shearing strength ratios have been taken from Table 5.5/2 in VDI 2230 (2015) according to the
strength classes. Undefined SAE classes are set to the ratio 0.6.
I Database Tool and External Tables 123
9.5.24 Bolts: Nut strength grade
▪ Comment: Text field for your own use.
▪ Definable values: Vickers hardness for standard thread for diameter D <= 16 mm [HV], Vickers
hardness for standard thread for diameter D > 16 mm [HV],Vickers hardness for fine thread for
diameter D <= 16 mm [HV], Vickers hardness for fine thread for diameter D > 16 mm [HV]
► Note:
The minimum value specified in the DIN EN ISO 898-2:2012 standard is assumed in the strength
classes. However, as this value depends on the diameter, in some strength classes, both values are
defined in the database. In the program, you can then specify which diameter the value is to be used
for. The same applies to differentiating between fine and standard threads. The program handles the
value that is being used differently, according to the selection in the interface.
9.5.25 Bolts: Coefficients of friction classes
▪ Comment: Text field for your own use.
▪ Definable values: Minimum coefficient of friction μmin[-] and Maximum coefficient of friction
μmax [-]
► Note:
The minimum and maximum coefficients of friction are always displayed in the database for the
coefficient of friction classes. The values are used to size the moments of friction for bolts.
The predefined values are taken from Table A5 in VDI 2230, Sheet 1 [1].
9.5.26 Bolts: Thread type
▪ Name: Text field for your own use.
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for threads begin with M04-???.dat.
▪ Coefficient used to calculate the flank diameter/core diameter
▪ Flank angle α: [°]
I Database Tool and External Tables 124
9.5.27 Bolts: Nuts
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for nuts begin with M04-???.dat.
▪ Unit in use: select whether the values in the file are to be read in mm or inches.
9.5.28 Bolts: Type
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for bolt types begin with M04-???.dat.
▪ Name: Text field for your own use.
▪ Screw thread type: selection list to show which screw thread type this bolt has.
▪ Unit in use: select whether the values in the file are to be read in mm or inches.
9.5.29 Bolts: Washer
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for washers begin with M04-???.dat.
▪ Unit in use: select whether the values in the file are to be read in mm or inches.
9.5.30 Selection of pinion type cutters
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for pinion type cutters begin with Z000-Cutter-?.dat.
9.5.31 Disc spring standard
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for disc springs begin with F040-?.dat.
9.5.32 Tolerances standard
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for tolerances begin with K10-???.dat.
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The tolerances according to DIN EN ISO 286 have been programmed directly into KISSsoft. For fit
(tolerance) classes H, h, JS and js, the tolerance has been extended up to the nominal length 10,000
mm (according to the standard, up to 3,150 mm). The values were determined by extrapolation.
9.5.33 Beam profiles
▪ Drawing file: image displayed on screen when a shaft is calculated.
▪ Values for profiles: height h [mm], width b [mm], cross section A [cm2], moments of gyration of
a surface relating to x-/ z-axis Ix/ Iz [cm4], moment of inertia in torsion It [cm4], moments of
resistance relative to the x- or z-axis Wx/ Wz[cm3], moment of resistance in torsion Wt [cm3]
9.5.34 Multi-Spline standard
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for multi-spline profiles begin with M02b-???.dat.
9.5.35 Materials
The materials consist of a database table Basic data Materials and the particular table for the
modules. The Basic data table lists the general material data. As the materials can then be
transferred to the individual module tables, you therefore only need to define the basis data once.
Module-specific data is then defined in the module tables.
In module-specific tables, you must always select one Base material.
9.5.35.1 Basic data: Materials
▪ Label according to DIN, BS, AISI, UNI, AFNOR, JIS, CN, Old label, Material number, Origin of
data, Comment: Text fields for your own use
▪ Young's modulus at 20°C E20: [N/mm2]
▪ Poisson's ratio ν: [-]
▪ Density ϱ: [kg/dm3]
▪ Coefficient of thermal expansion α: [10-6/K]
▪ Shearing modulus at 20°C G20: [N/mm2]
▪ Type of treatment: Select the type of treatment in this list.
▪ Material type: Select the material type in this list.
▪ Hardness value: This value is purely for information purposes and has a negligible effect on the
calculation.
I Database Tool and External Tables 126
▪ Unit of hardness: You can select this in this list.
▪ Core hardness value: This value is used, for example, for the strength calculation according to
AGMA 6101-F19/AGMA 6001-F19. However, for other calculations, the value is purely for
information purposes and has only a minor influence on the calculation. For case-hardened case
hardening steels, the value for the tensile strength Rm was taken from the DIN EN 10084
standard for a diameter between 16 and 40 mm, and was then calculated with the hardness
conversion of the Brinell hardness HBW.
▪ Core hardness unit: You can select this in this list. You can select Brinell hardness or Vickers
hardness as input values.
▪ Tensile strength Rm: [N/mm2] A max. of 10 different diameter ranges can be defined
▪ Yield point Rp: [N/mm2] A max. of 10 different diameter ranges can be defined
▪ Raw diameter d: [mm] A max. of 10 difference diameter ranges can be defined
9.5.35.2 Material Spring calculation
This table applies to Compression (F010), Tension (F020) and Leg springs (F030):
▪ Admissible shear stress: The database entries refer to external tables (see chapter 9.4,
External tables). Tables for springs begin with F01-???.dat. In this file, you can view or define
the Admissible shear stress, the values for the Goodman diagram and the values for the
relaxation diagram. If the curves of the relaxation diagram are only defined with 2 points, you
must set the values for tau3 and rel3 to 0 so KISSsoft can recognize them.
▪ Comment: Text field for your own use.
▪ Minimum and maximum wire diameter dmin, dmax [mm]
▪ Shearing modulus depending on temperature αG: [1/K]
▪ Use: selection list with the cold and thermo-formed variants
9.5.35.3 Material of plain bearings
▪ Comment: Text field for your own use.
9.5.35.4 Material of enveloping worm wheels
The table applies to worm wheels (Z080):
▪ Comment: Text field for your own use.
▪ Material characteristics: Selection list (such as CuSn-bronze/CuAl bronze/GJS40/GC25/PA-12)
I Database Tool and External Tables 127
▪ Mineral oil coefficient WMLOel: Material/lubricant factor for mineral oil
▪ Polyglycol coefficient (DIN)/ (ISO) WMLGDIN/ WMLGISO: Material/lubricant factor for polyglycol
▪ Polyalphaolefin coefficient WMLA: Material/lubricant factor for polyalphaolefin
▪ Material factor YW: (see DIN 3996, Table 5)
▪ Pitting strength σHlimT: [N/mm2] (We recommend you use reduced values as specified in ISO
14521)
▪ Shear fatigue strength τFlimT: [N/mm2]
▪ Reduced shear fatigue strength τFlimTred: [N/mm2] (If no slight deformation is permitted, you must
include reduced strength values in the calculation.)
9.5.35.5 Material Interference fit
▪ Comment: Text field for your own use.
9.5.35.6 Material of bolts
The table applies to the bolt module (M040):
▪ Comment: Text field for your own use.
▪ Permissible pressure pG: [N/mm2] (Data should be entered as specified in VDI 2230)
▪ Shearing strength τB: [N/mm2]
9.5.35.7 Material Welded joints
▪ Comment: Text field for your own use.
9.5.35.8 Material for disc spring calculation
The table applies to disc springs (F040):
▪ Comment: Text field for your own use.
▪ Goodman diagram: The database entries refer to external tables (see chapter 9.4, External
tables). Tables for the Goodman diagram begin with F04-???.dat.
▪ Young's modulus depending on temperature αE: [1/K]
I Database Tool and External Tables 128
9.5.35.9 Material of shaft-hub-connection
▪ Comment: Text field for your own use.
9.5.35.10 Housing material
▪ Comment: Text field for your own use.
9.5.35.11 Material Shaft calculation
The table applies to shafts (w010):
▪ Values for calculating strength according to Hänchen:
▪ Bending fatigue limit σbW: [N/mm2]
▪ Values for strength calculation according to DIN 743:
▪ Reference diameter db [mm], tensile strength Rm [N/mm2], yield point Rp [N/mm2], bending
fatigue limit σbW [N/mm2], tension/compression fatigue limit σzdW [N/mm2], torsion fatigue
limit τtW [N/mm2]
▪ Experimental data: The database entries refer to external tables (see chapter 9.4, External
tables). Tables for the experimental Haigh diagram begin with W01-???.dat.
▪ CrNiMo case hardening steel: When determining the size coefficient K1 for case hardening
steel, you need to specify whether the steel is CrNiMo case hardening steel. The materials
20NiCrMo13-4, 17NiCrMo6-4, 17NiCrMoS6-4, 18NiCr5-4, 17CrNi6-6, 18CrNiMo7-6,
14NiCrMo13-4, 22CrMoS3-5 and 15NiCr13 belong to this group. According to DIN 10084,
there is no significant drop in the tensile strength of these materials. These materials also
belong to this group according to Prof. Linke.
▪ Values for strength calculation according to FKM:
▪ Tensile strength for reference diameter Rm,N [N/mm2], yield point for reference diameter
Re,N [N/mm2], effective reference diameter for deff,N,p deff,N,p [mm], effective reference
diameter for Rm,N deff,N,m [mm], constant for calculating Kd (flow) ad,p , constant for
calculating Kd (fracture) ad,m, tension/compression fatigue limit for reference diameter
σW,zd,N [N/mm2], bending fatigue limit for reference diameter σW,b,N [N/mm2], shear stress
fatigue limit for reference diameter τW,s,N [N/mm2], torsion fatigue limit for reference
diameter τW,t,N [N/mm2]
▪ Elongation at break A: [%]
▪ FKM Group: Selection list showing the material group to which the entry belongs.
I Database Tool and External Tables 129
9.5.36 Material of gears
▪ Comment: Text field for your own use.
▪ File for hardness curve: The database entries refer to external tables (see chapter 9.4, External
tables). Tables for the hardness curve begin with Z22-???.dat. The material's measured
hardness value, to be displayed as a graphic in module Z22. Does not influence the calculation.
Here is an example of how to create this type of hardness curve in an external table.
Figure 9.5: Example of a hardness curve definition (Z22-100.dat)
▪ Woehler line file: The database entries refer to external tables (see chapter 9.4, External
tables). Tables for S-N curves (Woehler lines) begin with .dat.
You must input a file name for plastics here. The file contains the material data (Woehler lines,
Young's modulus, etc.) used in the calculation.
For metallic materials you can also input a file name here. The file contains the S-N curves
I Database Tool and External Tables 130
(Woehler lines) for bending strength and for Hertzian pressure that are used in the calculation, if
the Calculate with own Woehler line flag is set.
Figure 9.6: Example of a file with S-N curves (Woehler lines) for a metallic material
▪ Endurance limit root (ISO, DIN/ AGMA 2101) σFlim/sat, Endurance limit flank (ISO, DIN AGMA
2101) σHlim/sac: [N/mm2] Endurance limit values specified in DIN 3990 or ISO 6336 Part 5.
▪ Endurance limit root (AGMA 2001) sat, Endurance limit flank sac (AGMA 2001): [lbf/in2] Strength
calculation based on AGMA 2001.
▪ Average roughness height root/flank RzF/ RzH: [μm]
▪ Thermal contact coefficient BM: [N/mm/s0.5/K] This coefficient is needed to calculate the flash
factor. You will find more information about this in DIN 3990, Part 4, Equations 3.11, 4.17, 4.18
and 4.19. For the most commonly used materials, it is 13.795.
9.5.37 Rolling bearings
Rolling bearing tables are sub-divided into three different tabs:
▪ Basic data tab
▪ Additional data tab
▪ Internal geometry tab
I Database Tool and External Tables 131
9.5.37.1 Rolling bearing basic data
▪ Bearing label: The codes for the bearing series are as specified in DIN 623 Part 1.
▪ Comment: more detailed description of the bearing (e.g. SKF-Explorer, X-Life, etc.)
▪ Main dimensions of the bearing: Inside diameter d [mm], External diameter D [mm], Bearing
width b [mm], Corner radius rsmin [mm]
▪ Basic dynamic load rating C: [kN], Dynamic radial load rating Cr: [kN] (if radial and axial values
are predefined, e.g. cross roller bearing)
▪ Basic static load rating C0: [kN], Static radial load rating C0r: [kN] (if radial and axial values are
predefined, e.g. cross roller bearing)
▪ Dynamic axial load rating Ca: [kN] (if present, e.g. cross roller bearing)
▪ Static axial load rating C0a: [kN] (if present, e.g. cross roller bearing)
▪ Hybrid bearing: [Yes/No] Yes: if a hybrid bearing (ceramic rolling body). No: if not a hybrid
bearing.
▪ Coefficients X1, Y1, X2, Y2, e, e0, X01, Y01, X02, Y02
Defining individual coefficients:
▪
X1,Y1,e: Coefficients in formula P = X1*Fr + Y1*Fa for Fa/Fr <= e
X2,Y2: Coefficients in formula P = X2*Fr + Y2*Fa for Fa/Fr > e
X01,Y01,e0: Coefficients in formula P0 = X01*Fr + Y01*Fa for Fa/Fr <= e0
X02,Y02: Coefficients in formula P0 = X02*Fr + Y02*Fa for Fa/Fr > e0
X1,Y1,X2,Y2,e: For some bearings, these values are not imported from the
database. Instead they are imported from the files,
depending on the axial force.
Definition e0: P0 = X0*Fr + Y0*Fa -> with P0 = Fr at limit (SKF catalog) -> Fr = X0*Fr + Y0*Fa -> e0 =
Fa/Fr = (1-X0)/Y0
Ball bearing: depending on f0*Fa/C0
▪ at bearing clearance C0: Data is imported from file W05-100A.dat (single row bearing) and W05-
100B.dat (double row bearing)
▪ at bearing clearance C3: Data is imported from file W05-101A.dat (single row bearing) and W05-
101B.dat (double row bearing)
▪ at bearing clearance C4: Data is imported from file W05-102A.dat (single row bearing) and W05-
102B.dat (double row bearing)
▪ with no clearance: Data is imported from file W05-104.dat
I Database Tool and External Tables 132
Angular contact ball bearing: depending on f0*Fa/C0 and contact angle
▪ at contact angle 5°: Data is imported from file W05-100A.dat (single row bearing) and W05-
100B.dat (double row bearing)
▪ at contact angle 10°: Data is imported from file W05-101A.dat (single row bearing) and W05-
101B.dat (double row bearing)
▪ at contact angle 15°: Data is imported from file W05-102A.dat (single row bearing) and W05-
102B.dat (double row bearing)
▪ at contact angle 20°< α< 45°: Data is imported from file W05-103A.dat (single row bearing) and
W05-103B.dat (double row bearing)
► Note:
Bearing clearance class C2 is handled in the same way as C0. These formulae have been taken
from the "Die Wälzlagerpraxis" document [2].
▪ Speed limit when grease lubrication is nGmax: [rpm] Only one speed limit is specified for SKF
bearings. There is no distinction between grease and oil lubrication.
▪ Speed limit when oil lubrication is nOmax: [rpm] Only one speed limit is specified for SKF
bearings. There is no distinction between grease and oil lubrication.
▪ Weight m: [kg]
▪ Contact angle α0: [°] Input the contact angle for shaft bearings, taper bearings, etc.
for four-point contact bearings: If you input 0°, this is set to 35°
for axial spherical roller bearings: If you input 0° this is set to 50°.
▪ Permitted axial force F*azul: [-] Input the permitted axial force in % of Fr. The permitted axial
force is not checked if you input 0.
▪ Maximum permitted misalignment α: [min] If you input 0, the angle adjustability (i.e. a
comparison of the permitted angular deviation of the shaft with the effective angular deviation in
the bearing) is not checked.
▪ Thermal reference speed nθr: [rpm]
▪ Currently not evaluated in KISSsoft: Availability (0=in stock; 1=not in stock), price [in local
currency]
▪ Addition A-E: You can input additional data for specific types in these fields. (see table: Use of
additions A-E.)
▪ radial and axial spring stiffness cr ,ca: [N/μm]
▪ Spring stiffness for bending crot: [Nm/°] Input spring stiffness for inclination.
▪ Factor f0: used to define X and Y (for example, for deep groove ball bearings), because these
values depend on the factor f0*Fa/C0 .
I Database Tool and External Tables 133
▪ Minimum load P/C: Minimum load P/C (P: dynamic equivalent load: C: basic dynamic load
rating) is usually:
▪ 0.01 for ball bearings with a cage
▪ 0.02 for roller bearings with a cage, 0.04 for pure roller bearings with a cage
If you input 0 in the database, these values are used automatically in the calculation.
This entries only apply to radial load. The minimum axial force is calculated directly in the software.
▪ Fatigue load limit Cu: Coefficient for calculating the modified rating life
Type Addition A Addition B Addition C Addition D Addition
E
Angular contact ball Offset a (mm)
bearing (single row) (*2)
Angular contact ball Offset a (mm)
bearing (paired) (*2)
Cylindrical thrust Coefficient A (*1) Max. axial
roller bearing force (kN)
Taper roller bearing Width B (mm) Offset a Dimension C
(single row) (mm) (*2) (mm)
Taper roller bearing Dimension T Dimension C
(paired, O) (mm) (*1) (mm) (*1)
Taper roller bearing Dimension 2B Dimension
(paired, X) (mm) 2T (mm)
Barrel-shaped and Calculation Calculation
toroidal roller coefficient k1 coefficient k2
bearings (SKF: CARB, (SKF: CARB,
Internal Internal
geometry) geometry)
Spherical thrust roller Dimension d1 Dimension T2 Dimension Dimension Coefficient
bearing (mm) (mm) D1 (mm) T1 (mm) A (*1)
Table 9.3: Use of additions A-E
Descriptions given in additional data conform with those in the INA/FAG catalog 2017.
(*1) Values are only used for SKF bearings, as specified in the SKF catalog 2013.
(*2) Values for the mass a for FAG bearings have been provided by the manufacturer up to the
center point. In KISSsoft, half the bearing width was then added to this value for the database (this
I Database Tool and External Tables 134
may result in values that vary slightly from those in the bearing catalog). The value at the bearing
center was used in this calculation. This corresponds to the data we received from the manufacturer.
9.5.37.2 Rolling bearing Internal geometry
You can define and edit data for the internal geometry of most bearing types in the Internal geometry
tab. Many bearing manufacturers do not make this data available directly. However, in KISSsoft, you
can estimate this data by using the calculation methods specified in ISO 16281.
You need the details documented below to calculate inner geometry. For some rolling bearings, you
can also enter a user-defined roller profile definition file, which is a ".dat" file. You will find the
relevant information in section 28.1.2.1. "User-defined roller profile".
To handle bearings without an inner or outer ring more effectively, these profiles can be deactivated
either individually or together. However, you must define the internal geometry before you can use
this function. The corresponding internal and external bearing diameters, d and D, then refer to the
(average) operating pitch circle of the corresponding bearing housings and must be modified if
necessary. A slightly different reference diameter is therefore used to calculate the bearing
clearance. This might result in negligible differences when compared to the identical bearing with
rings. If a bearing side is defined as being without a ring, any calculations of fit used in shaft projects
are deactivated.
The load-bearing capacity correction factors (fC, fC0) are used to adjust the load-bearing capacity,
which is used to approximate the bearing geometry according to:
C' = C • fC
C'0 = C0 • fC0
▪ Deep groove ball bearing (single row), four-point contact bearing: Number of balls Z [-], Ball
diameter DW [mm], Reference diameter DPW [mm], Inside diameter of the rim, pressure side DBI
[mm], Outside diameter of the rim, pressure side DBA [mm], Radius of curvature, inside ri [mm],
Radius of curvature, outside ro [mm]
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Figure 9.7: Dimensions of the deep groove ball bearing, single row
▪ Deep groove ball bearing, double row: Same geometry value as for single row deep groove ball
bearings. Additional input: Row distance a [mm]
Figure 9.8: Figure: Dimensions of the deep groove ball bearing, double row
▪ Angular contact ball bearing (single row): Number of balls Z [-], Ball diameter DW [mm],
Reference diameter DPW [mm], Inside diameter of the rim, pressure side DBI [mm], Outside
diameter of the rim, pressure side DBA [mm], Radius of curvature, inside ri [mm], Radius of
curvature, outside ro [mm], Minimum initial tension vmin [mm], Maximum initial tension vmax
[mm], Minimum pretension force Fvmin [N], Maximum pretension force Fvmax [N]
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Figure 9.9: Dimensions of the angular contact ball bearing
▪ Cylindrical roller bearing (single row): Number of rollers Z [-], Diameter of roller DW [mm],
Reference diameter DPW [mm], Inside diameter of the rim, pressure side DBI [mm], Outside
diameter of the rim, pressure side DBA [mm], Roller length LWE [mm], Axial displacement
possibility non-locating bearing vl [mm], Axial displacement possibility fixed bearing vf [mm]
Figure 9.10: Dimensions of the cylindrical roller bearing
▪ Cylindrical roller bearing (double row): Number of rollers Z [-], Diameter of roller DW [mm],
Reference diameter DPW [mm], Inside diameter of the rim, pressure side DBI [mm], Outside
diameter of the rim, pressure side DBA [mm], Roller length LWE [mm], Row distance a [mm]
I Database Tool and External Tables 137
Figure 9.11: Dimensions of the double row cylindrical roller bearing
▪ Axial angular contact roller bearing: Number of rollers Z [-], Diameter of roller DW [mm],
Reference diameter DPW [mm], Roller length LWE [mm]
Figure 9.12: Figure: Axial angular contact roller bearing mass
▪ Taper roller bearing (single row): Number of rollers Z [-], Diameter of roller DW [mm], Reference
diameter DPW [mm], Roller length LWE [mm]
I Database Tool and External Tables 138
Figure 9.13: Dimensions of the taper roller bearing
▪ Double row self-aligning roller bearings: Number of rollers Z [-], Diameter of roller DW [mm],
Reference diameter DPW [mm], Inside diameter of the rim, pressure side DBI [mm], Outside
diameter of the rim, pressure side DBA [mm], Radius of curvature, inside ri [mm], Radius of
curvature, outside ro [mm]
Figure 9.14: Dimensions of the double row self-aligning roller bearing
▪ Needle roller bearing, Needle cage: Number of rollers Z [-], Diameter of roller DW [mm],
Reference diameter DPW [mm], Roller length LWE [mm], Axial displacement possibility non-
locating bearing vl [mm]
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Figure 9.15: Dimensions of the needle roller bearing/needle cage
▪ Deep groove thrust ball bearings: Number of balls Z [-], Ball diameter DW [mm], Reference
diameter DPW [mm], Radius of curvature, inside ri [mm], Radius of curvature, outside ro [mm]
Figure 9.16: Dimensions of the deep groove thrust ball bearing
▪ Cylindrical roller thrust bearings: Number of rollers Z [-], Diameter of roller DW [mm], Reference
diameter DPW [mm], Roller length LWE [mm]
I Database Tool and External Tables 140
Figure 9.17: Dimensions of the cylindrical roller thrust bearing
▪ Spherical roller thrust bearing: Number of rollers Z [-], Diameter of roller DW [mm], Reference
diameter DPW [mm], Roller length LWE [mm], Distance LWC of the maximum Roller diameter
[mm], Radius of curvature, inside ri [mm], Radius of curvature, roller Rp [mm], Radius of
curvature, outside ro [mm]
Figure 9.18: Dimensions of the spherical roller thrust bearing
9.5.38 Rolling bearing tolerance
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for rolling bearings begin with W05-??-??.dat.
I Database Tool and External Tables 141
9.5.39 Rolling bearing fit (tolerance) classes
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for rolling bearing tolerance classes begin with W05-???.dat.
9.5.40 Tooth thickness tolerances
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for tooth thickness tolerances begin with Z01-???.dat or Z9-???.dat.
▪ Interpret as:
▪ Tooth thickness allowances: the data is interpreted as tooth thickness allowances.
▪ Base tangent length allowances: the data is interpreted as the base tangent length
allowances (or normal play).
9.5.41 Toothed belt standard
▪ File name: The database entries refer to external tables (see chapter 9.4, External tables).
Tables for the toothed belt standard begin with Z091-???.dat.
▪ Calculation method:
▪ 1)"normal" toothed belts (RPP)
▪ 2) GT types (PolyChain)
▪ 3) AT types (Brecoflex)
▪ 4) PG types (PowerGrip)
Differences:
▪ Special calculation for toothed belts with integrated steel rope (Method 3)
▪ Calculating the operating factor: the special factor for the speed increasing ratio is added
(Method 1, 2 or 4) or multiplied (Method 3)
▪ Additional performance table for higher performance at greater conversions (Method 2)
▪ Calculation method for belt pre-tension:
▪ 1) in % of the circumferential force; slack = 1/50 of the tension length
▪ 2) in % of the maximum permitted circumferential force; slack = 1/50 of the tension length
▪ 3) in % of (operating factor*power(W)/circumferential speed reference circle (m/s))
(according to DAYCO RPP Panther) Slack = 1/64 of the tension length
▪ 4) in % of the circumferential force; Slack = 1/64 of the tension length
I Database Tool and External Tables 142
▪ Nominal range for power table b: [mm] belt width, which corresponds to the performance data
stored in the file (see file name).
▪ Coefficient for belt pre-tension f: 0 ... 1.0 (% factor for calculating the belt pre-tension
coefficient)
▪ Maximum belt speed vmax: [m/s]
▪ Summand for operation Fs: No influence
▪ Pitch p: [mm] pitch of the toothed belt
▪ Elasticity E: [N] Elasticity = force that doubles the length of a belt (with nominal width). If you do
not know this value, enter 0 as the guide value (in this case the elasticity is ignored when the
bending test is performed).
▪ Strain ε: [%] strain along the total length of the belt
▪ Weight per length q: [kg/m/mm] per meter length and millimeter width
File contents:
List of suggested standard numbers of teeth for toothed :TABLE LIST z.RadZahne
lock washers
List of suggested standard numbers of teeth for belts :TABLE LIST z.NormZahne
Minimum number of teeth, depending on the speed :TABLE FUNCTION z091k.factorINCR
(small disc)
Correction factor for powering up, depending on the :TABLE FUNCTION z091k.factorINCR
ratio (this is added to the operating factor)
Transmittable power depending on the number of teeth :TABLE FUNCTION z091k.powerNr
(small disc) and speed (small disc)
Correction factor for the number of contacting teeth :TABLE FUNCTION z091k.factorCorrEZ
(small disc)
Correction factor for belt length :TABLE FUNCTION z091k.factorLength
Correction factor for belt width :TABLE FUNCTION belt.bth
Correction factor for belt width (same values as shown :TABLE FUNCTION belt.beff
in the table above)
Disc width depending on belt width :TABLE FUNCTION z091k.ScheibenBreite
Belt type sizing: minimum transmittable power (lower :TABLE FUNCTION z091k.kWlower
limit) depending on the speed (small disc)
Belt type sizing: maximum transmittable power (upper :TABLE FUNCTION z091k.kWupper
limit) depending on the speed (small disc)
I Description of the Public Interface 143
10 Description of the Public Interface
10.1 Interfaces between calculation programs and
CAD - Overview
The closest contact point of calculation programs within a CIM concept is the one with the drawing
program (CAD). KISSsoft's public data interface can be freely formatted, enabling very powerful
communication with third party programs.
All input and output data can be exported in ASCII format. The scope and format of this data is freely
definable. For this, each calculation module contains a special, editable report file. The
MMMMUSER.RPT files are used as a template for this data transfer. The default setting is that these
files are empty. If you want to output data over the interface, you first have to expand the templates.
External programs can, in addition, transfer input data (also in ASCII format) to calculation modules.
This data is read automatically during start-up, and then displayed on the screen.
*The character string MMMM in a file name is a placeholder for the module to which the file refers.
Example: M040USER.RPT
10.1.1 Efficient interfaces
Automated data transfer between the calculation and CAD should only be set up if the benefits are
considerably greater than the effort required. For example, an interface between a bolt calculation
program and CAD is only of secondary importance since the information to be transferred (for
example that, due to the calculation, an M10 bolt has to be selected) is too limited and could be
transferred much faster "by hand". If, however, a standard parts library with bolts is available, the
bidirectional link between the three components (calculation program, standard parts library and
CAD) can prove very efficient.
The following efficient interfaces are available (but this list can be extended):
▪ General
▪ It should be possible to start the calculation programs from the CAD environment (for
example by pressing a function key). This enables you to perform a short calculation while
you are drawing, transfer the results and then continue drawing.
▪ Shafts and bearing calculation
▪ Output of a contour from the CAD system (i.e. a shaft from detailed or drawing with
combined elements) and reading it into the calculation program. (Problem: in many CAD
programs, it is unfortunately rather difficult to define the contour to be exported.)
I Description of the Public Interface 144
▪ Output of a shaft that has been optimized in the calculation program (including rolling
bearings etc.), reading it, and importing it into CAD as drawing information.
▪ Transfer of bending lines and similar data into the CAD system.
▪ Rolling bearings and plain bearings are calculated, and then the contour is transferred to
the CAD system. (Frequently, the CAD system already contains information on rolling
bearings, so that only the bearing label is of interest.)
▪ Gear calculation
▪ Calculation of fabrication data in the program and transfer of the required values to the CAD
as text. This is a very important function, since the recording of the data is very prone to
errors, with potentially serious consequences.
▪ Calculation of the exact tooth form in Page view and transfer to the CAD system.
(Although this results in very pretty drawings, it usually does not supply any necessary
information, except if the data undergoes further processing, i.e. via transfer onto a
wire electro-discharge machine.)
▪ Transfer of the schematic axial section or the Print Preview of the gears to the CAD system (but
can also be achieved just as quickly in CAD, manually).
▪ Machine elements
▪ Transfer the contour of calculated machine elements to the CAD such as bolts, V-belt
sheaves etc. (Frequently, the CAD station already contains appropriate, preprogrammed
information, so that only the parts definition is of interest).
▪ Shaft-hub connection
▪ The sizing or proofing of connections should be implemented directly in a CAD system, so
that known data from the CAD can be transferred into the calculation and the results of the
calculation can in turn be returned to the CAD system.
10.1.2 Open interfaces concept in KISSsoft
The KISSsoft interfaces concept has a simple, yet very flexible structure.
It should be possible to integrate calculation programs into all kinds of CAD systems as simply as
possible, and use them in different environments (operating systems such as MS Windows or UNIX).
The interface mechanism between the CAD system and KISSsoft is based on a text dataset (ASCII
file), and an ID is transferred together with the numerical value for all transfer data (see chapter 10.3,
Example: Interference fit calculation). This dataset can be of variable length, but only the values that
are known in the CAD system will be transferred. This depends on the CAD system and the currently
active drawing.
I Description of the Public Interface 145
KISSsoft will test the dataset transferred by the third party program, to ensure it is complete and
consistent, and, if necessary, you will be prompted to input additional data in the KISSsoft input
system. KISSsoft will then run the calculation and write the output data that the CAD system requires
to a second text dataset. It then returns this dataset to the CAD system. By using the report
generator you can select any format for the output file, i.e. KISSsoft adapts itself to the third party
program. The CAD can now read the data required by the situation and process it selectively.
This concept results in simple interface forms, which enables even non-specialists to write
applications quickly.
10.2 Defining input and output
10.2.1 Preamble
▪ In this description the KISSsoft program is always taken as a reference, i.e. an input file for
KISSsoft becomes an output file for the third party program and vice versa.
▪ For automatic data exchange with other programs you will require files with the name
MMMMUSER.RPT . You can adapt these files to your own requirements. However, if you have
purchased KISSsoft interfaces, you should act with caution, since these files are also required
for these interfaces.
I Description of the Public Interface 146
File name Storage location Description
MMMMUSER.IN <CADDIR> *) Input file for KISSsoft (is written by the third party
program)
User's temporary input file (= will be deleted when
imported into KISSsoft)
MMMMUSER.OUT <CADDIR> KISSsoft output file (will be written by KISSsoft and
read by the third party program). Temporary (=
should be deleted by the third party program)
MMMMUSER.RPT <KISSDIR> Defines the output format (similar to report), can be
permanent/optional (= is usually created once and
is retained)
Z10Gear1.RPT <KISSDIR> Defines the output format for the manufacturing
Z10Gear2.RPT data in the case of cylindrical gears (see below).
Z10Gear3.RPT Corresponds to MMMMUSER.rpt for this special
Z10Gear4.RPT case.
Z10Gear1.OUT <KISSDIR> Output file containing the toothing stamp
for cylindrical gears.
Z70Gear1.RPT <KISSDIR> Defines the output format for bevel gears.
Z70Gear2.RPT
Z17Gear1.RPT <KISSDIR> Defines the output format for crossed helical gears.
Z17Gear2.RPT
Z80Gear1.RPT <KISSDIR> Defines the output format for worm wheels.
Z80Gear2.RPT
Z9aGear1.RPT <KISSDIR> Defines the output format for spline connections.
Z9aGear2.RPT
Z??Gear1.OUT <CADDIR> Toothing stamp, similar to definition files.
Z??Gear2.OUT
*) If you specify the entire file name including the directory, it can also be read from any location.
10.2.2 Requirements placed on the third party program
To successfully run and use KISSsoft within a third party program, the following minimum
requirements must be met. The third party program must
1. have a query mechanism (i.e. macro language) for providing information, e.g. input data,
2. be able to write and read ASCII files,
3. be able to start a program.
I Description of the Public Interface 147
10.2.3 Used files
10.2.3.1 Input file
An input file with the name MMMMUSER.IN will be used. It has the same structure and the same
function as the saved calculations, except for its temporary status. The values are assigned to the
KISSsoft variable names with =. A separate row is used for each variable.
► Example
VERSION=2.5;
m02Aw.dWa=30¶
m02Aw.lW=20¶
m02An.lN=25¶
The input file will be read after the default values are predefined (see chapter 2.4, Defining your own
template files), i.e. the values of the temporary input file will overwrite the values set by the default.
Note: Temporary input files are used for frequently changing variables such as geometry and/or
performance data: data which typically changes from calculation to calculation. It would also be
possible to write this data to the template files, since they represent normal input variables. This
would, however, mean that the program generating these files had to interpret the data that has
already been written, i.e. had to accept permanent constraints, to enable it to completely define the
default and to reset to the default data again at the end.
10.2.3.2 Output file
To return the data that is relevant for the KISSsoft calling program, the specified output file
MMMMUSER.OUT will be generated immediately after a calculation. The scope and the format of the
output file will be defined in a report template called MMMMUSER.RPT window.
This means that KISSsoft can fully adapt itself to the syntax of a third party program. The range of
commands and the report generator's syntax is described in the Reports section (see chapter 8.5,
Report templates). Example report files are supplied to help you with this.
10.2.4 Temporary files
The input file MMMMUSER.IN input file is generated by the third party program and, after having been
read, will be deleted by KISSsoft. The MMMMUSER.OUT output file is deleted when KISSsoft starts,
and created again after a calculation.
I Description of the Public Interface 148
10.2.5 Explicitly reading (importing) and generating data
In addition to the previously described automatic definition you can also explicitly read data by
selecting File >Interface > Read data, or generate it by selecting File > Interface > Output data.
You can therefore select any point in time and use it for many varied tasks, i.e. to generate an order
form etc.
10.3 Example: Interference fit calculation
The following example of the Interference fit assembly calculation is used to illustrate the way that
the KISSsoft interfaces concept works, in more detail.
For the interference fit assembly between the gear rim and the cylindrical gear hub, you need to find
the one tolerance pairing that meets the following boundary conditions:
Permanent torque MD = 88000 Nm
The tolerance pairing involves a system of the standard drill hole (H).
Safety against sliding > 1.4
against fracture of the hub > 1.5
against fracture of the gear rim > 1.5
against the yield point of the hub > 1.1
against the yield point of the gear rim > 1.1
Procedure:
The necessary information for the geometry is extracted directly from the drawing, with a suitable
CAD routine, and converted to the interfaces format defined by KISSsoft:
m01allg.df=640
m01n.da=800
m01w.di=242
m01allg.l=200.
File contents M010USER.IN
Then, start the KISSsoft module. It accepts the geometry data and displays it in the main screen.
In the main screen, enter any parameters that are still missing, the torque, and the materials, and
then start the calculation. In KISSsoft, you can also size the tolerance pairing. Here, you are
I Description of the Public Interface 149
prompted to select suitable tolerance combinations from a list. The system then performs the
calculation with your final selection.
After you have exited the calculation, the results file is automatically converted into a format that can
be read by the CAD macro. The format of this result file is defined via the templates file
M010USER.RPT:
[SHAFT]
ntol_max = %f{m01w.tol.max}
ntol_min = %f{m01w.tol.max}
ntol_bez = %s{m01w.tol.bez}
[HUB]
ntol_max = %f{m01n.tol.max}
ntol_min = %f{m01n.tol.max}
ntol_bez = %s{m01n.tol.bez}
File contents M010USER.RPT
The result then looks like this:
[SHAFT]
wtol_max = 390.000000
wtol_min = 340.000000
wtol_bez = s6
[HUB]
ntol_max = 50.000000
ntol_min = 0.000000
ntol_bez = H6
File contents M010USER.OUT
This data is now attached directly to the appropriate dimension in the CAD system, via the macro.
Summary:
The individual tasks are therefore split up: Each side of the interface will perform only the tasks it is
best suited to. The CAD administers the geometry and passes this information on to the calculation
program, which knows how to process the data, and which, in turn, will return the result to the CAD.
I Description of the Public Interface 150
The CAD system and calculation program can be used efficiently together, with the defined interface.
10.4 Geometry data
KISSsoft has different interfaces for transferring geometry data (contours, drawings):
▪ DXF format (recommended for communication with most CAD systems)
▪ IGES format (which exports tooth forms as splines)
▪ BMP format (Windows bitmap)
▪ JPG/JPEG format (pixel image)
▪ PNG (Portable Network Graphic) format
10.5 COM interface
You can control KISSsoft remotely via a COM interface. It can easily be accessed from Visual Basic
or Excel.
10.5.1 Registering the server
Now register the KISSsoft COM server on your local computer.
There are two different ways of doing this:
▪ Right-click on the context menu and select "As administrator" to display the Windows prompt.
Then, go to the "... /bin32" subfolder and run the "KISSsoftCOM_Register.bat" file.
▪ To do this, enter these two command lines in a Windows input prompt, in the KISSsoft
installation bin32 directory:
KISSsoftCOM.exe /regserver
regsvr32 KISSsoftCOMPS.dll
You will need administrator rights to register the program.
10.5.2 Server functionality
The server has a number of functions that you can use to start a calculation module, read or set
values, and perform a calculation.
I Description of the Public Interface 151
▪ GetModule([in] BSTR module, [in] VARIANT_BOOL interactive) starts a calculation module
from the module descriptor (e.g. Z012 or W010). "interactive" defines whether the calculation
module is to be generated with a graphical user interface.
▪ Calculate() performs the main calculation for the active module.
▪ CalculateRetVal([out, retval] VARIANT_BOOL* isOk) runs the main calculation for the active
module, and returns a value to tell you whether the calculation is OK.
▪ SetVar([in] BSTR name, [in] BSTR value) is a function with which you can set variables to a
required value. This data is transferred as text. You will find the variable names in the report
templates, but there is no guarantee that all these variables will remain the same in the future.
▪ GetVar([in] BSTR name, [out, retval] BSTR* value) returns a variable from KISSsoft as text.
▪ ShowInterface([in] VARIANT_BOOL wait) displays the graphical user interface. Use the "wait"
parameter to specify whether the function is to wait until the dialog is closed.
▪ IsActiveInterface([out, retval] VARIANT_BOOL* isActive) shows whether a KISSsoft dialog
is active.
▪ IsActive([out, retval] VARIANT_BOOL* isActive) shows whether a module has been loaded.
▪ ReleaseModule() releases the loaded module again. You must always release a module again,
to reduce the load on the server.
▪ LoadFile([in] BSTR file name) loads the specified file.
▪ SaveFile([in] BSTR file name) saves the calculation in the specified file.
▪ CheckLicense ([in] name BSTR, [out, retval] VARIANT_BOOL* isOk) shows whether the
license is valid.
▪ GetININame([out, retval] BSTR* name) supplies the name of the loaded INI file.
▪ GetVersionFromFile([in] BSTR filename, [out, retval] BSTR* version) supplies the version
number of the KISSsoft module in the calculation file (e.g. 2.6). (The version number depends
on which module is being used)
▪ GetModulFromFile([in] BSTR filename, [out, retval] BSTR* name) supplies the KISSsoft
module label in the calculation file (e.g. M040). You must first fetch a calculation module
(GetModule).
▪ GetKsoftVersionFromFile([in] BSTR file name, [out, retval] BSTR* kSoftVersion) supplies
the KISSsoft version number (e.g. 03-2011), given in the calculation file.
▪ GetKsoftVersion([out, retval] BSTR* kSoftVersion) supplies the KISSsoft version (e.g. 03-
2011) that is registered and was started via the COM interface.
▪ GetDBName([in] BSTR db_name, [in] BSTR table, [in] SHORT flag, [in] LONG ID, [in]
LONG order, [out,retval] BSTR *name) Use the "flag" parameter to specify whether the ID
(flag = 0) or the result (flag = 1) is to be used as the input. The output is then either the order
and the name of the entry or the ID (in material database BEZ_DIN). No message is displayed if
an error occurs. A "False" is returned for the function.
I Description of the Public Interface 152
▪ GetDBValue([in] BSTR db_name, [in] BSTR table, [in] LONG ID, [in] BSTR fieldname,
[out,retval] BSTR *name) supplies the value present in this database field. No message is
displayed if an error occurs. A "False" is returned for the function. Please note that the bearing
manufacturers have not approved this function for directly extracting bearing data, which is
why this function is disabled.
▪ GetKsoftVersionSettings([out, retval] BSTR* kSoftVersionSettings) supplies the KISSsoft
version of the temporary settings folder in which the personal settings are stored (e.g. 03-2014).
▪ SetSilentMode([in] VARIANT_BOOL silent) defines whether messages are to be hidden or
not, so that calculations can be performed without you having to confirm system prompts.
▪ Report([in] LONG show) writes the report. You can specify whether or not this report is to be
displayed. The report is created in the Temp directory in the "KISS_?" sub-folder.
▪ ReportWithParameters([in] BSTR infile, [in] BSTR outfile, [in] LONG show, [in] LONG
type) creates the report using the specified report template (infile) in the predefined place with
the predefined name (outfile) and supplies the file type. You can enter file names either with or
without the path. When you enter the report template ("infile"), you should also input the file
extension (e.g."Z012ld0.rpt"). If you do not enter a path for this file the program will search the
default directory (see also Reports) for the file. You must also enter the file extension for an
output file. If you do not specify the path, the file is saved to the Temp directory with the name
"KISS_?". The file extension should match the specified type. Use the "show" parameter to
define whether the report is to be displayed, or not. Use the "art" (meaning "type") parameter to
define the output format. (art=0 → rtf format with *1; art=1 → rtf format without *1; art=2 → html
format with *1; art=10 → txt format without *1; art=20 → txt format in Unicode without *1) *1,
art=1000 → pprpt format with *1; art=1001 → pprpt format without *1)
▪ *1 = takes into account the data level
▪ Examples of possible combinations: With default report templates → RTF format:
ReportWithParameters("C:\Program Files (x86)\KISSsoft
2019\rpt\Z070ld0.rpt","C:\Temp\Z070ld0.rtf", 1, 0), HTML format: Call
ksoft.ReportWithParameters("Z070ld0.rpt", "C:\Temp\Z070ld0.html", 1, 2), PPRPT format:
ReportWithParameters ("C:\Program Files (x86)\KISSsoft
2019\rpt\Z070ld0.rpt","C:\Temp\Z070ld0.pprpt", 1, 1000); with drawing stamp report
template → TXT format:
ReportWithParameters("Z10GEAR1d.rpt","C:\Temp\Z010GEAR1d.txt", 1, 10)
▪ Message([out] VARIANT *strings, [out] VARIANT *types:, [out] LONG *numElem) returns
the messages from the last calculation in the first parameter, as an array containing strings. The
second parameter contains the particular message type (error, warning, info). The number of
existing messages is shown in numElem.
I Description of the Public Interface 153
▪ CallFunc([in] BSTR name) Use this function to run special calculations. A more detailed list of
the available calculations is available on request.
▪ CallFuncNParam([in] VARIANT paramArray) Use this function to run special calculations. A
more detailed list of the available calculations is available on request.
▪ SetLanguage([in] LONG Index) Use this function to change the language used for reports,
interfaces and messages. (0 = German; 1 = English; 2 = French; 3 = Italian; 4 = Spanish; 5 =
Russian; 6 = Portuguese; 7 = Chinese)
▪ GetLanguage ([out, retval] LONG* index) Reads the index of the language that is currently set.
Indexes are described in the SetLanguage() function description.
10.5.3 Example of a call from Excel
The best way to describe this functionality is to use an example. To use KISSsoft from Excel, you
must first select Extras > References and then select the KISSsoftCom type library in the Visual
Basic Editor.
The first example shows how to use a single gear calculation to define the tip and root circles of a
gear:
Public Sub ExampleKISSsoftCOM()
Dim ksoft As CKISSsoft
Dim da As String
Dim df As String
' get KISSsoft Instance
set ksoft = New CKISSsoft
' get KISSsoft module for single gear
Call ksoft.GetModule("Z011", False)
' set values
Call ksoft.SetVar("ZR[0].z", "20")
Call ksoft.SetVar("ZS.Geo.mn", "5.0")
Call ksoft.SetVar("ZR[0].x.nul", "0.5")
' Calculate
I Description of the Public Interface 154
Call ksoft.Calculate
' get values
da = ksoft.GetVar("ZR[0].da.nul")
df = ksoft.GetVar("ZR[0].df.nul")
' release module
Call ksoft.ReleaseModule
' release server
Set ksoft = Nothing
End Sub
The second example shows how to display the KISSsoft user interface:
Public Sub ExampleKISSsoftCOM()
Dim ksoft As CKISSsoft
Dim da As String
Dim df As String
' get KISSsoft Instance
Set ksoft = New CKISSsoft
' get KISSsoft module for single gear
Call ksoft.GetModule("Z011", True)
' show interface
Call ksoft.ShowInterface(True)
' get values
da = ksoft.GetVar("ZR[0].da.nul")
df = ksoft.GetVar("ZR[0].df.nul")
Call ksoft.ReleaseModule
Set ksoft = Nothing
I Description of the Public Interface 155
End Sub
The same example with "later binding" (the exact property or method is not determined until runtime,
which enables you to compile the Visual Basic client without having to know the exact function of the
call):
Public Sub ExampleKISSsoftCOM()
Dim ksoft As Object
Dim da As String
Dim df As String
' get KISSsoft Object
Set ksoft = CreateObject("KISSsoftCOM.KISSsoft")
' get KISSsoft module for single gear
Call ksoft.GetModule("Z011", True)
' show interface
Call ksoft.ShowInterface(True)
' get values
da = ksoft.GetVar("ZR[0].da.nul")
df = ksoft.GetVar("ZR[0].df.nul")
Call ksoft.ReleaseModule
Set ksoft = Nothing
End Sub
The fourth example shows a contact analysis that was run using the caControll.dat control file (you
will find an example file in the dat folder) and they way messages were processed after the
calculation:
Public Sub ExampleKISSsoftCOM()
On Error GoTo ExitOnErr
Dim ksoft As CKISSsoft
' get KISSsoft Instance
I Description of the Public Interface 156
Set ksoft = New CKISSsoft
' get KISSsoft module for gear pair
Call ksoft.GetModule("Z012", True)
' load File – change this to fit to a real file on your machine
Call ksoft.LoadFile("C:\yourPathHere\ExCOM3.z12")
' calculate
Call ksoft.Calculate
Dim ioData(0 To 2) as String
' Which calculation to start
ioData (0) = "CalculatePathOfContactForPairKS"
' controling file
ioData (1) = "C:\ yourPathHere\caControl.dat"
' Path for results
ioData (2) = "C:\ yourPathHere\prot"
' calculate contact analysis
Call ksoft.CallFuncNParam(ioData)
' Check for messages
Dim mess As Variant
Dim types As Variant
Dim numElem As Long
Dim typesElem As Long
Dim typesElemStr As String
Call ksoft.Message(mess, types, numElem)
If (numElem > 0) Then
Dim msg As String
I Description of the Public Interface 157
For i = 0 To numElem - 1
msg = CStr(mess(i))
typesElemStr = CStr(types(i))
typesElem = CLng(types(i))
If (typesElem = 0) Then
Call MsgBox(msg, vbInformation)
ElseIf (typesElem = 1) Then
Call MsgBox(msg, vbExclamation)
Else
Call MsgBox(msg, vbCritical)
End If
Next
End If
' close ksoft
Call ksoft.ReleaseModule
' no problems, so exit
Exit Sub
ExitOnErr:
MsgBox ("error occured when calling KISSsoft.")
End Sub
I 3D Interfaces 158
11 3D Interfaces
11.1 Overview of the available CAD interfaces and
their functionality
I 3D Interfaces 159
11.2 Generation of 3D gears
You must first perform a gear calculation to ensure that the results are consistent. Click on Graphics
> Settings to select the CAD system to which you want to export the selected element.
Then, select the Graphics > 3D Export menu option and then specify which individual gears you
want to generate, and the configuration (only possible as individual gears).
In the case of Siemens NX, generation is only possible if you have started KISSsoft from the NX add-
in menu, then run the gear calculation and clicked on the required generation button. In the case of
Creo Parametric (ProEngineer) and CATIA, you must run the CAD interface so that you can start the
gear generation process from KISSsoft. In the SolidWorks, Solid Edge and Inventor CAD systems,
click a generation button to run the CAD process, if it is not already open.
The default setting runs the gear generation process with a permitted tooth form error (tolerance
band) of 1 μm. If this tolerance is too large, you can open the Tooth form tab to change the
tolerance. Once this is changed, you must click Calculate again (Tooth form tab active), to transfer
the inputs and recalculate the tooth form.
Changing the generation type in the Tooth form tab (polylines, arc of circle approximation, splines)
only affects the 2D display. In Siemens NX, SolidWorks and Solid Edge, the part is generated with
splines. In Inventor, Creo Parametric (ProEngineer) and CATIA, it is created with arcs of a circle.
SolidWorks and Solid Edge also support other generation types, which you can change by entering
the additional APPROXIMATION=1 parameter in the KISS.ini (see chapter 2.6.9, Definitions in
[SOLIDWORKS]) file, in the relevant CAD system.
In the case of the gears, the transverse section of the tooth space is usually cut out from a cylinder
and then duplicated as a pattern. For worms with a helix angle > 50° and a number of teeth < 4 the
tooth space is cut out in the axial section and then duplicated.
11.3 Generating 3D shafts
Until now, it has only been possible to generate shafts in 3D in the SolidWorks, Solid Edge, Autodesk
Inventor and Siemens NX CAD systems.
First, a shaft calculation must be performed to ensure the results are consistent. Click on Graphics >
Settings to select the CAD system to which you want to export the selected element.
Then, click Graphics > 3D Export to select the shaft you require, and configuration (if you want to
generate more than one shaft). Each shaft is created individually in the configuration, in sequence, in
its own parts.
This enables you to create a 3D shaft in the CAD system at the click of a button, according to the
data from a KISSsoft shaft calculation.
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11.4 Viewer with neutral format interface
KISSsoft has a 3D viewer for displaying individual gears or a gear system. The viewer is activated
from the Graphics > 3D Geometry menu.
In the 3D viewer, you can export the solid model in STEP and Parasolid formats (text and binary).
Supported gears (see chapter 11.1, Overview of the available CAD interfaces and their functionality)
and details of how to operate the viewer (see chapter 25.3, Geometry 3D). You can change the
settings by selecting Calculation > Settings > 3D Generation.
11.4.1 Parasolid Export of 3D Shafts
Parasolid can be used to generate the solid model of the shaft. The available data formats for export
are STEP, Parasolid text (X_T) and binary (X_B).
Select File > Export > Shaft > 3D Geometry to generate the model. If the calculation model
contains a number of shafts, you can export these by selecting File > Export > Geometry 3D
System.
11.4.2 Face gear: 3D geometry
The 3D model of a face gear is generated by simulating the cutting process. In this simulation, there
are no limitations involving the helix angle, shaft angle or offset. The reference coordinates of the
model are defined according to Roth [3], and the corresponding positions of pinion and gear are
defined by equations (1) and (2).
(1)
(2)
Where rtS is the pinion reference radius and xS is the pinion profile shift coefficient. rtS in the cutting
operation is calculated from the pinion cutter.
To defined the shaft angle and the radial offset (? and a ), select Geometry > Details….
The face gear model is generated by simulating the cutting process, and the tooth flank is
approximated as a spline surface.
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The manufacturing process is based on the Parasolid core, where the quality of the model depends
on the settings made in Parasolid modeling (see Calculation > Settings > Parasolid).
► Note:
The strength calculation is performed with the assumption that the shaft angle is 90° and the radial
offset is 0. The shaft angle and radial offset are only used for 3D model generation, so the strength
calculation results may not be valid.
11.4.3 Bevel gear: generating a 3D model
The 3D geometry model for straight, helical and spiral bevel gears is defined according to ISO 23509
and the tooth form is calculated for several sections along the facewidth. The tooth form is placed
across the planar involutes of the virtual cylindrical gear, at ninety degrees. Then, the tooth flank
surface is generated by sweeping the tooth forms of the sections. The tooth forms in the individual
sections are transformed by the angle φβ into the relevant position. The angle of each section φβ is
calculated separately for the generating and face milling processes by using the auxiliary angles φ
and η. For this reason, the final tooth form along the facewidth is an extended epicycloid (generating)
or circular (milling) form.
Figure 11.1: Definition of the sections for tooth form calculation
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Figure 11.2: Transformation angle of generating (left) and face milling (right) processes
Machine tool manufacturers (such as Klingelnberg and Gleason) also have their own processes for
generating tooth forms that differ slightly from the procedures mentioned above. The tooth form is
called an octoid, and may differ slightly from our tooth form. However, we have ascertained that the
difference between the tooth forms is much less than the tolerance range, and will not cause any
problems in practical use.
11.4.4 Worm wheel: generating a 3D model
The 3D model of the enveloping worm wheel is generated by simulating the actual cutting process.
The tooth forms at several sections along the facewidth are calculated, and the tooth flank is
approximated as a spline surface. The model is generated using the best possible tool to
manufacture the worm. Theoretically, the tool generates the worm, with regard to arc of circle,
pressure angle, and tooth form. However, if the tool itself was manufactured to these specifications, it
would no longer be usable after resharpening, because it would be smaller than the worm. The tools
used to manufacture worm wheels are therefore slightly larger than the worm they are to create so
that they can be resharpened several times, as required [4]. To generate the model using the larger
tool, you can set the oversize factor in the Module specific settings window. You can enter the
oversize factor directly in the Oversize factor for worm wheel cutter (3D) input window.
In this case, the tool will have a larger tooth thickness, and therefore generate a smaller tooth
thickness on the gear. The cutting distance between the hob and the gear will then be changed
accordingly, to ensure a consistent result for the root and tip diameters on the gear.
11.4.5 General information about 3D modeling in Parasolid
If the model could not be generated correctly, you can improve it by modifying the Parasolid settings
(see Calculation > Settings > 3D Generation) or, if gears are involved, by reducing the permitted
deviation (Tooth form > Approximation for export > Permissible deviation tab).
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11.5 3D interface to SolidWorks
Manufacturer: KISSsoft AG
The interface between SolidWorks and KISSsoft is created by direct integration in the 3D CAD
system. Use this to run all KISSsoft calculation modules from within SolidWorks. Cylindrical or bevel
gears calculated in KISSsoft can be generated directly in SolidWorks as a 3D part (see chapter 11.2,
Generation of 3D gears) with a real tooth form. Shafts calculated with KISSsoft can be generated as
a 3D part comprising cylinder and cone elements (see chapter 11.3, Generating 3D shafts) directly in
SolidWorks. From within KISSsoft, you can start SolidWorks with one click on a button. The system
opens a new part, and generates the appropriate part. You can create cylindrical gears with straight
or helical teeth, which are outside or inside, racks with straight or helical teeth, or straight-toothed
bevel gears, as defined in DIN 3971, Figure 1, and shafts.
You can also add gear teeth to existing shafts (see chapter 11.5.1, Gear teeth if existing shaft data is
present). In addition, gear manufacturing data in the 2D range (see chapter 11.5.3.2, Adding
manufacturing data) can be automatically inserted on the drawing as a text field, with the interface.
The gear manufacturing data is attached to the relevant cutout (tooth space).
11.5.1 Gear teeth if existing shaft data is present
Procedure for manufacturing gear teeth:
1. Select the required area in the CAD system
2. In KISSsoft, select which gear (e.g. Gear 1) you want to generate on the cylinder.
Requirements:
▪ The cylinder diameter must already be the correct external diameter for the toothing before
generation starts.
▪ For internal toothing, a hollow cylinder must already be modeled before the gear teeth can be
cut out.
Toothing will be generated for inside and outside cylindrical gears with spur and helical teeth.
11.5.2 Integrate the KISSsoft Add-in (menu options in CAD)
You should register the Add-in when you install it. However, if this doesn't work and the KISSsoft
menu is not displayed in SolidWorks, you must register the Add-in.
Go to the KISSsoft installation directory and select the "SolidWorks\64bit" sub-folder. In it, double-
click on the "SolidWorksRegister64.bat" file to register the interface.
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If the KISSsoft Add-in is registered successfully, a message is displayed to confirm that this is the
case.
To delete the registration, double-click on the SolidWorksUnRegister.bat file in the KISSsoft
installation directory. A message is then displayed to confirm that deregistration was successful.
If the Add-in is not displayed directly in SolidWorks, select the Tools > Add-ins menu to open a new
window. You can then select the KISSsoftSWAdd-in in this window.
This integrates the KISSsoft menu options in SolidWorks. The menu remains present, even after a
restart, and only needs to be linked once.
The KISSsoft Add-in menu options are available in eight languages (English, Chinese, French,
German, Italian, Portuguese, Russian and Spanish). They use the same language as was selected
when KISSsoft was being installed. To set the language, open the kiss.ini file in the KISSsoft
installation directory, click on DISPLAYLANGUAGE, and set the language you require (0 = German,
1 = English, 2 = French, 3= Italian, 4= Spanish, 5= Russian; 6= Portuguese, 7= Chinese). This
language setting now also applies to your KISSsoft system.
11.5.3 Add-in functions (calls)
11.5.3.1 Calling KISSsoft from the Add-in
Select the Tools > KISSsoft menu option to open all the KISSsoft calculation modules directly. The
generation of a new/additional gear will then continue as described in the gear generation process
(see chapter 11.2, Generation of 3D gears).
11.5.3.2 Adding manufacturing data
The Add manufacturing data menu option only works in the Part view. Procedure for adding a gear
stamp to a drawing:
1. Open the part and select a tooth's Cutout.
2. Select the Adding manufacturing data menu option.
This creates a new draft document into which the gear stamp of the selected cutout for the gear teeth
will be inserted.
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11.5.3.3 Opening the calculation file for the created gear
The Open calculation file menu option only works in the Part view. Procedure for opening a
calculation file:
1. Open the part and select a tooth's Cutout.
2. Select the Open calculation file menu option.
This starts KISSsoft in each particular calculation module and opens the calculation file.
11.5.3.4 Simplified gear views
You can draw the gear in one of two different views. In the simplified view, you can create a section
display view of the gear in the drawing which only contains the gear's edge contours and reference
circle. Currently, the simplified view is only available for external teeth. The simplified view option is
not the default setting.
To view a simplified display, open the kiss.ini file in the KISSsoft installation directory and change
this entry:
SIMPLIFIEDPRESENTATIONNAME=Name
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The name given in the kiss.ini file is also the name of the view.
11.6 3D interface to Solid Edge
Manufacturer: KISSsoft AG
This interface creates the direct integration between the Solid Edge 3D CAD system and KISSsoft.
Use this to run all KISSsoft calculation modules from within Solid Edge. Cylindrical or bevel gears
calculated in KISSsoft can be generated directly in SolidWorks as a 3D part (see chapter 11.2,
Generation of 3D gears) with a real tooth form. Shafts calculated with KISSsoft can be generated as
a 3D part comprising cylinder and cone elements (see chapter 11.3, Generating 3D shafts) directly in
Solid Edge. You can start Solid Edge from within KISSsoft at the click of a button. The system opens
a new part, and generates the appropriate part. You can create cylindrical gears with straight or
helical teeth, which are outside or inside, racks with straight or helical teeth, or straight-toothed bevel
gears, as defined in DIN 3971, Figure 1, and shafts.
You can also add gear teeth to existing shafts (see chapter 11.6.2, Gear teeth if existing shaft data is
present). In addition, gear manufacturing data in the 2D range (see chapter 11.6.4.2, Adding
manufacturing data) can automatically be inserted on the drawing as a text field, with the interface.
The gear manufacturing data is attached to the relevant cutout (tooth space).
► Note:
The default template file (e.g. metric.prt) is used to generate gears. To use a user-specific template
file, either define a variable called USERPARTTEMPLATE in the [Solid Edge] section, in the
kiss.ini file, or overwrite the default template file and copy it to the user-specific template files folder
on the default path. If a user-specific path has been set for templates in Solid Edge, this path is used.
Otherwise, the default path for template files is used (e.g. ...\Solid Edge <version>\Template).
11.6.1 Changing the parameter for generation
In Solid Edge, you can toggle between two settings for copying the tooth space (pattern). The
possible modes are: SmartPattern and FastPattern. SmartPattern generates a more accurate tooth
form. However, this takes quite some time and creates a very large gear file. FastPattern is a less
accurate method, but takes less time and generates a smaller gear file. SmartPattern has always
been used to generate gears up to now, since otherwise the gears cannot be created or represented
correctly. In the kiss.ini (see chapter 2.6.8, Definitions in [SOLIDEDGE]) file in the KISSsoft
installation directory, you can set SMARTPATTERN=0, to copy the tooth space in FastPattern mode.
11.6.2 Gear teeth if existing shaft data is present
Procedure for manufacturing gear teeth:
1. In Solid Edge, draw a plane on the surface on which you want to cut out the gear teeth.
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2. Select this plane
3. In KISSsoft, select which gear (e.g. Gear 1) you want to generate on the cylinder.
Requirements:
▪ The cylinder diameter must already be the correct external diameter for the gear teeth before
generation starts.
▪ For internal toothing, a hollow cylinder must already be modeled before the gear teeth can be
cut out.
Toothing will be generated for inside and outside cylindrical gears with spur and helical teeth.
11.6.3 Integrate the KISSsoft Add-in (menu options in CAD)
You should register the Add-in when you install it. However, if this doesn't work and the KISSsoft
menu is not displayed in Solid Edge, you must register the Add-in.
Go to the KISSsoft installation directory and select the "SolidEdge\64bit" sub-folder. In it, double-click
on the "SolidEdgeRegister64.bat" file to register the interface.
If the KISSsoft Add-in is registered successfully, a message is displayed to confirm that this is the
case.
To delete the registration, double-click on the SolidEdgeUnRegister.bat file in the KISSsoft
installation directory. A message is then displayed to confirm that deregistration was successful.
Select Tools > Add-Ins and then Add-In-Manager. You can select/deselect the KISSsoft Add-in in
the Add-In Manager.
The KISSsoft Add-in is displayed in the main menu. This integrates the KISSsoft menu options in
Solid Edge. They are retained even after a restart.
The KISSsoft Add-in menu options are available in eight languages (English, Chinese, French,
German, Italian, Portuguese, Russian and Spanish). They use the same language as was selected
when KISSsoft was being installed. To set the language, open the kiss.ini file in the KISSsoft
installation directory, click on DISPLAYLANGUAGE, and set the language you require (0 = German,
1 = English, 2 = French, 3= Italian, 4= Spanish, 5= Russian; 6= Portuguese, 7= Chinese). This
language setting now also applies to your KISSsoft system.
► Note:
If the selected language uses Unicode fonts (e.g. Cyrillic for Russian), the Localization must be set to
this language (a country with this language) in the operating system.
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11.6.4 Add-in functions (calls)
11.6.4.1 Calling KISSsoft from the Add-in
Select the KISSsoft menu option to open all the KISSsoft calculation modules directly. The
generation of a new/additional gear will then continue as described in the gear generation process
(see chapter 11.2, Generation of 3D gears).
11.6.4.2 Adding manufacturing data
The Add manufacturing data menu option only works in the Part view. Procedure for adding a gear
stamp to a drawing:
1. Open the part and select a tooth's Cutout.
2. Select the Adding manufacturing data menu option.
This creates a new draft document into which the gear stamp of the selected cutout for the gear teeth
will be inserted.
11.6.5 Opening the calculation file for the created gear
The Open calculation file menu option only works in the Part view. Procedure for opening a
calculation file:
1. Open the part and select a tooth's Cutout.
2. Select the Open calculation file menu option.
This starts KISSsoft in each particular calculation module and opens the calculation file.
11.6.6 Simplified gear view
You can draw the gear in one of two different views. In the simplified view, you can create a section
display view of the gear in the drawing which only contains the gear's edge contours and reference
circle. Currently, the simplified view is only available for external teeth. The simplified view option is
not the default setting.
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To view a simplified display, open the kiss.ini file in the KISSsoft installation directory and change
this entry:
SIMPLIFIEDPRESENTATION=1
11.7 3D interface to Autodesk Inventor
Manufacturer: KISSsoft AG
The interface between Inventor and KISSsoft is created by direct integration in the 3D CAD system.
Use this to run all KISSsoft calculation modules from within Inventor. Cylindrical or bevel gears
calculated in KISSsoft can be generated directly in Inventor as a 3D part (see chapter 11.2,
Generation of 3D gears) with a real tooth form. Shafts calculated with KISSsoft can be generated as
a 3D part comprising cylinder and cone elements (see chapter 11.3, Generating 3D shafts) directly in
Inventor. From within KISSsoft, you can start Inventor with one click on a button. The system opens a
new part, and generates the appropriate part. You can create cylindrical gears with straight or helical
teeth, which are outside or inside, racks with straight or helical teeth, or straight-toothed bevel gears,
as defined in DIN 3971, Figure 1, and shafts.
You can also add gear teeth to existing shafts (see chapter 11.7.1, Gear teeth if existing shaft data is
present). In addition, gear manufacturing data in the 2D range (see chapter 11.7.3.2, Adding
manufacturing data) can automatically be inserted on the drawing as a table, with the interface. The
gear manufacturing data is attached to the relevant cutout (tooth space).
11.7.1 Gear teeth if existing shaft data is present
Procedure for manufacturing gear teeth:
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1. Select the required area
2. In KISSsoft, select which gear (e.g. Gear 1) you want to generate on the cylinder.
Requirements:
▪ The cylinder diameter must already be the correct external diameter for the gear teeth before
generation starts.
▪ For internal toothing, a hollow cylinder must already be modeled before the gear teeth can be
cut out.
Toothing will be generated for inside and outside cylindrical gears with spur and helical teeth.
11.7.2 Integrate the KISSsoft Add-in (menu options in CAD)
You should register the Add-in when you install it. However, if this doesn't work and the KISSsoft
menu is not displayed in Inventor, you must register the Add-in.
Go to the KISSsoft installation directory and select the "Inventor\64bit" sub-folder. In it, double-click
on the "InventorRegister64.bat" file to register the interface.
If the KISSsoft Add-in is registered successfully, a message is displayed to confirm that this is the
case.
To delete the registration, double-click on the InventorUnRegister.bat file in the KISSsoft installation
directory. A message is then displayed to confirm that deregistration was successful.
The KISSsoft Add-in menu options are available in eight languages (English, Chinese, French,
German, Italian, Portuguese, Russian and Spanish). They use the same language as was selected
when KISSsoft was being installed. To set the language, open the kiss.ini file in the KISSsoft
installation directory, click on DISPLAYLANGUAGE, and set the language you require (0 = German,
1 = English, 2 = French, 3= Italian, 4= Spanish, 5= Russian; 6= Portuguese, 7= Chinese). This
language setting now also applies to your KISSsoft system.
This integrates the KISSsoft menu options in Inventor. The menu remains present, even after a
restart, and does not need to be linked.
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11.7.3 Add-in functions (calls)
11.7.3.1 Calling KISSsoft from the Add-in
Select the KISSsoft menu option to open all the KISSsoft calculation modules directly. The
generation of a new/additional gear will then continue as described in the gear generation process
(see chapter 11.2, Generation of 3D gears).
11.7.3.2 Adding manufacturing data
The Add manufacturing data menu option only works in the Part view. Procedure for adding a gear
stamp to a drawing:
1. Open the part and select a tooth's Cutout.
2. Select the Adding manufacturing data menu option.
This creates a new draft document into which the gear stamp of the selected cutout for the gear teeth
will be inserted.
11.7.4 Opening the calculation file for the created gear
The Open calculation file menu option only works in the Part view. Procedure for opening a
calculation file:
1. Open the part and select a tooth's Cutout.
2. Select the Open calculation file menu option.
This starts KISSsoft in each particular calculation module and opens the calculation file.
11.8 3D interface to Siemens NX:
Manufacturer: KISSsoft AG
The interface between Siemens NX and KISSsoft creates the direct integration in the 3D CAD
system. Use this to run all KISSsoft calculation modules directly from within Siemens NX. Cylindrical
or bevel gears calculated in KISSsoft can be generated directly in NX as a 3D part (see chapter 11.2,
Generation of 3D gears) with a real tooth form. Shafts calculated with KISSsoft can be generated as
a 3D part comprising cylinder and cone elements (see chapter 11.3, Generating 3D shafts) directly in
NX. You can create cylindrical gears with straight or helical teeth, which are outside or inside, racks
with straight or helical teeth, worms, or straight-toothed bevel gears, as defined in DIN 3971, Figure
1, and shafts.
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If you are generating a new part, the New dialog opens first. In it, you can enter the name of the file
in which the part should be generated. When you use Teamcenter, its dialog is displayed
automatically so you can also generate or save the part in the Teamcenter environment.
You also have the option of adding toothing to existing shafts (see chapter 11.8.2.1, Gear teeth if
existing shaft data is present). In addition, gear manufacturing data in the 2D range (see chapter
11.7.3.2, Adding manufacturing data) can automatically be inserted on the drawing as a table, with
the interface. The gear manufacturing data is attached to the relevant cutout (tooth space).
11.8.1 Integrate the KISSsoft Add-in (menu options in CAD)
First, copy the supplied folder, e.g. NX1847, with its startup sub-folder, to a location that can be
accessed by users at any time.
The kSoftNX_d.men file contains the definition for the KISSsoft Add-in menu options. This file has
different names to reflect which language has been selected. For example, the _e in the file name
stands for English. The other language codes are _d for German, _f for French, _i: for Italian, _s:
for Spanish, _r: for Russian, _p: for Portuguese, and _c: for Chinese. You can copy the file for the
language you require to the startup folder. The KISSsoft menu will then be displayed in this
language.
► Note:
If the selected language uses Unicode fonts (e.g. Cyrillic for Russian), the Localization must be set to
this language (a country with this language) in the operating system.
KISSsoft is also available as a ribbon menu. The English menu with _e is embedded as the default
setting in the startup sub-folder. If you want to change the language in which the menu is displayed,
delete all the files in the startup folder whose name ends with _e. The "... \NX1847\64bit" sub-folder
contains a sub-folder for every available language (e.g. "kSoftNXRibbon_e" for English). You can
copy the entire contents of the folder that has the language you require to the startup sub-folder.
The menu will then be displayed in this language.
The kSoftNX1847.dll file (for example), which contains the links and commands for the menu
options, is also stored in this folder.
You must enter the path of the previously copied folder, for example, NX1847/64bit, in the
NX1847\menu\custom_dirs.dat file, in the NX directory, so that the NX system knows where the
files it is to use are stored.
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The KISSsoftCOM server should be registered as part of the installation process. However, if this
didn't happen, and the KISSsoft interface doesn't work, you must register the Add-in.
Go to the KISSsoft installation directory and select the NX1847\64bit sub-folder. In it, double-click on
the NX_Register64.bat file to register the interface.
If the KISSsoft Add-in is registered successfully, a message is displayed to confirm that this is the
case.
To delete the registration, double-click on the NXUnRegister.bat file in the KISSsoft installation
directory. A message is then displayed to confirm that deregistration was successful.
To ensure the KISSsoft icons are displayed next to the menu options, you must also set a system
variable with the path, to tell the program where the KISSsoft icons can be found.
Example: Set a system variable and this value as the path
KSOFT_ICONS
C:\Program Files(x86)\KISSsoft"version">The startup folder also contains the kSoftNX.ini file, in
which you can change the layers of the bodies, sketches, planes and drafts.
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11.8.2 Calling KISSsoft from the Add-in
Select the KISSsoft menu option to open all the KISSsoft calculation modules directly. By doing this
you can perform calculations in KISSsoft quickly and easily during the design process. The NX1847
(etc.) menu options are inactive while KISSsoft is open. In order to reactivate the CAD program, you
must close KISSsoft.
11.8.2.1 Gear teeth if existing shaft data is present
Requirements:
▪ The cylinder diameter must already be the correct external diameter for the gear teeth before
generation starts.
▪ For internal toothing, a hollow cylinder must already be modeled before the gear teeth can be
cut out.
For example, select the cylindrical gear pair calculation in the KISSsoft menu. The procedure for
generating the gear (see chapter 11.2, Generation of 3D gears) is identical to the procedure for
creating a new one.
If a part is already opened in Siemens NX, a window with 3 selection buttons is displayed:
1. In a new part
2. Available part, absolute positioning
3. Available part, relative positioning
Explanations of the individual selection options and their use:
1. Select In a new part to generate the entire gear.
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2. Select Available part, absolute positioning to select only one side surface on which the gear
teeth are to be cut. The generation process now generates fixed levels on which the gear teeth
will be positioned.
3. Select Available part, relative positioning to select one side surface and two levels (which cut
into the side surface), one after the other. The toothing can therefore be positioned at relative
levels (DATUM PLANE) and is not dependent on the absolute zero point. This positioning is
primarily required for the methodical working method defined in the Teamcenter "Master Model
concept".
The generation of toothing on existing cylinders is performed on both inside and outside cylindrical
gears with straight or helical toothing.
11.8.2.2 Adding manufacturing data to the drawing
You can select the Add manufacturing data menu option to insert a gear stamp of the current gear
in a drawing.
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▪ Teamcenter: If you are working in accordance with the Master Model concept, the features of
the master part are displayed automatically in the non-master drawing when you select Add
manufacturing data.
After you select this menu option, another window opens, in which you can select the object you
require. There, make these selections:
▪ Straight-toothed cylindrical gears: INSTANCE[0](4)TOOTH(4)
▪ Helical cylindrical gears/worms/Straight-toothed bevel gears: TOOTH
Click on OK to open a new drawing. The following window opens, and displays the Drawing view.
Click with the mouse click to align the upper left corner of the table with the manufacturing data on
the drawing. If you want to insert the data into an existing drawing sheet, you must select the tooth
space in the Drawing view once the required drawing sheet is opened. You can select the tooth
space in the next window that is displayed. You are then prompted to confirm that you want to
transfer the manufacturing data to the current drawing sheet.
Click on OK to position the manufacturing data on the drawing (by clicking with the mouse). Click on
Cancel to display a new drawing sheet into which you can insert the manufacturing data.
11.8.2.3 Opening the calculation file
Select the Open calculation file menu option to start KISSsoft. This loads the gear teeth calculation
file and the information is saved directly to the gear teeth feature (tooth space). After you select this
menu option, a window in which you select the required object is displayed:
▪ Straight-toothed cylindrical gears: INSTANCE[0](4)TOOTH(4)
▪ Helical cylindrical gears/worms/Straight-toothed bevel gears: TOOTH
When you click on the OK button, KISSsoft opens in the appropriate module with a loaded gear teeth
calculation file.
11.9 3D interface to Creo Parametric (ProEngineer)
Manufacturer: Applisoft Europe (Italy)
Cylindrical or bevel gears calculated in KISSsoft can be generated directly in Creo Parametric as a
3D part (see chapter 11.2, Generation of 3D gears) with a real tooth form. You can create cylindrical
gears with straight or helical teeth, which are external or internal, or straight-toothed bevel gears, as
defined in DIN 3971, Figure 1.
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In addition to the part, the system opens a drawing in which the gear manufacturing data appear in a
table. Open the CAD system before you start generating a part with the 3D interface to Creo
Parametric.
In the interface to Creo Parametric, you can enter additional variables in the files for the particular
gear (e.g. Z10GEAR1CAD.rpt) in the CAD directory. These additional variables will later be defined
as parameters and saved in Creo Parametric.
The parameters used for the generating process are already defined in Creo Parametric and can no
longer be used. Predefined parameters:
▪ pz, z, b, da, d, df, di, elica, USUnit
If you want to create a model of a part in US customary units (not metric), open the kiss.ini file (see
chapter 2.6.12, Definitions in [PROENGINEER]) and set the USCUSTOMARYUNITS parameter to 1.
You can also change an existing toothing without actually affecting the part (see chapter 11.9.3,
Modifying the selected 3D model). You can also cut gear teeth on an existing shaft (see chapter
11.9.2, Cutting gear teeth on an existing shaft).
A new dialog opens as soon as you start the generating process. This dialog has these three options:
1. Generate gear in new file
2. Generate gear on shaft
3. Exit
If you select Generate gear in new file, the gear is generated in a new part file.
► Note:
If you want to prevent the selection menu or message from appearing, you can specify this in (see
chapter 11.9.5, Changing base settings in the interface).
11.9.1 Integrating the KISSsoft Add-in
The KISSsoftCOM server should be registered as part of the installation process. However, if this
didn't happen, and the KISSsoft interface doesn't work, you must register the Add-in.
Go to the KISSsoft installation directory and select the ProEngineer sub-folder. In it, double-click on
the ProECreoRegister64.bat file to register the interface.
If the KISSsoftCOM server is registered successfully, a message is displayed to confirm that this is
the case.
To delete the registration, double-click on the ProEUnRegister.bat file in the KISSsoft installation
directory. A message is then displayed to confirm that deregistration was successful.
I 3D Interfaces 178
Use one of the three following methods to ensure the KISSsoft menu is present every time you start
Creo Parametric:
1. Copy the Protk_EditGear_Creo3_4_5_6_64bit.dat file (depending on ProE/Creo version) to the
Creo ...\Common Files\...\text\ sub-folder. (For Creo, copy the file to the ...\text\ sub-folder.)
Then, rename the file to Protk.dat.
If you use this method, you can change the Creo start directory to ensure the KISSsoft menu
always starts along with it.
However, if a different Protk.dat is already present, insert the lines in the
Protk_EditGear_Creo3_4_5_6_64bit.dat file into the Protk.dat file.
2. Then copy the Protk_EditGear_Creo3_4_5_6_64bit.dat file into the Creo start working directory
and rename the Protk.dat file.
In this method, you must copy the Protk.dat file into the start directory. The path is displayed in
the properties of the parametric.exe file.
3. Then, write these lines in the config.pro file (in Creo). In other words, define your own path:
protkdat C:\Program Files\KISSsoft<version>
Description of the content of the Protk.dat file:
NAME EditGear
EXEC_PATH C:\Program Files\KISSsoft"code">TEXT_PATH C:\Program
Files\KISSsoft????\ProEngineer\EditGear\text.GB
STARTUP DLL
ALLOW_STOP TRUE
UNICODE_ENCODING FALSE
END
EXEC_PATH and TEXT_PATH must be the absolute path of the installation.
STARTUP DLL and UNICODE_ENCODING FALSE are predefined (do not change them).
Use ALLOW_STOP TRUE to stop the Creo Parametric program (Tools > Auxiliary
Application > Stop).
You can delete this line in the Protk.dat file to prevent users from stopping the interface.
I 3D Interfaces 179
NAME EditGear and END must be present, although you can change the EditGear name if
required.
11.9.2 Cutting gear teeth on an existing shaft
If you run KISSsoft from the 3D export, this menu with the following 3 selection options is displayed:
1. Generate gear in new file
2. Generate gear on shaft
3. Exit
To modify an existing model:
1. Select Generate gear on shaft
2. In Creo Parametric, open the shaft on which you want to cut the gear teeth.
3. Set a new coordinates system to describe the point at which the gear teeth are to be cut. Select
the GearShaft menu option in the KISSsoft menu in Creo Parametric.
4. This opens another menu in which you can specify whether the gear teeth are to be cut across
the entire width or only across part of the shaft.
5. After you have made your selection, select the coordinates system in which the gear teeth are to
be inserted. The coordinates system you select must have a z-axis that is equal to the shaft
axis.
6. The gear teeth are then cut on the shaft.
11.9.3 Modifying the selected 3D model
When you export a tooth form from KISSsoft, the model in Creo Parametric is generated in a new
part.
To modify an existing model:
1. Import the model you want to modify into Creo Parametric, or use the current part.
2. In the KISSsoft menu, select Edit and then YES. This imports the current gear teeth.
3. Then, select Open calculation file. This menu then imports the appropriate gear teeth data to
KISSsoft.
KISSsoft can then regenerate the modified gear teeth. This modifies the current gear teeth.
I 3D Interfaces 180
11.9.4 Modifying the teeth on an existing shaft
Use this procedure to modify the gear teeth generated with the KISSsoft interface on an existing
shaft on an existing model:
1. Import the model you want to modify into Creo Parametric, or use the current part.
2. Select Edit Gear On Shaft, so you can select which gear teeth data is to be modified. KISSsoft
then opens with the data that was stored when the toothing element was generated.
3. Then, modify and recalculate the gear teeth in KISSsoft. You can then restart the 3D export of
the relevant gear teeth. Then, click on the cross in the top right-hand corner of the KISSsoft
window to close it. You are then prompted to confirm whether to save the temporary change.
4. Click on Yes to modify the model. If you click on No, the model remains unchanged.
11.9.5 Changing base settings in the interface
There are a number of ways in which you can set up the interface by setting environment variables:
KISS_PROE_INTERFACE_NO_MENU = YES
For users who cannot set up a connection to Creo Parametric (using PRO_COMM_MSG.exe).
Set this environment variable to YES to stop the interface trying to use this process to run the
connection. This also stops the warning messages, stating that no connection can be created, from
appearing.
KISS_PROE_INTERFACE_NO_MENU = NO
If you set this environment variable to NO, a warning is displayed if no direct connection to Creo
Parametric can be established.
The message describes how to generate the gear despite this.
KISS_PROE_INTERFACE_CLASSIC = YES
The additional dialog in which you can select either Generate gear in a new file or Generate gear
on shaft is then no longer displayed.
KISS_PROE_INTERFACE__CLASSIC = NO
A dialog in which you can select either Generate gear in a new file or Generate gear on shaft is
displayed.
If no environment variables are set, both these values are set to NO.
I 3D Interfaces 181
11.9.6 Saving the files to the PTC Windchill working directory
To save the generated interface files to the PTC Windchill working directory in the PLM system,
change the WORK_IN_CURRENT_FOLDER parameter setting in the SETUP.txt file from NO to YES.
The SETUP.txt file is located in the ...\ProEngineer\EditGear\SETUP.txt sub-folder, in the KISSsoft
installation.
If you have installed Creo Parametric on the server and started it from the client, temporary files are
written to the server, not to the client. To prevent this, set the variables listed below in the Setup.txt
file with this path.
APSF_WORK_DIR C:\temp
11.10 3D interface to CATIA
Manufacturer: SWMS (DE)
Cylindrical or bevel gears calculated in KISSsoft can be generated directly in CATIA as a 3D part
(see chapter 11.2, Generation of 3D gears) with a real tooth form. You can create cylindrical gears
with straight or helical teeth, which are external or internal, or straight-toothed bevel gears, as
defined in DIN 3971, Figure 1.
You can also add gear teeth to existing shafts.
You will find a more detailed description of the interface in a *.pdf file in the CATIA folder in the
KISSsoft installation directory.
I Answers to Frequently Asked Questions 182
12 Answers to Frequently Asked Questions
12.1 Changing the output of angles in reports
Is it possible to output angles (in calculations) in the KISSsoft angle report as degree values as well
as decimal numbers?
Current form: ##.#### °
Required form: ## ° ## ’ ## ’’
To do this, change the report template (*.rpt) accordingly. Read the notes in the manual about report
templates (see chapter 8.5, Report templates) before you do this. The calculation is then performed
in the report. A helix angle is used to show this method:
Previous format, as a decimal number:
Helix angle (grd) %11.4f {Grad(ZS.Geo.beta)}=>
Current format, now as a degree value:
Helix angle (grd) %i° %i' %i" {Grad(ZS.Geo.beta)} {(Grad(ZS.Geo.beta)-int(Grad(ZS.Geo.beta)))*60}
{((Grad(ZS.Geo.beta)-int(Grad(ZS.Geo.beta)))*60-int((Grad(ZS.Geo.beta)-
int(Grad(ZS.Geo.beta)))*60))*60}
12.2 Inputting materials for gear calculations in the
database
When comparing the materials used for gear teeth in a particular company, it became evident that
not all the required materials were present in the database provided by KISSsoft.
In particular, the following key values, necessary for gear calculation, are missing: include σ Flim/Sat,
σHlim/Sac, RzF, RzH and BM.
When you redefine materials and their properties, you must compare them with similar materials in
our materials database.
First of all, define the basic data for a material in the database. Then, define the gear-specific data for
this base material.
I Answers to Frequently Asked Questions 183
Then, calculate the values of σFlim/Sat, σHlim/Sac depending on the hardness values, as described in ISO
6336-5.
To do this, you can either use the relevant material diagram, the conversion function for inputting
your own materials (see chapter 17.1.12.1, Materials) or formulae from ISO. The Sat, Sac values are
converted on the basis of σFlim, σHlim.
A default value is used if no value is input for the thermal contact coefficient BM.
For total heights, specify average values with RzF 10µm and RzH 3µm. You will find more detailed
information about this in ISO 6336-2.
ISO 6336, Part 2 provides more information about the influence of the total height on the calculation
of flank load capacity when an additional material hardening factor, Zw, has been introduced.
12.3 How can I test the software?
A demo version of the software is available at (see chapter 1.1, Basic installation). Although the
demo version does not have an expiration date, its functionality is limited so that, for example, you
cannot change and store material data. The demo version is designed to give you an initial
impression of the software. For a detailed trial, request a test version (see chapter 1.3.1, Test
version). The test version runs for 30 days, is free of charge and is the same as the full version
(without third party programs).
12.4 What licenses are available?
Individual user licenses and network licenses are available for both KISSsoft and KISSsys. A network
license enables the software to be used at more than one workplace.
However, network licenses are not available for some of the third party products, for example, some
CAD interfaces.
12.5 Add your own texts in the results window
To enable this, define a new file in the KISSsoft installation directory in "…\ext\.rpt\". This file must
then be named using this convention: "Modulname + result.RPT" (e.g. for a cylindrical gear pair
Z012result.RPT).
Then define the new parameters or values that are to be added. These values are then also
displayed at the end of the Results window.
I Answers to Frequently Asked Questions 184
12.6 Restoring a previous stage in the calculation
Select File > Restore... (acts like the Undo function) to retrieve an earlier stage of the current
calculation file. For this reason, every calculation run stores the current stage as a restore point. The
list of restore points is deleted when you open a different file.
II
KISSdesign
Chapter 13 - 15
II User interface 186
13 User interface
When the KISSdesign user interface was created, great care was taken to ensure that gear
kinematics could be created and used as easily as possible. The intention was to prevent users from
getting lost in the multitude of functions. The number of necessary entries that could be defined was
kept to a minimum. As many predefined values as possible were to be used to do this.
With these constraints in mind, the main areas of the user interface are described below.
Figure 13.1: KISSdesign user interface with a range of different windows
13.1 Shaft view in the model tree structure
The Shaft view is on the left-hand side in the standard view. All the shaft calculations (shaft groups)
for a constructed gearbox are listed here in the form of a tree structure. In the same way as in the
shaft calculation module, every shaft calculation can include more than one shaft. Every shaft can
have machine elements such as couplings, gears and bearings.
13.2 Calculation view in the model tree structure
The Calculation view not only provides more information about the links between the individual shaft
groups, but also filters this information so that only specific elements and links are displayed. These
selection options are available here:
Transmissions
If you select Transmissions, the gear calculations that are to be considered in the gear units being
created are displayed. The gear calculations include the associated gears, which you can simply
drag and drop into the element from the Shaft view. You can use the mouse to connect the center
points of the gears, in the Sketcher, to achieve the same thing.
II User interface 187
Bearings
An overview of all the bearings is displayed here. If the bearing is connected to the housing on one
side (inner ring or outer ring), only the shaft that contacts the other side of the bearing is listed in the
bearing element. If both the inner ring and the outer ring of the bearing contact a shaft, both shafts
are listed. The convention here is that the top shaft represents the inner shaft of the bearing and the
lower shaft represents the outer shaft of the bearing.
Switching elements
Select this option to display all the switching elements used in the model. Shafts that are connected
to each other are listed in the switching elements. To add a shaft to an existing connection, click on a
shaft in the Shaft view and drag it to one of these elements. You can use the mouse to connect the
switching element on a shaft center with a node on the second shaft, in the Sketcher, to achieve the
same thing.
Planet carriers
All planet carrier elements are displayed in this window. Click on the associated integral planet gear
shaft and drag it from the Shaft view into this element. You can use the mouse in the same way in
the Sketcher to connect the carrier shaft (that was previously defined as the carrier) to the planet
shaft axis. This informs the system that a planetary gear stage is involved and that the added shaft
group is epicyclic.
Power flow
All of the model's kinematic boundary conditions are displayed in this area. A boundary condition is
created automatically for each coupling in the Shaft view.
System
The System tab is not currently used by the program. In future, information about the housing, oil
and housing temperature, lubricant and other global values will probably be displayed here.
13.3 Element Box
All the elements that can be used in the system are displayed in this window. These elements are
grouped according to category: shaft, gear, bearing, connection, force, transmission and power flow.
Click on an element to add it to the Shaft view or to the Calculation view (depending on what type of
element it is). Use the icons in the Element Box to create a model from the beginning or add
elements to an existing model.
13.4 Sketcher
Use the Sketcher to "draw" the gear unit's kinematics with the mouse. All the definitions you make in
the Sketcher are displayed simultaneously in the Shaft view and Calculation view. As a result, you
can create or modify the model directly in the Sketcher. You can switch between the windows at any
time.
II User interface 188
13.5 3D Viewer
The gearbox you have created is displayed in 3D here. You can move it, animate it and record it as a
video in this 3D Viewer. Use this view to check how shaft groups are positioned in space. You can
also modify the pressure angle in the gear calculations listed in the Transmissions selection in the
Calculation view.
13.6 Kinematics
This tab is where you specify the speeds and torque/power at the model's boundary conditions. The
conditions defined here should ensure that the system is kinematically defined. There are no other
functions for calculating kinematics. The system checks automatically after every entry you make, to
see if a solution can be found. If a solution with the predefined conditions is found, all the values are
updated accordingly.
13.7 Ratio
The ratios for individual stages can be defined in this tab. In this case, enter the number of teeth on
the two meshing gears to determine the ratio. Alternatively, you can predefine the stage ratio and the
number of teeth on a gear. In this case, the number of teeth on the other gear is calculated by the
system.
If you predefine the number of teeth: The number of teeth on a gear with external toothing must be a
positive value and the number of teeth on a gear with internal toothing must be a negative value.
If you predefine the ratio: If two gears with external toothing are meshing, enter the ratio as a
negative value, because the gears rotate in different directions (have a different "sense ofrotation").
However, if a gear with external toothing meshes with a gear with internal toothing, enter the ratio as
a positive value, because the gears rotate in the same direction (have the same sense of rotation).
13.8 Module specific settings
The settings for the elements to be used in the model are made in the "Module-specific settings".
Naming of the elements
In this tab, you can change the names of the elements that are to be used in the model. The suffix
"<autoInc>" after each name means that a number that always equals the number of added elements
of this kind is automatically inserted after the name.
II User interface 189
Figure 13.2: Standard element names
Geometric default settings
In this tab, you can preset the dimensions for the toothing geometry and bearing geometry. When
these elements are used in the model, the transmission is displayed with these predefined sizes in
the initial phase.
II User interface 190
Figure 13.3: Predefined toothing geometry and bearing geometry
13.9 Group modeling
You will find predefined gear stages in this window. You can select different cylindrical gear stages,
bevel gear stages and planetary stages. In addition to these stages, individual or paired movable
gears are present, which are primarily used for speed change gearboxes. If you click on a particular
stage several times, or enter a number, you can add several groups at the same time.
II Modeling 191
14 Modeling
Different methods for creating a gear unit model are provided in KISSdesign. All these methods can
be used in each phase in the model. Each step can be performed with different methods. You can
use a different method from one step to the next at any time. The possibilities are described below.
14.1 Creating a model with the Element Box
You can use the icons in the Element Box to create the model in Shaft view. Click on an icon in the
Element Box to insert it in the model tree structure, in Shaft view. The first element to start with is the
shaft calculation. A shaft element is always created automatically when the shaft calculation is
added. If a shaft calculation has several shafts with the same axis, you can insert them by clicking on
the shaft icon in the Element Box. You can click on the other appropriate icons in the Element Box to
insert gears, bearings or other connection elements such as couplings, synchronizers (switching
elements) or the carrier element beneath these shaft elements. To define a new shaft axis, you can
integrate a different shaft calculation by clicking on the relevant element in Shaft view.
After the shaft calculations with the shafts and their elements have finished, you can define the gear
stages as transmissions. To do so, click the blue gear calculation elements in the Element Box. Each
time you click on an element, the selected calculation element is listed in the Transmissions
selection, in the Calculations view window.
Now you need to define the references between the gears and the calculations. To do so, click on
the gears in Shaft view to select them, and then drag them into the associated gear calculation. Drag
over two, three or four gears, depending on the calculation type (two-gear, three-gear, planet or four-
gear calculation). Here, the convention that the sequence of gear elements from top to bottom
matches the sequence of gears in the corresponding KISSsoft calculations applies.
Once you have linked all gear calculations with the gears, you can define the system's driving and
driven conditions. Usually, a boundary condition is generated automatically for each previously
inserted coupling in the Power flow selection in Calculations view.
However, if you want to define other boundary conditions in the model manually, simply click on the
appropriate element in the Element Box. You can then left-click on a coupling element, that is to be
referenced, in Shaft view, to select, it and then drag it over to the previously inserted boundary
condition, to create the link with the couplings. This is the final step in creating a model for a simple
gear unit.
The model is displayed as a schematic sketch in the Sketcher tab at the same time. You can see
how the shaft groups are arranged in the 3D Viewer tab. You can define the boundary conditions in
detail in the Ratio tab.
II Modeling 192
14.2 Creating a model with the Sketcher
You can create the model in the Sketcher, using the mouse as a "drawing" tool, from the very start,
or later in the creation process. When you are "drawing" with the mouse, note these points:
To start and end a shaft, double-click. To insert nodes on the shafts, click once. When you have
finished drawing the shaft, a dashed blue line is displayed on the end of the mouse pointer. Click on
the required grid line to set the position of the associated shaft axis. You can also right-click on the
nodes on a shaft to select them, and then convert them into the appropriate element (bearing, gear,
coupling, etc.) via the selection list. If more nodes are needed at a later time, you can insert them by
clicking on a grid corner on the shaft twice. You can delete a node at any time by right-clicking on it
and then selecting "Delete".
You can double-click to begin defining another shaft and create it as described above. When you do
so, you can assign the shaft to the axis on a previously defined shaft or define a new axisby clicking
on a line in the Sketcher. The model in the Sketcher is built up simultaneously in the Shaft view.
When you create a new shaft axis in the Sketcher, a new shaft calculation is simultaneously
generated in Shaft view.
Once you have drawn the shaft axes with the shafts and their elements, you can now link the gears
with each other. To do so, drag and drop the gear element center points to link them with each other.
Until now, synchronizers and bearings have been defined as individual elements on a shaft. These
elements are often only completely defined between two shafts and can now also be assigned to a
second shaft by dragging and dropping their icon. Bearings that are not assigned to any other shaft
are considered to be fixed bearings in the housing. You can also assign the carrier icon to the axis on
your planet shaft(s) by dragging and dropping the carrier icon.
14.3 Creating a model with groups
Besides creating a model using the Element Box and Sketcher, you can use the Groups Assistant to
generate individual finished sub-assemblies. You can then merge the individual shafts in these
assemblies, by dragging and dropping them in the model tree structure, to create a single gear unit
concept from the individual groups.
II Special Calculations 193
15 Special Calculations
15.1 Modal analysis
This special calculation has been designed to calculate the eigenfrequencies and eigenmodes of a
complete shaft system, including the effect of gear connections between shafts.
To start running this calculation, click on "Modal analysis" in the "Calculation" menu. You must define
the number of eigenfrequencies to be calculated, and specify whether only torsional or all vibration
types are to be included, and whether gyroscopic effects are to be taken into account (does not apply
to torsional vibrations). You must also define which calculation method is to be used to calculate
tooth contact stiffness. The following selections are available for this last option:
▪ As defined in ISO 6336 Method B, if the tooth contact stiffness used here matches the
description in this standard.
▪ Using the contact analysis algorithm (for each gear pair), where a full contact analysis is
performed in the gear connections. If KISSsoft does not have a contact analysis calculation for a
particular gear pair type, or if the gear pair does not transfer power, the ISO 6336 process is
used for that specific pair.
▪ Infinite: the tooth contact stiffness is assumed to be infinite. Select this option if you want to
check limiting conditions.
▪ Ignore: the tooth contact stiffness is assumed to be zero and there is therefore no connection
between the vibrating shafts (each shaft is vibrating independently).
When the calculation is finished, the results can be accessed in the report or in the graphics.
Note that, when you perform a modal analysis for a planetary system, the calculation does not take
into account the effect of the positions of the rotating planets on the system's bending stiffness. This
is similar to the quasi-static calculation procedure usually followed in eigenfrequencies analysis.
15.2 Campbell diagram
A Campbell diagram can be used to investigate the effects of shaft speed on the eigenfrequencies.
This calculation can be used to define the critical eigenfrequencies for each speed.
To start running this calculation, click on the "Campbell diagram" menu option in the "Calculation"
menu. In this dialog, you can also specify the method for calculating the gear mesh stiffness (as
described in the Modal analysis section), the reference boundary for the calculation and the speed
range. You can also specify the number of eigenfrequencies that are to be taken into account in the
II Special Calculations 194
Campbell diagram. Finally, you also have the option of entering the number of resonance curves that
are to be included when the Campbell diagram is displayed as a graphic. A kinematic analysis of the
system is also performed for every speed of the reference boundary condition as part of the
calculation. The speeds of the shafts are updated and then a modal analysis is performed for each of
these reference speeds.
When the calculation is finished, the results can be accessed in the report or in the graphics.
15.3 Forced response
The "forced response" analysis can be used to calculate the real dynamic behavior of a shaft system
that is subjected to dynamic loads (because of unbalance masses). Deformations, rotation, forces
and torques are taken into account in the calculated behavior.
To analyze the unbalance response, select "Forced response" in the "Calculation" menu. You can
then select the method for calculating the mesh stiffness of the gears (refer to the Model analysis
section for a description of the selection options). You also have the option to select the boundary
condition that will be used to control the speeds in the system. You can also select the speed range
and the number of calculation steps.
Finally, you can also define the material damping for torsional, axial and bending vibrations in this
dialog. Note that the viscous damping of bearings must be defined separately for each bearing in the
shaft calculation.
When the calculation is finished, the results can be accessed in the report or in the graphics.
III
Gears
Chapter 16 - 26
III Introduction 196
16 Introduction
KISSsoft provides calculation modules for different toothing types, ranging from cylindrical gears in
different configurations to bevel gears and face gears to worm wheels. The input windows for the
different gear calculations are very similar. There are also calculation options for multiple modules.
The table below shows you all the input windows in the individual calculation modules.
Input window Section
Basic data 17.1
Rating (load) 8.5
Factors 17.3
Reference profile 17.4 is supported by all calculation modules
Tolerances 17.6
Modifications 17.7
Tooth form 17.8
Contact 17.10
analysis
Operating 17.12
backlash
Master gear 17.13
AGMA 925 17.14
16.1 table:
- single gear, - cylindrical gear pair, - pinion with rack, - planetary stage, - three gears,
- four gears, - bevel and hypoid gears, - face gears, - worms with enveloping worm
wheels, - crossed helical gears and precision mechanics worms, - splines (geometry and
strength).
16.1 Underlying principles of calculation
The geometry of straight or angled cylindrical gears is calculated according to ISO 21771 or DIN
3960. Many manuals and standards use very similar methods to calculate this geometry. In addition
to calculating the geometry, it is very useful to have information about how to check for defects
(undercut, insufficient active profile, etc.). Technical documentation provided by tooling
manufacturers or machine tool manufacturers may also include information about this.
Measurements for tooth thickness allowances and backlash can be selected according to different
standards, such as ISO 1328 (1970 edition) or DIN 3967. Manufacturing tolerances can also be
III Introduction 197
defined using standards such as ISO 1328 (DIN ISO 1328), AGMA 2000, AGMA 2015, DIN
3961:1978 or DIN 58405 to suit the particular situation.
Strength is calculated in accordance with, for example, ISO 6336 or DIN 3990, by verifying common
defects (tooth root fracture, pitting, scuffing, micropitting). These standards include the most
comprehensive and detailed calculation methods currently available. There are two methods that can
be used to calculate safety against scuffing. The integral temperature method of calculating scuffing
safety is mainly used in the automobile industry, whereas the flash temperature method is used when
turbo gear units are being manufactured. It has not yet been established which of these two methods
is the more reliable.
Micropitting is calculated according to ISO/ST 6336-22 (formerly ISO/ST 15144-1), Method B. This
method is very reliable for gears without profile modifications. However, in the case of gears with
profile modifications, it has been specified that the tip relief Ca must correspond to the optimum tip
relief Ceff (as proposed in the standard). If not, the verification must be performed without taking the
modification into account. This is a significant disadvantage, because modifications have a
considerable effect on micropitting. In this case, you should use Method A (see chapter 25.5.16,
Micropitting (frosting)).
In the USA, the AGMA 2001 standard must be applied when calculating resistance. This calculation
method differs so much from that required by DIN 3990 that the results cannot be compared. In
addition, there are numerous different methods that are used to calculate the resistance of plastic
gears.
One of the problems with applying DIN 3990 is the wide range of different calculation methods it
contains. There are around 10 different calculation variants that can be applied between Method A
(exact calculation involving measurements) and Method D (the simplest, rough calculation). It is
therefore no surprise that very different results can be obtained from applying calculations according
to DIN 3990 or ISO 6336 to the exact same gear wheel. Whenever possible, KISSsoft uses the most
detailed formulae for dimensioning and analyses during this calculation procedure. This procedure
corresponds to Method B. However, calculations performed using different programs may also give
very different results. It also takes a lot of time and effort to investigate the precise reasons for this. It
is therefore much more effective and efficient to use a reference program to perform the comparison.
One such program is the ST+ cylindrical gear program package developed by the FVA
(Forschungsverein Antriebstechnik, (Research Society for Transmission Techniques, Germany)), at
the Technical University in Munich. For this reason, KISSsoft includes the as in the FVA program
(DIN 3990) option, which supplies the same results as the calculation with the FVA code (see
chapter 17.2.1, Calculation methods). The differences between results obtained by KISSsoft and the
FVA program are negligible. They are due to the minor differences between the FVA program and
the regular version of DIN 3990. If requested, we can provide you with a number of different
documents to help you compare these methods.
Other interesting results are taken from Niemann's book [5]:
▪ Gear power loss with gear loss grade HV according to equation (21.11/4)
▪ Mean coefficient of friction μm according to equation (21.11/6) with 1 ≤ vt ≤ 50 m/s
▪ Gear power loss PVZ according to equation (21.11/3)
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17 Cylindrical gears
You can use KISSsoft's cylindrical gear calculation software to calculate a range of different
configurations.
▪ The single gear calculation has been developed to calculate the geometry and test dimensions
of individual gears
▪ The cylindrical gear pair is the most important configuration for geometry and strength. You can
also use it for additional calculations and several individual calculations at the same time.
▪ The planetary gear software checks the practical aspects of the configuration and monitors both
pairs of gears while they are being sized. The Fine Sizing function enables you to optimize the
center distance quickly and efficiently. You can usually input your own values here. However,
you must take into consideration that, as torque cannot be applied to the planet, it is not possible
to perform a strength analysis on a Wolfrom drive or on a Ravigneaux gear set.
▪ The configurations for three and four gears enable you to calculate a gear wheel chain, in which
torque is applied only to the first and last gear.
▪ Double planetary stages: You can also use the 4-gear chain to calculate a double planetary
stage. However, if gear 4 is an internal gear (negative number of teeth) a check is performed to
see whether it could be a double planetary stage (planetary repositioning stage with the sun in
the center). A note about this is added to the report in the "Supplementary data" section. If gear
4 is a double planetary stage, the center point is calculated under the assumption that M1 and
M4 coincide.
▪ The calculation used for a rack and pinion only includes one rack in the geometry calculation
and one cylindrical gear with an infinite number of teeth for the strength calculation.
As the input screens for the different configurations are very similar, they are described together in
the sections below.
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17.1 Basic data
The Basic data input window is one of the standard tabs (see chapter 5.1, Standard and special
tabs) and is subdivided into the two groups: "Geometry" and "Material and Lubrication".
17.1.1 Hand of gear for gear teeth
The direction of the helix angle of the gear (see Figure 19.3) defines the direction of the axial forces.
Helical gear teeth usually produce less noise than spur gear teeth, but generate an additional
bending moment and an axial force. A gear with continuous double helical teeth consists of two
halves of a helical gear with a different hand of gear. Although it does not generate any axial forces,
it must be possible to adjust the gear along its axis and it is more difficult to manufacture. In a
herringbone gear, click the button to set the gap width bn.
17.1.2 Normal module
Enter the normal module. The normal module defines the size of the teeth. A standard series is for
example defined in DIN 780 or ISO 54. However, if you know the pitch, transverse module or
diametral pitch instead of this, click on the button to open a dialog window, in which you can
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perform the conversion. If you want to transfer the diametral pitch instead of the normal module, you
can select Input normal diametral pitch instead of normal module (see chapter 17.20.1.5, Input of
normal diametral pitch instead of normal module) by clicking on Calculation > Settings > General.
17.1.3 Pressure angle at normal section
The normal pressure angle at the reference circle is also the reference profile flank angle. For
standard meshings, the pressure angle is αn = 20°. Smaller pressure angles can be used for larger
numbers of teeth to achieve higher contact ratios and insensitivity to changes in center distance.
Larger pressure angles increase the strength and enable a smaller number of teeth to be used
without undercut. In this situation, the contact ratio decreases and the radial forces increase.
17.1.4 Helix angle at reference circle
Enter the helix angle in [°]. Click the button in the Convert helix angle window to calculate this
angle from other values such as, for example, the overlap ratio and axial force.
Figure 17.1: Helix angle at reference circle.
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17.1.5 Center distance
As stated in ISO 21771, the center distance for external and internal toothings is positive for two
external gears and negative for an external gear paired with an internal gear. The number of teeth on
the internal gear and the axis center distance are always negative for internal toothing.
If you select the checkbox to the right of the axis center distance unit, the value used in the
calculation will remain constant. Otherwise, the center distance will be calculated from the profile shift
total.
Click the button to select one of the following sizing options:
▪ Fixed sum of profile shift coefficients. The center distance is calculated on the basis of a
predefined profile shift sum. Click the button to display a suggested value for the profile shift
sum, as defined in DIN 3992. The sum of profile shift influences the profile shift coefficients of
both gears as well as the operating pitch circle and the operating pressure angle.
▪ Fixed profile shift coefficient Gear 1 (or 2), balance specific sliding. Optimize axis center
distance with respect to balanced sliding: This option calculates the axis center distance in such
a way as to balance gear pair specific sliding (for cylindrical gears) for a specified profile shift of
a (selectable) gear. If the Own input menu option is not selected from the Own Input drop-down
list in the Reference Profile input window, this calculation is performed with automatic tip
alteration as specified in DIN 3960. You can also enter your own tip alteration value in the Basic
data input window by clicking the Details... button. In the Define geometry details window,
select the checkbox next to the Tip alteration input field.
17.1.6 Number of teeth
The number of teeth is, by default, a whole number. You can also enter the number of teeth as an
amount with values after the decimal place (see chapter 17.20.1.6, Input of number of teeth with
decimal places). For internal toothed gears, you must enter the number of teeth as a negative value
as stated in ISO 21771. For a pinion-ring internal gear pair, the center distance must also be entered
as a negative value (e.g. z1 = 20, z2 = -35, a = -7.5, mn = 1).
The minimum number of teeth is limited by geometric errors such as undercut or tooth thickness at
the tip. For example, if there are fewer than 17 teeth undercut will occur on spur gears without profile
shifts.
17.1.7 Facewidth
Normally the facewidth shouldn't be greater than 10 to 20 times the normal module, or also not
greater than the reference circle of the pinion. The contact pattern deteriorates if the facewidth is too
large. To transfer the axial offset bv , click the button to the right of the facewidth input field (see
III Cylindrical gears 202
also Fig. 14.3). The axial offset reduces the effective width for the strength calculation. The common
width is used to calculate the pressure. A certain amount of overhang is taken into account for the
Tooth root strength. The selected pinion width is often somewhat greater than the gear width.
Figure 17.2: Axial offset bv
In double helical gears* you must specify the total width of the gear teeth (i.e. the width of both
halves together with the gap). To set the gap width bn, click the button to the right of the drop-
down list for the hand of gear for gear teeth.
*Double helical gears are gears that consist of two gear halves; the first half is angled to the left and
the second half is angled to the right.
17.1.8 Profile shift coefficient
Preliminary note: If the profile shift sum has not yet been specified, click the Sizing button ( ), to
the right of the center distance input field, to display a suggested value for the distance in the Sizing
center distance window (see chapter 17.1.5, Center distance). The suggested value is based on
DIN 3992 recommendations for well balanced toothing (Area P4/P5). You will find more information
about this in DIN 3992 or in Niemann [6], Fig. 22.1/6.
The tool can be adjusted for manufacture. The distance between the production pitch circle and the
tool reference line is called the profile shift. To create a positive profile shift, the tool is pulled further
out of the material, creating a tooth that is thicker at the root and narrower at the tip. To create a
III Cylindrical gears 203
negative profile shift, the tool is pushed further into the material, with the result that the tooth is
narrower and undercutting may occur sooner. In addition to the effect on tooth thickness, the sliding
velocities will also be affected by the profile shift coefficient.
The distribution of the total profile shift affects the tooth thickness, sliding movements and strength
values. It can be performed according to a range of different criteria. To achieve this, use the various
sizing options provided by clicking the button in the Sizing of profile shift coefficient window:
▪ For optimal specific sliding
The value suggested here shows the profile shift for a cylindrical gear pair that has been
balanced for a specific sliding between the pinion and the gear. When more than two gears are
involved, the profile shift coefficient is set to the smallest value that corresponds to the specific
sliding movement at the root.
▪ For minimum sliding velocity
The minimum sliding velocity at the tip of the two gears is often used for speed increasing ratios.
In a cylindrical gear pair, this means both gears have the same sliding velocity and that the
access and recess length of the path of contact are also the same.
▪ For maximum root safety
The profile shift coefficient is determined iteratively for the range x *min, x*max .
▪ For maximum flank safety
The profile shift coefficient is determined iteratively for the range x *min, x*max .
▪ For maximum flank safety
The profile shift coefficient is determined iteratively for the range x *min, x*max .
▪ For gear 1 without undercut and point at tip (min)
The minimum value of the profile shift coefficient for gear 1 is calculated from the undercut
boundary of gear 1 and the minimum topland of gear 2.
▪ For gear 1 without undercut and point at tip (max).
The maximum value of the profile shift coefficient for gear 1 is calculated from the minimum
topland of gear 1 and the undercut boundaries of gear 2.
▪ For undercut boundary per gear.
The proposed value only refers to the selected gear. No check is performed to see whether the
resulting profile shift is also permitted for the other gear in the pair. For more information, please
refer to the explanations above.
▪ For minimum topland per gear.
The proposed value only refers to the selected gear. No check is performed to see whether the
resulting profile shift is also permitted for the other gear in the pair. You can specify the
minimum thickness of the topland in the dialog that you see when you select Calculation >
III Cylindrical gears 204
Settings > General > Coefficient for minimum tooth thickness at the tip. For more
information, please refer to the explanations above.
► Note:
The Sizing button is disabled if the "Maintain tip circle when changing profile shift" or "Maintain root
circle when changing profile shift" checkbox has been selected.
Click the button and KISSsoft will determine whether the profile shift coefficients are to be taken
from measured data or from values given in drawings.
The following options are available here:
▪ Base tangent length
Enter the base tangent length (span) and the number of teeth spanned here. This option cannot
be used for (internal) helical gear teeth because their base tangent length cannot be measured.
▪ Measurement over balls
To do this, enter this dimension and the diameter of the ball. In a gear with helical gear teeth
and an odd number of teeth, the measurement over balls is not the same as the measurement
over two pins. See Measurement over pins.
▪ Measurement over 2 pins
To do this, enter this dimension and the diameter of the pin. You must also enter a minimum
span for helical gear teeth and gears with an odd number of teeth, so the measurement can be
performed. The measurement over pins cannot be measured in internal helix gears.
▪ Measurements over 3 pins
Here, enter the measurement over pins and the pin diameter. For helical gear teeth and gears
with an odd number of teeth, this is equivalent to the measurement over two rollers. You cannot
use this option for internal and helical gear teeth, or gears with an even number of teeth.
▪ Tip circle
This is a rather imprecise calculation because the tip diameter does not always depend solely
on the profile shift.
▪ Tooth thickness at reference circle
Here, you specify the tooth thickness. You can also enter the arc length or chordal length, and
specify whether the value is in transverse or normal section.
► Note
If one of the two profile shift values appears in gray, this means it will be calculated by KISSsoft. This
is what happens when you select the checkbox for entering the center distance. If you overwrite a
gray field, it will become active and KISSsoft will calculate the value for one of the other gears.
III Cylindrical gears 205
17.1.9 Tooth thickness modification factor
A tooth thickness modification factor xs is not usually used for cylindrical gears. This is why you
cannot enter this factor in the user interface. However, in exceptional situations, you can use a tooth
thickness modification factor, e.g. via the DLL interface, in KISSsys or by editing the saved .Z12 file.
The RechSt.xs_Active = 1 and RechSt.xs_OwnInput = 1 variables must be set before you can set xs.
Then xs can be applied in the ZkegR[0].XS variables for gear 1 etc. More information about the tooth
thickness modification factor is provided in (see chapter 20.2.8, Tooth thickness modification factor).
17.1.10 Quality
In this input field, you specify the accuracy grade in accordance with the standard shown in brackets.
To Change the standard used for this calculation, select Calculation > Settings > General > Input
of quality. The accuracy grade according to ISO 1328 (DIN ISO 1328) is very similar to the same
quality in BS 436/2.
The manufacturing qualities that can be achieved are displayed in this table:
Manufacturing process Quality according to DIN/ISO
Grinding 2 ... 7
Shaving 5 ... 7
Hobbing (5)6 ... 9
Milling (5)6 ... 9
Shaping (5)6 ... 9
Punching, Sintering 8 ... 12
Table 17.1: Accuracy grades for different manufacturing processes
When converting qualities according to AGMA:
as defined in AGMA 2015-1-A01, Annex B.2, the total of the quality figures in Version 2015
(comparable with ISO) and Version 2000 equals 17.
Quality as specified in ISO 1328 Q. according to AGMA 2000
and AGMA 2015
1 16
2 15
3 14
4 13
5 12
6 11
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7 10
8 9
9 8
10 7
11 6
Table 17.2: Manufacturing quality values in different standards
If you want to define different tolerances, select Calculation > Settings > General and then select
Varying qualities in the dialog you see. This activates the Plus button next to Quality in the main
screen. Click the Plus button to display a new window in which you can enter the tolerances you
require.
You can input the tolerances in standard-specific tabs. The changes in the window are then applied
to all the gears in the calculation module.
This is the table in which you input any deviation from the base manufacturing quality (specified in
the "Basic data" tab). Example: The base manufacturing quality of gear 1 is 6. If you then input +2 for
the runout, the runout will be calculated with an manufacturing quality of 8.
In every case, only tabs (standards) that are possible for the calculation module are displayed. The
user entries remain in this window as long as you continue using the same calculation module. This
enables you to import a different file, and select the checkbox. The same entries will still be displayed
in the window next to the Plus button. You only need to input the data again if you change calculation
module.
Note about axis alignment tolerance according to ISO 10064:
The quality level used to input the axis alignment tolerances specified in ISO 10064 is usually the
same as the best accuracy grade for all gears. If, for example, gear 1 has Q6 and gear 2 has Q5,
quality level 5 is used for ISO 10064. You can also input these values in the Operating backlash
tab.
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17.1.11 Geometry details
Figure 17.3: Define geometry details input window for a cylindrical gear pair
To open the Define geometry details window, click the Details... button in the upper right-hand part
of the Geometry area. Here you can change the values for:
▪ Drawing number
▪ Rim thickness coefficient SR*
▪ Inside diameter di
▪ Inside diameter of gear rim dbi
▪ Web thickness factor bs/b*
▪ Web thickness bs
The drawing number is only used for documentation purposes. You can enter any text here.
The internal diameter is needed to calculate the mass moment of inertia. For solid wheels, enter 0.
For external wheels with webs, enter the relevant diameter di as shown in Figure 14.4. For internal
wheels, enter the external diameter of the gear rim. The inside diameter can be defined by entering
either di or the rim thickness coefficient SR*.
According to ISO or AGMA, the gear rim thickness sr, defined by the inside diameter of rim dbi,
affects the strength. If no gear rim thickness is present, you can enter a value of 0 for dbi. In this case,
the gear rim thickness sr will be determined from the diameter di. If a diameter for gear rim dbi has
been entered, the effective gear rim thickness Sr is determined from (df - dbi)/2. The gear rim
thickness Sr will be output in the report. Where thin gear rims are used, this factor can greatly
III Cylindrical gears 208
influence the calculation of safety factors. For thin gear rims, this value can also be calculated in
accordance with VDI 2737 (see chapter 17.20.5.13, VDI 2737: Calculation of gear rim).
Web thickness factor: If the inside diameter is <> 0, the value input for the web thickness (b s or bs/b)
is taken into account. If bs/b = 1.0 is set, this means no web is present. In this case, the gear body
coefficient CR is 1.0. The ratio b/bs can vary between 0.2 and 1.2. In this case, CR is then < 1 (if b/bs
< 1) or > 1 (if b/bs > 1). The coefficient CR is then used to calculate the tooth contact stiffness (cγα).
Figure 17.4: Dimensioning the diameter.
17.1.12 Material and lubrication
17.1.12.1 Materials
The materials displayed in the drop-down lists are taken from the materials database. If you cannot
find the material you require in this list, you can either select Own input from the list or enter the
material in the database (see chapter 9.4, External tables) first. Click the button to the right of the
materials drop-down list to display the Define material, Gear 1(2) window, in which you can select
the material you require from the database list of available materials. Select the Own Input option to
enter specific material characteristics. This option corresponds to the Create a new entry window in
the database tool.
Strength calculation with normal gear materials:
The cylindrical gear strength calculation formulae defined in ISO 6336, DIN 3990 or AGMA 2001 only
involve specific (most commonly used) materials and treatment methods. These are:
▪ Through hardening steel
▪ Case hardening steel
▪ Nitriding steel
▪ Structural steel
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▪ Grey cast iron with spheroidal graphite
▪ Cast iron with flake graphite
Strength calculation with unusual gear materials (not taken into account in standards):
▪ Stainless steel
▪ Free cutting steel
▪ Aluminum and bronze alloys
KISSsoft handles these materials in the same way as heat treatable steels. This affects a range of
less important values that are used to calculate the permitted tooth root and flank strength: factors
YNT, YdrelT, YRrelT, YX, ZNT. The infinite life strength values σFlim and σHlim must either be measured
or already be known. The S-N curve (Woehler lines) must be defined and used to achieve more
accurate calculations.
▪ Sinter
According to information from the company MIBA (A), sinter has similar properties to GC. For
this reason, all the factors specified in DIN or ISO, which depend on the material type, are
determined for sinter according to all the formulae that are applicable for GC.
Plastics
The strength of plastic gears can be calculated either according to Niemann VDI 2545 or VDI 2736.
The material properties (Young's modulus etc.) and the permitted tooth root and flank stresses are
greatly affected by the temperature and the type of lubrication. This is why calculating the
characteristics for plastic gears requires so much time, effort and experience, especially if only very
little material data is available. VDI guideline 2736 lists the tooth root and flank strengths for a
number of basic materials:
▪ Tooth root strength: POM, PA 12, PA66, PET, PE, laminates
▪ Flank strength: PA 12, PA6, PA66, PBT, laminates
▪ Tensile fatigue strength for worms: POM, PA46, PA66, PEEK
Materials manufacturers also provide gear data that can be used to calculate the strength of plastic
gears. If requested, KISSsoft can also provide the relevant material files.
KISSsoft users can also add their own material data to the plastics database. The appropriate DAT
file contains specific data for each material. The user can then edit the DAT files to calculate plastic
gears using the values for their own materials. They can then use the plastics manager (see chapter
66) to create new .dat files.
As defining the permitted root and flank limiting values takes so much time and effort, and because
these values are often not present, KISSsoft can also perform the calculation using very basic
material properties (e.g. a static calculation can be performed if tensile strength data is present).
III Cylindrical gears 210
As additional information, the name of the plastic includes an overview of the data that is available for
calculating plastic gears.
The data used to calculate plastic gears is available in this format: [S B Fog Wd].
Abbreviations used here:
S - The material's maximum or yield material strength is provided for calculating static root strength
B - S-N curves (Woehler lines) are provided for calculating the root infinite life strength
F - S-N curves (Woehler lines) for all lubrication types are provided for calculating the tooth flank
infinite life strength
Fo - S-N curves (Woehler lines) for oil lubrication are provided for calculating the tooth flank infinite
life strength
Fg - S-N curves (Woehler lines) for grease lubrication are provided for calculating the tooth flank
infinite life strength
Fd - S-N curves (Woehler lines) for a dry run are provided for calculating the tooth flank infinite life
strength
Fog - S-N curves (Woehler lines) for oil and grease lubrication are provided for calculating the tooth
flank
W - Wear coefficients for all lubrication types are provided for calculating wear
Wo - Wear coefficients for oil lubrication are provided for calculating wear
Wg - Wear coefficients for grease lubrication are provided for calculating wear
Wd - Wear coefficients for a dry run are provided for calculating wear
C- S-N curves (Woehler lines) are available for calculating the infinite life strength of the tooth root in
crossed helical gears
► Note:
When a calculation method according to Niemann or VDI is selected, the tooth root, tooth flank and
wear are calculated automatically, if the data for the calculation is present. If no data is present for
one or more of these methods, only the calculations for which data is available are actually
performed.
Converting hardness to infinite life strength values σHlim, σFlim
III Cylindrical gears 211
When you enter data for your own material, the hardness is converted into the infinite life strength
values σHlim, σFlim. To open the conversion dialog, click the appropriate conversion button next to
the input fields for the infinite life strength values σHlim, σFlim. The data is converted in accordance
with the ISO 6336-5:2003 formula described in section 5.
(The data for forged steels is used for "unalloyed/through hardened" and "alloyed/through hardened"
heat treatable steels.)
σHlim, σFlim=A*x+B
x: Hardness value in the unit used in the table (depending on the HV or HBW material type)
A,B: Factors for the particular material type and processing. (from Table 1, ISO 6336-5)
Figure 17.5: Convert infinite life strength values dialog window
Values for σHlim and σFlim that are required for the conversion specified in ISO 6336-5 are
displayed directly in the material screen under "Own input" if these values are possible with the
specified hardness and material type.
In the next conversion dialog, click on another conversion button next to the hardness input field to
start converting the hardness value. In the case of materials that are not alloys you can calculate the
hardness from the tensile strength value or other hardness values.
Shot peened gear
Selecting "Shot peened" only affects the alternating bending factor YM if this is calculated according
to ISO 6336-3, Annex B. This information is primarily required for documentation purposes, so that
this data can be added to drawings. It is well known that shot peening improves the root safety factor.
Until now, the standards for gear strength have not included any suitable data. However, if
measurements have shown the extent to which σFlim is increased by shot peening, this effect can be
taken into account either with the technology coefficient YT or by increasing σFlim.
III Cylindrical gears 212
17.1.12.2 Calculation of the wear coefficient kw for steel
According to Niemann [5], Table 21.6/5, and Plewe's dissertation [7], which calculates an
approximate guide value for coefficient of wear, kw depends on the size of the lubricant gap in the
operating pitch circle hc. The function defined by Plewe, kw = f(hmin), is valid for standard mineral oil
without high pressure additives.
Figure 17.6: Input window for wear coefficient
You should take care when using this guide value, because the existing information is far from
complete. In particular, very little is known about the influence of surface roughness and the influence
of lubricant additives. You should take careful measurements to check the wear factor to ensure
reliable results from the calculations.
Influence coefficient of lubricant: As stated in [5], adding suitable additives to a lubricant can
significantly reduce the amount of wear. The influence coefficient of the lubricant can therefore lie in
a range between 0.01 and 1.
Influence coefficient of material: Plewe took measurements from various different material pairings:
Gear made of through hardening steel paired with a hard or soft counter gear, gear pairs made of
case-hardening steel, and gear pairs made of nitriding steel. The value of kw as defined by Plewe
was then determined for these combinations. The influence coefficient can be used for other
combinations (if known). For more information, see [5].
17.1.12.3 Lubrication
Select the lubricant from a list. If you select Own Input, click the button to specify your own
lubricant.
III Cylindrical gears 213
If you see the note (with kw info) after the lubricant description, this means a lubrication influence
factor kwlub is present for this lubricant. This factor can then be used to determine the wear coefficient
kw more accurately.
You can select oil bath or oil injection lubrication, or grease lubrication, or none at all (dry run). You
can select dry run only when using a calculation method for plastics.
Click the button to the right of the lubrication type drop-down list to display the Define
temperatures window.
Figure 17.7: Define temperatures for dry run dialog window
Here, you can either specify your own lubricant temperature or enter the root and flank temperatures
for a dry run in the case of plastics. Usually, these temperatures are calculated for plastics. However,
you can also switch off the calculation and define your own temperatures.
17.1.12.3.1 Calculating the required amount of lubricating oil
When the injection lubrication method is used, the required amount of lubricating oil is calculated as
specified by Schlecht [8]. This assumes a difference of 10°C between the temperature of the oil at
the inlet and outlet. The specific heat capacity cp (Ws/(kg*K) and the specific weight at operating
temperature are defined as specified by Niemann [6].
17.2 Load
The Rating (load) input window is one of the standard tabs (see chapter 5.1, Standard and special
tabs) and is subdivided into the two groups Strength and Load spectrum.
17.2.1 Calculation methods
In the drop-down list, you can select the following calculation methods:
III Cylindrical gears 214
▪ 1. Geometry calculation only. If the "Rating" module is not selected in the "Calculation" menu,
only the geometry is calculated.
▪ 2. Static calculation. Unlike DIN 743 which, for example, has a specific method for static shaft
calculations, ISO 6336 does not have its own calculation method for static calculation. In a static
calculation, the nominal stress is usually compared with the permitted material parameters (yield
point and/or tensile strength). This performs a static calculation of cylindrical gears in KISSsoft.
In this calculation,the nominal stress in the tooth root (calculated using the tooth form factor Y F)
is compared with the yield point and tensile strength. (see chapter 17.2.1.1, Static calculation).
▪ 3. ISO 6336:2019 Method B (Calculation of load capacity of spur and helical gears). Method B is
used for this calculation.
▪ 4. ISO 6336:2006 Earlier version of ISO 6336, no longer valid.
▪ 5a. DIN 3990, Method B, YF Method B (Calculation of load capacity of cylindrical gears). This
calculation is also performed using Method B. However, either Method B or Method C can be
used to calculate the tooth form factor (We recommend Method C for internal toothings.
Otherwise, use Method B).
▪ 5b. DIN 3990, Method B, YF Method C.
▪ 6. DIN 3990, Part 41 (Vehicle Transmission), Method B (Load capacity calculation for vehicle
transmissions). Method B is used for this calculation. Two application factors must be
transferred to form the load spectra (see chapter 17.2.4, Application factor).
▪ 7. AGMA 2001-B88. (See AGMA 2001-C95)
▪ 8. AGMA 2001-C95. This edition of the AGMA 2001-C95 American national standard replaces
AGMA 2001-B88. The previous version of the AGMA standard has been retained because many
companies still use old versions of the guidelines. In fact, there are very few differences
between the old edition, B88, and the new edition, C95. However, the new edition does include
the service factor calculation.
The standard is implemented in its complete form and the dynamic factor and the face load
factor are calculated in accordance with AGMA recommendations. The geometry factors (for
tooth root and flank) are calculated entirely in accordance with ANSI/AGMA 908-B89.
In addition to all the relevant intermediate results, the following values are also supplied:
Pitting Resistance Power Rating, Contact Load Factor, Bending Strength Power Rating, Unit
Load for Bending Strength, Service Factor.
This calculation can also be used for every other cylindrical gear configuration (including
planetary stages). However, it is remarkable that the AGMA standard does not permit tooth root
III Cylindrical gears 215
strength to be calculated directly in internal gear pairs. In this case the calculation must be
performed using the graphical method (see chapter 17.2.7, Strength details (AGMA)).
▪ 9. AGMA 2001-D04.
Most recent version of AGMA 2001. Differs only slightly from the previous version, C95.
▪ 10. AGMA 2101-D04. (Metric Edition)
Equivalent to AGMA 2001-D04, but all values in SI units.
▪ 11. Special AGMA standards: 6004-F88, AGMA 6014-A06
Special standards used in the USA to calculate the strength of open gear rims. These
calculation methods are based on the AGMA 2001 or 2101 basic standards. However, some
factors have been specifically defined for special applications.
AGMA 6014 replaces the old AGMA 6004; but both methods are still available because AGMA
6004 is still requested.
▪ 12. AGMA 6011-I03: For turbo drives (High Speed Helical Gear Units) and API 613
The AGMA 6011 standard is a special edition for high-speed gear units and is less complex than
AGMA 2001 (or the metric AGMA 2101) base standards. In this case, "less complex" means
that some data is already predefined. For example, AGMA 2001 has the options "Open
gearing", "Commercial gear unit" and "Precision gear unit" for defining the face load factor,
whereas AGMA 6011 has "Precision gear unit" as a predefined requirement. AGMA 6011 also
provides information to help you select the application factor (Ka) for specific turbo-driven
applications and other useful notes about this type of gear unit (lubrication arrangement etc.). It
is therefore always possible to perform the calculation according to AGMA 6011 using AGMA
2001 or 2101 without causing any problems. To input data correctly for AGMA 2001, as
implemented in KISSsoft, that is also correct for AGMA 6011, you must be aware of the
constraints, and take them into consideration when entering the parameters. Select the AGMA
6011 method to save the user having to do this. In this situation, the program checks whether all
the constraints are set and, if not, displays a prompt asking the user if they want to make any
modifications.
Calculation according to API 613 (Special Purpose Gear Units for Petroleum, Chemical and Gas
Industry Services, 2003). API 613 states that the calculation must be performed according to
AGMA 6011. However, this also involves a number of special features. To perform the
calculation correctly, you must use our information sheet which describes the necessary checks
and inputs: kisssoft-anl-078-E-CylindricalGears API613.docx. The values required by API 613,
such as flank load K or the permitted value Ka, bending load S and the permitted value Sa, as
specified in Annex J of API 613, are documented.
▪ 13. AGMA 6015-A13: For rolling mill gears
The AGMA 6015 standard is a special edition for rolling mill gears and is less complex than
III Cylindrical gears 216
AGMA 2001 base standard. In this case, "less complex" means that some data is already
predefined. For example, AGMA 2001 has the options "Open gearing", "Commercial gear unit"
and "Precision gear unit" for defining the face load factor, whereas AGMA 6015 has "Precision
gear unit" as a predefined requirement. Other fundamental restrictions are listed in Chapter 1 of
the standard. Select the AGMA 6015 method to save the user having to do this. In this situation,
the program checks whether all the constraints are set. If not, the user sees a prompt asking
them if they want to make any modifications.
The permitted material properties for bending (sat) and pitting (sac) specified in AGMA 6015 for
the same material are different from the properties given in AGMA 2001. The values must be
defined by the user in accordance with Table 3 (sac) and Table 4 (sat) in AGMA 6015 and then
entered in the program (set material to "Own Input")!
AGMA 6015 provides conditions for "Service factors" in Annex C. The conditions are for
information purposes only (not binding) and must be discussed and agreed with the customer.
Enter the coefficients by selecting "Module specific settings" > "Required safeties" and then
clicking "Service factors" > "Service factors for AGMA".
▪ 14. GOST-21354-87
Calculation according to the Russian guideline (latest edition, 1987). Take the following notes
into account, (see chapter 17.2.1.2, GOST-21354-87).
▪ 15. Plastic as defined in Niemann
Please refer to [5] and Table 13.3 to see the differences.
▪ 16. Plastic as defined in VDI 2545 (YF, Method B) (thermoplastic materials used in gears). This
method has been withdrawn, and replaced by the new method, according to VDI 2736. This
regulation defines how calculations are performed on gears made of plastic or combinations of
plastic and steel. (see chapter 17.2.1.3, Plastics according to Niemann, VDI 2545 or VDI 2736).
▪ 17. Plastic as defined in VDI 2545 (YF, method C).
In this calculation method, the tooth form factor Y F is calculated according to Method C.
▪ 18. Plastic as defined in VDI 2545-modified (YF, method B).
This method was recommended for use by KISSsoft before VDI 2736 was published. VDI 2736
contains all the modifications recommended according to Tables 13.3 and 13.4. This method is
recommended for plastics with normal toothing. Transverse contact ratio εα< 1.9. See Table 14.4
for the differences between VDI und VDI-modified.
▪ 19. Plastic in accordance with VDI 2545-modified (YF, method C).
This method is recommended for plastics with deep tooth forms. Transverse contact ratio ε α<
1.9. See Table 14.4 for the differences between VDI und VDI-modified. See Table 14.4 for the
III Cylindrical gears 217
differences between VDI und VDI-modified. In this calculation method, the tooth form factor Y F
is calculated according to Method C.
▪ 20. Plastic according to VDI 2736.
We recommend you use this calculation method, VDI 2736, which was published for the first
time in 2014/15. It includes all methods described in Sheet 2 of VDI 2736 (empirical calculation,
tooth root, tooth flank, deformation, wear).
▪ 21. As in FVA program (DIN 3990). Supplies the same results as the FVA (Forschungsverein
Antriebstechnik: German Research Society for Transmission Techniques) Reference Program.
Based on DIN 3990 Method B with minor differences.
KISSSOFT regularly performs comparisons between calculation examples using the FVA's
STplus cylindrical gear calculation method. The first comparison was performed in 2002, with
STplus edition 1988. The next was in 2003 (with STplus 3.2). As new investigations mean that
STplus differs slightly in some places from DIN 3990, it was decided to implement this
calculation approach as "similar to FVA" in KISSsoft. The most recent comparison was
performed with STplus 6.0 in 2016. As the DIN 3990 standard has remained unchanged since
1985, the results for the various different programs have also remained much the same.
▪ 22. BV/Rina FREMM 3.1 Naval Ships and Rina 2010 (ISO 6336)
Calculation guidelines for ships' engines.
▪ 23. DNV 41.2, Calculation guideline for ships' engines
In principle, the Det Norske Veritas calculation guideline [9] for ships' engines corresponds to
ISO 6336 (root, flank) and ISO 13989 (scuffing). However, it does have some significant
differences, especially where S-N curves (Woehler lines) are concerned. These differences are
detailed in our kisssoft-anl-076-DE-Application_of_DNV42_1.pdf information sheet, which is
available on request.
▪ 24. Lloyd's Register, classification for ships
Calculation guideline for ships' gears
▪ 25. ISO 13691, High-speed special-purpose gear units
Calculation guideline for high-speed gear units
17.2.1.1 Static calculation
▪ Each coefficient (application factor, face load factor, transverse coefficient, dynamic factor) is set
to 1.0. The load at the tooth root is calculated with the tooth form factor according to ISO 6336
Method B and the helix angle (without the stress correction factor).
III Cylindrical gears 218
(12.1)
(12.2)
▪ It also calculates the local tooth root stress multiplied by the stress correction factor Y S . This
stress is approximately the same as the normal stress calculated in an FEM model. This stress
is then also output in the report:
(12.3)
17.2.1.2 GOST-21354-87
Quality according to GOST 21354-87
GOST only takes into account one quality, which is why the poorer quality of the two gears is used
during the calculation.
Q = max (Q1, Q2)
Infinite life strength values for root and flank
The infinite life strength values σFlim and σHlim are saved in the database, in KISSsoft, or you can
enter them, if you select "Own input".
Infinite life strength for tooth root
The infinite life strength sFlim is calculated as follows, according to GOST:
σFlim = σFlim0 * Yz * Yg * Yd * YA * YT
σFlim0 – nominal infinite life strength in the case of a limit load cycle (GOST 21354-87, Tables 14 to
17).
Yz - blank coefficient (GOST 21354-87 Table 13, Formula 10.3).
Yd – Takes into account the hardening of the root transition zone (GOST 21354-87, Tables 14-17).
Yg – takes into account the grinding of the root transition zone (GOST 21354-87, Tables 14 to 17).
YT – technology factor (GOST 21354-87, Table 13, Formula 10.2). The default technology factor
setting is 1.0, but you can change it in KISSsoft. Select Factors – Z-Y factors.
YA – alternating bending factor (GOST 21354-87 Table 13, formula 10.6). The alternating bending
factor setting is 1.0, but you can change it to your own input in KISSsoft. Select Factors –>
Alternating bending factor.
The Yd, Yg and Yz factors cannot be entered in KISSsoft and must be included directly when the
infinite life strength is entered.
In addition to the factors mentioned above, the infinite life strength defined in GOST must be divided
III Cylindrical gears 219
by 2.0 before being entered in KISSsoft. In the calculation, sFlim is then multiplied by the stress
correction factor YST = 2, in a similar way to in ISO or DIN.
Consequently, the correct entry for sFlim in KISSsoft, for calculations according to GOST, is:
σFlim (KISSsoft entry) = sFlim0 (according to GOST) * Yd * Yg * Yz / 2.0
Required minimum safeties
GOST has the special property that the minimum safety set for tooth root fracture and the flank
depends on the material type and the surface hardening. For this reason, you can enter minimum
safeties for every gear individually, for GOST, under "Settings" > "Required safeties".
Information about root rounding
In various GOST formulae, a distinction is made between whether the root rounding is ground or not.
To make this distinction, you must select "Rating" > "Details" > "Gear" and enter a suitable value.
Face load factor flank calculation KHb
The face load factor (flank) is calculated according to GOST, Table 6, Formula 7. The considerations
described in GOST 21354-87, Annex 6, are ignored.
Face load factor root KFb
The face load factor (root) is calculated according to GOST 21354-87 Table 13, Formula 4.
Dynamic factor KV
The dynamic factor is calculated according to GOST 21354-87 Table 6, Formula 6. If conditions (34)
and (35) specified in Formula 6 are not fulfilled, KISSsoft calculates the dynamic factor according to
GOST 21354-87 Annex 5.
Load spectra
Calculations with load spectra are performed using the rules defined by Palmgren-Miner, according
to ISO 6336-6.
Safety of the hardened layer
The safety of the hardened layer is calculated according to DNV 41-2.
17.2.1.3 Plastics according to Niemann, VDI 2545 or VDI 2736
The calculation methods used for plastics take special account of the fact that these materials are
very sensitive to extremes of temperature. The types of lubrication used here include oil, grease or
none at all (dry run). The acceptable load for each material is calculated from figures in data tables,
in DAT format, while taking into consideration the local temperatures at the tooth flank and root, and
the number of load cycles. The local temperature can be calculated when grease is used as the
lubricant or during a dry run. However, when oil is used as the lubricant, the oil temperature is used
as the local temperature. The calculation is performed for combinations of plastic/plastic and also
steel/plastic. The acceptable deformation is also checked. KISSsoft supplies data for the
following materials:
III Cylindrical gears 220
▪ Polyamide (PA12, PA6, PA66, PA46)
▪ Polyacetal (POM)
▪ Polyetheretherketone (PEEK)
▪ Polybutylene terephthalate (PBT)
▪ Polybutylene terephthalate (PET)
▪ Laminate
▪ Data about other materials is available on request
All the specific properties of each material are stored in text tables (DAT files) to enable the
integration of own materials (see chapter 9, Database Tool and External Tables). The strength of
plastics can be calculated either as defined by Niemann [10], or according to VDI 2545 (1981*) [11]
or VDI 2736 [12]. You can also use the modified calculation method as detailed in VDI 2545. This
calculates the stress using the tooth root stress correction factor Ys. The major differences between
the two methods are:
*Calculation method VDI 2545 has been withdrawn and replaced by VDI 2736.
Root Niemann VDI 2545 VDI 2545-mod. VDI 2736
YF C B or C B or C C
YS DIN 3990 1.0 DIN 3990 DIN 3990
Yε 1.0 8) 1/εα 7) 9) 1/εα 7) 9) DIN 3990
Yβ 1.0 DIN 399010) DIN 3990 10) DIN 3990
σFE 2 *σFlim σFlim 2 *σFlim 2 *σFlim
17.3 table: Differences between the calculation methods used to calculate the root safety factor for plastics
Flank Niemann VDI 2545 VDI 2545-mod. VDI 2736
Zε 1.0 DIN 3990 DIN 3990 DIN 3990
ZV DIN 3990 5) 10) 1.0 1.0 1.0
ZR DIN 3990 6) 10) 1.0 1.0 1.0
17.4 table: Differences between the calculation methods used to calculate the tooth flank load capacity for plastics
Tooth deformation: Very different calculation methods!
5) only for laminated wood, otherwise 1.0
6) only steel/plastic combinations, otherwise 1.0
7) For tooth form factor Y as defined in Method B: 1.0
F
8) the method sets the face contact ratio for the tooth root stress to the value 1.0. According to
Niemann, this is because the material data is not always precise. The formulae used in VDI 2545
correspond to those used in ISO 6336:1996.
9) For crossed helical gears = 0.25 + 0.75/εγ
10) For crossed helical gears = 1.0
III Cylindrical gears 221
17.2.1.4 Calculation method for scuffing
Scuffing is calculated according to flash temperature, using the integral temperature process.
The following selection options are available here:
▪ Corresponding to the strength calculation method
Here, if the DIN strength calculation method is used, scuffing is calculated as defined in DIN 3990-4.
For all other calculation methods, scuffing is calculated as specified in ISO TR 13989.
▪ Always according to ISO TR 13989
Scuffing is always calculated as specified in ISO TR 13989.
▪ Always according to DIN 3990-4
Scuffing is always calculated as specified in DIN 3990-4.
Contrary to DIN 3990-4, the following formulae are used for the tooth bulk temperature (analogous to
ISO ST 13989):
For injection lubrication, XS=1.2 (otherwise 1.0). There is little point in multiplying the oil temperature
(theoil) by the coefficient as specified in DIN 3990-4.
▪ Always according to DIN 3990-4, similar to STplus
STplus (Version 6.0) uses the original formulae according to DIN 3990-4 for the tooth bulk
temperature. In contrast, contrary to DIN 3990-4, the dynamic oil viscosity etaM is calculated
with the oil temperature (instead of the tooth bulk temperature).
Depending on which option is selected, the integral temperature and flash temperature are calculated
according to the appropriate standard.
17.2.1.5 Calculation method for micropitting
Micropitting is calculated according to ISO/ST 6336-22 (previously known as ISO/ST 15144-1).
Further information,(see chapter 16.1, Underlying principles of calculation) and (see chapter 25.5.16,
Micropitting (frosting)).
III Cylindrical gears 222
17.2.1.6 Tooth flank fracture calculation method
Tooth flank fracture appears in the area of the active tooth flank instead of in the area of the highest
bending stress at the 30° tangent.
Tooth flank fracture (TFF) can be calculated according to the draft ISO Technical Specification ISO
DTS 6336-4. Earlier investigations performed by Dr Annast in Munich [13] have been updated and
expanded by others. Witzig [14] has put together a first draft of ISO DTS 6336-4. Important: TFF as
specified in ISO TS 6336-4 can only be applied for case-hardened materials.
To display the necessary entries for tooth flank fracture, select Details in the Strength tab (see
Figure 17.13).
Hardening depth (HD)
You can input the intended hardening depth (for hardness HV400, for nitrided steels, or HV550 for all
other steels). You can also input the hardness HV300. This value is then used to display the
hardening curve as a graphic. The input applies to the depth measured during final machining (after
grinding).
When you input this data, the safety of the hardened surface layer is calculated automatically
according to DNV 41.2 [9]. A minimum value of t400 (nitrided steel) or t550 (all other steels) is used
here. If only the value for HV300 is known, this value is then used. However, the calculation should
then only be seen as an indication. The calculation is performed as described in the "Subsurface
fatigue" section in [9]. The values required to define the CHD hardening depth coefficient YC, as
specified in DNV 41.2, are also needed. The calculation does not use the same approach as the
calculation for the proposal for the recommended hardening depth, but still returns similar results. To
obtain a proposal for a sensible hardening depth, we recommend you call the relevant calculation by
selecting Report > Proposals for hardening depth. A maximum value for the hardening depth is
only used to check the hardening depth at the tooth tip. It is mainly used for documentation purposes.
There are three calculation options:
▪ Use a hardness file for the gear material, if this file already exists in the database
▪ Select an independent file with the hardness information,
▪ Directly enter the core hardness and a method for generating a theoretical hardness curve
according to Lang or Thomas (as in ISO DTS 6336-4)
Using measured hardening curves for tooth flank fracture according to ISO DTS 6336-4
Evaluations of measurements taken at wind power installations by Vestas (2017) in the ISO TC60-
WG6 committee have shown that reliable results cannot be obtained using measured hardness
curves according to the method specified in ISO DTS 6336-4 (due to the scatter of the individual
measuring points). We recommend that you use the theoretical hardness curve defined by Thomas
(or Lang) to approximate the measured hardness curve and then use this value in the calculation.
III Cylindrical gears 223
Figure 17.8: Structure of the hardness file (important: depth values must be entered in mm)
The results of the tooth flank fracture calculation are given in the special report (Select "Report" >
"Tooth flank fracture").
17.2.1.7 Elliptical deformation
Applicable on the external gear (Gear1) of an internal-external cylindrical gear pair. This enables you
to display the elliptical deformation of the race in a special gear unit in 2D. Typically z1+z2 = -2
applies here.
The contour of the race is stretched vertically by the lengthening factor and compressed horizontally
so that the root circumference of the ellipse matches the root circle circumference of the undeformed
gear. In a 2 D display, it is important you check:
- that the gear can be generated without collision over a pitch.
- that opposing sides mesh correctly.
If you need to make a modification, select a different lengthening factor or a different number of teeth
(if the total number of teeth is an even number). Values between 0 and 5 % can be used as the
lengthening factor.
Note: You cannot create a 3D output for this variant.
17.2.2 Service life
Enter the required service life directly in the input field.
Click the button to size this value. This process uses the minimum safety value for the tooth root
and flank strength to calculates the service life (in hours) for every gear and for every load you
specify. The service life is calculated according to ISO 6336-6:2006 using the Palmgren-Miner Rule.
The program displays the system service life and the minimum service life of all the gears used in the
III Cylindrical gears 224
configuration. Click the button to size the service life either with or without defining a load
spectrum (see chapter 17.2.8, Define load spectrum).
17.2.2.1 Number of load cycles
KISSsoft calculates the number of load cycles from the speed and the required service life. If you
want to influence the value, you can define it in the Number of load cycles for gear n window.
Click the button to access this. Here, you can select one of five different calculations for
calculating the number of load cycles.
1. Automatically The number of load cycles is calculated automatically from the rating life, speed,
and number of idler gears.
2. Number of load cycles Here, you enter the number of load cycles in millions. You must select
this option for all the gears involved in the calculation, to ensure this value is taken into account.
3. Load cycles per revolution Here you enter the number of load cycles per revolution. For a
planetary gear unit with three planets, enter 3 for the sun and 1 for the planets in the input field.
Note:
If the Automatically selection button in the calculation module is selected, KISSsoft will
determine the number of load cycles, taking into account the number of planets, in the
Planetary stage calculation module.
4. Load cycles per minute Here you enter the number of load cycles per minute. This may be
useful, for example, for racks or gear stages where the direction of rotation changes frequently,
but for which no permanent speed has been defined.
5. Effective length of rack The rack length entered here is used to calculate the number of load
cycles for the rack. The rack length must be greater than the gear's perimeter. Otherwise, the
calculation must take into account the fact that not every gear tooth will mesh with another. You
must enter a value here for rack and pinion pairs. Otherwise the values N L(rack) = NL(pinion)/10
are set.
► Note
This calculation method is used for transmissions that only travel over one oscillation angle.
Assume a scenario in which a reduction is present,
𝑧2
𝑖=
𝑧1
and an oscillation angle w in [°] from gear 2, where gear 2 constantly performs forwards and
backwards movements with the angle value w2. The effective endurance is given as the service life.
III Cylindrical gears 225
The two coefficients fNL1 and fNL2, which modify the absolute number of load cycles, NL, are now
calculated. To do this:
▪ a) Set the alternating bending factor of the pinion and gear to 0.7, or calculate it as defined in
ISO 6336-3:2006. In this case, one complete forwards/backwards movement is counted as one
load cycle.
▪ b) Coefficients fNL1 and FNL2 for pinion and gear are defined as follows:
𝑊1,2
𝑅𝑂𝑈𝑁𝐷𝑈𝑃( )
𝑓𝑁𝐿1,2 = 360
𝑊1,2
2∗
360
- w2 = oscillation angle gear 2
- w1 = W2*i
- ROUNDUP = round up to a whole number
The value in the counter displays the actual number of loads that occur during a complete cycle
(forward and backward oscillation) on the flanks (not teeth) that are most frequently subjected to
load. By rounding up this number to the next whole number, every rotation recorded is counted
as a load.
Then, to determine the required fNL1,2 factor, the actual number of loads that occur per flank is
divided by the number of loads that would occur per cycle, if rotation were to continue without a
backward rotation at the angle of rotation (1 load for each 360°).
Example calculation for fNL1.2:
Gear 1 rotates through a half cycle at 540° while gear 2 oscillates by 90° (i = 6).
In a complete cycle, the oscillation angle moves forwards once an backwards once.
The actual number of load cycles that occur in a complete cycle on the flanks that are most
frequently subjected to load (only one side of the tooth is taken into consideration) is then:
For Gear 1:
540
𝑅𝑂𝑈𝑁𝐷𝑈𝑃( )=2
360
III Cylindrical gears 226
For Gear 2:
90
𝑅𝑂𝑈𝑁𝐷𝑈𝑃( )=1
360
Without adjusting the coefficients, the number of counted load cycles in a complete cycle would then be:
For Gear 1:
540
2∗( )=3
360
For Gear 2:
90
2∗( ) = 0.5
360
The coefficients are therefore fNL1 and fNL2:
2
𝑓𝑁𝐿1 = = 0.667
3
1
𝑓𝑁𝐿2 = =2
0.5
▪ c) Then, input coefficients fNL1 and fNL2 in the Load cycles per revolution input field.
The strength calculation can now be performed for the correct number of load cycles, on the basis of
the data entered in steps a through d.
17.2.3 Reliability
Reliability is calculated according to Bertsche's study [15], in which the possible methods have been
described in great detail. The most commonly used approach, and one which is well suited to the
results that can be achieved in "traditional" mechanical engineering calculations, is "Weibull
distribution". In this case, Bertsche recommends the use of 3-parameter Weibull distribution. The
reliability R of a machine element is calculated as a function of the number of load cycles t using the
following equations.
Parameters T and t0 can be derived from the mathematically achievable service life of the
component, Hatt, as follows (with FO according to the calculation method, Table 1, β and ftB from
Table 2 according to Bertsche):
III Cylindrical gears 227
Calculation method Damage probability Fo
1% 10% Other Comment
Shaft, DIN 743 2.5% Assumed, not documented
Shaft, FKM guideline 2.5%
Shaft, AGMA 6001 * If kC = 0.817
Rolling bearing, ISO 281 * If coefficient a1 = 1.0
Tooth flank, ISO 6336; DIN 3990 *
Tooth root, ISO 6336; DIN 3990 *
Tooth flank, AGMA 2001 * If randomness factor KR=1
Tooth root, ISO 6336; AGMA * If randomness factor KR=1
2001
Table 17.5: 14.6a: Damage probability for different calculation methods when determining material properties
with
𝐻𝑎𝑡𝑡
𝐻𝑎𝑡𝑡10 =
𝛽 1 − 𝐹𝑜
√ 𝐼𝑛( )
(1 − 𝑓𝑡𝐵 ) ∗ 100 + 𝑓
𝑡𝐵
𝐼𝑛(0.9) Coefficient ftB Weibull shape parameter β
Shafts 0.7 to 0.9 (0.8) 1.1 to 1.9 (1.5)
Ball bearing 0.1 to 0.3 (0.2) 1.1
Roller bearing 0.1 to 0.3 (0.2) 1.35
Tooth flank 0.4 to 0.8 (0.6) 1.1 to 1.5 (1.3)
Tooth root 0.8 to 0.95 (0.875) 1.2 to 2.2 (1.7)
Table 17.6: 14.6b: Coefficients for a Weibull distribution according to Bertsche. The mean values used in KISSsoft are
given in brackets.
III Cylindrical gears 228
► Note:
Calculating reliability using Weibull distribution uses the calculated service life, and so also takes into
account the required safeties. To calculate reliability without taking required safeties into account, set
the safeties to 1.0.
17.2.4 Application factor
The application factor compensates for any uncertainties in loads and impacts, whereby K A ≥ 1.0.
Table 14.6 illustrates the values that can be used for this factor. You will find more detailed
comments in ISO 6336, DIN 3990 and DIN 3991.
When deciding which application factor to select, you must take into account the interrelationship
between the required safeties, assumed loads and application factor.
Operational behavior of Operational behavior of the driven machine
the driving machine
uniform moderate average heavy
shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
17.7 table: Assignment of operational behavior to application factor
DIN 3990, Part 41 (car gearboxes), distinguishes between application factors for flank strength K AH
and the tooth root strength KAF. Except for flank strength calculations, all other calculations (e.g.
resistance to scoring) use application factor KAF.
However, according to DIN 3990 Part 41, the application factor can also be less than 1.0. This is
intended to avoid the need to perform a calculation involving load spectra. For example, DIN 3990,
Part 41, Annex A, suggests the following values for a 4-speed car gearbox:
Gear R 1 2 3 4
NL 105 2 * 106 1.5 * 107 3 * 107 2 * 108
KAH 0.65 0.65 0.65 0.65
KAF 0.70 0.70 0.80 0.80
17.8 table: Application factor according to DIN 3990, Part 41
III Cylindrical gears 229
17.2.5 Power, torque and speed
Click the button next to the power input field (for the torque) to calculate the power (torque) so
that a predefined safety minimum (see chapter 17.20.6, Required safeties) can be maintained.
Power, torque and speed must always be defined with a positive value. Enter the working flank to
predefine the direction of rotation.
The button next to the speed input field now becomes visible for planetary stages. You can then
input a second value for speed (in addition to the speed of the reference gear). You can enter the
speed as either a positive or negative value. A positive value means that the second gear rotates in
the same direction as the selected reference gear. A negative value means it rotates in the opposite
direction.
► Note:
The button is also active for gear pairs (as it is when you call it from KISSsys), when you are
modeling epicyclic gears in KISSsys with gear pairs. You can then enter the speed of the planet
carrier [nSteg]. The main speed [n] of the reference gear with n - nSteg is then used in the calculation
to return the exact number of load cycles.
17.2.6 Strength details
Click on the Details... button to open the Define details of strength window, which is divided into
the System data and Pair data or Gear data tabs. Note that a different window layout is used for
calculations according to AGMA (see chapter 17.2.7, Strength details (AGMA)).
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17.2.6.1 System data
Figure 17.9: System data input window for a cylindrical gear pair
17.2.6.1.1 Profile modification
You can modify the theoretical involute in high load capacity gears by grinding/polishing the toothing.
You will find suggestions for sensible modifications (for cylindrical gears) in KISSsoft module Z15
(see chapter 17.7, Modifications).
The type of profile modification has an effect on transverse coefficients Hα and KHβ and on how
scuffing safety is calculated. The force distribution factor XΓ is calculated differently depending on the
profile modification. The main difference is whether the profile has been modified or not. However,
the differences between the versions for high load capacity gears and for smooth meshing are
relatively small. The strength calculation standard presumes that the tip relief C a is properly sized,
but does not provide any concrete guidelines. The force distribution factor XΓ , according to DIN
3990, depends on the type of profile modification as follows:
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Figure 17.10: Force distribution factor XΓ for different profile modifications
17.2.6.1.2 Limited life coefficients as defined in ISO 6336
Set the limited life coefficient ZNT to reduce the permitted material stress according to ISO 6336-
2:2006:
(12.14)
(12.15)
As stated in ISO 6336, this value is important for cylindrical gear calculations and is the reason for
the lower safeties for the range of endurance limit, compared with DIN 3990.
1. normal (reduction to 0.85 for 1010 cycles): The permitted material stress in the range of
endurance limit (root and flank) is reduced again. The limited life coefficients Y NT and ZNT are
set to 0.85 for ≥1010 load cycles.
2. increased if the quality is better (reduced to 0.92): Y NT and ZNT are set to 10 for ≥10 load cycles
(in accordance with ISO 9085).
3. with optimum quality and experience (always 1.0): This removes the reduction and therefore
corresponds to DIN 3990. However, this assumes the optimum treatment and monitoring of the
materials.
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17.2.6.1.3 Modification of S-N curve (Woehler lines) in the range of endurance
limit
In a standard Woehler diagram, the range of endurance limit is reached at a particular number of
load cycles. From this point onwards, the dynamic strength no longer changes even when the
number of load cycles increases. This behavior is called "according to Miner".
However, more recent investigations have revealed that there is actually no such thing as an infinite
life strength and that the S-N curve (Woehler line) should be modified in the infinite life strength
range.
In the range of endurance limit, you can therefore select the following modified forms:
▪ Miner (corresponds to DIN 3990, Parts 2, 3 and 6). Pitch ∞ (horizontal)
▪ According to Corten/Dolan. Pitch p
▪ According to Haibach modified. Pitch 2*p
▪ According to Haibach original. Lead 2*p-1 (according to [16])
The lead p mentioned here matches the S-N curve (Woehler line) according to ISO, AGMA or
DIN in the fixed period range, determined from YNT or ZNT. See also ISO 6336-6 [17].
The figure below (see Figure 17.11) shows the corresponding characteristics. Experience has shown
that performing a service life calculation with load spectra using the Miner method returns results that
are far too optimistic. We recommend you use the Haibach method of approach.
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Figure 17.11: Infinite life strength models
Note concerning calculations according to ISO or DIN:
The pitch (slope) of the S-N curve (Woehler line) for tooth bending in the time-dependent domain
(between N0 and N00) is defined using the YNT, YdrelT, YRrelT and YX coefficients for the static
and endurance cases, but in the endurance domain (NL > N00), only the YNT coefficient is used for
the static and endurance cases. The same applies for pitting with the ZNT, ZL, ZV, ZR and ZW
coefficients. This corresponds to the procedure used in ISO 6336 for the endurance domain.
However, this does mean that buckling occurs on the S-N curve (Woehler line) at N00, according to
the Corten/Dolan rule.
As an example: for case-carburized steel, the pitch (slope) of the S-N curve (Woehler lines) in the
endurance domain is 13.2, but in the range of endurance limit, it is approximately 10, depending on
the precise values for YdrelT, etc.
If all the coefficients, YdrelT, etc., are set to 1.0 using "Own Input", the S-N curve (Woehler line) will
be constant.
► Note:
The saved *.z?? files and the STANDARD.z?? file contain the ZS.CortanDolanFactors variable. This
can be set to = true. This can force the program to also extrapolate the YdrelT, YRrelT, YX, ZL, ZV,
ZR and ZW coefficients in the endurance range, in contrast to the ISO definition.
III Cylindrical gears 234
17.2.6.1.4 Tooth form factors
The tooth form factor YF takes into account how the tooth form affects the nominal tooth root stress
σF0. The stress correction factor YS takes into account the effect of the notch on the tooth root. These
two factors can be calculated in three different ways:
1. According to the formulae in the standard (normal)
As defined in ISO 6336 or DIN 3990, the tooth form and the stress correction factors are
calculated at the tooth root at the point at which the tangent and the tooth center line form an
angle of 30°. However, it is generally acknowledged that this method is rather imprecise,
especially for deep tooth forms.
2. Using graphical method
According to Obsieger [18], there is a more precise approach in which the product of the tooth
form factor YF and the stress correction factor YS is calculated and the maximum value is
determined. This method is based on the manufacturing process used for a specific tooth form
and is applied to all points in the whole root area. This maximum value is then used to calculate
the strength. Factors YF and YS are calculated according to the formulae in ISO 6336 or DIN
3990.
This is the recommended method, particularly for unusual tooth forms and internal toothings. If
required, this calculation procedure can also be applied in strength calculations as defined in
ISO 6336 and DIN 3990, as well as in fine sizing.
Note:
If you use the graphical method here, KISSsoft will calculate the tooth form before it calculates
the strength, each time. It takes its parameters either from the cutter data you entered previously
in the Tooth form input window (see chapter 25.2.1, Gear tooth forms) or from the default
settings in the Reference profile input window. The maximum value of the product of the tooth
form and stress modification factor is calculated at the same time and included in the stress
calculation.
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Figure 17.12: Figure: Tooth form factors using the graphical method
3. for internal toothing, according to proposal 2737
When calculating strength according to ISO 6336 or DIN 3990, select this option to use the tooth
form factor as defined in VDI 2737, which is more precise for internal toothing, because it
evaluates the stress at the point of the 60° tangent and derives the tooth form from the
manufacturing process with the pinion type cutter.
The calculation specified in ISO 6336 for calculating tooth root stress is more accurate than the
one implemented in DIN 3990. However, the calculation applied to the root rounding in the
critical point (for a 60° tangent) is still incorrect. The method defined in VDI 2737, Annex B is
much more accurate, which is why we recommend you use this method. If you select this option,
only the root rounding ϱF and the root thickness sFn in the critical cross-section is calculated in
accordance with the formulae in VDI 2737. All other sizes are calculated according to ISO 6336.
The table (below) uses 4 examples to show the large variations that still arise in root rounding
between the result defined in ISO 6336 and the effective values measured on the tooth form.
However, the calculation method stated in VDI 2737 is very suitable.
Gear x= Pinion Cutter ϱF in ISO 6336- ϱF in the current ϱF measured on ϱF with VDI
x0= 3 2006 and edition of ISO the tooth flank 2737
2007-02 6336-3 2007-04
-0.75 0.1 0.201 0.426 0.233 0.233
-0.75 0.0 0.175 0.403 0.220 0.220
0.0 0.1 0.298 0.364 0.284 0.286
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0.0 0.0 0.274 0.343 0.265 0.264
17.9 table: Comparison of root roundings
Note about calculating YF:
▪ The theoretical profile shift is used in the calculation if the allowance is As < 0.05*mn (in
accordance with ISO 6336-3). Otherwise the larger manufacturing profile shift xE.e (where the
theoretical contact ratio is applied) is used. This corresponds to the procedure used in the
STplus program (from Munich, Germany). An exact definition is not provided in the ISO
standard. However, a specific tolerance field can be predefined in the Module specific settings,
in Calculations. This value is then always used to calculate strength and for the transverse
contact ratio.
▪ According to the ISO standard, the reference profile for the entire toothing is to be used for the
calculation. For this reason, if you input the reference profile for pre-machining with
protuberance, and a manufactured profile with remaining protuberance is left after deduction of
the grinding allowance, the reference profile for final machining is used for the calculation. A
grinding notch is produced in the reference profile for pre-machining without a protuberance (or
a protuberance that is too small). To ensure that this situation can be correctly taken into
consideration, the pre-machining reference profile (with pre-machining manufacturing profile
shift) is used to calculate YF. The final machining reference profile is also used to calculate the
grinding notch and therefore define YSg (section 7.3 in ISO 6336-3).
17.2.6.1.5 Tooth contact stiffness
Tooth contact stiffness is required to calculate the dynamic factor and the face load factor. You can
use one of these calculation options:
1. In accordance with the formulae in the standard (normal)
In the standard calculation, the tooth contact stiffness cg is calculated using empirical formulae
(in ISO 6336, DIN 3990, etc.).
2. Using the tooth form
Using this option, the tooth form stiffness c' is calculated according to Weber/Banaschek's
dissertation [19]. This takes into consideration tooth bending, basic solid deformation, and
Hertzian pressure. The last condition determines the load dependency of c'. The contact
stiffness is determined using the effective tooth form (see Meshing stiffness (Z24)). The mean
value of the stiffness curve calculated using this method is then included in the calculation. If
required, this calculation procedure can also be applied in strength calculations as defined in
III Cylindrical gears 237
ISO 6336 and DIN 3990, as well as in fine sizing (Z04). The single spring stiffness c' is
calculated from the cg, by extrapolating c' from the formula for cg (ISO or DIN).
3. constant (20 N/mm/μm)
Using this option, the tooth contact stiffness is permanently set to
17.2.6.1.6 Small amount of pitting permissible
In specific cases, the appearance of a slight amount of pitting on the flank may be permissible. In a
range of materials, this results in higher flank safeties in the limited life range due to the changed S-N
curve (Woehler lines), as can be seen in either ISO 6336-2, Figure 6, curve 1 or DIN 3990-2, Figure
8.1.
17.2.6.1.7 Lubrication coefficient
The lubricant coefficient is needed to calculate the coefficient of friction, loss, micropitting and
scuffing.
As specified in ISO/TS 6336-22:
▪ 1.0 for mineral oils
▪ 0.6 for water-soluble polyglycols
▪ 0.7 for non-water-soluble polyglycols
▪ 0.8 for polyalphaolefins
▪ 1.3 for phosphate esters
▪ 1.5 for traction fluids
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17.2.6.2 Pair/gear data
Figure 17.13: Pair/gear data input window for defining details of strength
17.2.6.2.1 Structural factor XwrelT or structural factor Xw (scuffing)
The structural factor takes into account differences in materials and heat treatment at scuffing
temperature. The relative structural factor XwrelT(in DIN 3990 and in ISO TR 13989-2) or structural
factor Xw (in ISO TR 13989-1) is used, depending on which standard is used. However, XwrelT =Xw/XwT
and XwT= 1. This results in XwrelT = Xw. The two factors are identical.
However, the standards do not provide any details about how to proceed when different types of
material have been combined in pairs. You must input this factor yourself, because it is not set
automatically by KISSsoft.
Through hardened steels 1.00
Phosphated steels 1.25
Coppered steels 1.50
Nitrided steels 1.50
Case-hardened steels 1.15 (with low austenite content)
Case-hardened steels 1.00 (with normal austenite content)
Case-hardened steels 0.85 (with high austenite content)
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Stainless steels 0.45
Table 17.10: Structural factor as defined in DIN 3990, Part 4
The standard does not provide any details about how to this factor is to be applied when the pinion
and gear are made of different types of material. In this case it is safer to take the lower value for the
pair.
17.2.6.2.2 Grinding notch
As defined in DIN 3990 or ISO 6336, the effect of the grinding notch can be taken into account by the
coefficient YSg . Here, you input the ratio tg to the radius of grinding notch ϱg in accordance with the
figure in DIN 3990-3, section 4.4 or ISO 6336-3, Figure 5. KISSsoft then calculates a coefficient g =
YSg/Y S (a coefficient with which YS is multiplied).
The grinding notch depth tg is calculated using the distance of the 30° tangents from preliminary
contour and the finished contour. If an allowance for pre-machining has already been input in
KISSsoft, (see Figure. 14.11), then the ratio tg/ϱg can no longer be entered by the user. In this case, it
is defined by the program. A grinding notch occurs when a grinding depth (see chapter 17.7,
Modifications) has been entered, and no protuberances remain, either because no protuberance tool
was used, or the selected allowance was too small. The rounding radius ϱg is then defined by
generating the grinding wheel on the 30°- tangent (on the 60° tangent for internal toothings).
Figure 17.14: Grinding notch
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17.2.6.2.3 Pretension
The influence of a press fit or other processing methods that influence tooth root stress can be taken
into account with the pretension σP . This value influences the calculated tooth root stress as well as
the safety according to the following formulae:
For static strength:
For fatigue strength:
The pretension σP merely generates additional results in the reports. The results in the results
window remain unchanged. You define this under "Strength" > "Details".
► Note 1
This rule is not documented in the ISO standard. For this reason, we recommend extreme caution if
the pretension effect is to be taken into account. The formulae are proposed by Alstom Ecotecnia.
KISSsoft only shows this effect in the report.
► Note 2
If the main calculation (single load or load spectra) requires the use of this rule, the value σ’Flim must
be changed as follows, according to the equation for ’FG:
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σ’Flim has to be introduced instead of σFlim in the material values; then the main calculation is
performed using this pretension rule.
17.2.6.2.4 Moments of inertia
If required, you can enter the moment of inertia of the gears. This value is used when calculating the
dynamic factor. If you enter an invalid value (deviation > 100% from the expected value), the system
displays a warning. Usually, in such cases, the incorrect unit has been used for the input.
17.2.6.2.5 Optimal tip relief
To calculate safety against micropitting as specified in Method B in ISO/TS 6336-22, you must
specify whether or not the profile modification is to be assumed to be optimal. The same applies to
calculating the safety against scuffing. The software checks whether the effective tip relief (Ca)
roughly corresponds to the optimum tip relief (Ceff). If this check reveals large differences, i.e. Ca <
0.333*Ceff or Ca > 2.5*Ceff, a warning is displayed. In this case, the value you input is ignored and is
documented accordingly in the report.
17.2.6.2.6 Root rounding, ground
The setting specifying whether the root rounding is ground is only used in calculations according to
GOST.
17.2.6.2.7 Information about material hardness
For more information about material hardness, refer to section Kap14.9a: (see chapter 17.2.1.6,
Tooth flank fracture calculation method).
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17.2.7 Strength details (AGMA)
Figure 17.15: Define details of strength input window for calculating strength as defined in AGMA
► Note
Only values in the input window that differ from those defined in ISO are described here.
17.2.7.1 Limited life coefficients
The limited life coefficients determine which material values can be entered in the field for limited
time and strength. In standard applications, infinite life strength values up to 1010 load cycles are
reduced from 100% to 90% for the root and to 85% for the flank. According to AGMA, the reduction
in strength also extends beyond 1010 load cycles. In critical applications, where a gear unit
breakdown must be prevented at all cost, the material values are reduced even more, in comparison
to those used in standard application areas.
17.2.7.2 Tooth form factors
For cylindrical gears with small helix angles, or cylindrical spur gears, you can specify that the load is
to be applied either at the tip or at the single tooth contact point (the more precise option). For
cylindrical gears with a large helix angle (εβ ≥ 1) according to AGMA the force is always applied to a
single meshing point.
III Cylindrical gears 243
Calculating with the single tooth contact point results in a lower load at the tooth root because the
load is divided between the two teeth. However, this load distribution does not take place if large
single normal pitch deviations occur and therefore the force should be assumed to be placed at the
tooth tip.
As stated in AGMA, the contact point between the tooth form and the Lewis parabola is selected as
the critical root cross section. The stresses are determined here. AGMA does not provide a formula
for calculating internal toothings. Instead, it recommends you use the graphical method to calculate
the tooth form. The required data is to be taken from measurements. If you click the checkbox to
select the graphical method of calculating the tooth form factor, the software automatically calculates
the tooth form at the point where the Kf or I factor is greatest. In contrast to the method defined by
Lewis, where the calculation is only performed at the contact point of the parabola, the calculation
using the cross section with the greatest stresses gives more precise results, and is therefore the
method we recommend for external gears too.
17.2.7.3 Transmission accuracy level number
AV (or QV for AGMA 2001-C95 or earlier) is calculated according to the formulae defined in AGMA
2001 or 2101 and is extremely dependent on the accuracy grade (manufacturing quality). A V is
permitted to be one level higher or less than the accuracy grade (manufacturing quality) and is
needed to calculate the dynamic factor. You can overwrite this value if required.
17.2.8 Define load spectrum
Figure 17.16: Load spectrum group
In this group, you can also access load spectra that have been stored in the database. You can also
define the load spectra directly.
If you select Read, you can import a file (in either .txt or .dat format) with a load spectrum.
The "Example_DutyCycle.dat" file in the dat sub-folder in the KISSsoft installation directory is an
example of a file that shows how a load spectrum can be defined.
If you want separate factors (KHβ, Kγ, etc.) to be taken into account in the calculation with load
spectra for each load bin, open the Factors tab. In it, make the appropriate settings for the load
III Cylindrical gears 244
distribution coefficient Kγ (see chapter 17.3.3, Mesh load factor), the alternating bending factor YM
(see chapter 17.3.4, Alternating bending factor) and the face load factor KHβ (see chapter 17.3.6,
Face load factor). An example of how a load spectrum can be defined with factors (KHβ, Kγ, etc.), can
be seen in the "Example_DutyCycleWithFactors.dat" file in the dat sub-directory in the KISSsoft
installation directory.
A load spectrum can also be generated from a series of measurements with torque/speed/time if you
select the Torque measurement option. Click the Convert button below the Load spectrum table
to call this option, (see chapter 18.11, Torque measurement).
17.2.8.1 Type of load spectrum
The service life for load spectra is calculated as specified in ISO 6336, Part 6, and is based on the
Palmgren-Miner rule.
Three load spectra are predefined here, as shown in DIN 15020 (Lifting Appliances), along with
many other standard spectra. You can also input your own load spectra.
A load spectrum consists of several elements (up to 50 in the database or an unlimited number if
imported from a file). Each element consists of the frequency, speed, and power or torque. The data
always refers to the reference gear you selected when you input the nominal power (Performance-
Torque-Speed screen). The program stores these values as coefficients so that they are modified
automatically when the nominal power changes.
If two speeds that are not equal to zero have been predefined for planetary stages, you can select
two load spectra. In this case, only the speed factor is important for the second load spectrum.
► Note
The calculation takes into account the load dependency of the K coefficients (dynamic, face load and
transverse coefficients). If you want to examine the result in greater detail, you will find the most
interesting interim results in the Z18-H1.TMP text file (in the TMP directory).
17.2.8.1.1 Load spectra with negative elements
Load spectra with negative load bins (T < 0 and/or n < 0) can also be calculated as follows (this is
only applied to bins whose alternating bending factor is YM=1.0).
IMPORTANT:
A load bin is considered to be negative if the non-working flank is placed under load.
Coefficient for torque Coefficient Flank under load Actual load bin
for speed
+ + Working flank (*) evaluated as positive
III Cylindrical gears 245
+ - Working flank (*) evaluated as positive
- + Non-working flank evaluated as negative
- - Non-working flank evaluated as negative
(*) Working flank as entered in the Strength tab
Table 17.11: Evaluation of a load bin, depending on the prefix operator
You can select the following under "Details" in the "Strength" section, in the "Rating" tab:
▪ To calculate pitting safety
▪ Evaluate all negative load bins as positive (as up to now)
▪ Consider only positive load bins
▪ Consider only negative load bins
▪ Check both cases and document the less favorable case
▪ To calculate the tooth root safety
▪ Evaluate all negative load bins as positive (as up to now)
▪ For negative load bins, increase root stress by 1/0.7
▪ Increase bending stress for positive load bins by 1/0.7
▪ Check both cases and document the more realistic case
17.2.8.2 Classification of load spectra according to F.E.M. Guideline
The "Supplementary Data" section in the report for a load spectrum contains the spectrum factor k m,
and the machine classes L, T and M for a load spectrum, according to F.E.M 1.001 [20].
The spectrum factor km lies between 0 and 1 and describes the load on a machine caused by active
torque. If the load spectrum is 100% torque for 100% of the time, km equals 1. The spectrum class L,
according to table T.2.1.3.3 in F.E.M. 1.001, is calculated from the calculated spectrum factor km ,
and increases from L1 to L4 with the active torque.
The application class T is determined from the entire duration of the load spectrum. To do this, the
machine is assigned to one of the application classes T0 to T9, according to a duration of between
zero and 50,000 operating hours (see Tab. T.2.1.3.2 in F.E.M. 1.001). In each case, the predefined
and achievable application classes T are output in the report.
A machine class M is determined according to the determined application class T and spectrum class
L, according to table T.2.1.3.2 in F.E.M. 1.001. In each case, the predefined and achievable machine
classes M are output in the report. Machine classes M1 (short operating time, low loads) to M8 (long
operating time, high loads) are assigned, depending on the application class T and spectrum class L.
III Cylindrical gears 246
17.3 Factors
The Factors input window is one of the standard tabs (see chapter 5.1, Standard and special tabs).
17.3.1 Transverse coefficient
The transverse load factor kHα is calculated according to the selected calculation method. The
transverse coefficient takes into account uneven contact characteristics across a number of teeth.
When the contact ratio increases, the transverse coefficient also becomes larger depending on the
predefined manufacturing quality. A high contact ratio will result in a reduction of the root stresses.
The transverse coefficient will compensate for this effect for large single normal pitch deviations.
In unusual cases, the transverse coefficient will be unrealistically high. If you want to reduce the
transverse coefficient in this situation, simply click the checkbox to the right of the input field. You can
then change this value.
17.3.2 Dynamic factor
The dynamic factor takes into account additional forces caused by natural frequencies (resonance) in
the tooth meshing. It is usually calculated using the calculation method you selected, however you
can also input the value if it has already been derived from more precise measurements. To change
the value, click the checkbox to the right of the input field.
17.3.3 Mesh load factor
The mesh load factor takes into consideration the uneven load distribution across multiple planets or
idler gears. In this case, the load is multiplied by this coefficient. Dimensioning suggestion according
to AGMA 6123-C16:
Number of Planets
Application 2 3 4 5 6 7 8 9 Flexible
level Mounting
1 1.16 1.23 1.32 1.35 1.38 1.47 1.52 - without
2 1.00 1.05 1.25 1.35 1.38 1.47 1.52 1.61 without
3 1.00 1.00 1.15 1.19 1.23 1.27 1.30 1.33 without
4 1.00 1.00 1.08 1.12 1.16 1.20 1.23 1.26 with
17.12 table: Load distribution coefficient Kγ defined by the number of planets
Application level Description
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1 Typical of large, slow-turning planetary gear units
2 Moderate quality, typical of industrial gears
3&4 High quality gear units, e.g. for gas turbines
17.13 table: Meaning of the application level
► Note
Level 2, or higher, requires at least one floating element.
Level 3, or higher, requires a flexible gear rim.
In a flexible assembly, the planets must be mounted on flexible pins/shafts or on bearings with
couplings.
Depending on the toothing quality and the number of planets, use the Calculated according to
AGMA 6123 method to determine the distribution coefficient Kγ for application levels 1 to 3.
If a different load distribution coefficient is input for each element, when load spectra are in use, you
should select the Own input, per load stage method.
17.3.4 Alternating bending factor
The tooth root strength calculation is used solely to calculate pulsating load on the tooth root.
However, in some cases, the tooth root is subject to alternating bending loads (e.g. a planet gear in
planetary gear units). In this scenario you can change the alternating bending coefficient of individual
gears by selecting either the Own input or Own input, per load spectrum element methods. As an
alternative to transferring these values directly, select the Calculate in accordance with ISO 6336-3
Annex B method to calculate the coefficient. To do this, you must then open the Rating tab, go to
the Load spectrum section, and input the flow and fhigh parameters for each gear. fhigh must always
have the fixed default value of 100%.
ISO 6336-5:2003, section 5.3.3 and DIN 3990-5, section 4.3, state 0.7 as the value YM for pure cyclic
load. In ISO 6336-3:2006, Annex B, the stress ratio R for idler and planetary gears is taken into
account by using this formula:
(12.16)
(12.17)
fhigh Load on the flank side that is subject to the higher load (must always have the
fixed default value of 100%)
III Cylindrical gears 248
flow Load on the flank side that is subject to the lower load
M Dimensionless number depending
on the type of treatment and load type
(see Table B.1 in ISO 6336:2006-3, Annex B)
R Stress ratio
YM Alternating bending factor
Treatment Endurance strength Coefficient for static
proof
Steels
Case-hardened 0.8 to 0.15 YS 0.7
Case-hardened and shot peened 0.4 0.6
Nitrided 0.3 0.3
Flame/induction-hardened 0.4 0.6
Not surface-hardened steel 0.3 0.5
Cast steel 0.4 0.6
Table 17.14: Mean stress ratio M as specified in Table B.1 - Mean Stress Ratio - in ISO 6336:2006-3
According to Linke [21], the alternating bending factor (described there as Y A) is determined as
shown in Figure 14.19. For plastics, Niemann recommends [5] 0.8 for laminated fabric and 0.667 for
PA (polyamide) and POM (polyoxymethylene).
III Cylindrical gears 249
Figure 17.17: Alternating bending factor in accordance with Linke [21]
17.3.5 Load spectrum with alternating torque
Load bins can also be entered with negative torques.
The problem:
until now, no calculation guidelines have been drawn up to describe how to calculate gears with
alternating load spectra.
The only unambiguous case is when a change in moment takes place, during every cycle (and in
each element in the collective, i.e. load bin). At this point, a load change corresponds to exactly one
double-load with +moment and then with -moment. This instance can be calculated correctly by
entering the load spectrum of the +moments and the alternating bending factor YM for the tooth root.
The flank is also calculated correctly, because the +moments always apply to the same flank.
III Cylindrical gears 250
If, in contrast, the drive runs forwards for a specific period of time and then runs backwards, the
experts agree that the tooth root is not subjected purely to an alternating load (and possibly this is the
only point at which an alternating load change takes place). However, discussions are still raging as
to how this case can be evaluated mathematically. It is even more difficult to define how mixed load
spectra with unequal +moments and -moments for the tooth root are to be handled. For this type of
case, only the +moments are considered for the flank (with the prerequisite that the +moments are
equal to, or greater than, the -moments).
Note about handling load spectra with reversing torque:
A load progression as represented in the figure below, where the tooth is subjected to a load a few
times on the left flank, and then a few times on the right flank, can be converted into a load spectrum
as shown below. This is represented in an example here.
Load progression (example):
▪ 13 loads with 100% of the nominal load (100 Nm) on the left flank, then
▪ 9 loads with 80% of the nominal load (80 Nm) on the right flank, etc.
This results in the following process:
▪ 11 load cycles with 100% load, positive torque, pulsating; then
▪ 1 load cycle with 100% load on the left and 80% load on the right; then
▪ 7 load cycles with 80% load, negative torque, pulsating; then
▪ 1 load cycle with 80% load on the right and 100% load on the left;
then repeated again from the start.
This can be represented as a load spectrum as follows:
Frequency Torque Left flank load Right flank load
11/20 = 0.55 100 Nm 100% 0%
7/20 = 0.35 80 Nm 0% 100%
2/20 = 0.10 100 Nm 100% 80%
Table 17.15: Load progression shown as a load spectrum
III Cylindrical gears 251
Figure 17.18: Load progression
17.3.6 Face load factor
The face load factors KHβ,KFβ,KBβ take into consideration the influence of an uneven load distribution
over the facewidth on the contact stress, tooth root stress and scuffing stress. You can specify that
the face load factor is either to be set as a constant value or calculated from other values. If you
already know the face load factor KHβ, select the Own input method and input this value. Click the
button to display the Define face load factor window. In it, the calculation according to DIN/ISO
is displayed: in that calculation, you can use a number of parameters to calculate the value you
require.
The usual setting here is "Calculation according to calculation method". The face load factor is then
calculated according to the formulae used in the strength calculation standard (ISO, AGMA or DIN).
You will need to input some values for this. These values are displayed on the right of the window
(tooth trace modification, etc.) and are described in the sections that follow. You can input other
values by clicking the button in the "Define face load factor" window.
For the "Factor K' with stiffening" entry: the pinion has the effect that it stiffens the shaft (supporting
effect) if d1/dsh >1.15 and the pinion is created with a fixed interference fit or shaft/pinion on the piece.
The formulae proposed in the standards for defining face load factor KHb enable you to determine
KHβ very quickly (but only empirically, and therefore not very accurately). Determination of KHβ. The
KHβ factor calculated using these formulae is usually higher than it actually is, so the calculated value
is therefore on the conservative side. If you think the face load factor is too high (> 1.5), it is a good
idea to perform a more accurate calculation. To do this, use the "Calculation without manufacturing
allowance according to ISO 6336-1 Annex E" method.
Although the "Calculation according to ISO 6336 Annex E" method is very accurate, it requires quite
a lot of time and effort. As described in [17], it calculates any gaping in the meshing, and therefore
defines the load distribution over the entire facewidth. To perform this calculation, you will need to
know the exact dimensions of the shafts and support. Click the "Define axis alignment" button to
input the shaft values stored in the shaft calculation program for the relevant shafts.
III Cylindrical gears 252
The "Calculation with manufacturing allowance, as defined in ISO 6336 Annex E" method is the most
accurate method. It also requires you to specify the toothing tolerance fHβ (total tooth trace deviations
over the bearing facewidth) and set the axis alignment tolerance fpar (angular deviation of the axis
position in the plane of action). As described in [17], the load distribution over the facewidth is
calculated 5 times: First without deviation, then with (+fHβ,+ fma), (+fHβ,- fma), (-fHβ,+ fma), (-fHβ,- fma). The
largest face load factor KHβ determined here is then the end result.
Click the Sizing button next to the entry for IΣfHβI to display a subwindow that contains a range of
suggestions about how to take manufacturing errors into account.
The maximum suggestion shows the possible highest value for the tolerance interval for f par and ΣfHβ.
The statistically evaluated proposal shows tolerances that correspond to a statistically evaluated
tolerance interval with 99.7% probability.
The following formulae are used to define the total tolerance ftotal:
fpar = fΣβ-ISO * cos(αwt) + fΣδ-ISO * sin(αwt) (value in the plane of action, effect of housing manufacturing
errors as specified in ISO/TR 10064-4 or DIN 3964))
ftotal-maximal = ΣfHβ-max + fpar-max = fHβ1 + fHβ2 + fpar
ftotal-statistic = ΣfHβ-stat + fpar-stat = 3 * √[(fHβ1/3)2 + (fHβ2/3)2 + (fpar /3)2];
where the values are subdivided as follows:
ΣfHβ-max = +IfHβ1I + IfHβ2I;
fpar-max = IfparI
ΣfHβ-stat = ftotal-statistic * (fHβ1 + fHβ2) / (fHβ1 + fHβ2 + fpar);
fpar-stat = ftotal-statistic * fpar / (fHβ1 + fHβ2 + fpar);
► Note
See Module specific settings > Face load factor for settings involved in the calculation according
to ISO 6336 Annex E.
If you want to calculate the face load factor by applying a load spectrum for each element, select
either the Own input, per load stage, Calculation according calculation method or Calculation
with/without manufacturing allowance according to ISO 6336-1 Annex E, per load stage
method.
In the cylindrical gear pairs, three- and four-gear chains, and planetary systems, calculation module,
shaft calculation files can be called and used to calculate the relative displacement between the gear
flanks more accurately, based on the corresponding shaft bending lines (see chapter 17.3.7, Taking
into account shaft bending (face load factor and contact analysis)). The torque, power, and force, for
III Cylindrical gears 253
all the load elements involved in the shaft calculation are then modified according to the partial load
factor wt .
This means you can include any torsion that occurs in the gear. Here the calculation assumes a solid
cylinder or hollow cylinder (external diameter = root circle + 0.4*normal module or operating pitch
circle, depending on what has been predefined under "Settings", bore = inside diameter) is involved.
In other words, the internal diameter is taken into account and the torque on one side is zero. The
torque is distributed in a linear fashion along the facewidth (parabolic course of deformation by
torsion). You can select which side is to be subjected to torsional moment. In this case, I and II refer
to the same side, as is also the case when you enter the toothing corrections. The increase in torque
for a sun in planetary stages is taken into account by using multiple meshing (several planets).
Multiple meshing is not taken into consideration in any other configuration (e.g. for gear pairs). In
such situations, the correct torque curve can be used if the deformation is taken from the shaft
calculation.
The facewidth is divided into slices, to help you calculate the face load factor as defined in ISO 6336,
Annex E:
You can set the accuracy of the face load factor calculation according to Annex E in the "Define
number of slices" dialog. Click the Plus button next to the calculation method to open this dialog.
17.3.6.1 Tooth trace modification
You can achieve more balanced contact characteristics if you perform targeted tooth trace
modifications. Figure 14.21 shows the two most frequently used modifications.
Figure 17.19: End relief and flankline crowning
17.3.6.2 Cylindrical gear pairs
The calculation, as specified in ISO 6336, is based on an approximate estimate of the pinion
deformation. In many cases, this is extremely inaccurate and usually results in face load factors that
are much too high.
III Cylindrical gears 254
The face load factor is the ratio between the maximum and average line load. The basic equation
used for the face load factor corresponds to equation (41) in the standard:
*The equation numbers used in this section refer to ISO 6336:2006
(14.4)
The effective tooth trace variation Fßy, see equation (52) in the standard, is defined with the inclusion
of a linearized, specific deformation component fsh . The multiplier 1.33 in the equation stands for the
conversion of the linearized specific deformation progression into the real parabolic progression - see
equation. (14.5).
(14.5)
The manufacturer component of the tooth trace deviation f fma is derived from tolerances specified
by the manufacturer. If a standard procedure for checking the manufacturing quality is used, you can
apply this formula (equation (64) in the standard):
(14.6)
If you have used KISSsoft's shaft calculation software to calculate the exact flank line deviation due
to deformation (torsion and bending) in the plane of action, you can correct the approximate value fsh
extrapolated from the standard and therefore calculate the width factors much more precisely! The
formula as specified in ISO 6336 only applies to solid shafts or hollow shafts that have an internal
diameter that is less than half of the external diameter.
In Method C2, the face load factor is calculated using these equations:
Size Drop-down list Selection Equation No.
KHβ (8.04)/
(8.06)
Fβ (8.08)
Fβ position of the not verified or inappropriate (8.26)
contact pattern
favorable (8.27)
optimal (8.28)
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fsh (8.39)
fsh0 Tooth trace None 0.023 • γ (8.31)
modification
Flankline crowning 0.012 • γ (8.34)
End relief 0.016 • γ (8.35)
Solid 0•γ a)
Slight flankline crowning 0.023 • γ b)
Helix angle modification 0.0023 • γ b)
Flankline crowning + helix angle 0.0023 • γ b)
correction
γ Gear teeth straight/angled (8.32)
helical (8.33)
fma Tooth trace None 1.0 • fHβ (8.51)
modification
Flankline crowning 0.5 • fHβ (8.53)
End relief 0.7 • fHβ (8.52)
Total tooth trace modification 0.5 • fHβ a)
Slight flankline crowning 0.5 • fHβ b)
Helix angle modification 1.0 • fHβ b)
Flankline crowning + helix angle 0.5 • fHβ b)
correction
17.16 table: Overview of equations used according to DIN 3990:1987
a) same as DIN 3990, Equation (6.20)
b) same as ISO 9085, Table 4
Size Drop-down list Selection Value No.
KHβ (39)/
(41)
Fβ (43)
not verified or inappropriate (52)
Fβ position of the favorable (53)
contact pattern
optimal (56)
III Cylindrical gears 256
fsh (57)/
(58)
fma (64)
none 1/ 1
Flankline crowning 0.5/ 0.5 Table 8
End relief 0.7/ 0.7
B1/B2 Tooth trace total 0/ 0.5 (56)
modification Slight flankline crowning 1/ 0.5
Helix angle modification 0.1/ 1.0 Table 8
Flankline crowning + helix angle 0.1/ 0.5
correction
17.17 table: Overview of equations used according to ISO 6336:2006
Type of pinion shaft
Load as defined in ISO 6336:2006, Figure 13 (DIN 3990/1, Figure 6.8) or the bearing positioning is
shown in Figure 14.22.
III Cylindrical gears 257
Figure 17.20: Load as defined in ISO 6336:2006, Figure 13.
Load in accordance with AGMA 2001
The definition of s and s1 in accordance with AGMA 2001, Figure 13-3. Figure 14.23 shows the
bearing positioning as described in AGMA 2001.
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Figure 17.21: Load as defined in AGMA 2001, Figure 13-3
17.3.6.3 Planetary stages
The face load factors for planetary stages are calculated in a different way than for cylindrical gears.
The deformation component fsh is derived from the deformation of the mating gears on the shaft due
to torsion and bending. In order to simplify the situation for a pinion-gear pair, only the pinion
deformation (which is much greater) is taken into account.
Planetary stages are subject to the following significant deformations:
▪ Since the sun has several tooth meshings, all radial forces are canceled out. No bending takes
place because deformation is caused solely by torsion. However, the multiple meshing which
corresponds to the number of planets means this is greater than for normal integral pinion
shafts.
▪ A planet gear has two meshings with opposed torques, which prevents deformation due to
torsion. Bending may be calculated in the same way as for integral pinion shafts. However, the
circumferential force must be doubled because of the sun/planet and planet/internal gear.
▪ In most cases, rim deformation can be ignored. As a result, the torsion at the pinion and the
bending at the planet bolt must be taken into consideration for sun/planet meshing whereas, for
planet/internal gear, only the bending at the planet bolt is important. For most support
arrangements for planets, bending can be determined analytically using a procedure similar to
that specified in ISO 6336. The 4 most common cases are displayed below (see Figure 17.22).
III Cylindrical gears 259
Figure 17.22: Support arrangement for planets
a) Planets mounted with fixed clamped bolts on both sides
b) Planets are on bolts, which have flexible bearings in planet carrier
c) Planets mounted with gently tightened bolts (flexible bearings) on both sides
d) Planets mounted with fixed clamped bolts on one side
Configuration ISO 6336 DIN 3990 AGMA 2001
a Part 1, Formulae Chapter 15, (37)
Annex D 6.20/6.21/6.24/6.25/
b Part 1, Formulae Chapter 15, (37)
Annex D 6.24A/6.24B/6.25A/6.25B
c and d Part 1, Formulae as defined in Part 1, Chapter 15, (37)
Annex D Annex C, see [22].
Table 17.18: Configuration of planetary stages as defined in ISO, DIN and AGMA
For ISO 6336, see also the explanation in [22].
Equations 14.7a to 14.7d show the bending components in relationship to the distance x from the
start of the planet's bearing facewidth. As we are only interested in bending variation across the
facewidth, the constant term was left out of the equations so that fb(x = 0) is zero. Similar formulae
can be found in other technical documentation [23]. These equations apply for cases a through d:
III Cylindrical gears 260
64 𝐹𝑚 /𝑏 𝑥 4 𝑏𝑥 3 𝑏𝑥 2 (3𝑙 − 6𝑏 + 𝑏 2 /𝑙) 𝑏 2 𝑥(3𝑙 − 4𝑏 + 𝑏 2 /𝑙)
𝑓𝑏𝑝𝑙𝑎 = 2 4 ∗[ − − + ] (14.7a)
𝜋 𝑑𝑠ℎ 𝐸𝑝 24 12 48 48
(14.7b)
(14.7c)
(14.7d)
The sun's deformation due to torsion, as described in the equation (14.8), can be calculated from
Annex D (ft according to formula D.1).
(14.8)
In order to stay as close as possible to the methods used in ISO 6336 (and be able to apply formula
2), the average deformation components fbmpla (bending at the planet) and ftmso (torsion at the sun) will
be determined.
(14.9)
(14.10a)
(14.10b)
(14.10c)
(14.10d)
III Cylindrical gears 261
(14.11)
According to ISO 6336:2006, equation D.8, the linearized deformation components of the tooth trace
deviation fsh (in mm) will be:
(14.12)
(14.13)
This can then be used with equations (14.4) and (14.5) to calculate face load factors for the
sun/planet and planet/gear rim.
Formula symbol Unit Meaning
b mm Meshing width
cγβ N/(mm μm) Meshing stiffness
dpla mm Planet reference circle
dsh mm Planet shaft diameter
dso mm Sun reference circle
Ep N/mm2 Young's modulus for planet bolt/shaft
Eso N/mm2 Young's modulus for sun
fbpla mm Planet shaft deflection
fHβ μm Helix slope deviation according to ISO 1328
fmα μm Tooth trace deviation
manufacture error
fsh μm (Linearized) deformation components of the
tooth trace deviation
ftso mm Sun torsion deviation
Fm/b N/mm Average line load
(Fm/b)max N/mm Maximum local line load
Fβy μm Actual tooth trace deviation
KHβ [-] Face load factor
l mm Planet bolt/shaft length
III Cylindrical gears 262
p mm Number of planets
x mm Distance to the left side of the facewidth
κβ [-] Run-in factor
Table 17.19: Overview of formula symbols
17.3.6.4 Calculation of KHß with manufacturing errors
According to ISO 6336-1(E), the lead variation (fHb) and shaft misalignment (fma) errors are also
taken into account in the plane of action. In such a case, their combined effect is taken into account
for the flank gap in five cases:
▪ Case 1: fma = fHb = 0, i.e. no error
▪ Case 2: fma = |fma|, fHb = |fHb|, so positive values for both errors
▪ Case 3: fma = +|fma|, fHb = -|fHb|
▪ Case 4: fma = -|fma|, fHb = +|fHb|
▪ Case 5: fma = -|fma|, fHb = -|fHb|, so negative values for both errors
The face load factor KHß is calculated for all five cases, and the maximum value is selected as the
face load factor of the gear pair.
The positive direction always lies in the direction of the pinion's material, seen from a common point
of contact.
Figure 17.23: Definition of the positive direction
III Cylindrical gears 263
In all five cases, the manufacturing error is documented in the report and in the gaping and load
distribution graphics.
Proposed value for fhb and fma
Click on the Sizing button next to the input field for |fHb| to display suggestions of usable data for fHb
and fma.
"Maximum" shows the largest possible values for fHb and fma. The values are derived from the fHbT
(helix slope deviation) tolerances of the two gears and from the axis alignment tolerance (fΣβ and fΣδ).
The "statically evaluated" proposal displays the probable maximum values (99.7% probability). This
proposal is calculated as follows:
17.3.6.5 Defining the misalignment for individual parts
The following parts are assumed in a planets system:
▪ Sun wheel
▪ Planet carrier
▪ N planet gears with the corresponding n pins
▪ Internal gear
You can specify the position of these parts in the gear unit and the corresponding misalignment in
the Define axis alignment dialog. To display this dialog, click on the Axis alignment button in the
Factors or Contact analysis tab. All values refer to the shared facewidth.
You can define more parameters in the "Axis alignment, proportional" tab for load-specific
alignment of system elements:
▪ Tilting of the sun to the gear axis (see Figure 17.24). If no shaft file is used, the sun can be
handled as a "floating sun".
▪ Tilting of the planet carrier to the gear axis (see Figure 17.25)
▪ Tilting of the planet pin relative to the planet carrier in circumferential direction dt and in radial
direction dr (see Figure 17.26). To model a carrier deformation due to torsion, you must first set
a value for dt. This value refers to the planet's facewidth.
III Cylindrical gears 264
▪ The tilting of the planet gear is relative to the planet bolt axis. The positive misalignment (in
circumferential direction dt and radial direction dr) is defined according to the convention (see
Figure 17.26).
▪ The tilting of the internal gear relative to the gear axis (see Figure 17.24). The conical extension
of the internal gear can also be taken into consideration.
▪ The deformation of the planet bolt is caused by the twisting of the planet carrier. If the direction
of torque has been input in the "Torsion" tab, the software checks the values and issues a
warning message if the prefix for dt has not been entered correctly.
If the direction of torque has been input in the "Torsion" tab, the software assumes that dt
represents the twisting of the carrier due to torque. For this reason, the sign for dt is changed
when KHβ is calculated for load bins with a negative load factor.
Figure 17.24: Tilting of the sun and internal gear to the gear axis
III Cylindrical gears 265
Figure 17.25: Tilting of the planet carrier to the gear axis
Figure 17.26: Tilting of the planet pin to the planet carrier
III Cylindrical gears 266
Figure 17.27: Tilting of the planet to the planet pin
You can also use shaft files to define the alignment of all the shafts, except the planet pin. The shaft
files undergo the same checks as a gear pair. For example, the value input for gear torque in the
shaft calculation files must match the value entered for the gears in the calculation module. The
carrier shaft is characterized by its two couplings: one coupling transfers the torque to the sun wheel
and the other transfers the torque to the internal gear. The "effective diameter" for both couplings
must be the same as the sun-planet center distance. The "length of load application" must also be
appropriate for the facewidth of the planet gear. If a shaft file is used for the sun, planet or internal
gear, you must click on an additional Plus button to select the meshing that must be taken into
consideration.
The proportional axis alignment is scaled with the partial load wt (for contact analysis), or with the
ISO factors KV, KA and Kγ.
The angle to the first planet Θ defines where the first planet gear must be located for each system
definition. Every one of the subsequent planetary gears must have an angular offset of 2π/N to the
previous gear. The load distribution on the planet for the specified planet carrier misalignment is
dependent on the position of the planets. Modifying Θ will also change KHβ, which is why this entry
enables you to calculate the "worst case".
You can set the non-load-specific inclination/deviation error of axis in the "Axis alignment,
constant" tab.
In the "Torsion" tab, you set the side from which torque is introduced to the system or the side from
which it is produced (depending on whether the element is a driving or driven element). You can
select one of the following 3 options for inputting the direction of torque:
▪ Not taken into account
▪ Torque is applied/produced on side I
III Cylindrical gears 267
▪ Torque is applied/produced on side II
Each configuration is also displayed as a graphic so that the user can check their entries.
If a shaft file is used to define the shaft deformation, the torque is calculated automatically from the
results of the shaft calculation.
The planet carrier is usually more complicated than is specified in the shaft calculation. For this
reason, the carrier torsion is often greater than determined in the shaft calculation. Consequently,
you can either take the torsion deformation value from the shaft calculation or enter it under dt for
"planet bolt" (or use an FEM calculation to determine it).
17.3.6.5.1 Calculating planet carrier deformation with FEM
The deformation of the planet carrier causes the planet pin to become misaligned (the pin tilts at dt
and dr relative to the planet carrier axis). Use the Finite Elements Method (FEM) to calculate the
exact planet carrier deformation. A range of different options are available here:
▪ The calculated FEM results can be input directly as point coordinates and point deformations
(one node for each of side I and side II on a two-sided planet carrier; two nodes on one side for
a one-sided planet carrier, (see Figure)
Figure 17.28: Planet carrier tab
▪ Import the file with the FEM results for the planet carrier deformation. The deformations in both
nodes are then extracted from this file. The node coordinates do not need to be specified
exactly. The deformation data of the adjacent node is transferred.
III Cylindrical gears 268
Input some of the planet carrier's fundamental dimensions. KISSsoft then generates the carrier in 3D
and uses the relative torque to define the planet carrier's deformation.
Input this data:
Single- or two-sided planet carrier
Pin diameter (d)
Coefficient for the external diameter of the planet carrier (fwa)
Coefficient for the inside diameter of the planet carrier (fwi)
Coefficient for the wall thickness of the planet carrier, which may be different for side I and side II (f swl
and fswll)
Planet carrier width factor (fbpc)
Coefficient for planet carrier's connector (fdcon)
Coefficient for the planet carrier's internal connector (fdicon)
External flange diameter on side I (dfaI)
Flange length on side I (LfI)
Flange wall thickness on side I (SwfI)
External flange diameter on side II (dfaII)
Flange length on side II (LfII)
Flange wall thickness on side II (SwfII)
Planet carrier material (select this from the database).
These coefficients can all be input under "Details", either as coefficients or directly, as dimensions.
You can also click on the "Dimension planet carrier" and "Dimension flange" buttons to display
standard entries for this data.
Remember that you can also set the mesh fineness.
The coefficients and dimensions are shown in greater detail in the next figure. Depending on how the
direction of torsion is entered, side I or side II may not be required for a one-sided planet carrier.
III Cylindrical gears 269
Figure 17.29: Coefficients and dimensions for planet carriers
In addition to the carrier variants shown above, you can also input a step model of the carrier directly.
The point to remember here is that the carrier is clamped on the internal diameter of the flange. If no
flange is present, it is clamped on the internal diameter of the planet carrier. If both these diameters
are identical, it is clamped along the entire length of the flange and the internal diameter of the
carrier. If a step model is used, it is clamped at the specified flange diameter.
The FEM Solver KISSsoft calls in the background is the Code_Aster open source solver, which you
can find by clicking on www.code-aster.org . The preprocessor used to build the FE model is also an
open source program, called Salome, located at: www.salome-platform.org. To ensure you have the
correct versions, install both programs from the KISSsoft DVD, or download them from the KISSsoft
website. The only precondition for using this method is that Java is installed (it can be downloaded
from www.java.com ) and you have its bin path set correctly in KISSsoft, by selecting the JAVADIR
folder, where the java.exe can be found (Select Extras > Settings > Directories menu).
Remember that the folders for these FEM programs (FEPreProcessor and FESolver) can be copied
to any location. In KISSsoft, define this location by selecting Extras > Settings > Directories >
FEMDIR (this is usually the KISSsoft installation directory). MS-DOS naming conventions must be
III Cylindrical gears 270
used in some computer configurations. (If so, KISSsoft displays an appropriate warning message.)
Both the solver and the preprocessor are distributed under the GPL license, like the versions that can
be found on the websites mentioned above. (More details about this license can be found in these
programs' installation directories in KISSsoft, and on their websites).
17.3.6.5.1.1 Model and result view
To view the FEM model or the FEM results, either click on Display FEM results or run the Salome
program. To do this, click on "Open Salome" after the calculation has finished. You can then either
open the "PlanCarr.unv" file with the FEM mesh or the "PlanCarr.0.med" file with the FEM results. To
view the mesh in Salome, select the Mesh module from the drop-down list in the Salome toolbar and
then select File > Import > UNV file. To view the results, select the ParaViS module in Salome and
then open the "med" file mentioned above. More information about how to work with meshes and the
results files in Salome is provided in a special instruction file "kisssoft-anl-100-E-FEM-
Planetencarrier.docx". You can request this documentation from the Hotline.
17.3.7 Taking into account shaft bending (face load factor and
contact analysis)
Shaft bending can be taken into account using the "Define axis alignment" dialog. You can access
this dialog either from the "Factors" tab (provided that either the "Calculation according to ISO 6336
Annex E" or "Calculation with manufacturing allowance according to ISO 6336 Annex E" option is
selected, in the "Face load factor" field) or the "Contact analysis" tab.
17.3.7.1 Main settings
The Define axis alignment dialog is where you define the proportional and constant deviation error
of axis (fΣβp, fΣβc) and the inclination error of axis (fΣδp, fΣδc). The proportional deviation/inclination error
of axis is defined at the nominal torque and scaled with the corresponding ISO coefficients strategy
(see Load factors, Module specific settings in the Face load factor/Contact analysis tab).
Instead of defining the deviation and inclination of the axes directly (linear deformation model), you
can also use shaft calculation files for a more precise definition of the effect of bending and torsion
on the shafts on which the gears are mounted.
The "Define axis alignment" dialog is described below. This is where you determine the axis
alignment by using the shaft calculation files. In the "File Shaft Gear 1/Gear 2" fields, enter the file
name for the shafts to which the pinion (1) or the gear (2) belong. You must input the file name with
its entire path (for example C:\MyCalculations\ContactAnalysis\pinion_shaft.W10). However, if the
shaft files are stored in the same folder as the gear calculation file Z12, you only need to input the
name of the shaft calculation file (as shown in the figure).
The resulting scaling of the load is displayed in % in the upper part of the dialog.
III Cylindrical gears 271
Figure 17.30: Define axis alignment (planets and gear pair)
If a shaft file is used, click the additional Plus button to select the meshing to be taken into
consideration.
Conical expansion can be taken into account for internal gears.
17.3.7.2 Conditions for using shaft calculation files
If you are working with shaft files, the sizing parameters in the gears module must match those in the
selected W010 files. More specifically:
1. The pinion geometry must match the geometry defined for the pinion in shaft file 1. The
selection is based on the operating pitch circle, the direction (driving/driven) and the contact
flank. The same applies to the gear shaft.
2. The gear pair performance must match the gear performance defined in the shaft files.
3. The shaft rotation for both the pinion and the gear (according to shaft files W10) must be
consistent. For example, if the pinion rotates in a clockwise direction, the gear must rotate
counterclockwise. However, if the gear is an internal gear, both the pinion and gear must rotate
clockwise in this example.
From these conditions you can also easily see whether the shaft files can be used for the contact
analysis. If one of these conditions is not met, no calculation can be performed.
In addition to the conditions listed above, a number of other conditions (warnings) concerning the
helix angle, the facewidth, and the gear's working transverse pressure angle, are also checked.
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All the conditions can controlled with the "Permitted deviation shaft/ gear" entry or switched off by
clicking the "Suppress shaft/gear plausibility check" setting.
17.3.7.3 Effect of torsion on the body of the gear
You can take the effect of torsion on the body of the gear into account either by applying the results
of the shaft calculation or by inputting your own data (the same applies to side I and II). Obviously,
the results of the shaft calculation can only be referenced if shaft files have been used to define the
axis alignment.
If you defined the gear's torsion in "Side I/Side II"", then the torsion moment of resistance is
calculated from the root circle df and the internal diameter.
17.3.7.4 Handling bending and torsion using the results for the shaft
If a gear pair has been found and the shaft calculations performed successfully, the bending and the
effect of torsion are determined from the results for the shaft.
The results for bending in each shaft file are all transferred to a single coordinate framework, where
pinion contact occurs at 0° and gear contact occurs at 180°. The torsional angle of each gear is
assumed to be 0° on the side that is furthest to the left (side I, i.e. the side with the smallest Y-
coordinate in the shaft file) and every torsional angle for this particular gear then refers to this side.
17.3.8 Z-Y factors and the technology factor
Figure 17.31: Defining Z-Y factors
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If necessary, you can modify any of the factors that affect the permitted material values (root and
flank) as specified in ISO or DIN in the "Z-Y factors" window.
Factors ZL, ZV, ZR, ZW and ZX affect the pitting stress limit sigHG. Factors YT, YdrelT, YRrelT and
YX influence the tooth root safety limit sigFG.
You can predefine any of these factors in the range 0.5 to 2.0. However, if you input a value that lies
outside this range, it will be set automatically to 1.0.
The technology factor takes into account the change in tooth root strength caused by processing. In
this situation, the material's permissible stress is multiplied by YT ≥ 1.0. This factor is not specified in
the DIN or AGMA standards and is therefore set to 1.0.
You can only input gear rim factor YB for calculation methods according to ISO 6336. If you select a
different method, this flag is deleted and the factor is set to 1.0.
Tooth root area processing type Technology factor YT
Shot peening
Case-hardened/carbonitrided gear teeth 1.2
Not ground in the reinforced areas
Rollers
Flame- and induction-hardened gear teeth 1.3
Not ground in the reinforced areas
Grinding
For case-hardened 0.7 (general)
or carbonitrided gear teeth 1.0 (CBN grinding discs)
Cutting machining
Not for profile ground gear teeth! 1.0
17.20 table: Technology factor according to Linke
According to Bureau Veritas/RINA [24], the technology factors in Table 14.20.
Processing of tooth root area Technology factor Y T
Shot peening, Case hardening steel 1.2
Shot peening, Through hardening steel 1.1
Shot peening, Nitriding steel 1.0
17.21 table: Technology factors as defined by Bureau Veritas/RINA Directives
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Table 14.21 shows the technology factors as defined in ISO 6336-5:2003, section 6.7. These only
apply to tooth root bending stresses and shot peened case hardening steel.
Material class Technology factor Y T
ML 1.0
MQ 1.1
ME 1.05
17.22 table: Technology factor according to ISO 6336-5:2003, Section 6.7
17.3.9 General calculation procedure for KHbeta as specified in ISO
6336-1, Annex E.
1. Import the shaft files, select the correct gears, and then perform the initialization
2. Calculate the shafts and determine the bending lines and torsion in the point of contact (if
uniform load distribution is present, determine these values along the facewidth of the gear)
3. Take into account flank modifications from Z012 (not W010)
4. Calculate the gaps in the tooth contact, then the load distribution with tooth contact stiffness and
finally calculate KHβ.
5. Use the calculated load distribution to correct the load distribution on the original gears
6. Divide the gears into "sections" whose load values are defined in the previous step
7. Use the flank contact ratio (as a vector) from the previous iteration gk-1and the current flank
contact ratio gk to calculate the root of the sum of the square error.
If λ>0.1%, go back to step 2 and perform further iterations. Otherwise exit.
This procedure exactly follows the method described in ISO 6336-1, Annex E, but uses a stricter
iteration criterion.
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17.4 Reference profile
Figure 17.32: Reference profile input window
In contrast to traditional mechanical engineering, where a predefined standard reference profile is
most commonly used, the reference profile is often modified in precision mechanics. Input the gear
tooth reference profile or the appropriate tool in the Reference profile input window. You can input
this data either as coefficients, as lengths or as the diameter.
17.4.1 Configuration
The reference profile of the gear teeth is usually predefined. However, you can also define your own
hobbing cutter or pinion type cutter. The pinion type cutter parameters are also used in the strength
calculation to calculate the tooth form factor. You can also select Constructed involute for precision
engineering. In this case, the involute is defined directly together with a root radius.
17.4.1.1 Cutter: Hobbing cutter
Select the hobbing cutter you require from the selection list and then click the button, see Figure
14.17.
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Figure 17.33: Select hobbing cutter window
If you select a standardized profile (e.g. DIN 3972 III), the list displays the tools that are present in
the relevant cutter file. (The name of the cutter file list is entered in the database.) Click on the
Restrict selection using module and pressure angle checkboxes to only display tools whose
modules and pressure angles match those defined in the gear geometry. By default, only tools that
match the selected module and pressure angle are displayed. If tools are selected from the Tooth
form tab, cutters that meet the condition cos(αn)*mn = cos(αn1)*mn1 are also displayed. The standard
tolerance is set to + - 1°.
Figure 17.34: Reference profile for tool configuration: Hobbing cutter
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Hobbing cutters for asymmetrical gears:
Figure 17.35: Reference profile for asymmetrical gears for the configuration tool: Hobbing cutters
Select Own Input to directly define your own cutter:
▪ The cutter addendum coefficient h*aP0 defines the cutter addendum, which then defines the gear
root circle. A usual value is 1.25.
▪ The cutter tip radius coefficient ϱ*aP0 defines the cutter tip radius, which then defines the gear
root radius. The tip radius is limited by the maximum geometrically possible radius, depending
upon the profile addendum and the pressure angle. This value usually lies in the range 0.2 to
0.38.
▪ The cutter's dedendum coefficient h*fP0 defines the cutter's dedendum , which then defines the
tip circle, for a topping tool. A usual value for this is 1. In a non-topping tool, there has to be a
certain amount of clearance between the tool and the gear tip circle, which the software checks.
1.2 is a usual value for an addendum of the reference profile of 1.
▪ The root radius coefficient ϱ*fP0 defines the root radius of the cutter. In a topping tool, the root
radius cuts a tip rounding on the gear in most cases. Depending on the geometric conditions, a
chamfer or corner may occur on the tip.
▪ The protuberance height coefficient h*prP0 defines the protuberance length, measured from the
addendum. The protuberance is used as an artificial undercut to prevent a grinding notch from
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being created. The protuberance height can be calculated from the protuberance size and
angle.
▪ The protuberance angle α*prP0 is usually smaller than the pressure angle. However, in the case
of some special cutters, it may also be larger. In this case, no undercut is present, but the tooth
thickness at the root of the gear is larger. The protuberance angle can be calculated from the
protuberance size and height. If you enter the value "0", no protuberance will be present.
▪ When calculating the contact ratio, protuberance is not taken into account until it reaches a
certain value because a contact under load is assumed in the profile modification. To set the
threshold value that takes into account protuberance and buckling root flank for active
diameters, select the Calculation > Settings (see chapter 17.20.5, Calculations) menu option.
▪ The root form height coefficient hFfP0* defines the end of the straight flank part of the tool with a
pressure angle αn. The height is measured from the tool reference line.
▪ The ramp angle aKP0* defines a ramp flank or a profile modification that is present in the cutter.
The length is determined using the root form height coefficient. The angle must be greater than
the pressure angle αn. If you enter the value "0", this part will be ignored.
▪ The threshold value used for protuberance is also taken into consideration here when
calculating the diameter and the contact ratio (see chapter 17.20.5, Calculations).
▪ For the usual tools, the tooth thickness factor of reference line s *P0 equals s*P0 = π2. The value
can be overwritten for special tools.
▪ The addendum coefficient of the gear reference profile h*aP for a non-topping cutter is defined
with the usual value of h* aP = 1 of the gear reference profile or using the gear's tip circle. The
value can be calculated by converting the tip circle value.
17.4.1.2 Cutter: Pinion type cutter
Click the button next to the pinion type cutter designation to select a pinion type cutter for internal
and external gears from a list. Pinion type cutters as specified in DIN 1825, 1826 and 1827 are listed
here. You use this window in the same way as the Select hobbing cutter window in Figure 14.37.
The default setting is for the list to display only those tools that match the selected module, meshing
and helix angle.
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Figure 17.36: Reference profile for tool configuration: Pinion type cutter
Pinion type cutter for asymmetrical gears:
Figure 17.37: Reference profile for asymmetrical gears for the configuration tool: Pinion type cutter
Select Own input to directly define your own pinion type cutter:
▪ KISSsoft can prompt the number of teeth z0 for the cutter. If the number of teeth is too small, it
may not be possible to manufacture the cylindrical gear tip form circle and/or root form circle. If
the number of teeth is too great, it may cause collisions during manufacture.
▪ The pinion type cutter profile shift coefficient x0 is often unknown. However, it does influence the
root circle of the resulting gear. This value is set automatically, together with the number of
teeth.
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▪ A pinion type cutter tip often takes the form of a radius or a chamfer. The tip form is not defined
in the standards. To be on the safe side, a chamfer of mn/20 was set in the files. However, you
should check this value if necessary.
▪ The pinion type cutter addendum coefficient h*aP0 defines the pinion type cutter addendum that
in turn determines the pinion type cutter tip circle and the gear root circle. A usual value is 1.25.
▪ The pinion type cutter dedendum coefficient h*fP0 defines the pinion type cutter dedendum height
that in turn determines the tip circle for a topping tool. A usual value for this is 1. In a non-
topping tool, there has to be a certain amount of clearance between the tool and the gear tip
circle, which the software checks. 1.2 is a usual value for an addendum of the reference profile
of 1.
▪ The root radius coefficient of the pinion-type cutter ϱ*fP0 defines the radius at the cutter root. In a
topping tool, the root radius cuts a tip rounding on the gear in most cases. The input value is
only displayed for a topping tool.
▪ The protuberance height coefficient h*prP0 defines the protuberance length, measured from the
addendum. The protuberance is used as an artificial undercut to prevent a grinding notch from
being created.
▪ The protuberance angle α*prP0 is usually smaller than the pressure angle. If 0 is input, no
protuberance is present.
▪ When calculating the contact ratio, protuberance is not taken into account until it reaches a
certain value because a contact under load is assumed in the profile modification. To set the
threshold value that takes into account protuberance and buckling root flank for active
diameters, select the Calculation > Settings (see chapter 17.20.5, Calculations) menu option.
▪ The root form height coefficient hFfP0* defines the end of the tool involute with the pressure angle
αn. The height is measured from the tool reference line.
▪ The ramp angle αKP0* defines a ramp flank or a profile modification that is present in the cutter.
The length is determined using the root form height coefficient. The angle is greater than the
pressure angle αn. If you enter the value "0", this part will be ignored.
▪ The threshold value used for protuberance is also taken into consideration here when
calculating the diameter and the contact ratio (see chapter 17.20.5, Calculations).
▪ The addendum coefficient of the gear reference profile haP * with the usual value of haP * = 1
defines the gear's tip circle for a non-topping tool. The value can be calculated by converting the
tip circle value.
17.4.1.3 Reference profile
The reference profiles displayed here are taken from the database. If you can't find a suitable
reference profile here, you must first enter it in the database (see chapter 9, Database Tool and
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External Tables) (Z000.ZPROF). Alternatively, select Own Input from the drop-down list, to open a
dialog in which you can edit all the input fields, and so change all the reference profile parameters.
The Label input field is displayed under the Reference profile drop-down list. This is where you
enter the name of your own profile, which will then appear in the calculation report.
► Note
You do not create a new entry in the database when you define your own profile in the Own input
field.
The reference profile details are according to ISO 53, DIN 867 or DIN 58400. This is the reference
profile data for the gear. You can calculate the corresponding values in [mm] by multiplying it with the
normal module. Please note the following points:
▪ If the reference profile is set to Own Input, the tip alteration (see chapter 17.7, Modifications)
set to zero. For this reason, the addendum may change when you toggle from one window to
another.
▪ If you are using reference profile BS 4582-1:1970 Rack 2 to determine the correct tip and root
diameters, you must input an appropriate tooth thickness tolerance of
directly. The tip and root diameter will then match the values defined in BS 4582-1(8).
▪ The ramp flank is usually used to generate a tip chamfer (also called "semi-topping").
Alternatively, you can also use a small buckling root flank value to generate a profile
modification. However, profile modifications are usually defined in the Modifications (see chapter
17.7, Modifications) window.
▪ If the angle of the ramp flank is only slightly different from the pressure angle, it is not taken into
account in the contact ratio because the assumption for profile modifications is that the contact
ratio will not decrease under load. In contrast, the contact ratio should be reduced accordingly
for a chamfer. In Settings (see chapter 17.20.5, Calculations), you can specify the difference in
angle that is to be used as the threshold in profile modifications and chamfers.
▪ If a pre-machining tool is used, the additional measure for the pre-machining must be entered
separately. You must input the gear's reference profile for the pre-machining. The calculation of
the reference profile for final machining then takes the grinding wheel into account and
documents this in the report (see chapter 17.4.2, Pre-machining and grinding allowance).
▪ For profile modifications, where the angle difference < threshold value (see above), the tip form
height coefficient h FaP* does not change between pre-machining and final machining.
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Figure 17.38: Reference profile for configuration: Reference profile gear
▪ Reference profile for asymmetrical gears:
Figure 17.39: Reference profile for configuration: Reference profile for asymmetrical gears
▪ Click the button next to the Reference profile drop-down list to display a dialog which
contains proposals for reference profiles according to the following criteria:
▪ Both gears with (dNf-dFf) minimum
▪ Both gears at minimum topland (x is optimized to suit sliding velocity)
▪ Both gears at minimum topland (do not change x)
▪ Deep tooth form according to the theoretical profile contact ratio defined in the Sizing tab, in
the "Module specific settings" (Calculation > Settings)
▪ Click the button next to the "Reference profile" drop-down list to display a dialog window in
which you can select a gear, and then copy its reference profile properties.
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▪ haP* always applies as the normal gear reference profile. The tooth thickness on the reference
line is defined as
(12.19)
17.4.1.4 Constructed involute
When you select Constructed involute, you do not need to enter as many parameters as you do
when you select Reference profile. The essential difference is that the manufacturing process is not
simulated, and the involute is generated directly.
In the gear root, the involute is closed by a radius that is defined by the root radius coefficient ϱfP . In
theoretical involutes, the root radius coefficient is usually greater than the coefficient for a reference
profile, because the manufacturing process does not involve generation.
Figure 17.40: Reference profile for configuration: Constructed involute
For asymmetrical gears:
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Figure 17.41: Figure: Reference profile for asymmetrical gears for the configuration: Constructed involute
17.4.2 Pre-machining and grinding allowance
Often gears are premachined with a grinding allowance, then hardened and then ground. The tooth
flank, but not the tooth root, is usually involved in the grinding process.
Note: If a cutter, pinion type cutter or constructed involute is selected as the pre-machining tool, the
gear reference profile for pre-machining is calculated internally from the tool data.
In this case, the root circle is created by the pre-machining cutter and the flank by the grinding
process. To complete this process correctly, select either Pre-machining (i.e. pre-machining, with
own input, or with reference profile for grinding allowance III or IV as specified in DIN 3972) or select
Final machining. If you decide to use pre-machining, the Grinding allowance field is displayed.
You can also add your own tolerances to the database. Enter the pre-machining tool's profile
(exception: haP *) as the reference profile. For the tooth thickness deviations (tolerances), enter the
tooth thickness allowance for the finished gear teeth (As). In KISSsoft, the grinding allowance is
calculated for the finished gear teeth. The pre-machining is then performed using the following tooth
thickness allowance:
(12.20)
For special requirements, click the button in the Define grinding allowance tolerance window to
increase the tolerance. If a value is input for qmax-qmin, then qmax = q+(qmax-qmin)/2 and qmin =
q-(qmax-qmin)/2 are used to define the pre-machining allowances.
III Cylindrical gears 285
The tolerance interval qmax-qmin is limited to the smaller value of either 200% of the tooth thickness
tolerance interval (As.e-As.i), or 30%, or the grinding allowance (q).
KISSsoft then determines the reference profile that corresponds to the finished tooth form. This tooth
form will also be used to calculate the factors YF and YS for the tooth root strength. The tooth form is
then defined automatically by overlaying the pre-machining contour with the subsequent grinding
process. The root diameters are derived from the reference profile for pre-machining. The control
data (e.g. base tangent length) is calculated and printed out for both the premachined and the
finished gear teeth.
► Important exception
The addendum coefficient h aP* is the theoretical addendum coefficient that is used to calculate the
theoretical tip diameter coefficient. The appropriate minimum root height of the hobbing cutter h*fP0,
which is required to create the tooth form without topping, is output in the report. h aP* always applies
as the final machining reference profile for the gears. The tooth thickness on the reference line is π2
*mn.
17.4.3 Tip alteration
The tip alteration k*mn is usually calculated from the profile shift total to ensure that the tip clearance
does not change. However, if the reference profile is set to Own Input, the tip alteration will not be
calculated. In an external gear pair, a reduction in the tip alteration results in a negative value for the
tip circle reduction. In contrast, in internal toothings, the result is a positive value for both gears, and
therefore also an increase in the tooth height. In KISSsoft, the tooth height of internal toothing is not
increased, and therefore the tip alteration is limited to 0.
Alternatively, you can specify your own tip alteration. However, this only has an effect on non-topping
tools. Otherwise, the value is set to 0 when it is calculated. Click a Sizing button to calculate the
proposed value for a constant tip clearance.
Click the Conversion button to input a tip diameter (either da, daE or dai) which is used to convert
the tip alteration, using the reference profile present.
17.5 Manufacture
This tab is where you specify the manufacturing process for pre-machining and final machining. You
can also check whether special manufacturing processes, such as power skiving, can be used.
17.5.1 Details about the grinding process
This is where you define the grinding process. These inputs are necessary if a grinding allowance is
present in the Reference profile tab, or if profile modifications are added in the Modifications tab.
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The start of modification at the tip or root specifies the height at which the grinding process
processes the gear. The radius of the grinding wheel tip must also be predefined. If the grinding
process reaches the diameter that matches the selected start of modification at the root, the software
simulates the complete roll-off of the grinding tool. The grinding notch that may result is calculated
and taken into account in the strength calculation according to ISO/DIN. You can input the data as
coefficients, as lengths or as the diameter. Where profile modifications are defined over a particular
length (e.g. linear root relief), the length is measured from the selected start of the modification at the
tip or root.
The manufacturing process with a tool and gear can only be checked in the Manufacture 2D
graphic.
Usually, the tooth root area is not included in grinding. When you enter a value for Start of
modification at root you can, if required, also specify that the root area is included in grinding. The
grinding wheel addendum [h*grind] is also usually entered in this case. The profile modifications in the
root then start from the tip form height [hFa*grind] of the grinding wheel, but not before the gear's base
circle.
► Note:
Recommendation for the Generation or Form grinding setting:
if it is not known whether the grinding process is performed using the generation or form grinding
process, we recommend you select the "Form grinding" process, if you input finished teeth without a
pre-machining tool. We also recommend you select "Generation" if you input finished teeth with a
pre-machining tool.
17.5.2 Power skiving
Select this option if you need to check whether power skiving can be used as the final machining
process on a gear. Click the button to open a window in which you can enter specific additional
details.
Use the checks to generate a rough estimate of the limitations of the tool and the machine and also,
optionally, to show possible collisions between the tool and the workpiece. You can use the tests to
perform an initial evaluation, but this cannot be regarded as a replacement for a final analysis
performed together with the machinery manufacturer.
Tool selection
The Check for Power skiving dialog is where all the entries for the checks are defined. The
maximum and minimum possible skiving wheel diameters are the key values for selecting the
appropriate tool. These values are already stored for specific machines, and can also be entered
manually.
The default number of teeth on the tool is set to 20. Click on the button to calculate a suitable
number of teeth which takes into account all the currently active tests.
Meshing tool with work piece
III Cylindrical gears 287
Click on Meshing tool with work piece to define a tool/workpiece pairing with reference to the helix
angle. You can enter this value either as the axial crossing angle or as the helix angle of the tool.
The system then uses these values to check whether power skiving is actually possible for the tooth
geometry of this particular tool/workpiece combination.
Collision check
The system can also check the configuration for possible collisions between the workpiece and the
tool. To do this, select the corresponding scenarios in Collision check. In each case, enter the
relevant distance to the gear teeth, the "Groove width", and the relevant diameter, the "Groove
diameter".
Results
The results are listed in the report.
Fine sizing
The Check for Power skiving function is also available as part of the fine sizing process.
17.6 Tolerances
Figure 17.42: Tolerances input window
Gear teeth geometry is calculated for a backlash-free state. A slightly smaller tooth thickness is
manufactured, to prevent the gears jamming in practice. This reduction in tooth thickness (in contrast
to the backlash-free state) is known as the tooth thickness allowance. The upper tooth thickness
III Cylindrical gears 288
allowance is the upper limit of the tooth thickness. The lower tooth thickness allowance is the lower
limit of the tooth thickness.
► Example
Tooth thickness in a backlash-free state: 4.560 mm
Upper tooth thickness allowance: -0.050 mm
Lower tooth thickness allowance: -0.060 mm
This results in the actual tooth thickness: 4.500 to 4.510 mm
17.6.1 Tooth thickness tolerance
This drop-down list contains the tolerances listed below. You can also include your own tolerance
tables. You will find more detailed information about this in the section about the KISSsoft Database
tool (see chapter 9.4, External tables).
17.6.1.1 DIN 3967
Selection of a tolerance as specified in DIN 3967 (for a gear unit with a module greater than 0.5 mm).
Suggestions as defined by Niemann [5] (page 84):
Cast ring gears a29, a30
Ring gears (normal clearance) a28
Ring gears (narrow clearance) bc26
Turbo gears (high temperatures) ab25
Plastic machines c25, cd25
Locomotive gears cd25
General mechanical engineering,
Heavy machines, non-reversing b26
General mechanical engineering,
Heavy machines, reversing c25,c24,cd25,cd24,d25,d24,e25,e24
Vehicles d26
Agricultural vehicles e27, e28
Machine tools f24, f25
Printing presses f24, g24
Measuring gear units g22
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17.6.1.2 ISO 1328
The current edition of ISO 1328 no longer includes fit (tolerance) classes for tooth thickness
allowances. For this reason, many companies have continued to use the fit (tolerance) classes
specified in the old 1975 edition.
17.6.1.3 DIN 58405
Proposals as specified in DIN 58405, Part 2: Allowances for precision mechanics;
usual gear modifications as defined in DIN 58405 Sheet 2
Material Processing Center distance Base tangent
tolerance length tolerance
Hardened steel Ground 5J 5f
Heat treatable steel finely milled 6J 6f
Light metal finely milled 7J 7f
Light metal finely milled 8J 8f
Steel/laminate finely milled 6J 6e
Steel/laminate finely milled 7J 7d/7c
Light metal finely milled 8J 8d/8c
Plastic milled 9J 9e/9d
Plastic injection molded 10J 10e
17.6.1.4 Own Input
Select this option to input your own data. However, you should note that the values for tooth
thickness allowance, the normal or circumferential backlash (per gear) and the base tangent length
allowance all depend on each other. The (negative) base tangent length allowance corresponds to
the normal backlash.
17.6.2 Tip diameter allowances
You can specify the tip diameter allowances if a non-topping tool has been defined. In contrast, the
tip diameter allowances for a topping tool are defined from the tooth thickness allowances. These
allowances influence the effective contact ratio due to the effective tip circle.
Click the button to specify a tolerance field according to ISO 286. The tolerances prefix operator
is changed in internal toothings because the tip circle is used as a negative value in the calculation.
The tolerance class is saved internally and modified when the tip circle changes.
III Cylindrical gears 290
Click the button to specify the minimum and maximum tip diameter from which the allowances
are to be calculated.
17.6.3 Root diameter allowances
Root diameter allowances are usually calculated from the tooth thickness allowances. In the gear
cutting process, the gear backlash is produced by reducing the manufacturing distance of the tool.
This is why the root diameter allowances depend on the tooth thickness allowances.
A different manufacturing process is used in special cases, e.g. for sintered gears or extruded plastic
gears. The user can then input their own root diameter allowances.
Click the button to specify the minimum and maximum root diameter from which the allowances
are to be calculated. Click the button to specify a tolerance field according to ISO 286. This
defines the allowances, which only need to be entered once in the input screen. The tolerance class
is not saved for later use.
17.6.4 Center distance tolerances
The center distance tolerances are defined either by a standard tolerance taken from the database or
the value you enter in the Own Input field. They influence the gear backlash and the contact ratio.
17.6.5 Settings
The base tangent length and the mass across balls and rollers for the most suitable number of teeth
over which the measurement is to be taken, or the roller diameters, are specified in the report. If you
want to use a different number of teeth spanned, or a different diameter of ball/pin in an existing
drawing, this is where you can overwrite the values selected by the software.
However, no results are output if you enter values for which a measurement cannot be performed. If
the do not cancel when geometry errors occur (see chapter 17.20.1.8, Don’t abort if geometry
errors occur)option is selected, test masses are also output for cases in which they could not be
measured, for example, for points of contact above the tip circle.
► Note
The proposed ball/roller diameters are taken from the Z0ROLLEN.dat file. These values are taken
from the Z0ROLLENANSI.dat file for splines as defined in ANSI 92.1. This file corresponds to the
recommended diameters specified in DIN 3977. You can then use an Editor to modify the existing
ball/pin. You will find more detailed information about how to handle external datasets in the External
tables section (see chapter 9.4, External tables).
III Cylindrical gears 291
17.7 Modifications
You can define profile and tooth trace modifications, a tip chamfer or a tip rounding in the
Modifications input window.
Figure 17.43: Definition of modifications to the tooth end
▪ a) tip chamfer
▪ b) chamfer at tooth end
▪ c) tip end chamfer
► Note:
The tip end chamfer is not specified for gear calculations because it does not affect the strength.
However, if an unusually large chamfer is involved, hk' and bk' can be simulated by inputting, for
example, hk=0.3*hk'. The standards do not offer any guidance for this.
17.7.1 Type of modification
To create a new entry in the list of modifications, click the button. Double-click on a cell in the
Type of modification column to open a drop-down list if you want to change the value in that cell.
The next two sections (see chapter 17.7.4, Tooth trace modifications) and (see chapter 17.7.5, Sizing
modifications) describe the method for performing modifications according to ISO 21771.
Inputting different modifications for right or left flank: In the Flank drop-down list, you can specify
whether a modification is to be applied to the right flank, the left flank or to both flanks.
Definition of the right-hand/left-hand tooth flank (according to ISO 21771):
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17.7.2 Individual modifications per tooth
Each tooth in a cylindrical gear can be modified individually. To enable this option, click on
Module-specific settings -> General -> Individual modifications per tooth (even if Strength
calculation is not selected). Enter the modifications for each tooth in the Modifications tab, as
shown in the next figure. The applied modifications change the tooth form graphic for the
specific tooth (only in transverse section) and the 3D model.
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Figure 17.44: Figure: Applying individual modifications per tooth
17.7.3 Profile modifications
Profile modifications are actually variations of the involute and are known as height corrections. The
sections that follow detail the possible profile modifications you can make in the KISSsoft system.
► Note 1:
Before you can define height corrections, you must first input the length factor LCa* . The length factor
is the roll length Ly (from the start of the modification to the tip form circle or root form circle) divided
by the normal module: LCa* = (LdFa - LdC)/mn or L = (LdC - LdFf)/mn. The roll length Ly is calculated
according to ISO 21771, Equation 17, or DIN 3960, Equation 3.3.07.
The theoretical diameters da or dFa are always used to calculate the start of the modification on the
tip.
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► Note 2:
Measuring tip relief Ca directly on the tip circle may be inaccurate. If tip reliefs have been defined, the
report states the tip relief on a special measuring circle called dcheck, for measuring purposes.
Measuring circle dcheck = dFa.i - 0.02•mn
► Note 3:
Like tip reliefs, different profile modifications can also be predefined with negative Ca parameters in
exceptional circumstances. As the grinding process always removes material, a negative tip relief
results in a tooth form where the tooth root removes material at a constant rage (according to Ca). In
the range of the predefined modification length, the amount of material removed is reduced so that it
is reduced to zero at the tip (See Figure.).
Figure 17.45: Profile modification with negative Ca parameters
17.7.3.1 Linear tip and root relief
Figure(see Figure 17.46) shows the tip relief. The constantly increasing amount of material removed
in the transverse section, starting at dCa, up to the tip circle, refers to the theoretical involute. The
same applies to the root relief.
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Figure 17.46: Linear tip and root relief
where
dNa Active tip diameter dNf Active root diameter
dCa Modification end diameter (tip) dCf Modification end diameter (root)
LCa Resulting tip relief length LCf Resulting root relief length
Cαa Tip relief Cαf Root relief
A Tip neighboring point E Root neighboring point
LAE Resulting tooth height length1)
1) Corresponds to the meshing length gα
To represent tip reliefs in the KISSsoft system, input the value Cαa in the Value input field. The value
in the Coefficient 1 input field defines the quotient calculated from the calculated tip relief length L Ca
and normal module mn. Similarly, to represent root reliefs, input the values for Cαf and the quotient
from LCf and mn.
► Note
In the Modifications tab, you can specify that the modification starts at the root. The figure below
shows the situation when the modification starts at the active root diameter dNf.
17.7.3.2 Arc-like profile modification
The procedure used here is similar to the one used for a linear profile modification. difference is that
this method involves approximating an arc of circle which starts at the point where diameter d Ca
intersects with the unchanged tooth profile. The tangents of the arc of circle are identical to the
tangent of the unchanged tooth profile at this point. The benefit of this modification is that the
tangents do not change abruptly in the unchanged tooth form - circular pitch approximation transition
point.
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Figure 17.47: Arc-like profile modification
LCa Resulting tip relief length LCf Resulting root relief length
Cαa Tip relief Cαf Root relief
17.7.3.3 Progressive profile modification
The procedure used here is similar to the one used for a linear profile modification. The progressive
profile modification is also detailed in the description of tooth form options (see chapter 17.8.2.11,
Progressive profile modification)
Figure 17.48: Progressive profile modification
LCa Resulting tip relief length LCf Resulting root relief length
Cαa Tip relief Cαf Root relief
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17.7.3.4 Linear tip and root relief with transition radiuses
Figure (see Figure 17.49) shows tip and root relief with transition radiuses. The constantly
increasing amount of material removed in the transverse section, starting at d Ca, up to the tip circle,
refers to the theoretical involute. The same applies to the root relief.
Figure 17.49: Linear tip and root relief with transition radiuses
LCa Resulting tip relief length LCf Resulting root relief length
Cαa Tip relief Cαf Root relief
rCa Transition radius in the tip area rCf Transition radius in the root area
Tip relief with transition radius: Enter a Value for Cαa in the input field. The Factor 1 input field is
where you enter the quotient from the calculated tip relief length LCa and normal module mn.
The Factor 2 input field is where you enter the quotient from the transition radius in the tip area rCa
and normal module mn.
If coefficient 2 = 0, then rCa is calculated in such a way that LI = 0.8*LCa applies. The corresponding
Factor 2 is calculated and applied. If coefficient 2 is so large that LI < 0.75*LCa applies, then rCa is
calculated in such a way that LI = 0.75*LCa applies. The corresponding Factor 2 is calculated and
applied.
Similarly, to represent root reliefs, input the values for Cαf and the quotient from LCf and mn, and the
quotient from rCf and mn.
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17.7.3.5 Profile crowning (depth crowning)
Profile crowning (barreling) is where a constantly increasing amount of material is removed in the
transverse section in the direction of the tip and root circle, starting at the middle of the calculated
tooth flank length. Points A and E and the value Ca define the arc-like progression. Ca = Cαa = Cαf
applies for profile crowning. Eccentric profile crowning can be used for different crowning at the tip
and root.
The Roll length-centered and Diameter-centered profile crowning options are available here. Roll
length-centered profile crowning corresponds to the definition in ISO 21771. This modification results
in an arc of circle in the involute test diagram. Diameter-centered profile crowning results in an arc of
circle in the direction of the tooth height.
Figure 17.50: Roll length-centered profile crowning
where
dNa Active tip diameter dNf Active root diameter
Cαa Crowning at tip Cαf Crowning at root
LAE Resulting tooth height length1) LAB Length from tip to center of crowning
A Tip neighboring point E Root neighboring point
1) Corresponds to the meshing length gα
In the Value input field, in KISSsoft, enter the value Cα.
17.7.3.6 Eccentric profile crowning
In the Modifications tab, you can add eccentric roll length-centered profile crowning to the tooth
profile.
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The way the eccentric profile crowning is defined is the same as for eccentric flankline crowning, but
Factor 1 corresponds to the diameter ratio (dA - dX) / (dA - dE). Here, you should note that Factor 1 is
defined by the diameter, not by the length of path of contact. Therefore, if you input a value of 0.5 for
Factor 1, this does not correspond to the profile crowning, because this should run symmetrically to
the center point of the path of contact (dSm).Set
Factor 2 to define the root relief from the tip relief. You can use Factor 2 to set a different value for
Cαa and Cαf. Cαa = 'Value'; Cαf = Cαa • "Factor 2" then applies.
17.7.3.7 Linear tip relief with profile crowning
Linear tip relief with profile crowning is a combination of linear tip relief followed by crowning. The
entry in the Value field is for the crowning value Cβ. Factor 1 defines the length of the linear tip relief
(LCa/mn). Factor 2 defines the ratio of tip relief Cα (in μm) to mn (in mm), so therefore Cα/mn (μm/mm).
Figure 17.51: Linear tip relief with profile crowning
Cα Tip relief Cβ Crowning
LCa Roll length of the tip relief LAB Roll length of the active tooth height1)
A Tip neighboring point E Root neighboring point
1) Corresponds to the meshing length gα
This modification is usually applied to attempt to merge the linear tip relief without bending
tangentially into the crowning. A value for Factor2_opt=... is output in the Info field for this purpose. If
you input this value in the Factor 2 field, you will achieve exactly this.
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17.7.3.8 Shortened profile crowning
Figure 17.52: Shortened profile crowning
Caf: Root relief
Factor 1: Position of the arc midpoint
Factor 2: Shortening
► Note:
Shortened profile crowning is used in combination with a tip relief. The tip relief should start at S.
Otherwise, do not use this modification.
17.7.3.9 Pressure angle modification
You define the pressure angle modification in a similar way to tip/root relief(see chapter 17.7.3.1,
Linear tip and root relief). However, the difference here is that the value CHα stretches over the entire
tooth height (see Figure 14.28).
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Figure 17.53: Pressure angle modification
where
dNa Active tip diameter CHα Pressure angle modification
A Tip neighboring point δCHα Angle (in minutes)
LAE Resulting tooth height length1) B Root neighboring point
In KISSsoft, go to the Value input field and enter the value CHα.
Entering the modification as a value or an angle
If you select Pressure angle modification (value), enter the value CHα in the "Value" column. If you
select Pressure angle modification (angle minutes), enter the modification angle δCHα as minutes
of an angle in the "Factor 1" column.
17.7.4 Tooth trace modifications
Tooth trace modifications are deviations across the facewidth. The following sections detail the
possible tooth trace modifications you can make in the KISSsoft system.
17.7.4.1 Linear end relief I and II
A linear end relief is the constantly increasing removal of material from the tooth trace, starting from
particular points, in the direction of the front and rear face surface. In this case, the numbers for I and
II relate to both face surfaces (see Figure 17.54).
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Figure 17.54: Linear end relief I and II
where
Face I Face II
LCI End relief length LCII End relief length
CβI End relief CβII End relief
In KISSsoft, go to the Value input field and enter the value C βI(II). In the Factor 1 input field, enter the
quotient LCI(II) /bF where bF is the facewidth minus chamfer.
17.7.4.2 Arc-like end relief I and II
An arc-like end relief is the constantly increasing removal of material from the tooth trace, starting
from particular points, in the direction of the front and rear face surface. In this case, the numbers for
I and II relate to both face surfaces (see Figure 17.55).
Figure 17.55: Arc-like end relief I and II
where
Face I Face II
LCI End relief length LCII End relief length
CβI End relief CβII End relief
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In KISSsoft, go to the Value input field and enter the value C βI(II). In the Factor 1 input field, enter the
quotient LCI(II) /bF where bF is the facewidth minus chamfer.
17.7.4.3 Helix angle modification
You define the helix angle modification in a similar way to end relief(see chapter 17.7.4.1, Linear
end relief I and II). However, the difference here is that the value LCI stretches over the entire
facewidth (see Figure 14.30).
Figure 17.56: Helix angle modification
where
b Facewidth bF Usable facewidth
CHβ Helix angle modification δCHβ Angle (in minutes)
In the Value input field, in KISSsoft, enter the value CHβ.
Entering the modification as a value or an angle
If you select Helix angle modification (value), enter the value CHβ in the "Value" column. If you
select Helix angle modification (angle minutes), enter the modification angle δCHβ as minutes of
angle in the "Factor 1" column.
17.7.4.4 Flankline crowning
Flankline crowning is where material is removed constantly and symmetrically in the direction of the
face surfaces, starting from a common point and where the tooth trace remains constant. The
material is removed in an arc-like progression with the maximum at the point bF/2. Cβ = CβI = CβII
applies.
In KISSsoft, transfer the Cβl value to the Value input field.
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► Note
Eccentric crowning, with its maximum to the right of the point b F /2, is often used in practice. You can
define this modification by inputting centrical flankline crowning with an additional helix angle
modification (see chapter 17.7.4.3, Helix angle modification).
Figure 17.57: Flankline crowning
where
b Facewidth bF Usable facewidth
CβΙ Flankline crowning Side I CβII Flankline crowning Side II
bX Length I to crowning center point
17.7.4.5 Flankline crowning Sides I/II
This modification is similar to that for flankline crowning, but can be defined differently for each side.
In addition to flankline crowning, you can also use factors 1 and 2 to define the start and position of
Cß. Factor 1 is defined from bX/bF and factor 2 from bE/bF. Cß is defined at the distance bE from the
side of the gear.
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b Facewidth bF Usable facewidth
CßI Flankline crowning on side I CßII Flankline crowning on side II
bX I/II Length of crowning from side I/II to the bE I/II Length to starting point of Cß from side
center of crowning I/II
17.7.4.6 Eccentric flankline crowning
In the "Modifications" tab, you can add eccentric flankline crowning to the facewidth.
For eccentric crowning, the value defines the amount of modification and Factor 1 defines the
modification position from the side I divided by the facewidth (bX /bF ). The modification is defined as
a part of an arc of circle, whose center runs along the vertical line defined by Factor 1. The radii are
shown in the Information field according to your input. If you input a value of 0.5 for Factor 1, the
modification corresponds to general crowning.
You can use Factor 2 to set a different value for the modification on side II (CβII =CβI • Factor = 2).
17.7.4.7 Triangular end relief I and II
The corners are broken.
Figure 17.58: Triangular end relief I (left) and II (right)
where
CEa Tip relief dEa Modification end diameter
LEa Resulting triangular end relief length bEa Triangular end relief length
dEf Modification end diameter bF Usable facewidth
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In KISSsoft, enter the value CEa in the input field. In the Factor 1 input field, enter the quotient of
LEa/mn. In the Factor 2 input field, enter the quotient of bEa and facewidth b.
17.7.4.8 Twist
Twist is the torsion of the transverse section profile along a helix. Usually, the angle increases in a
linear progression from the start of the effective flank to its end. The definition in ISO 21771 is
incomplete because it only describes twist on the right flank. The definition according to GFT
(Getrag-Ford-Transmissions) is more complete and is therefore the standard solution used in
industry. Modification C can be either a positive or negative value.
Figure 17.59: Twist
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where
C Relief on dNa at I
dNa Active tip diameter dNf Active root diameter
The notation used here is also shown in the sections about helix angle modification (see chapter
17.7.4.3, Helix angle modification) and pressure angle modification (see chapter 17.7.3.9, Pressure
angle modification).
17.7.4.9 Twist due to manufacturing
In the Modifications tab, you can select "Twist due to manufacturing" as a modification. This is a
natural twist that occurs when flankline crowning is created on helical gears as part of the generation
process on standard grinding machines. The resulting twist depends on the value Cβ of the flankline
crowning, the helix angle and also the involute length. The calculation is performed using data
provided by the company Gleason-Pfauter, in Ludwigsburg, Germany. The formula used here
corresponds to equation 5.16 in Hellmann's dissertation [25]. Enter the value of the crowning to be
ground, Cβ, in the "Value" column. The resulting twist is then determined during the calculation
process, and is documented under "Information". The generation grinding process always creates a
negative twist.
Twist due to manufacturing can only be calculated if a generation grinding process is used. If a form
grinding process is involved, different methods that are suitable for the particular process must be
used to determine the resulting twist. Form grinding always generates a positive twist.
17.7.4.10 Topological modification
The Topological modification option enables you to define any type of modification. The actual
modification is described in the file that is to be imported. You will find an example of this type of
entry in the "topological_template.dat" file in the dat directory. The file's name indicates its purpose.
You can define coefficients in any slice and for any rolling depth. When the file is imported, these
coefficients are multiplied by the value entered under Ca. To display and check the modification,
select Graphics > 3D Geometry > Modifications.
You will find an Excel application, "Topological Crowning.xlsx", in the \dat directory. In that file, you
can edit the table in which the topological modification is defined and then copy it to a .dat file. This
Excel file also has an example of how to define a negative profile crowning.
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17.7.5 Sizing modifications
Figure 17.60: Figure: Sizing modifications
Click the button, as shown in the figure (see Figure 17.60), to open the Sizing modifications
dialog. The next two sections describe the basic method for performing profile and tooth trace
modifications.
17.7.5.1 Profile modification
1. Tip relief on the driven gear reduces the entry impact, whereas tip relief on the driving gear
reduces the exit impact. Tip reliefs are therefore usually applied to both gears. They are only
applied to the driven gear alone in exceptional circumstances.
2. When calculating the profile modification, you must always specify the tip chamfer. If not, the
active involute will not be included in the calculation.
3. Tooth contact stiffness is always calculated according to the selected calculation method.
Alternatively, the contact stiffness can also be determined from the tooth form (see chapter
17.2.6.1.5, Tooth contact stiffness).
4. The points along the length of path of contact are labeled according to ISO 21771. In a situation
involving a driving pinion, a tip correction must be applied on the pinion from H -DE to E (or D to
E) and on a gear, from A to H -AB (or from A to AB). For a driven pinion, the labels are swapped
according to ISO 21771 (A becomes E, E becomes A).
5. KISSsoft calculates the tip relief value for a nominal torque that has been changed by the
modification value. In the case of gears that do not always have the same operating torque, the
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modification value is assumed as approximately 50-75% of the maximum moment, evenly
distributed across the pinion and the gear. The default value for tip relief Cα is defined using the
mean value of the data as defined by Niemann. A (somewhat greater) value (C.I) is set as the
meshing start at the tip of the driven gear. The value C.II is set as the value for the meshing end
at the tip of the driving gear. When you select the For smooth meshing profile modification, the
value C.I is also set at the meshing end.
For deep tooth forms, where εα > 2, the load-dependent portion of tip relief is reduced,
depending on accuracy grade (manufacturing quality), to 12.5% (for quality level 8 and poorer)
and up to 50% (for quality level 5 and better).
6. KISSsoft also calculates the modification length, also known as the "long modification", which
extends from point A to point B of the length of path of contact. However, the "short
modification" only goes to point H-AB (the midpoint between A and B). Usually, the short
modification is selected. However, the modification length (from A to AB) should not be too
short. A minimum length (related to the tooth height) of 0.2mn should always be present. This
value is checked during sizing. If the length from A to AB is too short, the program prompts you
to use a minimum height of 0.2mn. However, the result of this is that the contact ratio in the
unmodified part will be less than 1.0 (< 2.0 for deep tooth forms where εα > 2). The program then
displays an message telling you of this.
Figure 17.61: Figure 14.34: Length of path of contact for a cylindrical gear
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Figure 17.62: Short (left) and long profile modification
7. The type of profile modification has an effect on how scuffing safety is calculated (see chapter
21.2.10.5.3, Structural factor XwrelT or structural factor Xw (scuffing)).
If you select For high load capacity gears according to the suggestion given in Niemann, the
profile modification at the end of the contact (point E on the path of contact) is somewhat less
than that at the beginning of the contact.
If you select For smooth meshing, the profile modification at the end of contact is set to the
same values as that for the beginning of contact.
17.7.5.2 Tooth trace modification
The procedure you use to size a width modification, for example, an end relief (see chapter 17.7.4.1,
Linear end relief I and II) or crowning (see chapter 17.7.4.4, Flankline crowning), is specified in ISO
6336, Part 1, Annex B.
If you are working with planets systems, the proposed tooth trace modification can be used to
compensate for a misalignment of the planet and the sun. It can also take into account the effect of
torsion on a particular gear. You will find more detailed information about the direction of torque and
the axis alignment in the "Defining the misalignment of individual parts" section.
However, be aware that this sizing suggestion only applies to planets with a symmetrical
misalignment because of the torsion that influences the carrier.
The proposed modifications (KHβ = 1) are only then correct if the system has a single planet. If
several planets are present, the program searches for the best compromise so that the proposed
modification minimizes the maximum KHß for all the planet contacts.
If ISO 6336-1, Annex E, is applied, an additional precise sizing of the tooth trace modification, as
eccentric crowning or centrical crowning with a helix angle modification.
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17.7.6 Notes about profile modification
If you select a short profile modification, the length of the modification at the tooth tip (or at the
tooth root) for both gears is defined such that the contact ratio of the part of the tooth flank that has
not been changed by the modification is still exactly 1.0 (for deep toothing with εα > 2 is still exactly
2.0). This type of profile modification is the one most frequently used because it always ensures a
sufficiently large transverse contact ratio (no matter what load is involved).
This short profile modification runs from point A of the path of contact up to the point H-AB (the
midpoint between point A and point B), or from E to H-DE. However, the result of this is that the
contact ratio in the unmodified part is 1.0.
If you want to design a gear unit that runs as quietly as possible, it is usually better to select the long
profile modification, because the transmission error is usually much lower in this case. To properly
evaluate the effect of a profile modification, we recommend you calculate the meshing under load
(see chapter 17.10, Contact analysis).
17.7.7 Using diamond dressing wheels and grinding worms
Select Modifications > Worm grinder/Dressing wheel and then click on the Conversion button
in the Manufacturing tab to call an option which enables you to find out whether suitable grinding
worms (with their associated diamond dressing wheel) are present for processing the gear. A list of
all suitable dressing wheels is generated from the "DressingWheel.dat" file. Dressing wheels which
are not suitable for the currently entered module and pressure angle are ignored when the file is
read.
The file to be loaded must be in the …\ext\dat\ or …\dat\ sub-folder, in the KISSsoft installation
directory (although KISSsoft will search for them in \ext\dat\ first). When the file is imported, lines that
start with a backslash are ignored.
In a line, all entries after the first are separated by semicolons (starting from the left):
1. Text, is ignored when the file is read
2. Text, is ignored when the file is read
3. Normal module [mm]
4. Pressure angle αn [°]
5. Profile crowning (depth crowning) radius rc [mm] (when "straight" is read, this radius is set to 1010
6. Length of the linear tip relief LRELIEF [mm]
7. Angle [°] or radius rRELIEF [mm] of the linear tip relief (if the angle value is in degrees and arc
minutes: x°xx or xØxx. If it is the radius: Rxxx)
8. Text, is ignored when the file is read
9. Text, is ignored when the file is read
10. Text, is ignored when the file is read
11. Position hp of the high point of the dressing wheel profile crowning (depth crowning) [mm] (stated
along the flank, from the tip)
12. Dressing wheel addendum hfpd [mm]
13. Dressing wheel dedendum hapd [mm]
14. Gap AL*ref between the flank of the dressing wheel and the grinding worm [mm] (measured
along the datum line)
15. Tooth root radius ϱ [mm] of the dressing wheel
16. Dressing wheel article number/label
17. Text, is ignored when the file is read
18. Text, is ignored when the file is read
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19. Number of starts, grinding worm
20. Reference circle [mm] of the grinding worm
Figure 17.63: Dressing wheel with linear tip relief
Figure 17.64: Dressing wheel with radial tip relief
This enables you to load the same dressing wheel several times, in different lines, with different
grinding worms, for example. Do not enter a semicolon at the start or end of the line. Do not leave
the last line in the file empty.
The system then displays the achievable tip and root modifications, according to the selected gear,
with the loaded dressing wheels, in the first window. Only gears for which pre-machining (without a
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topping tool) has been defined, and a machining input has been entered, are displayed.
The system then displays the suitability of the particular dressing wheel in the third column. Here, the
following apply: "" mean suitable without modification of the gap AL*ref ("air between the flanks"), ""
means suitable if the gap AL*ref is modified and "" means not suitable. The modifications and
toothing diameter are calculated using a tooth thickness tolerance position as stated in the value in
the Tolerances tab for the tooth form calculation. In addition, the system displays the target tip relief
Ca and the target modification length LCa* above the table, according to the selected gear
(according to the entries in the Modifications table in the Modifications tab).
When you select a dressing wheel, the system displays the basic data for the grinding process in a
second window called "Selected worm grinder/dressing wheel". You can move the dressing wheel by
Δh by modifying the gap AL*ref and also modify the grinding worm's lead angle and reference
diameter. The system then recalculates and then displays the modifications.
If a grinding worm has been finally selected, the data in profile modifications that most closely
matches the dressing wheel is adjusted. During this process, the data for the grinding worm and the
dressing wheel is written to the "Dressingwheel.tmp" file. This file is stored in the Windows Temp
folder.
These modifications are entered in the Modifications table, and all previous profile modifications are
deleted. The gear contour is now defined in the same way as it will be produced in the grinding
process with the selected grinding worm. Apart from that, you set the depth of immersion of the
grinding worm in the Final machining tab and set the grinding process to "Generation grinding" with
"Grinding of flank and root"
The report also contains the diameter of measuring ball circle dmess with the associated tip relief Ca.
The measuring circle lies between the tip form circle dFa and the start of the tip relief dCa (dmess =
(2*dFa + dCa) / 3).
► Note:
You can perform all the standard manipulations with dressing wheels described here in the
"Selected grinding worm/dressing wheel" window.
a) Sharpening the grinding worm
This is performed very frequently and regularly after the production of a certain number of gears.
Achieved by a radial feed of around 0.5 to 1.0 mm on the dressing device. Here, the gap AL*ref is
automatically kept constant by the dressing device. Resharpening with an unchanged AL*ref only
produces a minimal change in the worm lead angle.
b) Modifying the gap AL*ref (without changing the radial feed)
AL*ref can be increased on a grinding worm that has already been profiled (i.e. dressed). AL*ref can
only be reduced on a grinding worm that is new, i.e. has not yet been profiled.
c) Modifying the radial feed ("center distance" dressing wheel-grinding dworm )
a can only be increased on a grinding worm that is new, i.e. has not yet been profiled. The "a" value
can normally be reduced on a grinding worm that has already been profiled (i.e. dressed).
Theoretically, in this case (radial reduction), the gap AL*ref could be reduced at the same time. This
III Cylindrical gears 314
should prevent a minimal change to the grinding worm pitch (in a constant diameter dx), which would
need to be corrected.
Figure 17.65: Grinding worm with dressing wheels (examples shown with and without displacement Δh)
17.8 Tooth form
Figure 17.66: Tooth form input window
In addition to the actual calculation, the tooth form calculation offers a number of other options,
because it simulates manufacturing with a precisely defined cutter. These options include, for
example,
▪ tooth form modifications with profile modifications and root contour optimization
▪ taking into account several steps in the manufacturing with different tools
▪ calculating the cutter (pinion type cutter or hobbing cutter) required to manufacture the gear
teeth (for example, for tooth forms that have been imported from a CAD program or for modified
tooth forms)
▪ tooth form modifications for injection molds or for use in manufacturing pinion type cutters
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► Note
Special tutorials that specifically deal with tooth form modifications are available for use. These
tutorials can be downloaded from our website http://www.kisssoft.ch .
The Tooth form calculation module input window has of two columns. The left-hand column shows
which operations are to be performed on the gears. The right-hand column consists of the Tolerance
field for calculation and Approximation for export groups and the relevant operations group.
17.8.1 Context menu
Right-click in the operation directory structure group to display a context menu. This menu refers to
the active element in the directory (shown with a blue background).
Figure 17.67: Context menu in the tooth form calculation
The context menu gives you these selection options:
▪ Add operation Select this menu option to open a sub-menu that lists the operations that can be
performed on a particular gear (see chapter 17.8.2, Operations).
▪ Choose as result This result is usually displayed in the graphic and used in the strength
calculations. The default setting is for the results of the last operation to be displayed here,
unless the modification involves mold making, wire erosion, or a pinion type cutter.
▪ Activate/Deactivate Use this option to remove an operation that has been assigned to a gear
from the list without deleting it. The icon is then marked with a red cross. The Activate menu
option returns a deactivated operation to the list of active operations. The red cross then
disappears.
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▪ Rename Changes the name of an operation. Note that, if you change the name of an operation,
this does not change the area name in the right-hand sub-window.
▪ Delete Permanently removes an operation entry, along with all its associated parameters.
17.8.2 Operations
You can use a combination of different operations to calculate the tooth form. You can apply one
processing step after another, for example, using a hobbing cutter or a pinion type cutter and
applying modifications such as roundings or profile modifications. You can label each operation to
make it easy to identify at a later point in time.
17.8.2.1 Automatically
The default operation for the tooth form calculation is Automatically. The tooth form (with all its pre-
machining and final machining) is then generated using the data entered in the standard tabs (see
chapter 5.1, Standard and special tabs). Any modifications you have defined are taken into account
when generating the tooth form. You can also disable this part of the operation in the context menu.
The same applies to any tip chamfer or rounding you specify. If you select ZA as the flank shape, a
ZA worm will be generated. Otherwise a ZI worm is created.
► Note
If the Automatically operation has been disabled, none of the data input in the Reference profile or
Modifications input windows will be taken into consideration.
17.8.2.2 Generate cylindrical gear with hobbing cutter
To generate a cylindrical gear with a cutter, input the gear reference profile. When you add this
operation, the window is filled automatically, based on the values you defined in the Reference
profile input window. If the tool is a non-topping tool, the addendum of the reference profile is
determined automatically from the tip circle, and not transferred from the values you input. For
special applications (manufacturing a gear with a cutter with a different module), you can modify the
module mn and the pressure angle αn. You can then use the Sizing buttons. Click the Sizing buttons
( ) to calculate the correct value in each case for the specified base circle. Click the Cutter...
button to open the Define cutter window (see chapter 17.4.1.1, Cutter: Hobbing cutter) which displays
a list of tools. To define the tolerance field, you can either enter the generating profile shift
coefficients directly (Own inputs), or use the pretreatment or final treatment tolerances.
The hobbing cutter data can also be input as coefficients or as absolute lengths (mm or inch). These
selection options make your job much easier if the hobbing cutter data are the lengths (in mm or
inches) given in a drawing.
When sizing haP0*, the system calculates the value, which is then used to manufacture the involute
up to the active root diameter. The proposed value shown here is the exactly calculated value, to
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which 0.05 is added (to obtain a small distance between the root diameter and the active root
diameter).
If you use the Sizing button to define the grinding wheel, the radius ϱaP0 should be small (e.g.
0.1*mn), otherwise the grinding process may reach the root radius.
Figure 17.68: Operation: generate cylindrical gear with hobbing cutter
► Note
The cutter information entered here is independent of the data specified in the Reference profile
input window. In other words, the tooth form calculation is based exclusively on the values defined in
the Tooth form input window.
17.8.2.3 Generating a cylindrical gear with an imported hobbing cutter
You can import the cutter contour from the CAD system in dxf format. To do this, define a half tooth
(or a full tooth for an asymmetric tooth) from the predefined layer.
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Figure 17.69: Tool profile
You can either specify the layer that includes the contour or select ALL for all the data. You can then
decide whether to import the tool in transverse section or in normal section, and also change the
module. The profile shift coefficients you enter here determine the tooth thickness.
Click on the "Cutter for displaced generation" option to select a normal module for the tool that differs
from the cylindrical gear generated by the program.
Click on the "Input data as a reference" option to modify the module in the drawing. The cutter is then
scaled to the normal module specified in the basic data.
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
17.8.2.4 Generating a cylindrical gear with a pinion type cutter
If you want to calculate the tooth form of gears manufactured using a shaping process you must
define the geometry of the pinion type cutter.
Required input data:
▪ Reference profile of the pinion type cutter
In the reference profile of the pinion type cutter, swap the values of the tip and root used in the
reference profile of the work gear at x0 + xE = 0. In other cases, you need to input a
displacement at x0.
▪ Z0 number of teeth on the pinion type cutter
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▪ x0 profile shift for the pinion type cutter
(however, if x0 not known, you can use the cylindrical gear calculation to define the profile shift
from the tip diameter or the base tangent length (see chapter 17.1.8, Profile shift coefficient))
▪ or determine the length of the chamfer on the pinion tooth tip s or the radius of the rounding r on
the pinion tooth tip (see Figure 17.70)
Figure 17.70: Tool profile
17.8.2.5 Generating a cylindrical gear with an imported pinion type cutter
You can import a pinion type cutter as a .dxf file. To do this, define a half tooth (or a full tooth for an
asymmetric tooth) from the predefined layer (select ALL for all layers).
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Figure 17.71: Pinion type cutter coordinates
A: Middle tooth tip: Start of contour
E: Middle tooth space (middle of the tooth tip in asymmetric gears): End of contour
M: Center point (xm, ym is a required entry)
z: Number of teeth
Click on the "Input data as a reference" option to modify the module in the drawing. The cutter is then
scaled to the normal module specified in the basic data.
► Note
The file (.dxf) must only contain contours A to E in the layer you can specify for importing. In this
case, you must specify the number of teeth on the pinion type cutter and the manufacturing center
distance.
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
17.8.2.6 Reading (importing) a cylindrical gear
You can import a cylindrical gear directly as a .dxf file. To do this, define a half tooth (or a full tooth
for an asymmetric tooth) from the predefined layer (select ALL for all layers).
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Figure 17.72: Coordinate system for the import
A: Middle tooth tip: Start of contour
E: Middle tooth space (middle of the tooth tip in asymmetric gears): End of contour
M: Center point (xm, ym) is a required entry.
z: Number of teeth
Click on the "Input data as a reference" option to modify the module in the drawing. The cutter is then
scaled to the normal module specified in the basic data.
However, if the imported tooth form has straight elements (e.g. it is a polyline), the local normals and
bends must be calculated as approximations so that a contact analysis can be performed. In these
cases, click on the "Set local flank normal and local bending approximately" checkbox.
► Note
The file (.dxf) must only contain contours A to E in the layer you can specify for importing.
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
17.8.2.7 Adding tip rounding
You can add tip rounding as a tooth form modification. The rounding can be added either in the
transverse or axial section.
17.8.2.8 Adding tip chamfer
You can add a tip chamfer as a tooth form modification. The chamfer can be added either in the
transverse or axial section and is defined by the starting diameter and an angle.
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17.8.2.9 Linear profile modification
In a linear profile modification, the tooth thickness is reduced in a linear progression from the starting
diameter to the tip (relief Ca on each flank as a tooth thickness modification).
Figure 17.73: Linear profile modification
17.8.2.10 Logarithmic profile modification
In a logarithmic profile modification, the tooth thickness is reduced in a linear progression from the
starting diameter to the tip. The profile modification is calculated as described in FVA 609 [26].
Figure 17.74: Logarithmic profile modification
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Equations:
17.8.2.11 Progressive profile modification
In a progressive profile modification, the tooth thickness is reduced from a starting diameter to the tip
(relief Ca on each flank as a tooth thickness modification) in accordance with
(14.21)
. The coefficient controls the course of the relief. A coefficient of 5 represents a linear relief. For more
information, see also Figure 14.44. If a coefficient greater than 5 is used, the progressive profile
modification moves tangentially into the unmodified tooth flank. This is the preferred option if larger
reliefs are to be achieved. We do not recommend you use a coefficient of less than 5 (some of these
lower values are simply ignored by the program). Coefficients greater than 20 are also ignored. In
this case, a coefficient of 20 is used.
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Figure 17.75: Progressive profile modification
17.8.2.12 Entry curve as specified by Hirn
An entry curve that passes into the involute tangentially is applied to the tooth tip starting from the
specific diameter dbegin. This entry curve consists of three arcs of circle. The bend in the curve
increases from arc of circle to arc of circle, so that the final arc of circle is tangential to the tip circle.
This modified tooth form (also called a hybrid tooth) has significant benefits, because it results in
extremely quiet running, despite relatively imprecise production methods. For this reason, the
modification is applied for plastic products, for preference (see Figure 17.76).
Figure 17.76: Profile modification according to Hirn
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An entry curve is usually only applied to deep tooth forms with transverse contact ratios of greater
than 2.1. In addition, KISSsoft can use its sizing function to suggest a suitable starting point
(diameter) for the entry curve and the tip relief value. To do this, it uses the profile modification
calculation (see chapter 17.7, Modifications).
The start of the entry curve is defined as follows:
▪ For a transverse contact ratio of 2.0: The active involute is reduced until the transverse contact
ratio is exactly 2.0.
▪ For a transverse contact ratio of less than 2.0: The diameter is calculated so that an average tip
relief is created, i.e. a transverse contact ratio of above 1.0 is reduced by approximately 50%.
For example, from 1.8 to 1.8 - 0.5 . 0.8 = 1.4.
The exact definition is :
For a transverse contact ratio of less than 2.0: dBeginn = minimum (dPunktD, dPunktE0.2)
For a transverse contact ratio < 2.0: dBeginn = minimum (dPunktDE, dPunktE0.2)
The relief Ca at the tip is defined as shown here:
▪ For top lands less than 0.21 .mn: 0.5 . Tooth thickness - 0.01 .mn
▪ For top lands greater than 0.21 .mn: 0.10 .mn to 0.12 .mn
17.8.2.13 Elliptical root modification
The root fillet is replaced by an ellipse-shaped contour which progresses tangentially in the flank and
root circle. The aim is to achieve the greatest possible radius of curvature. The course of the contour
can be influenced by the coefficient in the range 1 ÷ 20. If you click on the Sizing button for the
diameter at the start of modification, the software suggests a value for the active root diameter
(slightly increased, to prevent problems when applying the modification to an undercut). The
definable length on the root circle is then set to > 0 if you want an area of the tooth form to run on to
the root circle. For example, this is a good idea if the root circle is to be measured with measuring
rollers.
The greater tooth thickness in the root area means that the generation process with the other gear in
the pair must be checked. For a mathematical description of contours that are similar to ellipses,
please contact KISSsoft Support and ask for the separate "kisssoft-anl-123-E-Elliptical root
modification" instructions.
17.8.2.14 Root radius
The root contour is replaced by an exact arc of circle with a specifically definable radius. After you
make this modification, check the generation process using the other gear in the pair.
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17.8.2.15 Tooth root reduction
The gear's tip diameter is reduced to the predefined diameter (or increased, in the case of internal
toothing).
17.8.2.16 Theoretical involute/form grinding
The tooth form is constructed mathematically. The involute is defined using the module and pressure
angle along with the tip and root diameter. The tooth thickness is defined by the profile shift
coefficients. You can also define a root radius (in the transverse section). This option is suitable for
involute gears that cannot be manufactured by a gear generation process (e.g. internal gears with 4
teeth) or for a processing step involving form grinding.
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
17.8.2.17 Cycloid
You can select a cycloid as a special tooth form. The cycloid is defined with two rolling circles and
the tip and root diameters. In the main calculation, the tooth thickness is defined by the allowances.
Rolling circle 1 rolls on the inside on the reference circle and therefore cuts the dedendum flank.
Rolling circle 2 rolls on the outside and generates the tip. Rolling circle 1 of the first gear should
correspond to rolling circle 2 of the second gear. Sizing a cycloid toothing is made easier if you
calculate the other gear in the pair using the data from the first gear during the optimization process.
Use the Stress curve and Kinematics analyses modules to analyze the strength and geometry
properties of cycloid toothings.
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
17.8.2.18 Circular arc teeth
The circular arc teeth special toothing type can be defined using the tooth flank radius and the tooth
thickness at the reference circle. An arc of circle is created in the root area.
A classic arrangement of circular pitched teeth, for example, as specified in NIHS 20-25 [27] consists
of an arc of circle with radius r starting from the reference circle, a straight line that progresses in the
direction of the center of the gear below the reference circle, and a full root rounding.
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Figure 17.77: Arcs of circle on the tooth
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
17.8.2.19 Straight line flank
You can select a straight line flank as a special tooth form. The straight line flank is defined by the
tooth thickness at the reference circle (theoretical toothing), the space width angle in transverse
section, the tip and root diameter as well as the manufacturing profile shift coefficient (dependent on
the tolerance). You can also predefine radii for tip and root rounding.
Figure 17.78: Straight line flank
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
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17.8.2.20 Generation with the other gear in the pair
You can use the other gear in the pair to calculate the tooth form on all the gears, except on gear 1
(gear number - 1). In this case, you can overwrite the manufacturing center distance and the tip
circle. The clearance between the gears can be generated either by reducing the manufacturing
center distance or by inputting the circumferential backlash. The tip clearance is achieved by
increasing the tip circle of the tool.
17.8.2.21 Calculating the reference profile
You can calculate the reference profile of an existing tooth form. A hobbing cutter can then be used
to manufacture it. The manufacturing center distance can be changed in this calculation. This has a
significant effect on the practicability of creating a tooth form using the generation process. In
contrast, the value you input for the profile shift has no effect on the profile. Instead this influences
the null point.
The calculated reference profile is then used as a cutter to calculate the cylindrical gear again. By
comparing the two tooth forms you can then evaluate the extent to which the tooth form can be
manufactured using the generation process. Click Tool to display the reference profile in the graphic.
17.8.2.22 Calculating a pinion type cutter
You can calculate a pinion type cutter for an existing tooth form. To do this, enter the number of teeth
on the pinion type cutter and the manufacturing center distance. The center distance has a significant
effect on the practicability of creating a tooth form using the generation process. Try out a number of
different values to find the best one.
The calculated pinion type cutter is then used as a tool for calculating the cylindrical gear again. By
comparing the two tooth forms you can then evaluate the extent to which the tooth form can be
manufactured using the generation process. Click Tool to display the pinion type cutter.
17.8.2.23 Generating a face gear with a pinion type cutter
This operation is not yet available. To generate a face gear, select the Automatically option. Define
the pinion type cutter in the Reference profile input window.
17.8.2.24 Generate a rack with a hobbing cutter
Once again, enter the rack's reference profile, as you do when generating a cylindrical gear using a
milling cutter. In this case, the addendum is only relevant if you are using a topping tool. The profile
shift is measured, starting from a reference line, which is defined by the rack height minus the
reference profile addendum in the main screen.
III Cylindrical gears 329
The profile shift coefficients can be either input directly or defined by the pre-machining and final
treatment tolerances.
17.8.2.25 Generating a rack with imported hobbing cutter data
You can define a cutter as a .dxf file. In this case, the contour must be output as follows so that it can
be read correctly by KISSsoft:
Figure 17.79: Tool profile
► Note
The file (.dxf) must only contain contours A to E in the layer you can specify for importing.
In addition to the contour, you must also define the manufacturing center distance. In this case, the
reference line for the center distance is defined using the rack height.
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
17.8.2.26 Generate rack with a pinion type cutter
Once again, enter the reference profile of the pinion type cutter, as you do when generating a
cylindrical gear using a pinion type cutter. The profile shift is measured, starting from a reference line,
which is defined by the rack height minus the reference profile addendum in the main screen.
The profile shift coefficients can be either input directly or defined by the pre-machining and final
treatment tolerances.
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Figure 17.80: Cutter tooth geometry
17.8.2.27 Generating a rack with imported pinion type cutter
You can generate a rack with an imported pinion type cutter. In this case, you must specify the
number of teeth on the pinion type cutter and the manufacturing center distance, in addition to the
pinion type cutter contour in .dxf format.
Figure 17.81: Coordinate system for the import
A : Mid tooth tip: Start of contour
E : Middle tooth space: End of contour
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M : Center point (xm, ym) is a required entry
z : Number of teeth
► Note
The file (.dxf) must only contain contours A to E in the layer you can specify for importing.
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
17.8.2.28 Importing the rack
You can import a rack directly as a .dxf file in the following format:
Figure 17.82: Tool profile
► Note
The file (.dxf) must only contain contours A to E in the layer you can specify for importing.
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
17.8.2.29 Generate a SA worm
This function is currently only available as the Automatically option.
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17.8.2.30 Importing the data for a worm into the axial section
You can also import a worm in its axial section. In this case the contour is basically the same as the
contour of the hobbing cutter, apart from the null point which forms the axis of the worm.
Figure 17.83: Tool profile
► Note
The file (.dxf) must only contain contours A to E in the layer you can specify for importing.
► Note
This operation should not be combined with the "automatic" operation, if this is not intended. To
deactivate "automatic", right-click "Deactivate".
17.8.2.31 Modification for mold making
When plastic gears are manufactured using the injection molding process, the material shrinks as it
cools. To counter this effect, and manufacture precise tooth forms, the size of the cutter must be
increased by the shrinkage amount. Shrinkage may occur either radially or tangentially depending on
what type of material is involved. If you enter the same values in the radial and tangential directions,
the strain will be uniform in all directions
If the gear is injection molded around an inlay body, you must also input the external diameter of this
body. The radial strains will then calculated using the "external diameter of inlay body".
The modifications only affect the transverse section of the tooth form. No strain in the axial direction
is present when a 3D volume model is generated. If you want to create an expanded 3D model of a
helical toothed gear (if the strain is to be the same in all three axes), you can achieve this by scaling
the module (mn), the center distance and the facewidth.
III Cylindrical gears 333
► Example
In the main screen, increase the module, center distance and facewidths by the required strain
coefficient.
Coefficient = 1.02
Then, do not input a value for strains in the tooth form calculation.
This modification also increases the lead height pz by the same coefficient. However, the angle of
rotation of the spirals across the facewidth remains the same.
Usual values are:
▪ Radial shrinkage approx. 2%
▪ Tangential shrinkage approx. 2%
17.8.2.32 Modification for wire erosion
In the erosion process, the electrodes must maintain a specific distance from the required shape,
because additional material is removed due to the spark gap. This is usually taken into account by
the machines involved in the wire erosion process.
When sink eroding an injection mold, the eroding wire must therefore be thinner than the required
shape by the amount of the spark gap. If a gear shaped electrode is used, the tooth will be
correspondingly thinner. To achieve this, enter a negative value for the spark gap. Usual values for
the spark gap are 0.03 to 0.07 mm.
After this modification you can also calculate the reference profile in the next step to determine the
shape of a hobbing cutter for the electrodes.
► Note
You can also use the wire erosion modification to check the practicability of using the wire erosion
method. If the aim is to erode external teeth, enter one modification with a positive wire radius and
then the second with a negative radius. If the aim is to erode an injection mold for external teeth, first
input a negative radius and then run a modification with a positive radius. By comparing the tooth
III Cylindrical gears 334
forms you can then see whether the form can be manufactured, or whether a practical form can be
created using these two steps.
17.8.2.33 Modification for pinion type cutter
The effective cutting angle and the draft angle of the pinion type cutter cause a tooth form
deformation in the projection of the pinion type cutter in the horizontal plane.
The conversion performed here deforms the tooth form in the horizontal plane so that the projection
once again shows the exact tooth form once the pinion type cutter has been manufactured.
By grinding with angle (effective cutting angle) Q moves to P (see Figure 17.84). If the projection P'
is to agree (exact contour in the horizontal plane), P must equal Q in the H plane.
(12.22)
(12.23)
(12.24)
where
Effective cutting angle
ξ Tip draft angle in axial section
M Pinion type cutter axis
ra Pinion type cutter tip circle radius
rp Coordinate of the point P
Conversion of the tooth form:
Given: Exact tooth form in polar coordinates P = r (Angle)
Searched for: Tooth form in H-plane P' = r' (Angle)
Solution: r' = r + tan( ) . tan(ζ)(ra-r)
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Figure 17.84: Pinion type cutter profile
17.9 Asymmetric gears
Click on "Module specific settings" in the "General" tab to calculate asymmetric gears. The user
interface has been changed to make it possible to enter additional parameters for calculating
asymmetric gears (pressure angle, reference profile, modifications, etc.).
The strength of asymmetrical gearing can be calculated according to ISO 6336, VDI 2545 and VDI
2736. However, the calculation methods have been modified to handle asymmetrical tooth forms on
the basis of the technical literature [28]. The calculation is performed twice– once for the right side,
and once for the left (however, in this case, both calculations are based on the special calculation
procedure for asymmetrical gearing).
The corresponding flank results are displayed in the graphics, depending on which working flank is
selected.
Not all the functions for asymmetrical gearing are currently available (unlike the functions for
symmetrical cylindrical gears). For example, pre-machining cannot be performed for asymmetrical
gears.
An overview of the advantages and disadvantages of asymmetric gears is given in [29].
III Cylindrical gears 336
17.10 Contact analysis
The load is taken into account when calculating the path of contact. This also calculates the face load
factor KHβ using the more precise method defined in ISO 6336-1, Annex E. In this case, the meshing
stiffness can be calculated either according to Weber/Banaschek [19], ISO 6336-1 or Own input
(see "Contact analysis/Face load factor" section in the Settings chapter).
You can view the calculation results in the report or select Graphic > Contact analysis to display it.
The contact analysis can calculate either the transmission error as a length on the path of contact in
mm or the angle of rotation error as an angle on the driven gear in °.
Resolution
You can select the levels "Own Input", "low", "medium", "high" or "very high" for the resolution.
Resolution defines the termination criterion of the convergence condition, ε (10^-3 to 10^-6).
Tc= the calculated torque and
Tn= nominal torque
of the contact analysis and the number of slices of the discretized model (see the Theory of contact
analysis section). The number of slices is automatically set according to the gear geometry and the
selected resolution. The higher the selected resolution, the higher the number of slices that are
defined automatically. You can also enter the number of steps, slices and pitches manually by setting
the accuracy of calculation to "Own input" and clicking the Plus button next to it. The number of steps
entered is per pitch.
Partial load and load factors
The "Partial load for calculation Wt" can be input for the load. The partial load is taken into account
both when calculating the shaft deformation and when calculating the nominal torque. The partial
load can be scaled by selecting Take into account load factors and entering ISO coefficients kΑ, Kγ,
and Kν. To perform the calculation according to ISO, set Take into account load factors to ‚KΑKγKν‘.
The "Resulting partial load factor W't" field shows the resulting partial load used for the contact
analysis.
If the Take load spectrum into account option is selected, contact analysis is calculated using one
of the load spectra defined in the Rating tab. To take into account individual load bins, you must
select the element with the Consider only one load bin in the load spectra option in the Rating
tab. When load spectra are taken into account, the configuration of the driving wheel, the working
flank, and the direction of rotation, change according to the load bin's algebraic sign.
Coefficient of friction
III Cylindrical gears 337
If a "coefficient of friction" has been defined, the contact analysis calculates the power loss using the
friction force Fr. Click on the Sizing button to the right of the "Coefficient of friction" to size the
coefficient of friction according to ISO/TS 6336-22. The partial load and the load factors are then
taken into account in the contact analysis when the coefficient of friction is sized. The coefficient of
friction between the flanks is assumed to be a constant in the meshing.
Runout error
You can enter the runout error Fr here. This is then included in the contact analysis as a modification
to the center distance. You should always perform a calculation with a positive and a negative runout
error in the selection list with that name.
Single normal pitch deviation
You can predefine the single normal pitch deviation ƒpt here. The program them calculates a
proposed value for the single normal pitch deviation. This can be entered with either a positive or
negative prefix operator. The results are then output for the case that the distance is too large or
small. The contact analysis is performed over two pitches when single normal pitch deviation is taken
into account.
Note:
Numerical problems may arise if the selected single normal pitch deviation is too large relative to the
partial load.
III Cylindrical gears 338
Manufacturing deviation
To take the effect of manufacturing errors (fpar, ΣfHβ) into account, select an appropriate value from
the "Manufacturing allowances" drop-down list in the Contact analysis tab.
The manufacturing error increases the flank gap in the normal flank direction.
Figure 17.85: Figure: Definition of the positive direction of manufacturing errors fma and fHβ
A linear error distribution is assumed here so that the manufacturing error on side I is 0, is at its
maximum on side II, and increases in a linear progression along the facewidth. Manufacturing errors
are taken into account in pairs either positively or negatively.
Center distance and center distance tolerance
The "Center distance" field displays the center distance used for the calculation. This corresponds to
the center distance in the selection list, either the "Center distance tolerance", the three center
distance allowances (lower/middle/top) or the nominal center distance or the center distance defined
by the user.
Wear
III Cylindrical gears 339
You can use the wear iteration function to define wear along the tooth flank in more detail because it
performs several steps of the contact analysis with the worn tooth flank. However, this does
significantly increase the time it takes this calculation to run. Click the Calculate wear iteratively
checkbox to select this option.
You can input the maximum permitted wear per step. In the contact analysis shown below, the
service life after one iteration was reduced by only applying the maximum permissible wear. In the
next step in the contact analysis process, the tooth form with wear is taken into account. The process
is repeated until the total service life is reached.
In the Module specific settings (Contact analysis tab), you have the option of defining the extent to
which the results of the iterative wear calculation are to be smoothed.
Conical profile shift coefficients
If this option is selected (in the Calculation > Settings > Contact analysis tab), the profile shift
coefficients in the Basic data can be overwritten, and a conical profile shift can be added to the gear
pair with reference to gear 1. When used together with an axial offset, this can reduce the toothing
clearance.
17.10.1 Theory of contact analysis
Contact analysis is based on the theory of deformation δ of the meshing of gear pairs as stated in
Weber/Banaschek [19]. It can be split into three components:
▪ Gear body deformation
▪ Bending
▪ Hertzian Flattening
Bending:
Gear body deformation:
Hertzian flattening:
III Cylindrical gears 340
The total deformation δ has the effect that the contact point is displaced along the path of contact
and the theoretical length of path of contact is elongated, in comparison to the actual length of path
of contact. The transverse contact ratio under load is therefore greater than in the load-free state.
The spring equation F=δ*C can be applied to calculate the components of the single contact stiffness
from the individual deformation components and the normal force. The following applies for the tooth
pair spring stiffness in a meshing gear pair:
1 1 1 1 1 1
= + + + +
𝐶 𝐶𝐵1 𝐶𝑅1 𝐶𝐻1/2 𝐶𝑅2 𝐶𝐵2
17.10.2 Asymmetrical gear teeth in the contact analysis
If the contact analysis is performed with asymmetric gear teeth, all the deformation components are
calculated with a modified version of the Weber/Banaschek formulae [19] according to Langheinrich
[30]. Essentially, this means that the simplified assumption of the symmetrical tooth thickness
specified in Weber/Banaschek [19] x' should be replaced by the actual tooth thickness S zy and the
clamping point calculation should be modified to suit the new circumstances, as stated in [30].
17.10.3 Discretized model
A discretized toothing model has been generated so that the deformation theory of meshing in gear
pairs developed by Weber/Banaschek can be applied to three dimensional cylindrical gears with
helical gear teeth. To achieve this, the teeth are distributed in N slices across the width and are
coupled together by torsional stiffness Cc.
𝐶𝑅+𝐵,𝑖 + 𝐶𝑅+𝐵,𝑖+1
𝐶𝑐 = 0.04𝑁 2
2
0.04: Empirical coefficient confirmed by comparative calculations with FEM. The user can change
this coefficient (slice coupling factor) in the Module specific settings.
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17.10.4 Reduced stiffness on the side edges
The reduced normal tooth thickness at the edge of a helical gear tooth then has the effect of reducing
the bending stiffness of the tooth to the edges.
Figure 17.86: Illustration of two cuts for a gear with helical teeth
𝑆𝑟𝑒𝑑 0.5
𝐶𝑟𝑒𝑑 = 𝐶 ( )
𝑆𝑛
Exponent 0.5 was evaluated in comparative analyses with FEM and LVR. The reciprocal value of this
exponent (border weakening factor (buttressing)) can be changed by the user. It has a decisive effect
on the buttressing effect that occurs in helical gear teeth.
III Cylindrical gears 342
17.10.5 Contact analysis model for planetary systems
In the contact analysis for planetary systems, the planet carrier is rotated around a fixed sun and
internal gear. Each of the N planets uses the two pair stiffnesses of sun/planet and planet/internal
gear to adapt its rotating position and thereby compensate for all torques. This approach also
involves an iterative calculation of the system so that the sun's torque corresponds to the nominal
torque.
17.10.6 Meshing position for contact analysis
Normally, the contact analysis is performed for a pitch (or for a system period in the case of planetary
systems). The meshing position angle of the gears involved here is calculated as follows:
for a cylindrical gear pair, for a pitch, the base meshing position ifor N meshing positions is:
TE = transmission error
For a planetary system, for a pitch, the base meshing position (sun and planet carrier) i, for N
meshing positions, is:
III Cylindrical gears 343
Here, the following apply:
p = system period
C = planet carrier
S = sun
H = internal gear
TEc = transmission error, planet carrier
sn = tooth thickness, sun
dw = operating pitch diameter
cx,y = position of the first planet in the Cartesian coordinate system
17.11 Gear pump
If you ignore the return volume, you can calculate the transport volume when you perform the normal
calculation. You will find the parameter for this in the Basic data input window (see chapter 17.1,
Basic data). In this case, click the Calculation of the displacement volume of gear wheel pumps
checkbox in the Calculations tab in the Settings window, which you display by selecting the
Calculation menu.
Click on Calculation to perform a more detailed calculation in the Gear pump tab.
The system calculates and displays the changes to the critical parameters of a pump that occur
during meshing. These include geometric parameters such as the pinched volume (between two
meshed tooth pairs, return volume), the volume with a critical inflow area (if possible, the flow of oil
should be kept constant), the narrowest point (minimum distance between the first tooth pair without
contact), inflow speed, oil inflow at the entry point (with Fourier analysis to evaluate the noise levels)
and volume under pressure at input. Other important information is the progression of torque on the
two gears, the progression of the Hertzian pressure σH, the sliding velocity vg and the wear coefficient
III Cylindrical gears 344
σH .vg. Hertzian flattening can be included when calculating forces because this effect has a
significant influence. The pinched volume depends on how the pump construction functions under
pressure at input or output. This is defined by the appropriate input value and has a considerable
effect on the torque curve. When the pinched volume is reduced, you see a significant momentary
increase in compression in this volume. This produces strong pulsing forces on the support and
therefore generates noise. A pressure release groove must be installed to avoid this increase in
pressure. For this reason, it is very useful to calculate and display pressure flow in the pinched
volume.
Using this calculation, you can analyze any type of cylindrical gear with involute and non-involute
tooth forms. At present, the only fundamental restriction is that this procedure is limited to spur gear
teeth.
Optimization strategies for gear pumps
The most important and critical problems regarding gear pumps are
▪ Noise
▪ Efficiency
▪ Size
▪ Wear
A number of tips about the criteria you can use to evaluate pumps are provided below.
▪ Noise:
Variations in flow through the pump generate noise in the pipes. For this reason, the flow (Q)
should be as continuous as possible. The enclosed volume (V1) should not be reduced during
the generation process. A reduction in this volume would create a massive increase in
compression in V1 and generate dynamic forces on both the bearing and the shafts. This effect
can be reduced by the precise sizing of relief grooves. The inlet speed of the oil through the
narrowest point should be kept as low as possible.
▪ Efficiency:
The return volume should be kept as low as possible.
▪ Size:
The KISSsoft Fine Sizing functions provide a very efficient method for achieving the highest
possible displacement volume for a specified size.
▪ Wear:
Take into account how the wear coefficient progresses (sliding velocity and Hertzian pressure
between the tooth flanks)
III Cylindrical gears 345
► Note:
You will find more detailed information about gear pump analyses in KISSsoft-anl-035-E-
GearPumpInstructions.doc [31] (available on request).
▪ The "Gear pump" report shows the input torque on gear 1 [T1] and the torque transferred from
gear 1 to gear 2 [T1Contact].
▪ You should use the torque at the point of contact in the strength calculation and the contact
analysis (calculated from Pout and Pin). Enter this data in the Basic data tab.
▪ The total power [P] and torque [T1] at the pump inlet are only documented in the "Gear pumps"
report. Otherwise, they are not used. All the graphics shown under "Graphics" > "Gear pump"
are based on the printout. The torque curve used in the graphic is the input torque [T1].
17.12 Operating backlash
In addition to calculating the theoretical backlash as defined in DIN 3967, the backlash after
mounting (including toothing deviations, deviation error of axis according to ISO 10064 or DIN 3964
(see Table 17.23), form and mounting deviations) and the operating backlash (including the
temperature differences between the gears and the housings) can also be calculated. To calculate
the operating backlash, input a temperature range for the gears and the housing, and the maximum
and minimum difference in temperature between them. Two cases are calculated simultaneously,
one that produces the maximum operating backlash (with the given temperature inputs), and one that
produces the minimum operating backlash.
If the module < 1, the statically evaluated circumferential backlash is also calculated according to
DIN 58405.
The reduction of the backlash due to single flank deviations is then calculated with tolerances Fb, Ff
and fp according to the corresponding quality standard.
The reduction in clearance due to single flank deviations is not taken into account for crossed helical
gears.
The effect of the runout error can also be taken into consideration. In this case, the roller runout
tolerance (determined using the approximation formula Fr = Fi'' - fi'') is used instead of the runout
error Fr for module < 1.
Bearing center Axis alignment accuracy class
distance
1 2 3 4 5 6 7 8 9 10 11 12
LG (nominal length)
in mm
up to 50 5 6 8 10 12 16 20 25 32 40 50 63
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more than 50 and up 6 8 10 112 16 20 25 32 40 50 63 80
to 125
more than 125 and up 8 10 12 16 20 25 32 40 50 63 80 100
to 280
more than 280 and up 10 12 16 20 25 32 40 50 63 80 100 125
to 560
more than 560 and up 12 16 20 25 32 40 50 63 80 100 125 160
to 1000
more than 1000 and 16 20 25 32 40 50 63 80 100 125 160 200
up to 1600
more than 1600 and 20 25 32 40 50 63 80 100 125 160 200 250
up to 2500
more than 2500 and 25 32 40 50 63 80 100 125 160 200 250 320
up to 3150
Table 17.23: Deviation error of axis according to DIN 3964, values in [mm]
As shown in Table (see Table 17.23), the values in the Axis position accuracy and Distance between
bearings input fields are used to calculate the axis deviation error according to DIN 3964. Backlashes
are calculated as specified in DIN 3967.
Circumferential backlash calculation:
The circumferential backlash is calculated on the reference circle with the following formula,
according to DIN 3967:
In KISSsoft, the operating backslash is calculated in the operating pitch circle, using the more precise
formula:
Planetary gear units are handled differently in the operating backslash calculation. Here, there are 2
operating pitch diameters for the planets (sun/planet and planet/internal gear). The change in
operating pitch diameter due to thermal expansion is defined here for the operating pitch circle
determined in this process.
In addition, the change in tip clearance due to thermal expansion (and water absorption for plastics)
is also calculated.
III Cylindrical gears 347
Any strains that occur in the body of the gear also change its pitch. A single normal pitch deviation
occurs as soon as both gears show unequal strain. The increase or decrease in pitch caused by
thermal expansion is defined as follows:
pt pitch
a coefficient of thermal expansion
Q temperatures
fpt single pitch deviation
Plastics also expand due to water absorption.
17.12.1 Temperatures
The Reference temperatureT is the ambient temperature specified for manufacturing. The tooth
thicknesses input here apply to this temperature.
The Temperature range gears for specific gears defines the thermal expansion coefficient for
individual gears. The wheel bulk temperature of the scuffing calculation can be used as here as a
starting point.
Taken together with the coefficient of thermal expansion, the Temperature range housing then
defines the coefficients of thermal expansion that occur for the housing.
The Permitted temperature difference defines the maximum permitted difference between the gear
temperature and the housing temperature.
17.12.2 Relative water absorption during swelling
Input this value as a percentage of the volume. To calculate clearance, DIN 3967 specifies that: For
plastics, the linear expansion due to water absorption detailed in DIN 3967 is approximately 1/3 of
the amount of water absorbed. However, for fiber-reinforced plastics, it is only around 1/12 of the
volume of water absorbed. If you click this checkbox, this phenomenon is taken into consideration
when calculating the change in volume. Click on the Conversion button to calculate the relative water
absorption during swelling, as a percentage, from the relative volume of water absorbed.
III Cylindrical gears 348
17.12.3 Coefficient of thermal expansion for housing
If you select a material from the database, this field merely provides information about the coefficient
of expansion of the selected housing material. In this case, you cannot change the value. However, if
you have set the Housing material drop-down list to Own input, you can enter your own value.
17.12.4 Take into account the bending of the shafts and width
modifications
To enable you to use this option, the load distribution calculation (KHβ) according to ISO 6336-1,
Annex E, must be enabled (it is used to calculate the shaft bending). It then determines the position
with the lowest backlash change Δjt.i across the facewidth. (This position is documented in the "Face
load factor" report). For load spectra, the lowest value found in all bins is determined.
If Δjt.i is negative, the operating clearance is reduced. This therefore changes the minimum operating
clearance. (The maximum operating clearance remains unchanged, as it represents the load-free
state.) If Δjt.i is positive, the operating clearance increases. This therefore changes the maximum
operating clearance. (The minimum operating clearance remains unchanged.)
To determine the backlash change caused by bending, only the components in the axial plane,
including the component of the tooth trace modification in the peripheral direction, are taken into
account. The bending component normal to the axial plane is not considered, as the flanks lie above
the entire facewidth, under load (if KHβ < 2), and therefore do not cause any backlash change.
17.12.5 Tooth deformation
Tooth deformation is only taken into account if the line load w>=100 N/mm (otherwise the calculation
of the bending according to ISO 6336 is too inaccurate). Tooth deformation is only taken into account
in the case of the minimum operating clearance. (The maximum operating clearance remains
unchanged, as it represents the load-free state.) It is questionable whether taking the tooth
deformation into consideration is sensible. The calculation of the bending is only approximate and
can result in the combined result being too conservative.
17.13 Master gear
You can use this KISSsoft calculation module to size and check master gears.
To perform a test for a double flank composite transmission, one master gear is required. It is then
rotated on a test device, together with the gear to be tested. In the test run, the test gear and the
master gear are pressed lightly together so that no backlash is generated. The deviation in center
distance is then measured carefully. The difference between the minimum and maximum value
calculated here is the tooth-to-tooth composite error. To obtain accurate information about how the
test gear will run after installation in the gearbox, the test gear's active involute should be generated
as completely as possible during the test run. However, it is essential that you prevent the master
gear from meshing too deeply in the root area: If the value for the test gear root form circle is not
III Cylindrical gears 349
achieved, this will cause meshing interference which will, in turn, generate measurement results that
are massively incorrect. You can call the master gear sizing function for each gear in a particular
calculation. When you open the sizing window, the default values for a suitable standard master gear
taken from DIN 3970 are displayed. The analysis functions check the maximum and minimum
tolerance fields of the tooth thickness of the test gear whose involute is being processed. The report
then shows which area of the active involute has been tested, or not tested. If the value for the root
form circle is not achieved, the program displays a warning to prompt you to reduce the tip circle
diameter of the master gear. This calculation is also available for cylindrical gears with a minimum
number of teeth greater than 4. Click the Save button to save the master gear data and the master
gear-test gear pair as KISSsoft files.
Take into account total radial composite deviation (according to AGMA 2002): When calculating the
smallest test center distance [aMin], the theoretical center distance stated in AGMA 2002 (equation
8.5) is further reduced by the total radial composite deviation (Vcq specified in AGMA 2000). If the
manufacturing tolerances specified in ISO or DIN are being applied, Fi" is used for that purpose. If
the tolerances specified in AGMA are applied, Vcq is used here:
17.14 AGMA 925
In this input window, you can specify the probability of scuffing and wear and the susceptibility to
micropitting (frosting), as specified in AGMA 925.
AGMA 925-A03 Effect of Lubrication on Gear Surface Distress calculates the conditions in the
lubrication gap across the gear meshing. AGMA 925 defines how to calculate the lubrication gap
height while taking into account the flank deformation, lubricant properties, sliding velocity, and local
Hertzian stress. The standard then uses this base data to calculate the probability of wear. The wear
is caused by the metal surfaces contacting each other if the lubrication gap is too narrow. The
probability of wear calculated by the standard is greater than the values that occur in practice.
The standard does not give any indications about safety against micropitting (frosting). However,
data provided by the relevant technical literature, and the results of research, reveal that there is a
direct correlation between the minimum lubrication gap-to-surface roughness ratio and the
occurrence of micropitting (frosting). You can therefore use this calculation method to optimize gear
teeth for micropitting (frosting). AGMA 925 also includes a definition of the probability of scuffing.
This analysis uses the same base data (Blok's equations) as the calculation of scuffing according to
the flash temperature criteria given in DIN 3990, Part 4. However, defining the permitted scuffing
temperature according to AGMA 925 presents more of a problem, because of the lack of
comprehensive or generally applicable information. In particular, there is no reference to a scuffing
load capacity specification as given in the FZG test. There is therefore a tendency to underevaluate
oils that have effective EP additives.
The values for the compression viscosity coefficient α of typical gear oils vary between
0.00725mm2/N and 0.029mm2/N, and are defined as follows in AGMA 925-A03:
III Cylindrical gears 350
(14.25)
where
α Compression viscosity coefficient mm2/N
k see Table 2 in AGMA 925-A03 -
ηM Dynamic viscosity for tooth temperature θM mPa . s
In practice, calculating wear according to Wellauer results in risk of wear values that are too high. For
this reason, the analysis is performed according to Dowson (as in Annex E of AGMA 925). The report
shows the results for both methods.
17.15 Root stress FEM
This special calculation is used to derive the stresses at the root of a gear tooth using the FEM
method. The user must select the gear pair and the specific gear to be analyzed. The tooth's fixation
condition (required boundary condition for the FEM analysis) can either be the inside or external
diameter of the gear (for external and internal gears), the sides of the gear segment selected for the
analysis, or the inside or external diameter with sliding on the side. The last variant (diameter fixed,
sliding sides) is usually the best.
Mesh density can be also defined, but we recommend that the highest possible value is retained,
since the accuracy of the stress calculation is very dependent on the mesh density.
You can also select the stress type to be used to search for the maximum stress. This can be either
the maximum normal stress or the Von Mises stress. As the calculation is used to analyze the tooth
root bending stress, we recommend you use the nominal stress. You can then select either a plane
stress state or a plain strain as modeling assumptions for a 2D analysis. We recommend you use
plain strain for standard gears. Plane stress is suitable for gears with a very small facewidth
(facewidth smaller than tooth thickness).
During the calculation, the exact geometry of the gear is calculated and a segment of it is kept for the
FEM mesh generation. Automatic mesh generation creates a finer mesh in the gear root area. You
can find FEM mesh statistics in the final report. The load is calculated in the 2D analysis and applied
to the force application angle at the point of contact of the individual tooth. The total length of path of
contact and the associated load distribution from the contact analysis calculation are used in a 3D
analysis. The path of contact goes through the point on diameter denm in the middle section. Usually,
the HPSTC (Highest Point of Single Tooth Contact) is used here.
In the 2D analysis for helical gears, the equivalent spur gear is calculated and used, according to ISO
6336-3. Select the relevant option to save the data for the equivalent spur gear after the FEM
calculation. However, if you save the equivalent spur gear data, it will overwrite the original data for
III Cylindrical gears 351
the gear.
Finally, there is a button for automatically starting the FEM pre- and post-processor used by
KISSsoft. This can be useful if you want to see the FEM mesh and/or the stresses on the gear.
Special basic instructions about using this FEM tool are available from KISSsoft support. You can
also display FEM results by clicking Graphic > FEM > Display FEM results.
Display the stress diagrams from FEM results
The stresses along the tooth form are displayed in the graphics. The progressions of the tooth root
stresses are displayed over the common facewidth for 3D FEM as follows:
▪ the maximum occurring stress according to the maximum normal stress criterion and the
equivalent stress according to von Mises.
▪ the stress at the 30° tangent point (external teeth) or 60° tangent point (internal toothing),
according to the maximum normal stress criterion and the equivalent stress according to von
Mises. The location of the tangent point is defined using the formulae in the standard. The stress
is then displayed at the point at which the tooth root stress is calculated according to the
standard.
17.16 Rough sizing
KISSsoft has very powerful sizing functions, which are described in this and the following sections.
The process for sizing a gear stage, from start to end, involves rough sizing, followed by fine sizing
and, finally, by sizing the modifications.
III Cylindrical gears 352
Figure 17.87: Phases involved in sizing gears
Rough sizing proposes possible gear teeth configurations based on the data entered for the ratio and
the load. The purpose of rough sizing is to ascertain the possible range of suitable solutions, all sized
for the specified torque, according to all the specified required safeties. The total weight is possibly
the most important output, because this can be regarded as roughly proportional to the
manufacturing cost. The weight of the different solutions usually varies by a factor of up to 3!
III Cylindrical gears 353
Figure 17.88: Gear sizing, Phase 1
To call the rough sizing function, either go to the Calculation menu and select the Rough sizing
option or click on the icon in the Tool bar.
At present, you can apply this to cylindrical gear pairs with internal or external teeth, and to planetary
gears. The nominal ratio is the most important input parameter. For an internal gear pair, the ratio
must be entered as a negative value in the Geometry area. For planetary stages the nominal ratio
must be > 2.0.
The operating data (power, speed, etc.) is taken from the KISSsoft main window (and can be
changed there if required). You can also specify
a helix angle or a required overlap ratio (e.g. εβ= 1.0).
Some important design parameters for gear stages can be set (ratios b/mn, B/d1 and b/a). All three
parameters are always taken into account during rough sizing. Since these parameters may restrict
each other, you can specify which parameter is to be prioritized by selecting the appropriate button.
Click on the Calculate button to display a list of suggested values that you can use to set the
parameters for your gears.
The parameters in the results table are displayed with formula symbols which match the formula
symbols used in the rest of the interface, and in the reports. Hover the mouse pointer over a formula
symbol in the table to display a description of it in plain text. Right-click on the results table to open a
dialog, in which you can either hide or display additional parameters.
Rough sizing automatically finds the most important tooth parameters (center distance, module,
number of teeth, width) for the required power and ratio, using the strength calculation according to
the selected calculation standard. Dimensioning is performed according to predefined minimum
safeties (see chapter 17.20.6, Required safeties).
To specify the intervals for the ratios b/mn-, b/a, b/d, select the Calculation menu option in the
Settings > Sizings menu. (see chapter 17.20.4, Sizings)
The program displays a number of different solutions which you can select. You can then use them
to perform an optimization in fine sizing. The window remains open, to enable you to select more
solutions. You will find more detailed information about fine sizing in section 17.17.
III Cylindrical gears 354
The most important result of this sizing process is that it enables you to define the achievable center
distance ranges and module ranges, as well as the facewidth. You can then decide how much space
is required for the gear unit itself.
If you select the DIN 3990 calculation method, the standard modules specified in DIN 780 Series I
and II are used. If you select a calculation method according to AGMA and enter the module as
"Diametral Pitch", the module series according to ISO 54 is converted into diametral pitch and then
applied. The module series specified in ISO 54 Series I and II are used for all other calculation
methods. As ISO 54 Series I and II only go up to a standard module m =1, this standard module
series for m < 1 has been extended by the addition of values from DIN 780.
Solutions with a number between 1 and 5 show solutions with any module. Solutions from 6 onwards
show solutions with standardized modules according to DIN 780 (series of modules for gears).
▪ Number 1: Solution with the most exact ratio
▪ Number 2: Solution with the greatest center distance
▪ Number 3: Solution with the smallest center distance
▪ Number 4: Solution with the largest module
▪ Number 5: Solution with the smallest module
You can fix the center distance for special cases. However, in these cases, you must remember that
the program's sizing options are not exhaustive, and fine sizing represents a better alternative.
Sizing of strength for a planetary gear
When performing rough sizing for planetary stages, it is assumed that the rim is static. If the rim
rotates, you must change the speed after sizing.
▪ Proposal of number of teeth according to Niemann
Table of standard numbers of pinion teeth according to Niemann [5], Table 22.1/8.
Ratio u 1 2 4 8
Through hardened or hardened
Counter-through hardened to 230 HB 32..60 29..55 25..50 22..45
Over 300 HB 30..50 27..45 23..40 20..35
Cast iron 26..45 23..40 21..35 18..30
Nitrided 24..40 21..35 19..31 16..26
case-hardened 21..32 19..29 16..25 14..22
Click the Sizing button to transfer these values to fine sizing automatically.
III Cylindrical gears 355
17.17 Fine sizing
The fine sizing function is one of KISSsoft's most powerful tools. It generates and displays all the
possible geometry variants (module, number of teeth, etc.) for the specified facewidth and center
distance (the gear rim diameter is usually specified for planetary stages and the center distance
varied accordingly). The solutions are displayed as graphics, so you can easily see the best possible
macrogeometric variant for your purpose.
Figure 14: Gear sizing, Phase II
To call the Fine sizing function, either go to the Calculation menu and select the Fine sizing option
or click on the icon in the Tool bar.
If you input a nominal ratio, a center distance, and intervals for the module and helix angle, as well as
the pressure angle, KISSsoft calculates and displays suggestions for the number of teeth, module,
helix angle and profile shift. It also shows the deviation from the nominal ratio, the specific sliding and
the contact ratios. This module can also be used to size planetary stages and three gears trains.
All the variants found by this process can be evaluated by a wide range of different criteria (accuracy
of ratio, weight, strength, tooth contact stiffness deviation etc.)
Depending on your requirements, limits can also be set on the most important parameters (tip circle,
root circle, minimum number of teeth, tolerated undercut etc.). In addition to creating text reports
detailing the solutions and the summary, the summary can also be displayed as a graphic.
The facewidth appears in the input screen, where you can modify it if required.
17.17.1 Necessary entries in the input window
Before you start the fine sizing process, you must enter the following data correctly in the Basic data
or Geometry and Strength standard tabs to ensure the calculation returns the results you require.
Geometry:
▪ Reference profile
III Cylindrical gears 356
▪ Number of idler gears/planets (to configure planetary gear stage, 3-gear and 4-gear)
Strength:
▪ Materials
▪ Power/Speed
▪ Application factor
▪ Required service life
▪ Lubrication
17.17.2 Conditions I
You can predefine the module range for cylindrical gears. If the module flag is set, you can predefine
the increments. If the module flag is not set, you can only use modules from the standard module list.
For cylindrical gear pairs, you can either input a fixed center distance (the usual approach) or specify
an interval for the center distance. To do this, click the checkbox to the right of the Center distance
input fields.
If planetary gear units are involved, you can either perform the calculation with a predefined center
distance or with a predefined V-circle (dp = d+2*x*mn) for the internal gear. In practice, it is usually
the internal gear diameter that is fixed (gear size remains the same) and the center distance that is
varied. In this case, we recommend you first input the required output reduction and the V-circle, then
click the Sizing button for the center distance.
Note:
You should check the center distance interval after you change the reference circle or select a
variable center distance. You may then need to repeat the sizing process.
17.17.2.1 Limiting the tip diameter
Solutions whose tip circle exceeds the specified value are rejected. Solutions for internal teeth are
rejected if |da| < |dalimit|. If you do not want to limit the tip value, you can input either 0 or 1010 .
However, the following problem prevents this option being used sensibly in practice: If a gear is to be
installed in an existing housing, it is critical that it does not touch the walls of the housing.
17.17.2.2 Limiting the root diameter
Solutions whose root circle falls below the specified value are rejected. Solutions for internal teeth
are rejected if |df| > |dflimit|. If you do not want to limit the root diameter, you can input 0.
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However, the following problem prevents this option being used sensibly in practice: If a gear is
mounted on rolling bearings in a speed change gear unit, you must guarantee a minimum thickness
of material between the bore and the root circle.
17.17.2.3 Maximum no. of solutions
Proposal: 50 ...250
If the program finds more than the specified number of solutions, you see a warning message and an
appropriate note is entered in the report.
► Note
You should only perform a final evaluation after all the possible solutions have been displayed.
Otherwise, you run the risk that the optimum solution will not be displayed.
17.17.2.4 Limiting the number of teeth
You should not normally use this option and it is therefore inactive by default. However, by clicking
the individual checkboxes, you can still fix this parameter. A useful application for this option is when
for sizing a planetary gear which has already been modified to fit inside a predefined internal gear. In
this case, the module, the number of teeth and the profile shift are predefined for gear 3.
17.17.3 Conditions II
Here, the reference profile h*aP of the individual gears can be varied step-by-step The dedendum h*fP
is determined via the required tip clearance to the counter gear (h*fP2 - H*aP 1). If this value is not
changed, the tip clearance value in every variant will be the same as the value entered in the Basic
tab.
You can also specify that the maximum possible tip rounding radius, ϱ*fP , is always set
automatically.
17.17.4 Conditions III
You can specify other essential functions in the Conditions III tab.
1. Show values of KISSsoft Basic Tab as additional variant with number 0
The toothing data in the KISSsoft Basic tab can also be displayed as a variant with the number 0
(table and graphic). However, the data at the start of the fine sizing process must be consistent
before this can happen. This option can either be enabled or disabled. When you enable this
option, you must restart the fine sizing process so the variant can also be displayed.
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2. If you click on the Only calculate geometry
checkbox, no strength calculation is performed.
3. Strength calculation with load spectrum
Before you can perform calculations with a load spectrum, you must specify a load spectrum in
the KISSsoft main window before you start the fine sizing process and run the calculation (to
ensure the data is consistent). In this case, when you start the fine sizing process, you are
prompted to confirm that you want to perform the calculation with a load spectrum. The flag in
the window only shows whether (or not) a load spectrum is being used. You cannot change this.
4. Permit undercut
If this option is selected, solutions with undercut are not rejected.
5. Reject results with specific sliding higher than 3
Usually specific sliding should not be greater than 3.
6. Consider minimum tooth thickness
If this option is selected, solutions with tip tooth thickness that is less than the predefined
minimum tooth thickness (see Calculation > Settings General) will be rejected.
7. Allow small geometry errors
Minor meshing interference and similar geometry errors will now be tolerated when the system
calculates variants! You can make separate settings to take into account the undercut and the
minimum tooth thickness at the tip (see points 2 and 4). You must set this option if the program
finds solutions where the number of teeth is less than 7, or in other exceptional situations. We
do not recommend you set this option in any other situation!
Note:
In these situations, you must also change the minimum number of teeth accordingly (see point
11).
8. Suppress integer ratios
If this option is selected, results with whole number gear ratios will be rejected.
9. List of cutters for reference profile
Instead of using the predefined reference profile, you can use a list of hobbing cutters for fine
sizing. In this case, the calculation is performed for every default cutter in the given module and
pressure angle range and the tool is displayed in the results list. The same hobbing cutter is
used for each gear. Internal toothings are not affected by this setting.
10. Sizing of deep tooth forms
Special reference profiles with larger addendums and dedendums are used for deep tooth
forms. This sizing function εα=εαtarget calculates the necessary reference profile εαtarget on
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the basis of the required transverse contact ratio. If this function is active in fine sizing, the
reference profile for every solution is calculated so that the exact required transverse contact
ratio is achieved. As a result, only those solutions that have exactly the required transverse
contact ratio are displayed.
However, the εα>= εαtarget function only changes the transverse contact ratio when the
transverse contact ratio of the original reference profile results in a transverse contact ratio that
is smaller than εαtarget.
Note:
In both cases (εα= εαtarget and εα>= εαtarget), you must ensure that automatic tip alteration
k*mn is not performed (and is set to zero). Both the reference profile h*aP value and the tip
alteration k*mn have the same effect on the tip circle, which is why only one of these two values
should be changed.
11. Transmission error
If the Contact analysis option is selected, contact analysis is performed for every variant. If the
Contact analysis and sizing of profile correction option is selected, the length and value of
the profile modification (correction) is determined automatically according to the settings made
for the correction method. Click the button to display the profile modification setting window.
The modification method includes the objective (for high load capacity or smooth meshing), tip
and/or root relief, length (short or long), and the types (linear, arc, progressive, and linear with
transition radius). It is important to note that the transmission error can be minimized only for
one load, and the partial load for sizing should be set correctly according to the applied load
level.
During the transmission error contact analysis, most of the default settings are used to prevent
the calculation generating an inaccurate result. However, the coefficient of friction and accuracy
of calculation are not used. Input the settings in the main program, in the Contact analysis tab.
You can also specify the accuracy of the calculation, however, we strongly recommend you use
"average" or "deep" to reduce the processing time. Therefore, the transmission error in fine
sizing may not be exactly the same as you get in the contact analysis, depending on which
settings have been selected.
The default values are as follows:
- Calculation for: right flank
- Torque for gear A: not considered
- Torque for gear B: not considered
- Partial load range for calculation: 100 %
- center distance: Average center distance allowance
- Single pitch deviation: 0 mm
- Deviation error of axis: 0 mm
- Inclination error of axis: 0 mm
Then, the results list shows:
- Transmission error (PPTE)
- Medium wear on the tooth flank (delwn1, delwn2)
- Maximum flash temperature (theflamax)
- Variation in bearing forces (VarL)
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The calculation time increases significantly with the transmission error calculation option. We
therefore recommend you limit the number of results before starting the calculation.
12. Suspend results which do not meet required safety factors
Variants which do not meet the predefined minimum safety levels (see Calculation > Settings
> Required safeties) will be rejected.
Note:
Variants with insufficient safety against scuffing will not be rejected.
13. Sizing of profile shift coefficient x1
Fine sizing usually generates 3 or 4 variants in which only the profile shift differs. In this case,
the profile shift x1 is changed in increments of 0.1. Here you can specify the criterion used to
determine the largest profile shift used, x1.
14. Minimum number of teeth zmin
Practical values range for the minimum number of teeth:
For gears with helical teeth: 7 to 9
For spur gear teeth: 10 to 12
Click the button to display a suggested value for the minimum number of teeth.
Note:
If you want to find solutions in which the number of teeth is less than 7, you must first select the
Allow small geometry errors option.
15. Minimum distance between root form diameter and active root diameter dNf - dFf
Meshing interference occurs if the active root diameter is less than the root form diameter. Here,
you can specify a minimum value for the distance between the active root circle and the root
form circle, i.e. between active and manufactured involutes. The input value is the minimum
difference between the two diameters.
16. Minimum distance between root form circle and base circle dFf - db
If the start of the manufactured involute is closer to the base circle, this will cause greater wear
on a tool during the manufacturing process. Here, you can specify a minimum value for the
distance between the root form circle and the base circle. The input value is the minimum
difference between the two diameters.
17.17.5 Results
Click the Report button to open the editor and display a list of the best results. A brief description of
the criteria used to evaluate the best variants is given here. Please note that these criteria are not
relevant to every case, and only need to be queried in particular applications!
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1. Evaluation of the variants for the accuracy of gear ratio:
The difference between the actual gear ratio and the required gear ratio is evaluated here.
2. Weight: this is an indicator for the manufacturing price
3. Specific sliding: maximum value
4. Sliding velocity: maximum value
5. Ratio AC/AE
AC: length of path of contact from meshing point to pitch point
AE: total length of path of contact
"Pushing" sliding occurs in the AC area of contact (the sliding velocity of the driving gear is
greater than that of the driven gear). As this area is critical for unlubricated plastic gears, the
AC/AE relationship should be as small as possible in this case.
6. Evaluate variants for vibrations:
The variation in the total stiffness of the meshing is evaluated. The lower the variation, the
better.
The calculation is based on empirical formulae unless the Calculate mesh stiffness option is
set in "Conditions II".
7. Evaluate variants for strength:
Evaluate root and flank safety with regard to required safety. Although safeties of less than the
required safety are given a very negative evaluation, large safety margins above the required
safety have very little influence.
8. Transmission error (PPTE)
Transmission error is displayed if the corresponding option is set in "Conditions II".
9. Evaluation Summary:
The Summary evaluation weights each component to form a total evaluation coefficient. To set
the weighting of individual components, select Calculation > Settings > Evaluation. This
weighting depends to a great extent on which solution you require, for example, whether you
want a solution that is optimized for noise reduction or strength.
► Note
The Rough sizing section includes a complete list of all the available parameters (see chapter 17.16,
Rough sizing). You will find information about noise optimization in [32].
17.17.6 Graphics
The graphic in the Fine Sizing window gives you a quick overview of the number of solutions. Three
parameters can be displayed simultaneously. You can change them in the selection lists. In addition
to the two axes, the third parameter is displayed as a color.
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17.17.7 Geometry fine sizing for 3 gears
Definition of center distances:
Center distances cannot be changed in the fine sizing process. The center distances entered in the
Basic data tab are used in this calculation.
17.17.8 Geometry-Fine Sizing for 4 gears
Center distances cannot be changed in the fine sizing process. The center distances entered in the
Basic data tab are used in this calculation.
However, if gear 4 is an internal toothing, you can also select the double planetary stage option. If
you select the double planetary stage option, the internal gear's V-circle is also checked and the
required output reduction is z3/z2. In this case, all center distances are varied automatically, and all
possible solutions are displayed. Values for αM213, clearance13 and clearance24 are displayed in
the results.
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Figure 17.89: Figure: 4-gear configuration
17.17.9 Additional strength calculation of all variants
The KISSsoft system also calculates the strength (tooth root, flank and scuffing) for every variant and
displays these values in a list. This option can be used for cylindrical gear pairs, planetary stages and
cylindrical gear stages that have an idler gear. If you click on the Only calculate geometry checkbox
in the Conditions II tab, the calculation does not include tooth safeties.
17.18 Sizing modifications
Sizing the profile and tooth trace modifications is the last and most complex phase in sizing a gear.
This modification variant generator can save you time and effort by calculating the optimal
modifications directly.
Figure 14.: Gear sizing, Phase III
To call the Modifications sizing function, either click the icon (Toolbar icon), or select the
Calculation menu and then click on Modifications sizing.
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If you call the Optimization functions without opening the Contact analysis tab, the default settings
in the tab will be used in the calculation.
17.18.1 Conditions I/II
Conditions I
The Conditions I tab is where you define basic modifications that will not be changed, and which are
valid for every solution. To automatically adopt modifications already defined in the Modifications
tab, click the Import modifications button.
Select the "Cross-vary value, factor 1, factor 2" option to run an additional variation of the
coefficients with the value of the modification value.
If the "Without contact analysis, only service life calculation with KHbeta according to ISO
6336-1, Annex E" option is enabled, the solution range is only performed using the service life and
KHbeta calculation.
Every modification can be calculated for a larger partial load area. You can set this in the Partial
load area field. The torque range used for contact analysis and calculating the face load factor is
also output here. Select Consider load spectra to use load spectra here.
Select the Calculate shaft deformation just once for each partial load (calculated with basic
modifications only) option for KISSsoft to calculate the diagrams of bending only once for the
shafts, for each partial load, and not for every modification configuration. This option makes the
calculation slightly less accurate. However, if you are performing calculations with only a few load
cases, but a lot of modification configurations, this option can significantly speed up the sizing
process.
Conditions II
The Conditions II tab is where you define the modifications you want to vary. By entering the
number of steps per modification, you can define the number of steps between the minimum value
and the maximum value, starting from the minimum value. If the "Synchronize with no." column
contains a different value than the line number of it's own, the modification is synchronized with the
modification you selected, and all the variants are executed with the same number of steps.
17.18.2 Results
All the solutions are displayed as graphics in the Results tab. You can then select the solution that
best suits your requirements. Click on Accept or double-click on the solution to transfer its data to the
Modifications tab.
The most important results in the result overview:
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▪ ID: solution ID. You can use this ID to search for more details about the results in the reports.
▪ Wt: Partial load of the calculated solution in % (depending on the number of iteration steps
specified in the "Number of steps for partial load" field), e.g. 50% partial load relative to the
nominal load defined in the Basic data tab.
▪ Hmin: The minimum service life achieved by the gear pair in hours
▪ PPTE: Amplitude of the transmission error of the driven gear along the path of contact in [µm] or
angle of rotation error [°] of the driven gear.
▪ rel. PPTE: Relative amplitude of the transmission error/angle of rotation error in relation to the
uncorrected toothing.
▪ εa: Transverse contact ratio under load
▪ KHβ: Face load factor (if the calculation is performed with load spectra, only the face load factor
for the last load bin is ever displayed)
▪ σHmax: Maximum Hertzian pressure that occurs in the gear teeth
▪ Slam: Safety against micropitting as specified in ISO TR 6336-22
▪ η: Efficiency
▪ ΔWnA/B: Wear on gear A/B
▪ ΔT: Torque amplitude of the driven gear
▪ Modifications: You can select options in the context menu to display all the modifications (right-
click in the Results window).
17.18.3 Graphic I
All the solutions are displayed as graphics in the Graphic I tab. You can display a maximum of up to
10 graphics at the same time. Each graphic can process its own dataset.
Select the required partial load from the partial load selection list (red is the largest partial load, blue
is the smallest partial load).
17.18.4 Graphic II
This graphic gives you a quick overview of the number of solutions. Three parameters can be
displayed simultaneously. You can change them in the selection lists. In addition to the two axes, the
third parameter is displayed as a color.
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17.18.5 Report
The results are documented in three different, detailed reports. We suggest you begin by looking at
the summary report which gives a broad overview. The other two types of report are considerably
longer, and also document intermediate results.
The main calculation performs a series of contact analysis calculations. Each one has a different
combination of modifications with all the intermediate steps, and for each wt% level. A contact
analysis without modifications is also performed, to provide a basis for comparison.
A frequently asked question:
How can I use the "Optimize modifications" function to vary the length of the modification and the
relief Ca independently of each other to find out which combination of length/value gives the best
result?
Reply: For example, if you want to vary the tip relief Ca between 100 and 220 mm, and vary the
length factor between 0.78 and 1.56, to determine all the possible combinations of value - length.
17.19 Measurement grid
A measurement grid report is available for cylindrical and bevel gears (select Calculations >
Measurement grid). This report is not available for face gears and enveloping worm wheels.
Setting Description
Gear Setting the gear for calculating the measurement grid.
Measurement grid Setting the measurement array for the calculation.
area
0: Tooth flank
1: Fillet surface
Measurement Setting the report format for a particular measurement machine
machine
0: Klingelnberg
1: Gleason
Number of columns Setting the number of columns across the facewidth (>=3)
Number of columns (number of sections – 2) for parasolid settings, because
the sections should not include both ends of a tooth.
Number of rows Setting the number of rows across the tooth profile (>=3)
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Distance from root Distance from root form circle. Default value 0.1* normal module (middle).
form circle
Distance from tooth Distance from tooth tip. Default value 0.1* normal module (middle).
tip
Distance from side Distance from side I for cylindrical gears, distance from toe for bevel gears.
I/toe
Default value is (facewidth)/(number of columns + 1).
Distance from side Distance from side II for cylindrical gears, distance from heel for bevel gears.
II/heel
Default value is (facewidth)/(number of columns + 1).
The report includes the coordinates and the normal vector of the grid points in the format [XP YP ZP
XN YN ZN]. The reference point and the tooth thickness angle are displayed in the report header.
The reference coordinates of the data may differ according to which type of measuring machine is
used. For example, the following convention applies to Klingelnberg machines.
Figure 17.90: Measurement grid for cylindrical gears and bevel gears for Klingelnberg machines
The sequence of index numbers for points and sections is defined according to ISO/TR 10064-6, i.e.
the index for lines runs from bottom to top, and the index for columns runs from side II (heel) to side I
(toe).
17.20 Settings
To open the Module specific settings window, select the Calculation menu and then click on the
Settings menu option. A huge number of these settings are available for cylindrical gear
calculations. You can activate the widest variety of possible special functions. Normally there is no
need to change the settings.
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17.20.1 General
17.20.1.1 Input quality
The manufacturing allowances that are output in the report and used for particular coefficients in the
strength calculation procedure are defined either in the ISO 1328 (DIN ISO 1328), DIN 3961:1978 or
AGMA 2015 standards. You can specify which standard is to be used. If you click the Calculation
method for strength option, the system applies the standard that is best suited to the strength
calculation method (for example, ISO 1328 is used if you are using the ISO 6336 calculation
method).
17.20.1.2 Varying qualities
If you select this option, the Plus button is displayed next to the Quality field in the main screen. You
can then use this to input specific tolerances manually.
You will find a more detailed description of this in Qualities (see chapter 17.1.10, Quality).
17.20.1.3 Fp tolerance as specified in tables in DIN 3962
The total cumulative pitch deviation Fp given in the tables in DIN 3962 can be very different from the
Fp calculated in accordance with the formulae in DIN 3961.
17.20.1.4 Extrapolating tolerance values
The tolerances detailed in ISO 1328:2013, DIN ISO 1328:2018, AGMA 2000 and AGMA 2015, are
calculated using the formulae in each particular standard and with the effective geometric data (mn,
d, b…). The range of validity must be defined in each case. For example, the tolerances specified in
ISO 1328 apply for a module range 0.5 mm <= mn <= 70 mm. However, these formulae cannot be
applied to gear teeth that lie outside of the range of validity. Despite this, these formulae are still used
in such cases, due to the lack of any other information. In KISSsoft, the relevant limiting value is
usually used to determine tolerances (for example, in the ISO standard, the tolerance is defined as
70 mm, and for a module it equals 80 mm). Alternatively, you can select Extrapolate tolerance
values to calculate tolerances using the effective value (i.e. with 80 mm). In this case, in ISO 1328
(2013 edition), tolerances are also output when the helix angle is greater than 45°.
In DIN 3961:1978 and ISO 1328 (1996 edition), tolerances are calculated with the geometric mean
values and therefore no extrapolations can be performed here.
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17.20.1.5 Input of normal diametral pitch instead of normal module
If you select this option, the Normal module input field in the Basic data or Geometry input window
is replaced by the Diametral Pitch input field.
17.20.1.6 Input of number of teeth with decimal places
In KISSsoft, you can perform a calculation with a fractional number for the number of teeth. We
recommend you use this option for arcs of circle or for non-symmetrical teeth.
17.20.1.7 Allow large profile shift
Use this option to significantly increase the range of profile shifts that can be used (- 1.2 ≤ x*≤ +1.5).
This is very useful for special cases. We recommend you use it for: cylindrical gears, bevel gears,
worms, crossed helical gears.
17.20.1.8 Don’t abort if geometry errors occur
If you select this option, the software will continue the calculation even if severe geometry errors,
such as pointed teeth, meshing interference etc. occur. This option enables you to continue the
calculation in critical cases, however, you should then use its results with extreme caution!
17.20.1.9 Maintain tip circle when changing profile shift
In KISSsoft, the reference profile is usually maintained and the tip and root circle are modified to suit.
If you select this option, the tip circle is maintained, and the reference profile is modified to match it
when the profile shift is changed. The tip circle value is maintained as long as the number of teeth
and the transverse module stay the same. This option is only available if the Center distance
checkbox is selected.
17.20.1.10 Maintain root circle when changing profile shift
In KISSsoft, the reference profile is usually maintained and the tip and root circle are modified to suit.
If you select this option, the root circle is maintained and the reference profile is modified to match it
when the profile shift is changed. The root circle value is maintained as long as the number of teeth
and the transverse module stay the same. This option is only available if the Center distance
checkbox is selected.
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17.20.1.11 Tooth form calculation
Using points (instead of curves) for the tooth form definition
The tooth form calculation uses a highly reliable algorithm to generate the tooth form from curves
(lines, involutes, arcs of circle, etc.). In a few, rare cases, this algorithm does not produce a usable
solution. In those situations, it may be sensible to use the alternative algorithm, which uses points.
Use the alternative algorithm for tooth forms that are defined with points.
The tooth form calculation uses a highly reliable algorithm for determining the points on a tooth form.
However, in a few special cases, this algorithm does not provide a good solution. In such situations,
using an alternative algorithm may help.
17.20.1.12 "Generate GDE format (VDI 2610)" and "Generate detail data for
profile diagram, tooth trace diagram and tooth form"
Click on "Generate GDE format (VDI 2610)" and "Generate detail data for profile diagram, tooth trace
diagram and tooth form" to calculate the individual points used to generate the profile diagram and
the tooth trace diagram. This option also calculates the points for the particular tooth form. Click on
"Report/Special reports/Detailed data for profile, tooth trace diagram and tooth form" to display a
report documenting the points for the diagrams and the tooth form points. The special "GDE output"
report displays the "GEAR DATA EXCHANGE" (GDE) file in .xml format. To use this option, first
save the file as a .txt file and then change the file extension to .xml. Up to now, the
<section_identification>, <section_geometry> and <mating_data> sections have been created.
However, if several gears, or even several gear pairs, are to be mapped, first gear 1, then gear 2,
and then the <mating_data> section, for pair 1, is written to the file, followed by the same data for
pair 2 (if present), etc., until all the gears have been added to the file.
17.20.1.13 Factor for minimum tooth thickness at tip
For manufacturing reasons, a specific minimum tooth thickness at the tooth tip must always be
achieved. The minimum tooth thickness is: module x coefficient. As defined in DIN 3960, the
coefficient is usually 0.2.
17.20.1.14 Factor for minimum tip clearance
The tip clearance is the distance between one gear's tip circle and the root circle of the other gear in
the pair. You can specify a minimum tip clearance. If this clearance (taking into account the tip circle
and root circle allowances) is not reached, the software displays a warning message.
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17.20.2 Plastic
17.20.2.1 Allow simplified calculation according to DIN 3990/ISO 6336
If you select this option, you can use the calculation methods for steel gears to calculate plastic
gears. This calculation is performed according to the infinite life strength values listed in the materials
database. The values for the plastics given in this database apply for oil lubrication, a temperature of
70°C and number of load cycles 108. In contrast to the calculation according to VDI 2545 or VDI
2736, the strength values do not depend on the temperature and lubrication type.
The calculation is performed in the same way as for through hardening steel, with the appropriate S-
N curve (Woehler line) as defined in ISO 6336.
17.20.2.2 Calculation of flank safety
Flank safety for plastic gears is calculated as specified in VDI 2545 or 2736 (in a similar way to the
calculation for steel gears). In other words, flank safety is defined using Hertzian pressure with the
permitted material value for pressure σHlim . However, measurements taken from plastic gears have
often shown that their tooth flanks wear in a similar way to the tooth flanks in worm gears. For this
reason KISSsoft can calculate safety against wear as an alternative. Flank safety is calculated using
σHlim if the material database (or the material file with extended data in that database) includes data
for σHlim.
Safety against wear is calculated if wear data is present in the material database. If data for both
calculations is present, the system performs both calculations. If data for only one calculation is
present, the corresponding safety is displayed automatically.
17.20.2.3 Gearbox type
You can select either a closed, semi-open or open gear unit. This has an effect on the
temperature calculation according to VDI 2545.
17.20.2.4 Properties which depend on material combinations
The coefficient of friction, wear coefficients and heat transfer coefficients, which significantly depend
on the selected material combination, can now be defined in separate .dat files. The material-
dependent properties are defined in the CoefficientOfFriction.dat, WearFactors.dat and
HeatTransferCoefficient.dat files, stored in the kiss/dat directory.
To enable these options, select Module specific settings > Plastic and select the properties for
which material-dependent properties should be read from a file. If the options are selected, the
values for the coefficients of friction and the wear coefficient (defined in the individual material .dat
files) will be overwritten by the values in the material pairing .dat files. The values defined for the heat
III Cylindrical gears 372
transfer coefficient in VDI 2736-2 will be overwritten by the values defined in the
HeatTransferCoefficient.dat file.
The properties for material pairings are displayed in the figure below.
Material pairings are defined as "material ID number_material ID number_". A .dat file contains
information used to describe a TABLE FUNCTION in different ways. You will find the material ID
number in the ID column, in the Database tool: select Database tool > Material of gears. The
function can also be used for user-defined materials.
Figure 17.91: Defining the properties for material combinations in the appropriate DAT file
17.20.2.5 Consider dry material properties
If materials (such as PA6, PA66, etc.) are used, whose mechanical properties (Young's
modulus, tensile stresses, tooth root and flank fatigue) change significantly when they absorb
water, activate this option to calculate the mechanical properties of dry materials. If data is
already available for dry materials, it can be added to the corresponding DAT material file (see
Figure 17.91). For example, you can use material file Z014-PA66_VDI2736.DAT.
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17.20.2.6 Permissible maximum wear of tooth thickness
When you calculate wear safety (see chapter 17.20.2.2, Calculation of flank safety), you must specify
a permitted wear threshold value. A usual value for plastic is 15% (tooth thickness wear in the
reference circle). If no, or only very little, wear can be tolerated, we recommend you input a value
between 5 and 10%.
17.20.3 Planets
Check if mounting of planets is possible
Planets are usually arranged with a constant pitch on the planet carrier (if 3 planets are involved,
they will each be at 120 degrees etc.). In these situations, the number of teeth must fulfill certain
conditions to ensure the planets can be mounted correctly. KISSsoft performs the check if this
checkbox is selected.
Minimum distance between 2 planets
You can specify a minimum distance between the tip circles of two planets in this input field. If this
minimum distance is not reached, the system displays a warning message.
17.20.4 Sizings
17.20.4.1 Required transverse contact ratio
You can specify the required transverse contact ratio for sizing deep tooth forms.
17.20.4.2 Ratio of facewidth to normal module
The facewidth to normal module ratio is a characteristic value used to achieve reasonable
dimensions for gear stages. If very narrow gears are involved, the axial stiffness of the teeth cannot
be guaranteed, for this reason, b/mn should be greater than 6 (see Niemann, Table 22.1/7 [5]).
If the gears are too wide, it is essential that the load is spread evenly across the entire facewidth,
depending on the gear type and accuracy grade, b/mn should therefore be less than 15 to 40 (see
Niemann, Table 22.1/10 [5]).
17.20.4.3 Ratio of facewidth to reference circle, gear 1
The facewidth to reference diameter ratio is a characteristic value used to achieve sensible
dimensions for gear stages. Depending on what type of heat treatment is involved, this ratio should
be less than 0.8 to 1.6 (see Niemann, Table 22.1/5 [5]).
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17.20.4.4 Ratio of facewidth to center distance
The facewidth to center distance ratio is a characteristic value used to design standard gear units of
modular construction. Depending on the stiffness of the housing, this value should be smaller than
0.3 to 0.5 (see Niemann, Table 22.1/6 [5]).
17.20.4.5 Sizing of gear geometry
The Coefficient for active tip - form diameter difference and Coefficient for tip clearance (also known
as "form clearance") are settings that are needed for the functions used to size the reference profile,
in the "Reference profile" tab and in Fine sizing. For example, you may need to adjust the reference
profile to achieve an exact form clearance and to ensure that the minimum tip clearance is also
exceeded.
17.20.5 Calculations
17.20.5.1 Calculate form diameters from tooth form
The tooth form calculation simulates the manufacturing process. In doing so it calculates the effective
undercut in the tooth root. Select the Calculate form diameter from tooth form option to calculate
the tooth form in every calculation run, define any undercut that is present and include it in the
calculation. This is then used to calculate the transverse contact ratio and the root and tip form
circles (generated diameters). As KISSSOFT already automatically calculates the form diameters
correctly for protuberance and undercut, we recommend you no longer use this option.
You can select whether the root form circle, the tip form circle, or both these values, are to be
included in the tooth form. Up to now, the form diameter for racks has not been taken from the tooth
form.
► Note:
If this option is selected and profile modifications have been predefined, the calculated form diameter
will be at the beginning of the modification. This often results in very small transverse contact ratios
εα.i and εα.e. This is correct because, the tooth form at the start of the modification no longer exactly
matches the involute. However, the message that is displayed, to inform the user that the transverse
contact ratio is too low, is rather confusing. If the profile modification has been sized correctly, so that
meshing under load involves a whole tooth height, this message can be ignored. This is because the
transverse contact ratio under load corresponds to the theoretical transverse contact ratio εα.
Generally speaking, we recommend you do NOT use this option with profile modifications.
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17.20.5.2 Calculation with own S-N curve (Woehler line)
The S-N curve (Woehler line) of metallic materials is usually defined by the endurance limit values
sigFlim, sigHlim, entered in the database, and the finite life calculation values Y NT (root) and ZNT
(flank) in accordance with ISO, AGMA or DIN. If this option has been selected, and you input your
own S-N curves (Woehler lines) for material, the strength calculation is performed using your S-N
curve (Woehler lines).
If you use your own S-N curves (Woehler lines) to calculate plastics, the Calculation with own S-N
curve (Woehler line) flag has no effect.
Notes about calculation methods using your own S-N curves (Woehler lines):
▪ You can use the calculation methods specified in ISO and DIN for metallic materials.
▪ The S-N curves (Woehler lines) are stored in a file (see under: Database). The material's
allowable stress (sigFadm for root and/or sigHadm for flank) is defined according to the number
of cycles NL.
▪ The endurance limit values sigFlim and sigHlim, that are input directly in the database, are also
required for documentation purposes and should be detailed together with the S-N curve
(Woehler line) data, in a meaningful combination. We recommend you use the value of
sigFadm/sigHadm if NL=10^7 for sigFlim/sigHlim.
▪ The service life factors, factor YNT and ZNT are defined and reported as follows: YNT = sigFadm /
sigFlim, ZNT = sigHadm / sigHlim
▪ The other factors which influence the permitted material value, such as Ydrel, YRreIT, YX, ZL,
ZV, ZR and ZW, are calculated and used in accordance with the selected calculation method
(ISO or DIN). For this reason, the selected permitted material value sigFG or sigHG is not
exactly equal to the value sigFadm/sigHadm from the S-N curve (Woehler line).
17.20.5.3 Calculation with operating center distance and profile shift according
to manufacture
Cylindrical gear geometry according to DIN 3960 is based on the calculation of the gear teeth (which
is theoretically without clearance). This enables the sum of the profile shifts with the specified center
distance to be calculated.
Use this option to enter the profile shifts independently of the center distance. This is very useful as it
provides a way to check the limits of a toothing (clearance, contact ratio etc.) if there are major
variations in the center distance (e.g. in the case of center distance tolerance fields).
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17.20.5.4 Calculate moment of inertia from tooth form
The toothing moment of inertia is calculated exactly from the tooth form in the tip to root diameter
range. To achieve this, the KISSsoft tooth form calculation is run automatically for each calculation
and defines the effective tooth form by the numerical integration of the moment of inertia. The result
is output in the calculation report. The calculation is also performed in fine sizing and the results are
documented.
17.20.5.5 Calculation of the displacement volume of gear pumps
This option calculates the transport volume without taking the return volume into consideration. If you
select this option, the tooth spaces are integrated numerically to calculate the transport volume and
the result is output in the report. In Fine sizing, the transport volume of each variant is also calculated
and output. This enables you to identify, for example, the variant with the largest displacement
volume.
17.20.5.6 Calculating the displacement volume of gear pumps
According to ISO 6336 (or DIN 3990), the Hertzian pressure is only monitored for the driving gear at
the single tooth contact point B, and in D the pressure is only monitored for the driven gear. This
option can be used to check both gears at points B or D, depending on which one is subject to the
greater Hertzian pressure.
17.20.5.7 Take into account user specific additions
If KISSsoft AG has added customer-specific upgrades to the software, you can select them and view
them here.
17.20.5.8 Calculate lubrication factor with oil temperature
Unlike in ISO 6336 and DIN 3990, where the calculation is always performed with an oil viscosity of
J= 40oC, the lubrication coefficient is calculated with oil viscosity at operating temperature when you
click this checkbox. If this option is selected, the material pairing factor ZW is also calculated with the
viscosity at the operating temperature.
17.20.5.9 Strength calculation using average tolerance field (of tooth form)
By default, values for theoretical gear teeth (without allowances) are referenced for calculation. When
you enable this checkbox, KISSsoft performs the calculation with the average allowances for the
center distance, root diameter and tooth thickness. This option is suitable for use where large
tolerances are present.
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This option has no influence on calculations performed according to AGMA.
17.20.5.10 Take protuberance into account
If the angle difference (protuberance, or buckling root flank) to the pressure angle is greater than the
maximum difference defined here, its influence on the tip and root form circles, and also the
transverse contact ratio, are taken into account. The contact ratio then reduces accordingly.
17.20.5.11 Power-on time
The software also takes into account the power-on time when calculating the number of load cycles
(multiplied by the service life).
The power-on time is also taken into account for plastic gears when calculating the flank and root
temperature. For worm gears, this time is also included when calculating the thermal safety.
Note about calculating temperature:
It is assumed that heat is constantly dissipated, but that, in contrast, heat is only generated during
the specified power-on time. The precondition for this is that the gear unit is only run for a short
period of time (maximum 15 minutes), and is then stopped again. If this is not the case, the power-on
time must be set to 100%.
17.20.5.12 Safety factor for the calculation of the shear stress at hardening
depth
The safety factor is multiplied by the shear stress, which is then used to calculate the hardness. The
hardening depth is then defined using this value.
17.20.5.13 VDI 2737: Calculation of gear rim
The strength calculation for internal toothings is not very accurate. A significant improvement is
needed. Gear rims are often subject to stresses that can affect their load capacity. At present, VDI
2737 is the only guideline that includes gear rim stress and the influences associated with this. The
calculation is performed in two steps
1. Tooth root fracture safety (static and endurance) without taking the gear rim influence into
account.
2. Tooth root fracture safety with gear rim influence. In this case, the maximum shear stress in the
tooth root outside the meshing can in some conditions be greater than the actual bending stress
in the tooth that is under load.
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The notch factor Y S , as in ISO 6336:2006, is defined as the place at which the tangent on the flank
and the tooth center line form an angle of 60o.
The results of the calculation specified in VDI 2737 are detailed in their own section in the normal
report.
Factor for maximum load (VDI 2737)
To calculate static safety in accordance with VDI 2737, input a maximum load factor. This is then
multiplied with the nominal torque. To calculate the infinite life strength, the nominal torque is, as
usual, multiplied with the application factor KA .
17.20.5.14 Calculating the size factors for small gears
Calculation of size factors for small gears similar to that stated in FVA report 410:
If mn < 1, the size factors (according to DIN or ISO) are ZX and YX > 1.
► Note
If you use this method, you may need to adjust the required safeties that have been used up to now.
This is because much higher computational safeties are produced.
17.20.6 Required safeties
You must set required safeties, not only for every service life calculation, but also for rough sizing
and fine sizing.
Calculating reliability using Weibull distribution uses the calculated service life, and so also takes the
required safeties into account. To calculate reliability without taking required safeties into account,
set the safeties to 1.0.
Safeties are not size-dependent
Experience has shown that much lower minimum safeties can be used for smaller modules. Although
the standards do not provide any information about this, this knowledge is based on experience with
many different applications. However, if you do not require size-dependent safeties, you can still
select the "Safeties are not depending on size" variant.
Minimum safety for calculation according to AGMA
In the tooth strength calculation according to AGMA 2001, the permitted tooth bending stress sat is
half the size of the value specified in ISO 6336. Although its meaning is similar, the corresponding sat
value in the ISO standard must be multiplied by a factor of 2, the reference gear's stress correction
factor Yst. Therefore, if the tooth strength is calculated according to AGMA 2001, the resulting safety
III Cylindrical gears 379
is approximately 50% less than that in the calculation using ISO 6336. As a consequence, the safety
required for the calculation according to AGMA 2001 is smaller.
Service coefficient
Some applications of the AGMA calculation method require a predefined service coefficient. In actual
fact, this is merely a minimum safety. For this reason, if required, you can input Service coefficient
CSF for flank strength and KSF for tooth bending strength.
17.20.7 Contact analysis/face load factor
17.20.8 Contact analysis
Calculation method contact stiffness: Here you can select either the calculation method defined by
Weber/Banaschek [19] (dynamic stiffness analysis: default setting), the method defined in ISO 6336-
1 Method B and Own Input.
Single contact stiffness: If "Own Input" has been selected as the contact stiffness calculation
method, you can enter your own value for the single contact stiffness.
Slices linking factor: Slices linking factor of the discretized toothing model.
Border weakening factor: Border weakening factor for a weakening of stiffness on the edge of helical
gear teeth.
Correction factor for Hertzian stiffness (according to Winter): Correction factor for Hertzian
flattening as described in the experiments performed by Winter/Podlesnik [33].
Number of orders in the amplitude spectrum (transmission error/contact stiffness): This is where
you enter the number of orders to be calculated. At least one order must be calculated, and the
calculation must be performed with no more than half the number of meshing positions (set this value
in the Contact analysis > Accuracy of calculation tab).
Flash temperature and micropitting with coefficient of friction according to ISO/TS 6336-22: This
overwrites the coefficients of friction defined in the Contact analysis tab with a coefficient of friction
sized according to ISO/TS 6336-22.
Interpolate stress increase caused by tip rounding: In the case of a tip rounding, the calculation of
the tooth form results in a sudden change in the radii of curvature. This in turn results in stress
increases at this transition point in the contact analysis calculation. For this reason, you can specify
whether the mathematical solution is to be used, to perform the calculation, or whether this stress
increase is to be interpolated.
Calculate force excitation: Force excitation (according to FVA Report 487) results from toothing
stiffness and the average transmission error. In contrast to the process for calculating transmission
III Cylindrical gears 380
error, calculating the excitation force enables a better evaluation of how different toothing variants
generate noise. This is because the gear meshing forces, not the equalizing movement (transmission
error), of the gears, are the decisive factor in generating noise.
Conical profile shift: Select this option to enable the conical profile shift in the Contact analysis tab.
Take into account plastic deformation: Use this setting to specify whether plastic deformation is to
be taken into account in the contact analysis. If plasticity is to be taken into account, the maximum
contact stress, calculated using the elastic contact theory, is reduced on the basis of the specified
"Maximum permitted flank pressure". If the maximum elastic flank pressure is exceeded, the radii of
the contact body are changed locally so that the resulting elastic i.e. contact stress matches this
maximum value. Only a percentage rate of the new radii is used, on the basis of the specified
"Weighting of the plastic deformation".
Smooth iterative wear calculation: If you select this option, the tooth form is smoothed after every
iteration of the wear calculation.
17.20.8.1 Display
Unit of the transmission error Here, you can select either the length on the length of path of contact
(transmission error) or the angle on the driven gear (angle of rotation error).
Smooth results: This function uses a low-pass filter to smooth the results (Hertzian pressure, tooth
root stress on gear 1/2, safety against scuffing and safety against micropitting). By default, this
function not selected, but it can be used to smooth the results if they are affected by strong numerical
noise.
Area analyzed on tooth height: This defines the maximum area along the tooth height for evaluating
the results (Hertzian pressure, tooth root stress on gear 1/2, safety against scuffing and safety
against micropitting). This setting generates additional results and does not change the results of the
contact analysis.
Area analyzed on facewidth: This defines the maximum area along the facewidth for evaluating the
results (Hertzian pressure, tooth root stress on gear 1/2, safety against scuffing and safety against
micropitting). This setting generates additional results and does not change the results of the contact
analysis.
Draw data for path of contact: If this option is enabled, the results of contact analysis are displayed
quadratically in the 3D diagrams. This makes the data suitable for export as a matrix.
Take into account backlash in the transmission error graphic: When this setting is selected, the
backlash is taken into account in the transmission error. This causes a displacement of the value of
the transmission error even though the amplitude remains the same.
Smooth results: This function uses a low-pass filter to smooth the results (Hertzian pressure, tooth
root stress on gear 1/2, safety against scuffing and safety against micropitting). By default, this
III Cylindrical gears 381
function not selected, but it can be used to smooth the results if they are affected by strong numerical
noise.
Area analyzed on tooth height: This defines the maximum area along the tooth height for evaluating
the results (Hertzian pressure, tooth root stress on gear 1/2, safety against scuffing and safety
against micropitting). This setting generates additional results and does not change the results of the
contact analysis.
Area analyzed on facewidth: This defines the maximum area along the facewidth for evaluating the
results (Hertzian pressure, tooth root stress on gear 1/2, safety against scuffing and safety against
micropitting). This setting generates additional results and does not change the results of the contact
analysis.
Interpolate stress increase caused by tip rounding: In the case of a tip rounding, the calculation of
the tooth form results in a sudden change in the radii of curvature. This in turn results in stress
increases at this transition point in the contact analysis calculation. For this reason, you can specify
whether the mathematical solution is to be used, to perform the calculation, or whether this stress
increase is to be interpolated.
17.20.8.2 Face load factor
Load factors: Defines how load factors KV, KA and Kγ are used. They can be taken into account when
calculating load distribution and axis alignment according to ISO 6336-1, Annex E.
Iterating the load distribution of the meshings (only affects planetary stages): If shaft data is used
to define the axis alignment, a constant load distribution over the facewidth is initially assumed when
bending is calculated in the shaft calculation. This is a satisfactory approximation if the load
distribution is fairly well distributed, and the face load factor is therefore not greater than 1.3
(maximum 1.5). If the load distribution is less favorable, return the load distribution value from the
gear calculation to the shaft calculation, and calculate bending again with the modified (and not
linear) load distribution. This produces a more accurate, modified load distribution. This iterative
determination of the load distribution across all the meshings is then performed until the load
distribution stops changing in all the meshings. Be aware that this option only shows an effect if at
least one of the deformation components is linked with the shaft calculation.
Tooth contact stiffness: This defines whether tooth contact stiffness is calculated according to ISO
6226 (Cγβ), (default setting) or whether it is constant with Cm = 11 N/mm/μm as defined in AGMA
927-01.
Calculating the moment of resistance in torsion: If the calculation of torsion due to deformation in
the "Define axis alignment" dialog is set to "Side I/II", the diameter specified here is used in the
calculation.
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17.20.9 Summary
Weighting the individual component to evaluate the Summary coefficients in Fine Sizing (see
chapter 17.17.5, Results).
17.20.10 Diagrams
17.20.10.1 Meshing in the diagrams
You can select different values for the x-axis from a drop-down list.
Here, you can select the roll angle, the length (length of path of contact), the diameter of gear A and
the angle of rotation.
You can also decide whether the x-axis (path of contact) and y-axis (facewidth) are to be displayed
as scales in the 3D diagrams or not at all.
► Note
If you select the angle of rotation for the x-axis the gear axis is 0°.
17.20.10.2 Reliability
Factors and parameters for calculating reliability according to Bertsche [34].
Factor ftB Weibull shape parameter β
Shaft 0.7 to 0.9 (0.8) 1.1 to 1.9 (1.5)
Ball bearing 0.1 to 0.3 (0.2) 1.1
Roller bearing 0.1 to 0.3 (0.2) 1.35
Tooth flank 0.4 to 0.8 (0.6) 1.1 to 1.5 (1.3)
Tooth root 0.8 to 0.95 (0.875) 1.2 to 2.2 (1.7)
Table 17.24: Table: Coefficients for Weibull distribution according to Bertsche. The mean values used in KISSsoft are
given in brackets.
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17.20.11 Generate a 3D model
This is where you modify the parameters used to generate 3D models.
▪ Under "Model type", specify the type of model to be generated (volume model, skin model,
cutting model). The volume model can be used for other applications such as machining by
CNC or finite element analysis. The skin model is most suitable for contact analysis. The cutting
model is only suitable for the gear models that use cutting simulation, such as face gear and
enveloping worm gear, and is used to view the actual cutting simulation.
▪ The Number of cutting steps sets the number of cuts per half pitch for the cutting process. The
minimum value is 1, and the default value is 20. The quality of the final model can be increased
by increasing the number of cutting steps, but this also increases the probability of
manufacturing errors. The "Scale factor" is used for solving the failure problem. If the operation
fails, we recommend you use a lower number of generation steps with a larger scale factor.
▪ The Number of sections along facewidth defines the number of sections along the facewidth for
approximating the tooth flank form. The minimum value is 2, and the default value is 11.
Normally, the quality of the final model can be improved by increasing this value, but we do not
recommend that you set a number that is excessively high, compared with the facewidth. The
coefficient is used for the gear models using cutting simulation and gear models using multiple
cross sections, such as spiral bevel gears and cylindrical gears with lead modification.
▪ The Scaling factor for the cutting model is used to scale the model during the cutting simulation
process. The minimum value is 1, and the default value is 10. Sometimes the cutting simulation
can fail due to an internal operation error in the Parasolid kernel, especially when the model has
a very small module and/or a large number of generation steps. To prevent this type of
operating error, use the model with its size set by the scale factor in the cutting process.
Consequently the cutting model can have different dimensions than the actual design. However,
the volume and skin models are automatically returned to their original scale (size) after the
operation, and therefore have the same dimensions as the entered gear.
III Cylindrical gears 384
▪ The "Modeling operation tolerance" sets the tolerance for the internal operations of the
Parasolid kernel, such as the chordal approximation and clash detection in Boolean operations.
The default value is 1 μm.
▪ The Rendering quality sets the resolution of the resulting graphics in the 3D geometry view.
This is used only to improve the viewer display (usability) and does not affect the quality of the
generated model. If the rotation operation in the viewer is slow, you can increase the quality
value to speed up the operation. The default value is 5 μm.
▪ Click on Constant root radius along the facewidth to specify the method used to generate the
root fillet radius for a bevel gear. The bevel gear's root fillet radius changes by the factor of the
normal module along the facewidth. If you set this flag, the constant root radius defined by the
normal module is used in the middle section. (Available for bevel gears)
▪ The Constant protuberance along the facewidth value sets the protuberance of the bevel gear's
reference profile. The protuberance of the bevel gear's reference profile changes by the factor of
the normal module along the facewidth. If you set this flag, the constant protuberance defined by
the normal module is used in the middle section. (Available for bevel gears)
▪ If Display 2D geometry for outside and inside is selected, the tooth forms on the internal and
external sides are represented as a 2D graphic. (Available for bevel gears)
▪ If Generate tooth system model in the saved position is selected, the system model is
generated at the position you saved. This position is saved in the calculation file, and you will be
able to restore the contact pattern's checking position in the future. (Available for bevel gears)
▪ Click on Number of points on the edge of cut for spline approximation to specify the number of
modeling (intermediate) points on each edge that are used to approximate the spline curves for
the root area or the tooth flank. The figure shows a diagram in which the points that are to be
used are scanned. The end points (nodes) are removed because they add waviness to the
curve. We use only the intermediate points on the cutting edge if it can be assumed that the
parametric distance between the points is the same. We usually recommend that more points
are used in the root area. However, this model will help the user determine the optimum value.
(Available for enveloping worm gear)
▪ Click on Oversize factor for worm wheel cutter to define the coefficient used to increase the
worm wheel cutter. There are different methods of implementing the interference tool. Those
methods include the axial pitch method, the base pitch method, the extra thread method, and
the normal pitch design method. KISSsoft uses the normal pitch method because this is
practically regarded as the industry standard. These methods are based on the principle, that
the worm wheel cutter uses the same normal pitch and the same normal pressure angle in the
normal section as the worm. The cutting distance between the hob and the gear will then be
changed accordingly, to ensure a consistent result for the root and tip diameters on the gear. If
you are using the oversize factor, the generated surface will not be match the worm surface and
III Cylindrical gears 385
will not give the best contact pattern. Therefore we recommend you do not use the oversize
factor if you want to use theoretical surface geometry rather than a conventional cutting method.
In practice, the tooth thickness of the cutter is increased to take the tooth thickness tolerance of
the worm wheel into account. In this case, we recommend you use a small oversize factor to
compensate for the tolerance order to get the best contact. (Available for enveloping worm gear)
▪ Click on Cutter shaft angle change to modify the worm wheel cutter shaft angle during the
simulated milling run. The angle can be both positive and negative. The positive angle is defined
as shown below. (Available for enveloping worm gear)
▪ Click on Change in pressure angle of the worm wheel cutter in normal section to set the worm
wheel cutter to a different pressure angle than the worm. (Available for enveloping worm gear)
▪ Click on Flank shape of worm wheel cutter to set a different tooth form for the worm wheel
cutter than for the worm. Extensive research has shown how different combinations of tooth
forms can be used to get a better contact pattern in worm wheels. This setting is used for this
purpose. If this option is not selected, the same tooth form is used for both the worm wheel
cutter and the worm. (Available for enveloping worm gear)
▪ Click on Axial expansion, to take the axial length expansion/contraction factor α of the gears
into account for injection-molding or sintering processes. The helix angle value for helical gear
teeth is based on the new facewidth, calculated again from
𝑡𝑎𝑛𝛽
𝛽 = 𝑡𝑎𝑛−1
𝛼
.
17.21 Tooth thickness
Select the Calculation > Tooth thickness menu option to calculate the normal tooth thickness and
the normal spacewidth at any diameter.
The tooth thickness is output as an arc length and as a chordal length. To help measure the tooth
thickness, the chordal height is output along with the tooth thickness allowances.
17.22 Tooth form export
In the Calculations menu, click on "Tooth form export" to export the shape of the gear or tool to a
text file, as coordinates.
There are a number of settings available here for the export functions:
▪ select the cross-section
▪ select the operation
III Cylindrical gears 386
▪ select the separator
▪ text file format
▪ reduce the number of points
▪ remove duplicate points
III Bevel and Hypoid Gears 387
18 Bevel and Hypoid Gears
Use this module to calculate the geometry and strength of straight, helical and spiral bevel gears
(gear axes intersect, offset is 0) and hypoid gears (crossed gear axes, offset not equal to 0).
Geometry as specified in ISO 23509 and DIN 3971, tolerances according to ISO 17485 and DIN
3975, strength calculation as specified in ISO 10300 (replacement cylindrical gear toothing method),
AGMA 2003, DIN 3991, or Klingelnberg in-house standard KN 3030. The calculation only includes
the geometry of bevel gears insofar as is necessary for the strength calculation (see chapter 18.4.1,
Methods used for strength calculation), no matter which manufacturing process is used.
18.1 Underlying principles of calculation
18.1.1 General
The geometry of bevel gears is calculated according to ISO 23509 or DIN 3971. The strength
calculation is performed in two steps. A virtual cylindrical gear toothing is defined first. This is then
used for the strength calculation in a similar way to cylindrical gears. The process is described in
[35], [36] and [10].
Bevel gear machine tool manufacturers (such as Klingelnberg in Germany) also have their own
methods that differ slightly from the processes mentioned above.
Hypoid bevel gears are primarily used in vehicle axle drives. Strength is calculated by defining a
virtual cylindrical gear toothing.
18.1.2 Overview of the bevel gear manufacturing process and the
terminology used in it
Various manufacturing processes are used to create bevel gears. Unlike cylindrical gears, the tooth
length forms and tooth depth forms differ according to which manufacturing process is used. In
particular, the process used to manufacture bevel gears with spiral teeth uses a multitude of terms,
the most important of which are described below.
The most important differences are shown in the tooth length form, which can be manufactured as an
arc of circle (face milling procedure), epicycloid or involute toothing (face hobbing process). Circular
arc teeth were developed by the company Gleason, and are produced using the face milling
approach, in which every gap is milled separately, and then the gear is rotated further by the width of
that tooth space. Epicycloid gear teeth are used by Oerlikon and Klingelnberg. In this process, the
gear rotates constantly during the milling process. Only the palloid manufacturing process is used to
create the involute tooth length form. Although, nowadays, Klingelnberg and Gleason, the market
leaders in machine manufacturing, can produce toothing using both the face milling and face hobbing
III Bevel and Hypoid Gears 388
processes, these companies are still associated with their traditional processes in the technical
literature. For more details, see (see chapter 18.1.3, Calculation according to Klingelnberg, Gleason
and Oerlikon) and (see chapter 18.2.1, Type).
Although alternative processes for bevel gears are available, they are not listed here.
18.1.3 Calculation according to Klingelnberg, Gleason and Oerlikon
The strength calculation defined in ISO 10300 or DIN 3991 only includes the relationships (module,
helix angle) in the middle of the facewidth in the virtual cylindrical gear toothing method calculation.
The shape of the bevel, and the process used to manufacture it, are ignored. As a result, the strength
calculation method can be applied no matter which procedure is being used. This also reflects the
experience that the load capacity of spiral bevel gears is only slightly affected by the manufacturing
process.
The geometry calculation procedure defines the dimensions, such as diameter and tooth thickness,
in the middle of the facewidth. It also calculates the diameter at the outside and inside end of the
facewidth. These dimensions depend on the type of the bevel. However, the dimensions of the gear
blank may differ from the results calculated by machine-specific software because the processes are
not described in sufficient detail. This is particularly true for the Gleason process.
▪ Klingelnberg process:
The Bevel gear (KN3028 and KN3030) and Hypoid gears (KN3029 and KN3030) calculation
methods enable you to calculate geometry and strength and check the manufacturing process
according to the Klingelnberg in-house standard. However, these methods do not calculate the
machine settings for the selected Klingelnberg machine. When you input formula data from a
Klingelnberg program, you must remember that the toothing data, such as module and helix
angle, always applies to the middle of the facewidth (unless otherwise specified).
▪ Gleason process:
Depending on which calculation program Gleason uses, toothing data such as the module and
helix angle, is either predefined for the outside end of the facewidth or for the middle of the
facewidth.
Use the Conversion from GLEASON data sheets dialog window to convert Gleason data from
the outside end of the facewidth into data for the middle of the facewidth (see chapter 18.2.1,
Type). Once this data has been converted, you can perform the strength calculation. Although
the bevel dimensions (tip and root diameter) do not always exactly match the actual geometry,
they are close enough to enable you to check the assembly conditions (in a gearbox). This
procedure does not check to see whether the part can be manufactured on Gleason machines.
III Bevel and Hypoid Gears 389
▪ Oerlikon process:
The Oerlikon process is broadly similar to the Klingelnberg process (select the Klingelnberg
bevel type).
18.2 Basic data
18.2.1 Type
You will find a drop-down list for the type on the top left of the screen, in the Geometry tab.
The following bevel gear shapes are available here (see Figure 18.1):
Figure 18.1: Basic types of bevel gears
▪ Standard, Figure 1 (tip, reference and root cone apex in one point)
The geometry is calculated according to ISO 23509. No offset possible. If you click the Sizing
button, the cone angle is calculated so that the bevels meet each other in the crossing points of
the gear axes (similar to the standard specified in ISO 23509, Annex C.5.2). In this case, the tip
III Bevel and Hypoid Gears 390
clearance is not constant. We recommend this type for the simplified sizing of form-forged,
injection molded or sintered bevel gears.
▪ Standard, Figure 4 (pitch and root apex in one point)
Sizing of the tooth tip angle of gear 2 according to ISO 23509, Annex C.5.2, or own input. No
offset is possible. The tip clearance is constant. A constant tip clearance is taken into account
while calculating the cone angle of the counter gear.
▪ Standard, Figure 2 (tip, reference and root cone apex NOT in one point)
Sizing of the addendum angle and dedendum angle of gear 2 according to ISO 23509, Annex
C.5.2 or own input. No offset possible. A constant tip clearance is taken into account while
calculating the cone angle of the counter gear. We recommend this type for bevel gears with
straight or helical teeth with general cone angles, for example differential bevel gears.
▪ Constant slot width, Figure 2, (face milling, Gleason-Duplex)
The geometry is calculated according to ISO 23509. You can perform this calculation either
without offset (Method 0, spiral bevel gears), or with offset (Method 1, hypoid gears). If you click
the Sizing button, the cone angle is calculated with a "constant slot width" (ISO 23509, Annex
C.5.2). The tip clearance is constant. Gap 2 in Figure 5 does not change. A typical application of
this is a ground bevel gear toothing produced in the "completing" process (duplex), where the
pinion and the bevel gear are each ground in one work step. This process requires machines
that have an additional helical motion.
▪ Modified slot width, Figure 2, (face milling, Gleason)
The geometry is calculated according to ISO 23509. You can perform this calculation either
without offset (Method 0, spiral bevel gears), or with offset (Method 1, hypoid gears). If you click
the Sizing button, the cone angle is calculated with a "modified slot width" (ISO 23509, Annex
C.5.2). Gap 2 in Figure 5 changes. A typical application is the 5-section process, where the
pinion is manufactured with 2 different machine settings, and a modified slot width is
consequently created. The bevel shape is often also referred to as a TRL (Tilted Root Line).
▪ Uniform tooth depth, Figure 3 (face hobbing, Klingelnberg)
The geometry is calculated according to ISO 23509. You can perform this calculation without
offset (Method 0, spiral bevel gears), with offset (Method 3, hypoid gears) or according to KN
3028 and KN 3029. The tip and root cone are parallel. Applications are the cyclo-palloid®
process and the palloid process. Palloid toothing is characterized by an involute tooth length
form with a constant normal module over the facewidth.
▪ Uniform tooth depth, Figure 3 (face hobbing, Oerlikon)
The geometry is calculated according to ISO 23509. You can perform this calculation either
without offset (Method 0, spiral bevel gears), or with offset (Method 2, hypoid gears). The tip and
root cone are parallel. Applications are Oerlikon processes such as Spiroflex and Spirac.
III Bevel and Hypoid Gears 391
18.2.1.1 Converting or inputting Gleason toothing data
The Conversion button and the Plus button are enabled for the Standard, Figure 2, Constant
slot width, Modified slot width and Uniform tooth depth types. Using these two icons, you can enter
data according to the Gleason definition.
Select the button if a Gleason data sheet is present. You can then input the data in the window
and then click on Calculate. When the calculation is finished, the Report and Accept buttons will be
enabled. Click on the Report button to generate a short report. If you want to generate a more
detailed report, click the button in the main menu. Click the Accept button to transfer the data
to the main window.
Click the button to open a dialog window in which you can calculate bevel gear data according to
different Gleason methods. The results of the geometry calculation will not match the Gleason
dimensions sheet exactly, but will be close enough to calculate strength according to ISO 10300 (or
AGMA or DIN).
In the "Type of gear" selection list, you can select one of a number of different Gleason methods (the
default setting is to use a constant helix angle):
1. Constant helix angle (straight or angled)
A constant helix angle represents a bevel gear with a constant helix angle. You can modify the
helix angle to compare the geometry data with the Zerol geometry data if required. If you click
the Accept button to close the dialog, the calculation is usually performed with the selection
"Standard, Figure 4 (part and root apex in one point)".
2. Duplex (constant slot width)
The term "duplex" refers to bevel and hypoid gears that are manufactured with a constant slot
width across the entire tooth length of both gears. These gear types usually have a spiral angle
of 35° in the middle of the facewidth with a continuously changing spiral angle in the axial
direction. If you selected Duplex (constant slot width) and then clicked the Accept button to close
the dialog, the calculation is usually performed with a "Constant slot width".
3. Spiral toothing, default (modified slot width)
These gear types usually have a spiral angle of 35° in the middle of the facewidth with a
continuously changing spiral angle in the axial direction. This gear type is described as having a
"modified slot width". If you select this gear type, and then click on Accept, the calculation is
usually performed with a "modified slot width". In this case, the root gap of the gear pair is
constant over the entire tooth length and any gap modifications are performed on the pinion.
4. Zerol "Duplex taper"
This is a Zerol design (see Zerol), but a root angle variation is performed to achieve duplex
III Bevel and Hypoid Gears 392
dimensions. If you select Zerol duplex and then close the dialog by clicking the Accept button,
the calculation is usually performed with the "Constant root gap" selection.
5. Zerol "standard"
The Zerol standard is a gear pair with a spiral angle of less than 10° in the middle of the
facewidth, with a continuously changing spiral angle in the axial direction. In this case, the
internal spiral angle is usually negative. To ensure the program can take into account the
change across the tooth length, a value of b=0.001 is assumed for the case b=0. If you close the
dialog by clicking the Accept button, the calculation is usually performed with a "modified slot
width".
18.2.2 Mean normal module
You can input the normal module in the center of the facewidth. However, if you know the pitch,
transverse module or diametral pitch instead of this, click on the button to open a dialog window
in which you can perform the conversion. If you would rather input the diametral pitch instead of the
normal module, select the Input normal diametral pitch instead of normal module option in
Calculation > Settings > General.
18.2.3 Pitch diameter gear 2
The external reference diameter of gear 2 (de2) is usually entered for bevel and hypoid gears. This is
useful for designers because the bevel gear's assembly conditions are often predefined by the
housing. The module is then recalculated (not optional).
18.2.4 Pressure angle at normal section
For standard meshings, the pressure angle is αn = 20°. You can use smaller pressure angles for a
larger number of teeth to achieve higher contact ratios. Greater pressure angles increase the
strength and enable a smaller number of teeth to be used without undercut. In this situation, the
contact ratio decreases.
For hypoid gears, click the button to enter the pressure angle for the driving flank and the driven
flank independently from each other. The driving flank is the concave flank of the pinion and the
convex flank of the gear. The driven flank is the convex flank of the pinion and the concave flank of
the gear.
18.2.5 Pressure angle driving/driven flank: Hypoid gears
Bevel gears are usually able to withstand stress better when driven by the concave pinion flank, i.e.
when the sense of rotation and spiral direction of the driving pinion rotate in the same direction.
III Bevel and Hypoid Gears 393
The concave flank of the pinion is usually called the driving flank (index D for "Drive"), and the
convex flank is known as the driven flank (index C for "Coast"). On the bevel gear, the concave flank
is the driven flank (index C) and the convex flank is the driving flank (index D). Since the effective
pressure angle on the driving flank is greater by the amount of the limit pressure angle, and on the
driven flank it is less than the pressure angle in a normal section, by the amount of the limit pressure
angle, the pressure angle on the driving flank and driven flank can be entered independently.
As specified in ISO 23509, you should input the nominal design pressure angle for hypoid gears as
αdD, αdC. This is used to calculate the generated pressure angle ("effective pressure angle") α nD, αnC
for the driving side (index D for "Drive") and the effective pressure angle αeD, αeC for the driven side
(index C for "Coast").
The equations specified in ISO 23509 are:
αnD = αdD + fαlim * αlim
αeD = αnD - αlim
If, as a result, αnD is known, adD can be calculated as follows:
αdD = αnD - fαlim * αlim
αdC = αnC + fαlim * αlim
or if αeD has been specified, αdD can be calculated like this:
αdD = αeD + αlim * (1- fαlim)
αdC = αeC - αlim * (1- fαlim)
The limit pressure angle αlim is calculated and output in the report.
The limit pressure angle influence factor fαlim has been introduced so that you do not always need to
take the total value of the limit pressure angle into consideration when calculating the flank angle on
the tool. For forming tools (Klingelnberg process), fαlim = 0. If you use the procedure with a constant
slot width (Gleason), fαlim = 0.5 is set, otherwise fαlim = 1.0 is often used.
However, if more accurate data is not available, you can use the pressure angle in the normal
section in the calculation (with αdD = αdC = αn and fαlim = 1.0).
► Note
These input fields are only available if you are calculating the strength of hypoid gears (see chapter
18.4.1, Methods used for strength calculation).
III Bevel and Hypoid Gears 394
18.2.6 Spiral and helix angle
The angle is input in the middle of the facewidth. In the case of helical-toothed bevel gears, the helix
angle remains constant across the facewidth. However, in spiral bevel gears the spiral angle
changes across the facewidth.
In hypoid gears, the spiral angle is specified in the middle of the facewidth for Gear 2. This value is
then used to calculate the value for Gear 1 (pinion).
You can select any value as the spiral angle in the middle of the facewidth. However, we recommend
you use a larger angle of between 30° and 45° to ensure optimum running performance. You should
only select a value that is less than this guide value if the bearing load has to be reduced.
III Bevel and Hypoid Gears 395
Figure 18.2: Spiral and helix angle
Click the button to the right of the spiral angle input field to display the Additional data for spiral
teeth window, where you can check the internal and external spiral angle for spiral bevel gears.
18.2.7 Addendum angle and root angle
All the necessary data required to create the bevel gear drawing can be calculated from the
addendum angle and dedendum angle. These are the tip and active root diameter on the outside and
inside bevel, and the tooth thickness on the external and internal cone diameter (see Figure 18.3)
III Bevel and Hypoid Gears 396
and (see Figure 18.4). In the case of bevel gears with spiral teeth, the addendum angle and
dedendum angle are calculated using the selected method [ISO 23509 or DIN 3971].
Figure 18.3: Dimensioning a bevel gear
Figure 18.4: Dimensioning a bevel gear according to Klingelnberg
III Bevel and Hypoid Gears 397
18.2.8 Angle modifications
In some less than ideal situations, it may happen that the cutter head cuts into any shaft pins that are
located immediately next to the toothing. If this cannot be prevented by modifying either the design or
the toothing data, the cutter tip level at the calculation point at dm of the gear and pinion can be tilted
by a slight angle ϑk from its intended position δo1,2 towards the reference cone angle δE1,2 (see Figure
18.3) and (see Figure 18.4).
18.2.9 Number of teeth
You will find reference values for bevel gears with a shaft angle of 90° in this table.
u 1 1.25 2 2.5 3 4 5 6
z1 18..40 17..36 15..30 13..26 12..23 10..18 8..14 7..11
Table 18.1: Recommended pairing transmission ratio u - number of teeth, pinion z1 in accordance with Niemann [10].
18.2.10 Facewidth
The facewidth should not usually be larger than the one given in the recommendations (facewidth
ratio to outer cone distance (see chapter 18.2.7, Addendum angle and root angle), module ratio (see
chapter 18.9.2, Module ratio)). The contact pattern deteriorates if the facewidth is too large.
18.2.11 Profile shift coefficient
You will find reference values for the profile shift coefficient of bevel gears with a shaft angle of 90° in
this table:
u 1 1.12 1.25 1.6 2 2.5 3 4 5 6
x* 0.00 0.10 0.19 0.27 0.33 0.38 0.40 0.43 0.44 0.45
Table 18.2: In accordance with Niemann, 24/4 [10] recommended transmission ratio u - profile shift coefficient x*
Click on the button to the right of the profile shift coefficient input field to display the minimum
profile shift coefficient for the pinion required to prevent undercut, and also the recommended value
according to Niemann [10].
► Note
The ISO 23509 standard defines two different data types that can be used to describe tooth height
factors and profile shift. The formulae used to convert data between these two data types are listed in
ISO 23509. The Gleason calculation sheets also give partial descriptions of coefficients K and C1.
Although these are very similar to data type II, there are slight differences. Click the button to
convert data type II data.
III Bevel and Hypoid Gears 398
18.2.12 Tooth thickness modification factor
Use the tooth thickness modification factor to modify the tooth thicknesses of the pinion and bevel
gear. You can do this to compensate for tooth root strengths. You will find reference values for bevel
gears with a shaft angle of 90° in this table
u 1 1.12 1.25 1.6 2 2.5 3 4 5 6
xs 0.00 0.010 0.018 0.024 0.030 0.039 0.048 0.065 0.082 0.100
Table 18.3: Recommended pairing transmission ratio u - tooth thickness modification factor xs in accordance with
Niemann [10].
► Note
The tooth thickness modification factor is achieved by using different tools. Please contact the
manufacturer if you are using universal tools. If individual cutter sizes are used, the backlash occurs
when the pinion and bevel gear have different tooth thickness factors.
18.2.13 Quality
In this input field, you specify the manufacturing quality in accordance with the standard shown in
brackets. To change the standard used for this calculation, select Calculation > Settings > General
> Input of quality. The manufacturing quality defined in ISO 17485 is very similar to that specified in
DIN 3965.
You will find notes about the achievable toothing quality in the Manufacturing process (see chapter
18.3.1, Manufacturing process).
18.2.14 Shaft angle
The shaft angle for bevel gears is usually 90°. However, you can perform the calculation for any shaft
angle.
18.2.15 Offset
The offset is 0 for bevel gears. The offset for hypoid gears is greater than or less than 0. This
application enables you to achieve higher contact ratios and greater strength at the tooth root. It is
primarily used in automotive engineering (see Figure 18.5).
► Note
A positive hypoid offset is almost always applied to hypoid bevel gears, because this is the only way
of achieving the improvements to the characteristics described above.
III Bevel and Hypoid Gears 399
Figure 18.5: Hypoid bevel gear configurations. Positive offset (a > 0): Gear 1 left-hand spiral, Gear 2 right-hand spiral.
Negative offset (a < 0): Gear 1 right-hand spiral, Gear 2 left-hand spiral
18.2.16 Geometry details
Click the Details... button in the upper right-hand part of the Geometry area to display the Define
details of geometry dialog window. You can enter these parameters here.
The V-, H- and J misalignments of the bevel gear pinion are system data and are used to calculate
the contact pattern.
III Bevel and Hypoid Gears 400
Figure 18.6: Misalignment of the bevel gear pinion for calculating the contact pattern
You can specify the drawing number and the internal diameter for each gear. The data for
dimensions yo, yu and the mounting distance (see chapter 18.2.16.1, Pitch apexes to front and back
of gear blank/mounting distance) must be taken into account.
18.2.16.1 Pitch apexes to front and back of gear blank/mounting distance
The Pitch apex to the front of the gear blank is the distance from the pitch apex to the front face of
the unworked blank, in the axial direction.
The Pitch apex to back of gear blank is the distance from the pitch apex to the rear face of the
unworked blank, in the axial direction.
The Mounting distance can be defined as required. Usually, this means the distance from the pitch
apex to the shaft shoulder in integral bevel pinion shafts is specified for the next rolling bearing. In
contrast, in the case of bevel gears (without a shaft), the mounting distance usually corresponds to
yo. This distance is usually specified on the assembly drawing and checked during mounting.
III Bevel and Hypoid Gears 401
Figure 18.7: Figure: Bevel gear dimensioning
18.3 Process
18.3.1 Manufacturing process
The next table shows the relationship between the manufacturing process and the achievable
accuracy grade.
Process Achievable accuracy grade
(ISO 17485, DIN 3965)
Milling only 8
Lapping 7
Skiving 6
Grinding 6
Table 18.4: Interrelationship between manufacturing process and achievable accuracy grade
III Bevel and Hypoid Gears 402
18.3.2 Manufacture type
Either "generated" or "formate" can be selected as the accuracy grade for the two processes. In gear
sets with ratios greater than 2.5, the bevel gear (gear 2) is usually only "formate". The pinion (gear 1)
is always generated. In a cyclo-palloid® toothing, the pinion and bevel gear are always generated.
Manufacturer's data for spiral teeth: Face Milling and Face Hobbing
The process used to manufacture bevel gears with spiral teeth is closely linked to this manufacturing
process. There are two basic processes used here. The arc of circle toothing process (face milling,
traditionally known as the Gleason process) and the continuous face hobbing (face hobbing,
traditionally known as the Klingelnberg and Oerlikon process). For more details, see Calculation
process (see chapter 18.1.3, Calculation according to Klingelnberg, Gleason and Oerlikon).
18.3.3 Cutter radius
In the case of spiral teeth bevel gears, the size of the cutter radius rc0 influences the curvature of the
flanks and therefore also the properties of the bevel gear pair. This effect applies both to the position
of the contact pattern and the strength, and must be taken into account when calculating the
transverse coefficient KFa according to ISO 10300.
► Note
This parameter is not present if you use the Klingelnberg method to calculate strength. In that case,
you select the cutter radius together with the machine type.
18.3.4 Number of blade groups
The number of blade groups describes the number of cutter blade groups on the cutter head used to
manufacture bevel gears with spiral teeth and, when face hobbing is in use, this number, together
with the cutter radius, influences the bevel of the tooth length. You must enter the number of blade
groups as defined in ISO 23509, Annex E or as specified in the manufacturers' instructions.
18.4 Load
18.4.1 Methods used for strength calculation
You can select the following methods:
III Bevel and Hypoid Gears 403
▪ 1. Bevel gears, static calculation
Implements the strength calculation for cylindrical gears (see chapter 17.2.1, Calculation
methods).
▪ 2. Differential, static calculation
The static calculation can be used for differential gears. In a typical construction of rear axles
with one bevel or hypoid gear on the differential housing, the torque on gear 2 (side shaft gear)
is specified to calculate differential bevel gears. The torque on gear 2 is half the torque on the
differential housing. You must also input the number of strands (click on "Details – Number of
strands"). For "2-pinion designs", input 2 strands. For "4-pinion designs", input 4, etc. The
calculation is performed with the highest circumferential force F1 or F2 (see Figure 18.8)
Figure 18.8: Bevel gears in differential gears
III Bevel and Hypoid Gears 404
▪ 3. Bevel gears, ISO 10300, Method B (C)
ISO 10300, Parts 1, 2, 3: Load capacity calculation for bevel gears.
▪ 4. Bevel gears according to ISO 10300 (2014)
ISO 10300, parts 1, 2, 3, 4 and 20: Load capacity calculation for bevel and hypoid gears.
▪ 5. Bevel gears according to AGMA 2003-B97 or AGMA 2003-C10
ANSI/AGMA 2003-B97 or AGMA 2003-C10: Rating the Pitting Resistance and Bending Strength
of Generated Straight Bevel, Zerol Bevel and Spiral Bevel Gear Teeth
▪ 6. Bevel gears according to DIN 3991
As specified in DIN 3991, Parts 1, 2, 3, 4: Load capacity calculation for bevel gears.
This calculation is usually performed as defined in method B, and the tooth form factor is
calculated with method C.
▪ 7. Bevel gears Klingelnberg KN 3028/KN 3030
This calculation is the same as the Klingelnberg in-house KN 3028 and KN 3030 standards.
These are mainly based on DIN standards. The calculation supplies the same results as the
reference program used by Klingelnberg.
▪ 8. Bevel gears Klingelnberg KN 3025/KN 3030
This calculation is the same as the Klingelnberg in-house KN 3025 and KN 3030 standards.
These are mainly based on DIN standards. The calculation supplies the same results as the
reference program used by Klingelnberg.
III Bevel and Hypoid Gears 405
▪ 9. Bevel gears Plastic
This calculates the equivalent cylindrical gear pair (see also DIN 3991). Here the calculation is
performed according to Niemann/VDI/VDI-mod. in the same way as the cylindrical gear
calculation (see chapter 17, Cylindrical gears).
▪ 10. DNV41.2, Calculation standard for ships' engines
The Det Norske Veritas calculation guideline [9] for ships' engines corresponds in principle to
ISO 10300 (root, flank) and ISO 13989 (scuffing). However, it does have some significant
differences, especially where S-N curves (Woehler lines) are concerned. These differences are
detailed in our kisssoft-anl-076-DE-Application_of_DNV42_1.pdf information sheet, which is
available on request.
▪ 11. Hypoid gears according to ISO 10300
▪ 12. Hypoid gears, according to Klingelnberg KN 3029/KN 3030
This calculation is the same as the Klingelnberg in-house KN 3029 and KN 3030 standards.
These are mainly based on DIN standards. The calculation supplies the same results as the
reference program used by Klingelnberg.
▪ 14. Hypoid gears, according to Klingelnberg KN 3026/KN 3030
This calculation is the same as the Klingelnberg in-house KN 3026 and KN 3030 standards.
These are mainly based on DIN standards. The calculation supplies the same results as the
reference program used by Klingelnberg.
► Note
For additional notes about the strength calculation as specified in Klingelnberg, see (see chapter
18.14, Notes about calculations according to the Klingelnberg standard).
18.4.2 Driving gear and working flank gear 1
To define flank alignment, you require the data for the driving gear (pinion or bevel gear) and the
working flank (left flank or right flank) on gear 1. This data is then used together with the definition of
the spiral direction (see figure below) to determine the flank alignment for the driving and driven gear.
III Bevel and Hypoid Gears 406
Figure 18.9: Definition of driving and driven flank for right- and left-hand helix bevel gears
18.4.3 Power, torque and speed
Click the button next to the power input field (for torque) to calculate the power (torque) that is
needed to maintain a predefined minimum level of safety (see chapter 17.20.6, Required safeties).
18.4.4 Required service life
You enter the required service life directly in this input field.
Click the button to size the service life based on the minimum safeties for tooth root and flank
strength. The service life for all the gears in the configuration is displayed. You can also click the
button to size the service life with or without defining a load spectrum (see chapter 17.2.8, Define
load spectrum). More detailed information about defining load spectra is provided here (see chapter
17.2.8, Define load spectrum).
III Bevel and Hypoid Gears 407
18.4.5 Application factor
The application factor compensates for any uncertainties in loads and impacts, whereby K A ≥1.0. The
next table provides information about the coefficient values. You will find more detailed comments in
ISO 10300, ISO 6336, DIN 3990 and DIN 3991.
Operational behavior of Operational behavior of the driven machine
the driving machine
uniform moderate average heavy
shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
Table 18.5: Assignment of operational behavior to application factor
18.4.6 Strength details
Click the Details... button on the upper right-hand part of the Strength area to display the Define
details of strength dialog window.
The parameters described in other places are:
▪ Limited life (see chapter 17.2.6.1.2, Limited life coefficients as defined in ISO 6336)
▪ Modification of S-N curve (Woehler lines) in the range of endurance limit
▪ Tooth flank with load spectrum
▪ Tooth root with load spectrum
▪ Minor pitting (see chapter 17.2.6.1.6, Small amount of pitting permissible)
▪ Tooth mass temperature
▪ Lubricant factor XL
▪ Toothing is well run in
▪ Relative structural factor (see chapter 21.2.10.5.3, Structural factor XwrelT or structural factor
Xw (scuffing))
18.4.6.1 Profile modification
Profile modification (in the sense of tip relief) is not usual for bevel gears. The run-in amount
specified in ISO 10300 is the most commonly used.
III Bevel and Hypoid Gears 408
18.4.6.2 Profile crowning (depth crowning)
ISO 10300 states that two values for profile crowning can be entered: "strong" or "low". This value
changes the load distribution within the path of contact and therefore affects all the relevant safeties
such as flank, root or scuffing.
18.4.6.3 Effective facewidth calculated with
Flank and root safety as defined in ISO 10300 is calculated with the length of the contact line on the
middle of the tooth height lbm. Select this checkbox to perform this calculation with a modified width
instead of using the one defined in ISO 10300.
The usual contact pattern width is 0.85*facewidth (for example, as specified by ISO 10300). If you
have sufficient experience, or are performing the calculation with contact analysis, you can modify
this value.
► Note
You can only see this value if you are using the ISO 10300 calculation method.
18.4.6.4 Oil level
The oil level value is used to calculate scuffing according to ISO 10300-20. The depth of immersion
influences power loss and therefore the bulk temperature.
18.5 Reference profile
18.5.1 Default values for tip clearance
The tip clearance for spiral bevel gears is usually 0.2 to 0.3 times the mean normal module.
However, a greater amount of clearance is used for toothing that is manufactured with tilt. This
prevents the tooth tip intersecting with the root of the opposing gear.
Default values are (as stated in the "Kegelräder" book produced by Klingelnberg [37]):
"Gleason, modified slot width" process: 0.3
"Gleason, constant slot width" process: 0.35
III Bevel and Hypoid Gears 409
"Klingelnberg, palloid" process: 0.3
"Klingelnberg, cyclo-palloid" process: 0.25
"Oerlikon" process: 0.25
18.5.2 Default values for addendum coefficients
The addendum coefficient is usually 1.0.
18.6 Contact analysis
In the Bevel and Hypoid gears module, the contact analysis calculates the path of contact under load
for bevel gears with straight, helical, and spiral teeth. Hypoid gears are not supported.
A pair of bevel gears with virtual cylindrical gear toothings are approximated for the analysis. Each
one of the gears in this cylindrical gear pair has a number of teeth that varies across the facewidth,
an operating pitch diameter, and a helix angle (spiral toothing). For a more detailed description of the
theory of contact analysis, refer to the Cylindrical gear contact analysis section (see chapter 17.10,
Contact analysis) and [19].
Axis alignment
The contact analysis takes into account the specified H, G and V misalignment, and also the
direction of the torsion. As for contact analysis for cylindrical gear pairs, the deformation of the shafts
can also be taken into account when calculating bevel gears (see chapter 17.3.7, Taking into account
shaft bending (face load factor and contact analysis)). When the deformation of the shafts is taken
into account, the equivalent H, G and V misalignment is also documented in the contact analysis
report.
Other settings for the contact analysis can be made in the Module specific settings (see chapter
18.15.5, Contact analysis).
18.7 Modifications
The Modifications input window is where you define the profile and lead correction, and a tip
chamfer or a tip rounding, and specify the depth of immersion of the grinding wheel.
You will find data about the tip chamfer, and also the profile and tooth trace modifications (see
chapter 17.7, Modifications).
For technical, manufacturing-related reasons, not all modifications which could be used for cylindrical
gears are used for bevel gears.
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Tip alterations are used for bevel gears, in special cases, to ensure sufficient tip clearance is
achieved. The definition of the data to be input here is shown in the figure (see Figure 18.10).
Figure 18.10: Tip alterations for bevel gears
Use the tip alteration Sizing button for the internal face to generate a suggested value for a constant
tip width with 0.2*normal module, corresponding to length bk (tip relief width), as specified in the
Klingelnberg in-house standard. To do so, the calculation according to Klingelnberg KN 3028 is
required.
The length and width values for the gear body can be modified on the inside and outside (for the 3D
view). Then, click the conversion button to generate modifications with a parallel axis bearing. This
then opens a window, in which you can use the sizing function for the external face to generate a
proposed value for the maximum possible height of the modification, h_ake, up to the external cone
length diameter. The maximum possible length of modification l_ake is limited to half the facewidth
so that the unchanged tooth height remains in the tooth middle, in the 3D model of the bevel gear.
Select the "Modified blank" option to generate special forms of the gear body(see Figure 18.11)
III Bevel and Hypoid Gears 411
Figure 18.11: Gear body modification on the external face of the bevel gear
You can also click the conversion button to perform a conversion for the internal face. This then
opens a window, in which you can use the sizing function for the internal face to generate a proposed
value for the maximum possible height of the modification, h_aki, up to the internal cone length
diameter.
Select the "Modified blank" option to generate special forms of the gear body(see Figure 18.12).
The Sizing button in this window for "Distance in axial direction to the pitch apex yaimod"
calculates yai in such a way that the bevel gear body is given a shape according to Δyai=0, (see
Figure 18.12), left or right.
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Figure 18.12: Gear body modification on the inside face of the bevel gear
18.8 Factors
18.8.1 Bearing application factor
The tables below show the bearing type → mounting factor for different standards.
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Support for pinion and bevel gear Bearing application factor
a b c
both on both sides 1.00 1.05 1.20
one on both sides, one floating 1.00 1.10 1.32
both floating 1.00 1.25 1.50
Table 18.6: Mounting factor according to ISO 10300
a: Contact pattern in the gearbox tested under full load
b: Contact pattern in the gearbox tested under partial load
c: Contact pattern only tested in specific tests
Support for pinion and bevel gear Bearing application factor
both on both sides 1.10
one on both sides, one floating 1.25
both floating 1.50
Table 18.7: Mounting factor according to DIN 3991
Support for pinion and bevel gear Bearing application factor
both on both sides 1.10
one on both sides, one floating 1.10
both floating 1.25
Table 18.8: Mounting factor according to AGMA 2003
The face load factors KHβ,KFβ and KBβ are calculated as follows from the mounting factor KHβbe as
defined in the standard:
(15.7)
18.8.2 Dynamic factor
To calculate the dynamic factor Kv, as defined by Klingelnberg, use the coefficient K1 either for
preliminary calculations based on the planned manufacturing method (lapped, HPG) or on the basis
of the derived accuracy grade (see also Klingelnberg standard KN 3030, Table 5.2-1 or 5.2-2).
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18.8.3 Bevel gear factor at flank and root
To calculate the strength of bevel gears, use virtual cylindrical gear toothing with equations that apply
to the strength calculation for cylindrical gears. The bevel gear factors are then used to correct the
systematic differences in the calculation between cylindrical gears and bevel gears. These factors
are defined in the relevant standards.
Standard Bevel gear factor, flank ZK
ISO 10300 0.80
Niemann 0.85
Table 18.9: Bevel gear factor, flank ZK, depending on standard
Standard Bevel gear factor, root YK
ISO 10300 is calculated, see Part 3 of the standard
Niemann 1.00
Table 18.10: Bevel gear factor, root YK depending on standard
18.9 Rough sizing
The method used to size bevel and hypoid gears, according to suggestions from technical literature
[Kegelräder, pub. Klingelnberg], provides geometrically satisfactory sizing recommendations for gear
pairs. This proposal does not provide sufficiently precise solutions to the problems of achieving the
required safeties against tooth fracture and pitting, because it is based on values gathered through
years of experience. If you verify gear teeth that have been dimensioned according to this method,
you may discover certain deviations from the required safety values.
18.9.1 Facewidth ratio
Depending on how and where a gear unit is to be used, the facewidth should be in a specific ratio to
the cone distance and correspond to the following values:
Light and medium-heavy load 3.5 ≤ (Re/b) ≤ 5.0
gear units for machines and vehicles
Heavy load 3.0≤ (Re/b) ≤ 3.5
gear units for machines and vehicles
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18.9.2 Module ratio
The normal module mn should be in a ratio to the facewidth b within specific limits which can only be
exceeded (or not reached) for exceptional reasons:
surface hardened bevel gears at risk of tooth fracture 7 ≤ (b/mn) ≤ 12
bevel gears at risk of pitting or 10≤ (b/mn) ≤ 14
through hardened or not hardened
18.10 Fine sizing
To start the Fine Sizing process, click the Calculation menu and select the Fine Sizing option or
click the icon in the Tool bar.
If you input a nominal ratio, a center distance, intervals for the module and helix angle, and the
pressure angle, the system calculates and displays all the possible suggestions for the number of
teeth, module, helix angle and profile shift. It also shows the deviation from the nominal ratio, the
specific sliding and the contact ratios. This module can also be used to size planetary stages and
three gear chains.
All the variants found by this process can be evaluated by a wide range of different criteria (accuracy
of ratio, weight, strength, etc.).
Depending on your requirements, limits can also be set on the most important parameters (minimum
number of teeth, tolerated undercut, etc.). In addition to creating text reports detailing the solutions
and the summary, the summary can also be displayed as a graphic.
18.10.1 Required entries in the standard tabs
Before you start the fine sizing process, you must enter the following data correctly in the Basic data
or Geometry and Strength standard tabs to ensure the calculation returns the results you require.
Geometry:
▪ Reference profile
▪ Type: Standard, Gleason, Klingelnberg
Strength:
▪ Materials
▪ Power/Speed
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▪ Application factor
▪ Required service life
▪ Lubrication
18.10.2 Conditions I
18.10.2.1 Maximum no. of solutions
If the program finds more than the specified number of solutions, you see a warning message and an
appropriate note is entered in the report.
► Note
You should only perform a final evaluation after all the possible solutions have been displayed.
Otherwise, you run the risk that the optimum solution will not be displayed.
18.10.2.2 Normal module (middle), reference diameter, length of reference cone
Use the three available options to vary and restrict the gear size.
18.10.3 Conditions II
You can define more parameters in the Conditions II tab.
18.10.3.1 Addendum coefficient gear 1 (middle), addendum coefficient gear 2
(middle)
You can vary the reference profile of the bevel gears by changing the addendum coefficients of gear
1 and gear 2. You can then calculate the dedendum coefficients of the counter gear (gear 2 and gear
1) by specifying the addendum coefficient and the "Required tip clearance".
18.10.3.2 Addendum angle gear 2, dedendum angle gear 2
By varying the addendum and dedendum angle on gear 2 you can then vary the tooth height along
the facewidth. To calculate the addendum and dedendum angle on the mating gear (gear 1), input a
constant tip clearance (parallel tip cone and root cone for the mating gear).
Restrictions due to gear type: You cannot vary the cone angle for gear types for which the angle
cannot be changed. You cannot vary the addendum angle and root angle of the "Standard, Figure 1"
type. Although the face angle can be varied for the "Standard, Figure 4" type, you cannot vary the
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root angle. The addendum angle and root angle cannot be varied at all for the "Uniform tooth depth,
Figure 3" types.
► Note
These options for varying the parameters in Conditions II are useful for differential bevel gears,
which are characterized by major geometric variations during manufacture. However, do remember
that the usual conditions must be met when using conventional manufacturing methods for spiral
teeth.
18.10.4 Conditions III
You can define more parameters in the Conditions III tab.
1. Show values of KISSsoft main calculation as additional variant with number 0
The toothing data displayed in the KISSsoft Basic tab can also be displayed as a variant with number
0 (table and graphic). However, the data at the start of the fine sizing process must be consistent
before this can happen.
2. Only calculate geometry
If you select this setting, no strength calculation is performed.
3. Strength calculation with load spectrum
Before you can perform calculations with a load spectrum, you must specify a load spectrum in the
KISSsoft main window before you start the fine sizing process and run the calculation (to ensure the
data is consistent). In this case, when you start the fine sizing process, you are prompted to confirm
that you want to perform the calculation with a load spectrum. Click the Strength calculation with
load spectrum option to perform the calculation with a load spectrum, otherwise the calculation is
performed without a load spectrum.
4. Suspend results which do not meet the required safeties
Variants which do not meet the predefined minimum safety levels (see Calculation > Settings >
Required safeties) will be rejected.
5. Transmission error
If the Calculation of the transmission error option is selected, contact analysis is performed for
every variant. During the transmission error contact analysis, most of the default settings are used to
prevent the calculation generating an inaccurate result. However, the coefficient of friction and
accuracy of calculation are not used. Input the settings in the main program, in the Contact analysis
tab. You can also specify the accuracy of the calculation. We strongly recommend you use "medium"
or "low" to reduce the processing time. As a consequence, the transmission error in fine sizing may
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not be exactly the same as you get in the contact analysis, depending on which settings have been
selected.
▪ The default values are as follows:
▪ Calculation for: right flank
▪ Torque for gear A: not considered
▪ Torque for gear B: not considered
▪ Partial load range for calculation: 100 %
▪ Center distance: Average center distance allowance
▪ Single normal pitch deviation: 0 mm
▪ Then, the results list shows
▪ Transmission error (PPTE)
▪ Medium wear on the tooth flank (delwn1, delwn2)
▪ Maximum flash temperature (theflamax)
▪ Variation in bearing forces (VarL)
The calculation time increases significantly with the transmission error calculation option. For this
reason, we recommend you limit the number of variants to be calculated before you start the
calculation.
18.10.4.1 Ratio of cone distance to facewidth
A standard sizing characteristic value for bevel and hypoid gears is the "Ratio of cone distance to
facewidth". If this flag is set, solutions which lie outside this range are rejected.
► Note
Make this range relatively small when calculating bevel gears with spiral teeth. Select a larger range
for differential gear bevel gears.
18.10.4.2 Ratio of facewidth to normal module
A standard sizing characteristic value for bevel and hypoid gears is "Ratio of facewidth to normal
module". Small values result in modules that tend to be large and sizings that are optimized for root
strength. If this flag is set, solutions which lie outside this range are rejected.
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► Note
Make this range relatively small when calculating bevel gears with spiral teeth. Select a larger range
for differential bevel gears
18.10.4.3 Only take solutions into account if the following conditions are fulfilled:
The user can also define other criteria to ensure unsatisfactory solutions are rejected. These values
are calculated and checked on the virtual cylindrical gear toothing:
1. Minimum distance of active diameter to form diameter dΝf - dFf
Meshing interferences occur if the active root circle is less than the root form circle. Here you can
specify a minimum value for the distance between the active root diameter and the root form circle,
i.e. between active and manufactured involutes. The input value is the minimum difference between
the two diameters. Only solutions greater than, or equal to, the input value are taken into account in
the results view.
2. Minimum transverse pressure angle at a point on root form circle alphafF
For differential bevel gears, a minimum profile angle in the transverse section is required to ensure
the axial demoldability. Only solutions greater than, or equal to, the input value are taken into
account in the results view.
3. Minimum root rounding radius in the reference profile rhofp
A minimum root rounding radius may be required for reasons of manufacturability (absolute value in
mm). Only solutions greater than, or equal to, the input value are taken into account in the results
view.
4. Minimum tip clearance c
A minimum tip clearance may be required for reasons of manufacturability (absolute value in mm).
This is compared with tip clearance c. Only solutions with a tip clearance greater than, or equal to,
the input value are displayed in the results view.
5. Minimum tooth thickness on tip form circle sFvan
The minimum tooth thickness on the tip form circle, sFvan, is critical for achieving the required tip
rounding radius. This calculation takes into account the tip alterations from the Modifications tab.
Only solutions with a tooth thickness at the tip form circle that is greater than, or equal to, the input
value are displayed in the results view. The tooth thickness sFvan is checked in the middle of the
facewidth. Select Additions for differential gears in the Module specific settings if you also want
the tooth thickness to be checked outside and inside, in sections I and II.
6. Manufacturing must be possible with tip rounding rK
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Only solutions in which the tip rounding rK as defined by the entries in the Modifications tab can be
executed are displayed in the results view.
► Note
If Module specific settings –> Differential gears has been selected, these criteria are also
checked in an "inside" and "outside" section. Only solutions which meet the predefined criteria are
then taken into account.
18.10.5 Results
Click the Report button to open the editor and display a list of the best results. A brief description of
the criteria used to evaluate the best variants is given here. Note that these criteria are not relevant
to every case, and only need to be queried in particular applications!
18.10.6 Graphics
The graphic in the Fine Sizing window gives you a quick overview of the number of solutions. Three
parameters can be displayed simultaneously. You can change them in the selection lists. In addition
to the two axes, the third parameter is displayed as a color.
18.11 Torque measurement
The calculation option for defining a load spectrum for gears using the measured torque curve
enables you to generate a load spectrum from a measured torque curve. If all the torque measuring
points are positive, the "simple count" method is used. In more complex torque curves with positive
and negative values, the "Rainflow" method is used and a load spectrum with alternating bending
factors YM that takes alternating torque into account is determined.
This calculation option is available for all gear calculations that can perform calculations with load
spectra.
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A load spectrum that can be used with KISSsoft is then determined from a measured torque curve.
When using this method on a tooth, you must be aware that one tooth is subjected to load during
meshing when the gear is rotated and then the load is removed again. The torque curve on the tooth
is therefore changed by adding a point with torque zero after every measuring point (torque, speed,
time).
To start the calculation, click on the selection list below Calculation in the title bar above "Torque
measurement" or go to the Strength tab and click the sizing button below the Load spectrum
table.
18.11.1 Grid and spread
The maximum and minimum torque are defined when the torque points are imported. The number of
required torque load bins you enter are then used to create the torque grid. The number of
measuring points that fall within a particular torque load bin are counted and used to define the
frequency of each load bin. The greater the number of torque load bins, the more accurate the
resolution and the greater the number of load bins in the resulting load spectrum. Load spectra with a
greater number of load bins also take significantly longer to calculate. You must think carefully about
how accurate you want the evaluation to be (high load bin number) and how fast (low load bin
number).
Usually, including in ISO 6336-6, the torque grid is predefined with a constant load bin width.
However, as usually only the 2 to 10% load bins with the highest torques are damaging, spreading
the torque distribution can improve accuracy without increasing processing time. Spreading means
that the width of the load bins in the high torque range becomes narrower and the width in the lower
range increases correspondingly. You can view the load bin width in the "Interim results" report.
18.11.2 Multiplier
The imported torque can be multiplied using the multiplier fT. The imported speed is then multiplied
with 1/ fT accordingly. This is a good idea if the torque measurement is performed on the gear unit's
input (or output) side and the load spectra are to be determined individually for each gear stage.
18.11.3 Torque curve
Two different torque curve cases can occur:
Torque is always positive (or zero): In this case, the "counting method" can be used to perform the
conversion for the gears. The tooth root is only ever subjected to pulsating load. A matrix containing
the torque and speed interval is formed and then each measuring point is put into the appropriate
category ("counting"). This results in a load spectrum that has elements with different torque and
speed (extended "simple count" method). The normal calculation ("all teeth") assumes that each
measuring point on the torque curve occurs on each tooth. The "Determine load spectrum for a
specific angular position" option is not activated. However, the torque curve is usually measured over
III Bevel and Hypoid Gears 423
a short time period and it is then assumed that this curve repeats constantly over the entire rating life.
Every tooth therefore experiences every torque measuring point over time. The exception to this are
actuators, where torque is always experienced in the same position. In this case, each tooth is only
ever subjected to exactly the same torque.
Torque has positive and negative values: For the tooth flank, this is covered by only taking positive
values into account. However, alternating load occurs at the root. This means that the Rainflow
method must be used to determine significant occurrences of alternating load from the torque curve
[1, 2]. The Rainflow method produces a matrix which shows how often a torque curve from Tupper to
Tlower occurs. The matrix therefore has a torque interval in both axes: once for Tupper and once for
Tlower. In the Haigh diagram, Tupper and Tlower can then be used to determine the alternating bending
factor YM (ISO 6336-3) and the torque TISO. The Rainflow method is usually applied with stresses, not
with torques. As the tooth root bending stress and torque are proportional, you can also use the
torque. However, to ensure the correct values are determined, the torque must be multiplied with the
dynamic factor KV and the face load factor for the root KFβ! This is because KV depends on the
speed, which is no longer taken into account in the subsequent Rainflow calculation. And KFβ is not
proportional to the torque, which is why it is different for Tupper and Tlower.
As the torque must be multiplied with KV*KFβ, this creates the problem that the load spectrum
calculated using these values can only be applied to the root. KΗβ must be used for the tooth flank.
For this reason, once the load spectrum has been calculated using the Rainflow results, the torque of
each load bin is divided by KFβ. The load spectrum then only contains KV and can therefore be used
for the root and for the flank.
Either the Amzallag method or the ASME method can be used as the Rainflow method. Amzallag is
used in ISO 12110-2 [3]. The calculation used in KISSsoft is checked using the example in Annex B
of ISO 12110-2.
18.11.4 Calculation
The load spectrum calculation is performed for the reference gear and can usually also be performed
for the gear pair (planetary gear stage, 3-gear, 4-gear). The normal calculation ("all teeth") assumes
that each measuring point on the torque curve occurs on each tooth. This approach is correct if the
torque's prefix operator never changes. However, if alternating torque occurs, this approach is only
correct if the time interval between the individual measuring points is long enough to allow the gear
being considered to perform one full rotation (or more).
If the Determine load spectrum for a specific tooth option has been selected, the speed and time
information is used to calculate when a particular torque measuring point occurs on a selected tooth.
The calculation is then performed. A load spectrum that has been determined in this way then only
applies to the selected tooth according to its angular position on the reference gear. Despite this, it is
possible to obtain a "generally" applicable load spectrum by selecting Determine and use the
angular position with average damage to find a tooth which has experienced "average" damage
when compared to all other teeth. This is a good option if the measured torque curve occurs
repeatedly and the gear that is being analyzed has different angular positions at the start of the
approach. In the case of actuators and similar mechanisms, where the angular position at the start
III Bevel and Hypoid Gears 424
always remains the same, we recommend you select the Determine and use the angular position
with maximum damage option. This is because each tooth always experiences the same torque
curve and the tooth that is subjected to the highest load is relevant for calculating the rating life. The
damage experienced by an angular position is evaluated by using the Rainflow method to determine
the corresponding load spectrum and then calculating the equivalent torque Teq as detailed in ISO
6336-6, Equation A.2.
Click the Graphic selection button to display the torque curve on a single tooth.
The number of measuring points per meshing must be constant to ensure that a load spectrum with
the correct frequency distribution per element can be achieved. For this reason, the measuring point
with highest and lowest torque is determined in each meshing, and then used throughout the
calculation. All other measured points will be deleted. On request, the calculation can also be set so
that only the measuring point with the highest torque is defined in each meshing, and then this value
is used throughout the calculation.
If several measured points of a single rotation of the gear are measured, the number of torque
changes increases progressively when the points that do not occur on the tooth under investigation
are removed. The load spectrum of the individual tooth therefore includes a greater proportion of
alternating bending loads, which results in lower tooth root safeties.
Example:
torque measurement with 100,000 measuring points, one measurement every 0.1 s. The torque
prefix operator changes every 30 s. The gear with 20 teeth rotates once per second.
This results in 1 change per 300 measuring points, i.e. a change frequency of 1/300 = 0.333%.
In contrast, tooth X on the gear only "experiences" every 10th measuring point (10 points per second,
1 rotation per second). In other words, only 30 measuring points in 30 s, a change frequency of 1/30
= 3.33%!
As the calculation is complex, a very large number of interim results can be displayed. This helps you
check its progress effectively. To display interim results, click on the appropriate flag in Interim
results.
Once the calculation has finished, you can transfer the load spectrum to the Strength tab. Here, the
system checks whether particular settings need to be changed, to ensure the calculation can be
performed correctly. The necessary changes are displayed. Simply select "Yes" to confirm, if you
want to apply them. For example, the application factor must be set to 1.0. If you are using the
Rainflow variant, the dynamic factor must be set to 1.0 because KV is present in the torque.
18.11.4.1 Use in the script editor
The Import torque -> Determine load spectrum -> Service life calculation and Damage function work
well in the script editor. A call to the CalcSafetyTooth_MeasuredTorque () function performs all 3
steps.
III Bevel and Hypoid Gears 425
The CylGearPair16 example includes a script. In this case, the number of load bins in the torque grid
is increased incrementally from 50 to 250 and the damage to the root of Gear 1 is output.
18.11.5 Notes
Grid for torque resolution
The grid resolution has a major influence on the result. As the measuring points are arranged over
the torque grid, their distribution to load bins with high torques, in particular, has a significant effect.
On the other hand, defining a grid with a very high resolution will result in a correspondingly large
number of load bins and calculations that take much longer to run.
Torque curve Maximum variation Suggested number of grid elements nR
ΔT/Tmax < = 0.5
Only positive 50
(ΔT = Tmax-Tmin)
Only positive ΔT/Tmax > 0.5 50-100
Positive and negative (50) 100-200
The values in this table apply for a constant load bin width.
Sampling rate
The sampling frequency (when recording torque measuring points) should not affect the result
(unless it is too slow and load peaks are overlooked as a consequence). The sampling rate must be
significantly higher than the torque signal frequency. See also DIN 45667 "Classification methods for
evaluation of random vibrations".
Speeds
If the Rainflow method is used, only the torques at the measuring points are processed. Their
associated speeds are ignored. Therefore, the average speed for all the measuring points is
calculated. In the load spectrum, this value is then assigned to all load bins. For this reason, the
dynamic factor of each measuring point is defined. The Rainflow method is then performed with
T*KV. The speed values would also be ignored if the "Simple Count" method is used. However, this
method can be expanded by distributing the measuring points in a torque-speed matrix to ensure the
speed is included in the load spectrum.
Input files
In CSV format with the following information per row, optionally with:
a) Torque
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b) Time; Torque
c) Time; Speed; Torque
Comment lines must start with //.
Click the "Data type CSV (delimiter-separated)" option when saving the CSV file in Excel.
If the value for "Speed" in variant a) or b) is missing, the nominal speed is used instead.
If the value for "Time" in variant a) is missing, a time of 1 second between two torque points is
assumed.
You will find an example in the \Example directory: "TorqueData from Round Drive.csv" file.
18.12 Measurement grid
A measurement grid is required so that topological measurements can be performed on the flank
surface. KISSsoft calculates the measurement grid in Gleason and Klingelnberg formats. For more
precise instructions about these entries, please contact KISSsoft Support and request the document
KISSsoft-anl-068-E-3D Geometry of Spiral Bevel Gear.pdf.
18.13 Topological modifications
When re-engineering existing bevel gears, simply import the measurement grid from an existing
bevel gear into KISSsoft and then calculate a topological modification. For more precise instructions
about these entries, please contact KISSsoft Support and request the document KISSsoft-anl-068-E-
3D Geometry of Spiral Bevel Gear.pdf.
18.14 Notes about calculations according to the
Klingelnberg standard
18.14.1 Bevel gears with cyclo-palloid® gear teeth
Geometry, manufacturability and strength calculation of bevel gears as defined in the Klingelnberg
cyclo-palloid® process.
As stated in the Klingelnberg in-house standard KN 3028 (geometry and manufacturing) and KN
3030 (strength calculation) a complete calculation is performed for cyclo-palloid®toothing:
III Bevel and Hypoid Gears 427
▪ Calculate machine distance for machine types FK41B, AMK400, AMK635, AMK855, AMK1602
with all relevant cutters, cutter radii and number of times the machines have been started. A
warning is displayed if you select an incorrect machine type or cutter tip.
▪ You can specify any shaft angle, or angle modification here.
▪ Overall geometry, modules (inside, middle, outside), spiral angle (inside, outside), checks on cut
back, undercut space, calculation of profile shift for balanced sliding, checks on backwards cut,
checking and calculating the necessary tip shortening on the internal diameter, transverse
contact ratio and overlap ratio, tooth form factor and stress correction factor.
▪ Calculation of all toothing dimensions.
▪ Calculates pitting, tooth root and scuffing load capacity (as defined by the integral temperature
criterion) with all modifications in the KN 3030 in-house standard.
18.14.2 Hypoid gears with cyclo-palloid gear teeth
Geometry, manufacturability and strength calculation of hypoid gears (bevel gears with offset)
according to the Klingelnberg process.
As stated in the Klingelnberg in-house standard KN 3029 (geometry and manufacturing) and KN
3030 (strength calculation) a complete calculation is performed for cyclo-palloid toothing:
▪ Calculate machine distance for machine types FK41B, KNC40, KNC60, AMK855, AMK1602
with all relevant cutters, cutter radii and number of times the machines have been started. A
warning is displayed if you select an incorrect machine type or cutter tip.
▪ You can use any value as the shaft angle, angle modification, pressure angle for the driving and
driven flank.
▪ Overall geometry with calculation of the facewidths, modules (inside, middle, outside), spiral
angle (inside, outside), undercut boundary, calculation of gap widths, checks on backwards cut,
checking and calculating the necessary tip shortening on the internal diameter, transverse
contact ratio and overlap ratio, tooth form factor and stress correction factor either for the driving
or driven flank.
▪ Calculation of all toothing dimensions.
▪ Calculation of pitting, tooth root and scuffing load capacity (as defined by the integral
temperature criterion for the replacement crossed helical gear) with all modifications in the KN
3030 in-house standard.
18.14.3 Bevel gears with palloid gear teeth
Geometry and strength calculation of bevel gears according to the Klingelnberg process.
III Bevel and Hypoid Gears 428
A complete calculation for palloid gear teeth is performed according to the Klingelnberg KN 3025 in-
house standard (Geometry, Edition No. 10) and KN 3030 (strength calculation).
▪ Take into account palloid milling cutter dimensions by specifying a small diameter dK and milling
cutter cut length SF. You can also input special milling cutters here.
▪ A warning is displayed if the cutter does not cover the crown wheel at either the inner or outer
end of the tooth
▪ You can select any shaft angle, or angle modifications
▪ Overall geometry, modules (inside, middle, outside), spiral angle (inside, middle, outside),
checks on profile shift for balanced sliding and undercut space, checking and calculating the
necessary tip shortening on the internal diameter, profile and overlap ratio, tooth form factor and
stress correction factor
▪ Calculation of all toothing dimensions
▪ Calculate forces for contact pattern core for reference cone length Rpr and Rm
▪ Calculate pitting, tooth root and scuffing load capacity (as defined by the integral temperature
criterion) for all modifications in the Klingelnberg standard KN 3030 (taking into account the
forces at cone distance Rpr)
► Note
The forces at cone distance Rm are used for the transfer to KISSsys, to ensure that forces can be
calculated independently of the toothing procedure. However, including the theoretical contact
pattern core in the Klingelnberg in-house standard is very difficult to implement in the manufacturing
process.
18.14.4 Minimum safeties
We recommend you use the following minimum safeties:
Application Minimum safeties
Flank 1.1 ... 1.2
Root 1.5 ... 1.6
Scuffing 1.8 ... 2.0
Table 18.11: Recommended minimum safeties
18.14.5 Surface roughness at tooth root
Treatment Surface roughness [mm]
through hardened 0.016
III Bevel and Hypoid Gears 429
lapped 0.016
hard-cut 0.008
Table 18.12: Surface roughness values
18.14.6 Manufacturing quality for bevel gears
Treatment Quality number
through hardened 7
lapped 7
hard-cut 6
Table 18.13: Manufacturing quality for bevel gears
18.14.7 Characteristic number
The product of the lubrication, speed and roughness factor ZLZVZR for different surface treatments is
shown in the next table:
Treatment Characteristic number ZLZV ZR
Through hardened 0.85
Lapped 0.92
Hard-cut 1.0
Table 18.14: Characteristic number ZLZV ZR depending on surface finish
► Note
You will find a similar definition in ISO 10300-2:2001, section 14.4. Here the characteristic number is
also dependent on the defined level of roughness Rz.
18.14.7.1 Single normal pitch deviation
This is calculated according to DIN 3965.
18.14.7.2 Meshing stiffness
The meshing stiffness is assumed to be constant.
III Bevel and Hypoid Gears 430
18.15 Settings
In the Calculation menu, you will find the Settings option. Select this sub-menu option to display the
Module specific Settings window. From here, you can access the tabs listed below to input other
calculation parameters (see chapter 17.20, Settings)
18.15.1 General
During the mounting process, you can modify the mounting distance to achieve additional backlash.
You can also specify how much additional backlash you require with Δj (enter this as a coefficient in
the module). The required axial displacement for the integral pinion shaft Δα1 and the gear shaft Δα2
is then calculated according to ISO/ST 22849. The additional backlash that would be achieved by
entering a predefined modification to the mounting distance is also calculated.
18.15.2 Calculations
18.15.2.1 Coefficient of friction for hypoid gears
Due to longitudinal sliding, hypoid gears have more power loss than spiral bevel gears. For this
reason, the calculation of gear meshing forces in KN 3030 takes the coefficient of friction into
account. If necessary, you can enter the size of the coefficient of friction in the Module specific
settings.
18.15.3 Differential gears
18.15.3.1 Additional geometry calculations, external and internal
If the extensions for differential gears are selected, the geometry parameters are calculated at
positions Li and Le. The data for the virtual cylindrical gear toothing at these two positions is then
also documented in the report. The tip alteration can then also be applied up to underneath the cone
length.
III Bevel and Hypoid Gears 431
18.15.3.2 Entries for the webbing
As an alternative to entering these values manually, click on the Modifications tab to use an
algorithm to enter the webbing values. The permissible pressure for the thrust washer is used to
determine the external diameter of the thrust washer. The distance from bore to thrust washer
(Delta05Bf) includes the radial distance of the bore to the internal diameter of the thrust washer and
is used, together with the bevel gear bore, to determine the internal diameter. The value for the
required webbing thickness at the thrust washer (SBfAS) includes the axial distance of the external
diameter of the thrust washer to the webbing on the outside of the root. This distance is used to size
the webbing on the outside of the root (webbing length and height, see Modifications tab).
The required inside wall thickness (for dFi) includes the radial distance from the bore to the webbing
at the inside root.
Click the appropriate Perform appropriate tip and root shortening automatically option and the
software will define the webbing in the Modifications tab. The root reductions are determined using
the values input as described above. Tip reductions are defined using the value input as the
necessary tip clearance for the root webbing (of the counter gear).
18.15.4 Helpful information about the Generation of 3D model tab
► Note:
For more precise instructions about these entries, please contact KISSsoft Support and request the
document KISSsoft-anl-068-E-3D Geometry of Spiral Bevel Gear.pdf.
18.15.5 Contact analysis
Calculation method contact stiffness: Here you can select either the calculation method defined by
Weber/Banaschek [19] (dynamic stiffness analysis: default setting), the method defined in ISO 6336-
1 Method B and Own Input.
Single contact stiffness: If "Own Input" has been selected as the contact stiffness calculation
method, you can enter your own value for the single contact stiffness.
Slices linking factor: Slices linking factor of the discretized toothing model.
Border weakening factor: Border weakening factor for a weakening of stiffness on the edge of helical
gear teeth.
Correction factor for Hertzian stiffness (according to Winter): Correction factor for Hertzian
flattening as described in the experiments performed by Winter/Podlesnik [33].
Number of orders in the amplitude spectrum (transmission error/contact stiffness): This is where
you enter the number of orders to be calculated. At least one order must be calculated, and the
III Bevel and Hypoid Gears 432
calculation must be performed with no more than half the number of meshing positions (set this value
in the Contact analysis > Accuracy of calculation tab).
Flash temperature and micropitting with coefficient of friction according to ISO/TS 6336-22: This
overwrites the coefficients of friction defined in the Contact analysis tab with a coefficient of friction
sized according to ISO/TS 6336-22.
Interpolate stress increase caused by tip rounding: In the case of a tip rounding, the calculation of
the tooth form results in a sudden change in the radii of curvature. This in turn results in stress
increases at this transition point in the contact analysis calculation. For this reason, you can specify
whether the mathematical solution is to be used, to perform the calculation, or whether this stress
increase is to be interpolated.
Calculate force excitation: Force excitation (according to FVA Report 487) results from toothing
stiffness and the average transmission error. In contrast to the process for calculating transmission
error, calculating the excitation force enables a better evaluation of how different toothing variants
generate noise. This is because the gear meshing forces, not the equalizing movement (transmission
error), of the gears, are the decisive factor in generating noise.
Conical profile shift: Select this option to enable the conical profile shift in the Contact analysis tab.
Take into account plastic deformation: Use this setting to specify whether plastic deformation is to
be taken into account in the contact analysis. If plasticity is to be taken into account, the maximum
contact stress, calculated using the elastic contact theory, is reduced on the basis of the specified
"Maximum permitted flank pressure". If the maximum elastic flank pressure is exceeded, the radii of
the contact body are changed locally so that the resulting elastic i.e. contact stress matches this
maximum value. Only a percentage rate of the new radii is used, on the basis of the specified
"Weighting of the plastic deformation".
Smooth iterative wear calculation: If you select this option, the tooth form is smoothed after every
iteration of the wear calculation.
18.15.5.1 Display
Smooth results: This function uses a low-pass filter to smooth the results (Hertzian pressure, tooth
root stress on gear 1/2, safety against scuffing and safety against micropitting). By default, this
function is deactivated, but can be used to smooth the results if they are affected by strong numerical
noise.
Analysis area on tooth height: This defines the maximum area along the tooth height for evaluating
the results (Hertzian pressure, tooth root stress on gear 1/2, safety against scuffing and safety
against micropitting). This setting generates additional results and does not change the results of the
contact analysis.
Analysis area on facewidth: This defines the maximum area along the facewidth for evaluating the
results (Hertzian pressure, tooth root stress on gear 1/2, safety against scuffing and safety against
III Bevel and Hypoid Gears 433
micropitting). This setting generates additional results and does not change the results of the contact
analysis.
III Face gears 434
19 Face gears
Face gears are a special type of bevel gear. Although a face gear pinion is a normal cylindrical gear,
it has a complex 3D-tooth form. Unlike a bevel gear, a face gear is absolutely unaffected by axial
displacement. For this reason, face gears are much easier to assemble.
The KISSsoft Face gears calculation module calculates the geometry of pairs of straight or helical
cylindrical gear pinions with face gears with offset and with any shaft angle Σ. In this case, the
strength and 2D geometry are calculated for an offset of 0 mm and a shaft angle Σ=90°. In every
other case, you can perform the pre-sizing with these restrictions and then add the required hypoid
offset and shaft angle to the 3D volume model. In the Geometry docking window, you can display
the tooth form of a face gear for its inside, middle and outside diameter or for any number of sections
all at the same time. You use this tool to check for undercut and pointed teeth on the internal or
external diameter of the face gear. In the Modifications input window (tab), you will find the
value/length of tip alteration at outside (inside) hake(i), lake(i) input fields. Here, you can input additional
parameters that will help prevent pointed teeth occurring in the gear. The system calculates the tooth
form on the face gear by simulating manufacturing using a pinion type cutter. The strength
calculation is based on the use of established standards for cylindrical or bevel gears.
19.1 Underlying principles of calculation
A face gear has features in common with a curved rack. However, unlike this simple gearbox, when
sizing a face gear, engineers are always confronted with the restrictions posed by that very bending.
As the tooth flank in a straight-toothed face gear must run parallel to one radius of the face gear - the
contacting pinion has flanks parallel to its own axis - the immediate result of the theorem of
intersecting lines is that the pressure angle must reduce from outside to inside. This equation [38] is
the central formula for sizing the geometry of face gears. Here it is applied for spur gear teeth. See
equation (16.1).
(16.1)
with
d2 diameter of face gear
mn normal module pinion
z2 number of teeth on face gear
αn pinion pressure angle on the reference circle
α2 pressure angle on face gear for diameter d2
III Face gears 435
From this, you can, for example, define the pressure angle from the external diameter to the internal
diameter. If the inside tooth flanks are steep, the involute will be short and only bear a small part of
the tooth height. The risk of an undercut in the direction of the crown gear center grows. Any
undercut here would further reduce the usable area. The result is a minimum internal diameter and a
maximum external diameter, which limit the total facewidth of the face gear. This is a fundamental
difference to the bevel gear set. A pair of bevel gears can transmit higher torques because of its
increased facewidth. Face gears are limited in this respect. However, if you select the right axial
offset bv, i.e. by moving the facewidth middle b/2 relative to the reference circle dPm, you can optimize
the maximum permitted facewidth.
When sizing a face gear, it is a good idea to define a minimum and a maximum pressure angle and
then the achievable internal and external diameter. If external conditions limit this diameter (this
usually affects the external diameter), you can use the conversion in equation (16.1) to change the
range available for the module.
(16.2)
In addition to having the figures to hand, you may find it helpful to view the teeth as a graphic in this
situation.
The vast majority of applications use face gears with spur gears. However, face gears with helical
teeth, when sized correctly, do offer a number of benefits such as noise reduction and strength.
Unfortunately, these benefits are offset by the problem that the tooth flanks are not symmetrical, i.e.
the left flank no longer matches the right flank. In practice, this means that any undercut that occurs
will happen earlier on one flank than on the other. These differences in the flanks also have a
significant influence on strength, which results in a difference between the shaft senses of rotation
when the gear transmits power. However, if only one sense of rotation is used, (as is the case for
power tools), you can optimize the flank involved without having to take the effect on the rear flank
into account.
Experience has shown that theoretical observations of geometry to decide which involute functions,
lines and arcs of circle to use, to describe a tooth form, will sooner or later reach their limit. A tried
and tested, and much more reliable, means of calculating tooth forms is to simulate the generation
process or, even better simulate the manufacturing process. To do this, the trajectory of a point on
the active surface of the tool is followed until its velocity normal to the tool surface reaches a zero
crossing (see Figure 19.1).
III Face gears 436
Figure 19.1: Spur curve (blue) of the pinion type cutter tool (red) on the face gear (green)
These places are potential points on the tooth form surface. The actual points on the surface must
then be identified separately from the "imaginary" points at which, although the normal speed also
disappears, the remaining points are also marked as being outside of the material. One of the most
difficult aspects of the procedure described here is how to separate the real points from the
imaginary points. In addition to referring to the usual standard algorithms for classifying points in a
level, you must also use empirical approaches that use the known properties of the tooth form to be
sure of achieving a well-defined tooth form with sufficient safety. This enables you to match the data
derived from calculating a 3D tooth form for a face gear with the data derived from generating with a
pinion type cutter, using a classic manufacturing method. By outputting the 3D body in IGES, STEP
or SAT format, you can then design the form in any CAD system. The face gears can then be
manufactured in either an injection molding, sintered or precision forging process. However, 2D cross
section view is much more suitable if you want to check a face gear for undercut or pointed tooth tips.
This displays the inside, middle and outside of the face gear tooth form all at the same time. If you
then rotate the gears step by step, you can check every aspect of gear generation very accurately. If
a tooth is pointed, or if the meshing ratios are not good enough, you must reduce the tooth height in
the same way as you do for hypoid gears. To reduce the gear's sensitivity to errors in the axis
alignment or the center distance, you can permit flankline crowning on the tooth flank (tooth trace).
You can generate this quite easily for face gears by using a pinion type cutter that has one or more
teeth more than the pinion in the manufacturing process [3]. When you compare the tooth forms, you
can see the effect that the increased number of teeth on the pinion type cutter had on the generated
tooth form. However, if the face gear has a large axial offset bv, you can move the barreling to one
side! In every axial section through the cylindrical gear, the face gear gear unit corresponds to a
III Face gears 437
pinion-rack gear unit. Using the rack theory as a basis, you can therefore define the pressure angle,
contact lines and contact ratio in each section.
The examples in this section are based on the publication in [39].
19.2 Basic data
19.2.1 Normal module
Enter the normal module. However, if you know the pitch, transverse module or diametral pitch
instead of this, click on the button to display a dialog window in which you can perform the
conversion. If you want to transfer the diametral pitch instead of the normal module, you can select
Input normal diametral pitch instead of normal module by selecting Calculation > Settings >
General.
If the geometry of a face gear has been completely defined, you will receive the following message
after clicking the button:
III Face gears 438
Figure 19.2: Information window for sizing the normal module
The strength calculation is performed for the mean diameter of the face gear as part of the bevel
gear calculation performed according to ISO 10300 or DIN 3991. If the axial offset bv <> 0, the
conditions for this type of calculation have not been met. For this reason, the functionality triggered
with the button supports the conversion of normal module mn and pressure angle αn, to ensure
that bv = 0. Although this changes the root fillet radius of the pinion, the shape of flank remains the
same.
► Note
We recommend you only use this conversion method when you perform the strength calculation. The
conversion changes the module and you can no longer use the tool. For this reason, you must save
your geometry data before you perform the conversion.
III Face gears 439
19.2.2 Pressure angle at normal section
The normal pressure angle at the reference circle is also the reference profile flank angle. For
standard meshings, the pressure angle is αn = 20°. You can use smaller pressure angles for a larger
number of teeth to achieve higher contact ratios. Greater pressure angles increase the strength and
enable a smaller number of teeth to be used without undercut. In this situation, the contact ratio
decreases and the radial forces increase.
► Note
The working transverse pressure angle αwt changes across the width of the gear teeth.
19.2.3 Helix angle at reference circle
Enter the helix angle in [°]. Click the button in the Convert helix angle window to calculate this
angle from the helix angle at base circle βb or from the helix angle at tip circle βa. Helical gear teeth
usually generate less noise than spur gear teeth. However, they also have the disadvantage that
they involve additional axial force components.
Figure 19.3: Helix angle
III Face gears 440
19.2.4 Axial offset
The axial offset is the distance from the pinion center to the mean diameter of the face gear.
Click the button to the right of the Axial offset input field to calculate greatest possible width of the
face gear b2 and the corresponding axial offset bv, so that the pressure angle lies within the
predefined limits.
Figure 19.4: Axial offset of the face gear
19.2.5 Profile shift coefficient
The tool can be adjusted during the manufacturing process. The distance between the production
pitch circle and the tool reference line is called the profile shift. To create a positive profile shift, the
tool is pulled further out of the material, creating a tooth that is thicker at the root and narrower at the
III Face gears 441
tip. To create a negative profile shift, the tool is pushed deeper into the material, with the result that
the tooth thickness is smaller and there is more danger of undercut. In addition to the effect on tooth
thickness, the sliding velocities will also be affected by the profile shift coefficient.
You can modify the profile shift according to different criteria. To achieve this, use the various sizing
options provided by clicking the button in the Sizing of profile shift coefficient window:
▪ For undercut boundary
▪ For minimum topland per gear.
You can specify the minimum thickness of the topland under Calculation > Settings > General
> Coefficient for minimum tooth thickness at the tip.
► Note
The pinion should have a reasonable high value for the tooth thickness at the tip because the pinion
type cutter used to manufacture a face gear has a somewhat higher tip and still must not be
permitted to become pointed.
Click the button and KISSsoft will determine whether the profile shift coefficients (see chapter
17.1.8, Profile shift coefficient) are to be taken from measured data or from values given in drawings.
19.2.6 Quality
In this input field, you specify the accuracy grade in accordance with the standard shown in brackets.
To change the standard used for this calculation, select Calculation > Settings > General > Input
of quality. The accuracy grade according to ISO 1328 (DIN ISO 1328) is very similar to the same
quality in AGMA 2015.
The manufacturing qualities that can be achieved are displayed in the next table.
Manufacturing process Quality according to ISO
Grinding 2 ... 7
Shaving 5 ... 7
Hobbing (5)6 ... 9
Milling (5)6 ... 9
Shaping (5)6 ... 9
Punching, Sintering 8 ... 12
Table 19.1: Accuracy grades for different manufacturing processes
III Face gears 442
► Note
The values in brackets can only achieved in exceptional situations.
19.2.7 Geometry details
Click the Details... button in the upper right-hand part of the Geometry area to display the Define
details of geometry dialog window. You can enter these parameters here.
19.2.7.1 shaft angle
You can select your own shaft angle here. However, to perform a strength calculation you should set
it to Σ = 90°.
19.2.7.2 Internal diameter
The internal diameter is needed to calculate the mass moment of inertia. As defined in ISO or AGMA,
the gear rim thickness does affect the strength. For solid wheels, enter 0. For external wheels with
webs, enter the relevant diameter di.
The internal gear rim diameter is required for calculations according to ISO or AGMA. Where thin
gear rims are used, this factor can greatly influence the calculation results, as shown in the figure.
III Face gears 443
Figure 19.5: Dimensioning the diameter
19.2.7.3 Height of face gear
To define the height of face gear haFG →5ba0bcda23990
19.2.8 Material and lubrication
The materials displayed in the drop-down lists are taken from the materials database. If you cannot
find the material you require in this list, you can either select Own Input from the list or enter the
material in the database (see chapter 9.4, External tables) first. Click the button to display the
Material pinion (Face gear) window, in which you can select your material from a list of materials
that are available in the database. Select the Own Input option to enter specific material
characteristics. This option corresponds to the Create a new entry window in the database tool.
19.3 Load
19.3.1 Methods used for strength calculation
To enable developers to use the calculation method they require, KISSsoft can perform the strength
calculation either according to ISO 6336, DIN 3990, DIN 3991, ISO 10300 or DIN 3991.
19.3.1.1 Only geometry calculation
If you select this method, no strength calculation is performed. Therefore, you no longer need to
enter the data that is only required for the strength, such as power, application factor, etc.
III Face gears 444
19.3.1.2 Static strength
▪ The strength calculation for cylindrical gears is implemented here (see chapter 17.2.1,
Calculation methods).
19.3.1.3 Method ISO 6336-B/Literature
We recommend you use the method described here.
The method used to calculate the strength of face gears as originally proposed by Crown Gear [38],
is based on the cylindrical gear calculation according to DIN 3990. The inclined lines of contact in a
face gear increase the total contact ratio due to pitch overlap. This can be compared with the overlap
ratio in helical gear cylindrical gears (an overlap ratio is also present in helical face gears due to the
helix angle βn). You can therefore derive the virtual helix angle βv from the inclination of the lines of
contact. In the strength calculation, this effect is taken into account by helix load factors Y β and Zβ.
The value at the middle of the facewidth is then used as the transverse contact ratio εa. It is clear that
the face load factor KHβ and transverse coefficient KHa according to DIN 3990 cannot be used for face
gears. In crown gear calculations, these values are usually set to K Hβ = 1.5 and KHa = 1.1, and
therefore enable the same procedure to be used as the one for calculating bevel gears (DIN 3991,
ISO 10300). However, the international acceptance of the strength calculation method specified in
ISO 6336 makes it a logical alternative to DIN 3990. As ISO 6336 is very similar to DIN 3990, the
same restrictions also apply.
In contrast to the Crown Gear program, the following data is used in the calculation:
- The arithmetical facewidth (pitting) corresponds to the minimum contact line length (Lcont)
- The circumferential force Ft is determined from dPm (middle of facewidth)
19.3.1.4 Crown Gear Method (DIN 3990)
This calculation method produces results that correspond to those produced by the Crown Gear
program. The underlying principle of calculation is described earlier in the "ISO 6336/Literature" (see
chapter 19.3.1.3, Method ISO 6336-B/Literature) method.
The main differences between it and the "ISO 6336/Literature" method are:
▪ The calculation is based on the method defined in DIN 3990.
▪ The arithmetical facewidth (pitting) corresponds to the facewidth (even if the minimum contact
line length is shorter than the facewidth).
▪ The circumferential force Ft is determined from dPd (reference circle = module * number of teeth),
even if dPd is not the middle of the facewidth.
III Face gears 445
19.3.1.5 Similar to ISO 10300, Method B
As already mentioned, you can use ISO 10300 as a good alternative method for calculating the
strength of bevel gears. Face gears are classified as bevel gears and can therefore be regarded as
bevel gears where the cone angle is 0° (pinion) and 90° (face gear). The strength of bevel gears is
calculated on the basis of the virtual cylindrical gear (cylindrical gear with the same tooth form as the
bevel gear). However, for a face gear the virtual gear number of teeth for the pinion is z 1v = z1 and for
the gear z2v it is infinite. If you verify the examples, using the Crown Gear program (similar method to
the one defined in DIN 3990) and the ISO 10300 method in KISSsoft, you will get a good match of
values. The deviation in root and flank safeties is less than 10% and usually less than 5%. This
shows that both calculation methods in DIN 3990 and ISO 10300 (DIN 3991) are reliable and
effective.
19.3.1.6 Analogous to DIN 3991, Method B
The same notes as for the "Analog to ISO 10300" (see chapter 19.3.1.5, Similar to ISO 10300,
Method B) method also apply here.
19.3.2 Service life
The value in the Service life input field is used together with the speed to calculate the number of
load cycles.
19.3.2.1 Number of load cycles
KISSsoft calculates the number of load cycles from the speed and the required service life. If you
want to influence the value, you can define it in the Number of load cycles for gear n window.
Click the button to access this. Here, you can select one of five different calculations for
calculating the number of load cycles.
1. Automatically The number of load cycles is calculated automatically from the rating life, speed,
and number of idler gears.
2. Number of load cycles Here, you enter the number of load cycles in millions. You must select
this option for all the gears involved in the calculation, to ensure this value is taken into account.
3. Load cycles per revolution Here you enter the number of load cycles per revolution. For a
planetary gear unit with three planets, enter 3 for the sun and 1 for the planets in the input field.
Note:
If the Automatically selection button in the calculation module is selected, KISSsoft will
determine the number of load cycles, taking into account the number of planets, in the
Planetary stage calculation module.
III Face gears 446
4. Load cycles per minute Here you enter the number of load cycles per minute. This may be
useful, for example, for racks or gear stages where the direction of rotation changes frequently,
but for which no permanent speed has been defined.
5. Effective length of rack The rack length entered here is used to calculate the number of load
cycles for the rack. The rack length must be greater than the gear's perimeter. Otherwise, the
calculation must take into account the fact that not every gear tooth will mesh with another. You
must enter a value here for rack and pinion pairs. Otherwise the values N L(rack) = NL(pinion)/10
are set.
► Note
This calculation method is used for transmissions that only travel over one oscillation angle.
Assume a scenario in which a reduction is present,
𝑧2
𝑖=
𝑧1
and an oscillation angle w in [°] from gear 2, where gear 2 constantly performs forwards and
backwards movements with the angle value w2. The effective endurance is given as the service life.
The two coefficients fNL1 and fNL2, which modify the absolute number of load cycles, NL, are now
calculated. To do this:
▪ a) Set the alternating bending factor of the pinion and gear to 0.7, or calculate it as defined in
ISO 6336-3:2006. In this case, one complete forwards/backwards movement is counted as one
load cycle.
▪ b) Coefficients fNL1 and FNL2 for pinion and gear are defined as follows:
𝑊1,2
𝑅𝑂𝑈𝑁𝐷𝑈𝑃( )
𝑓𝑁𝐿1,2 = 360
𝑊1,2
2∗
360
- w2 = oscillation angle gear 2
- w1 = W2*i
- ROUNDUP = round up to a whole number
The value in the counter displays the actual number of loads that occur during a complete cycle
(forward and backward oscillation) on the flanks (not teeth) that are most frequently subjected to
load. By rounding up this number to the next whole number, every rotation recorded is counted
as a load.
III Face gears 447
Then, to determine the required fNL1,2 factor, the actual number of loads that occur per flank is
divided by the number of loads that would occur per cycle, if rotation were to continue without a
backward rotation at the angle of rotation (1 load for each 360°).
Example calculation for fNL1.2:
Gear 1 rotates through a half cycle at 540° while gear 2 oscillates by 90° (i = 6).
In a complete cycle, the oscillation angle moves forwards once an backwards once.
The actual number of load cycles that occur in a complete cycle on the flanks that are most
frequently subjected to load (only one side of the tooth is taken into consideration) is then:
For Gear 1:
540
𝑅𝑂𝑈𝑁𝐷𝑈𝑃( )=2
360
For Gear 2:
90
𝑅𝑂𝑈𝑁𝐷𝑈𝑃( )=1
360
Without adjusting the coefficients, the number of counted load cycles in a complete cycle would then be:
For Gear 1:
540
2∗( )=3
360
For Gear 2:
90
2∗( ) = 0.5
360
The coefficients are therefore fNL1 and fNL2:
2
𝑓𝑁𝐿1 = = 0.667
3
1
𝑓𝑁𝐿2 = =2
0.5
III Face gears 448
▪ c) Then, input coefficients fNL1 and fNL2 in the Load cycles per revolution input field.
The strength calculation can now be performed for the correct number of load cycles, on the basis of
the data entered in steps a through d.
19.3.3 Power, torque and speed
Click the button next to the power input field (for torque) to calculate the power (torque)
appropriate to maintain a predefined minimum level of safety (see chapter 17.20.6, Required
safeties). Click the button next to the Speed input field to enter the direction of rotation of the face
gear as specified in the Define sense of rotation window (see Figure 19.6).
Figure 19.6: Helix angle on a face gear: right; helix angle on the pinion: left; direction of rotation: to the right
19.3.4 Application factor
The application factor compensates for any uncertainties in loads and impacts, whereby K A ≥1.0. The
next table provides information about the coefficient values. You will find more detailed comments in
the ISO 6336 standard.
Operational behavior of the driven machine
III Face gears 449
Operational behavior of uniform moderate average heavy
the driving machine shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
Table 19.2: Assignment of operational behavior to application factor
19.3.5 Strength details
Click on the Details ... button to display the Define details of strength window, which is divided into
System data and Pair data.
19.3.5.1 Profile modification
You can modify the theoretical involute in high load capacity gears by grinding the toothing. You will
find suggestions for sensible modifications (for cylindrical gears) in KISSsoft module Z15 (see
chapter 17.7, Modifications). The type of profile modification has an effect on how the safety against
scuffing is calculated. The load sharing factor XΓ is calculated differently depending on the profile
modification. The main difference is whether the profile has been modified or not. However, the
differences between the versions for high load capacity gears and for smooth meshing are
relatively small. The strength calculation standard presumes that the tip relief C a is properly sized,
but does not provide any concrete guidelines. The load sharing factor XΓ is calculated as follows,
depending on the type of profile modification according to DIN 3990:
III Face gears 450
Figure 19.7: Force distribution factor XΓ for different profile modifications
19.3.5.2 Limited life coefficients as defined in ISO 6336
Set the limited life coefficient ZNT to reduce the permitted material stress according to ISO 6336-
2:2006:
(12.14)
(12.15)
As stated in ISO 6336, this value is important for cylindrical gear calculations and is the reason for
the lower safeties for the range of endurance limit, compared with DIN 3990.
1. normal (reduction to 0.85 for 1010 cycles): The permitted material stress in the range of
endurance limit (root and flank) is reduced again. The limited life coefficients Y NT and ZNT are
set to 0.85 for ≥1010 load cycles.
2. increased if the quality is better (reduced to 0.92): Y NT and ZNT are set to 10 for ≥10 load cycles
(in accordance with ISO 9085).
III Face gears 451
3. with optimum quality and experience (always 1.0): This removes the reduction and therefore
corresponds to DIN 3990. However, this assumes the optimum treatment and monitoring of the
materials.
19.3.5.3 Optimal tip relief
To calculate safety against micropitting as specified in Method B in ISO/TS 6336-22, you must
specify whether or not the profile modification is to be assumed to be optimal. The same applies to
calculating the safety against scuffing. The software checks whether the effective tip relief (Ca)
roughly corresponds to the optimum tip relief (Ceff). If this check reveals large differences, i.e. Ca <
0.333*Ceff or Ca > 2.5*Ceff, a warning is displayed. In this case, the value you input is ignored and is
documented accordingly in the report.
19.3.5.4 Hardening depth, known by its abbreviation "EHT"
You can input the intended hardening depth (for hardness HV400, for nitrided steels, or HV550 for all
other steels). The input applies to the depth measured during final machining (after grinding).
When you input this data, the safety of the hardened surface layer is calculated automatically
according to DNV 41.2 [9]. The calculation is performed as described in the "Subsurface fatigue"
section in [9]. The calculation is performed using different solutions than the calculation of the
proposal for the recommended hardening depth, but still returns similar results (see chapter 24.6,
Proposal for the hardening depth EHT).
19.3.5.4.1 Load spectra with negative elements
Load spectra with negative load bins (T < 0 and/or n < 0) can also be calculated as follows (this is
only applied to bins whose alternating bending factor is YM=1.0).
IMPORTANT:
A load bin is considered to be negative if the non-working flank is placed under load.
Coefficient for torque Coefficient Flank under load Actual load bin
for speed
+ + Working flank (*) evaluated as positive
+ - Working flank (*) evaluated as positive
- + Non-working flank evaluated as negative
- - Non-working flank evaluated as negative
(*) Working flank as entered in the Strength tab
III Face gears 452
Table 19.3: Evaluation of a load bin, depending on the prefix operator
You can select the following under "Details" in the "Strength" section, in the "Rating" tab:
▪ To calculate pitting safety
▪ Evaluate all negative load bins as positive (as up to now)
▪ Consider only positive load bins
▪ Consider only negative load bins
▪ Check both cases and document the less favorable case
▪ To calculate the tooth root safety
▪ Evaluate all negative load bins as positive (as up to now)
▪ For negative load bins, increase root stress by 1/0.7
▪ Increase bending stress for positive load bins by 1/0.7
▪ Check both cases and document the more realistic case
19.4 Factors
Figure 19.8: Coefficients input window in the Face gears module
19.4.1 Face load factor
Face load factors KHβ take into consideration the influence of an uneven load distribution over the
facewidth on the contact stress, tooth root stress and scuffing stress. For face gears, we recommend
you use approximately the same coefficients (see chapter 18.8.1, Bearing application factor) as for
bevel gears.
19.5 Modifications
The Modifications (see chapter 17.7, Modifications) (tab) input window in the Face gears
calculation module basically includes the same functionality as for cylindrical gears. Its special
features are listed below:
III Face gears 453
19.5.1 Addendum reduction
You specify the addendum reduction hake(i) and the length of the addendum reduction lhake(I)
5ba0bcda23990 in the Modifications input window in the Modifications area. The tip is then altered
to prevent the tooth becoming pointed. When you specify an addendum change, we recommend you
display the entire modification for the 3D export, so that you can increase the number of sections
calculated under Calculation > Settings > General (see chapter 19.6.1, General).
Figure 19.9: Characteristic values of a face gear
19.5.2 Type of modification
In the List of modifications (see chapter 17.7.1, Type of modification), you can only make changes to
the pinion.
19.6 Settings
Click on Calculation > Settings or select the icon to display the window for the Module
specific settings sub-menu. From here, you can access the tabs listed below and input other
calculation parameters in them.
19.6.1 General
The Number steps for tooth form calculation input field defines how many equidistant section
levels N ≥ 3 are to be distributed between the outside and internal diameter of the face gear. The
default value here is N = 3 which defines section levels r2 = d2i/2, r2 = d2e/2 and r2 = (d2i + d2e)/4.
III Face gears 454
► Note
You should select N > 10 to ensure an adequate spatial resolution for your 3D export.
19.6.2 Sizings
The values entered in the Minimum and Maximum pressure angle in transverse section αt,min/max
input fields define the range that contains the values for the face gear tooth flank pressure angle
across the width. These values are used, for example, when sizing the facewidth of face gear b2 and
axial offset bv.
19.7 Notes on face gear calculation
19.7.1 Dimensioning
In KISSsoft, a wide variety of procedures that differ greatly from other commonly-used procedures,
e.g. for cylindrical gears, for dimensioning the complex tooth forms in face gears. For a face gear,
you must select a geometry that prevents the creation of pointed teeth on the outside face of the gear
and ensures that no (or very little) undercut occurs on the inside face. You must perform these
checks when you calculate the tooth form. The actual geometry calculation procedure converts the
data into the equivalent bevel gear and the virtual cylindrical gear. In the tooth form calculation
process, a face gear is calculated in a number of sections set along its facewidth. To specify the
number of required sections, select the Calculation menu. Then, select Settings > Module specific
settings > General > Number of sections for tooth form. In the dialog that is then displayed,
define the number of sections. In the Geometry graphics window, you can display the tooth form
simultaneously on the internal diameter, external diameter and in the middle of the tooth. You can
see here whether the top land (normal crest width) and undercut are acceptable.
You can take these measures to prevent pointed teeth or undercuts occurring in the gear:
▪ change facewidth offset bv
▪ reduce the facewidth
▪ change the pressure angle
▪ alter the tip in the outside part of the facewidth.
► Notes
▪ To generate a crowned tooth form: You can generate flankline crowning on the tooth trace of
face gears by using a pinion type cutter that has one or two more teeth than the meshing pinion.
Use the data buffer function in the 2D display (select Graphics > Geometry > Meshing) to
check the difference between the generated tooth forms. To do this, define a pinion type cutter
with the same number of teeth as the pinion used to calculate the tooth form. Save the face gear
III Face gears 455
tooth form by clicking the Save curve button and then increasing the number of teeth on the
pinion type cutter. If the face gear has a large axial offset bv, you can displace the crowning to
one side.
19.7.2 Pinion - Face gear with Z1 > Z2
No provision has been made for calculating a pinion – face gear pairing when the number of teeth on
the face gear (Z2) is less than the number of teeth on the pinion (Z1), because this situation does not
happen very often. However, under certain conditions, you can still determine the geometry of this
type of pairing.
To do this, select Module specific settings and click the Do not cancel if geometry errors occur
checkbox. Then, we recommend you follow these steps:
▪ Reduce the facewidth of the face gear (for example, by half)
▪ Starting with Z2 = Z1, zoom Z2 out step by step, performing a calculation after every step and
correcting the inside, middle, and outside aspect of the cuts and, if necessary the tooth height, in
the 2D display.
▪ Once you achieve the required number of teeth Z2, try to increase the facewidth of the face gear
again, and modify bv if necessary.
III Worms with enveloping worm wheels 456
20 Worms with enveloping worm wheels
The worm geometry is calculated according to ISO 14521 or DIN 3975. Tooth thickness and control
measurement values (base tangent length, measurements over rollers and balls of the worm wheel)
are calculated as specified in ISO 21771. Manufacturing tolerances according to DIN 3974.
You can size the facewidth, center distance, lead angle etc. Strength calculation is performed as
defined in ISO 14521 or DIN 3996 with: efficiency, temperature safety, pitting safety, wear safety,
tooth fracture and deflection safety. Data for various different worm wheel materials are supplied.
You can also calculate the starting torque under load, which is a critical value when sizing drives.
Flank forms: ZA, ZC, ZI, ZK, ZN (equivalent to A, C, I, K, N according to ISO TR 10828:2015), ZH
(equals ZC)
These figures show how to dimension a worm wheel.
Figure 20.1: Dimensioning a worm wheel
20.1 Underlying principles of calculation
The underlying geometric relationships are defined in ISO 14521 or DIN 3975. You will find additional
information, and other important definitions, such as the various worm flank forms (ZA, ZC or ZI, ZH,
ZK, ZN), in [10]. Strength (tooth fracture, pitting, wear and temperature safety) is calculated
III Worms with enveloping worm wheels 457
according to ISO 14521 or DIN 3996. These calculations take much less time and effort to perform
than those required for cylindrical gears. Worms can be checked throughout the manufacturing
process by using what are known as "three wire measurements". This corresponds to the principle of
the measurement over two balls that is used for worm gears (and also for cylindrical gears).
However, the calculations involved in ascertaining the three wire measurement are very complex. A
very useful method for standard flank forms has been developed by G. Bock [40] at the
"Physikalisch-Technisches Bundesanstalt" (German national metrology institute) in Berlin. This
method takes into account the shape of the worm's flank, which is why it is used in KISSsoft.
► Note
When you use the term "module" you must differentiate clearly between the axial and the normal
module.
Note about how to use the application factor
In cylindrical gear and bevel gear calculations, the application factor KA is usually multiplied by the
power, for example, so that KA=1 with P= 5 kW gives exactly the same safeties as KA=2 and P=2.5
kW. However, this is different for worm calculations performed according to the ISO or DIN standard
and may lead to confusion.
The forces and torques are multiplied by the application factor. In contrast, the power is not multiplied
by the application factor when determining the bearing power loss PVLP and when calculating the total
efficiency ηGes. Therefore, if KA=2 and P=2.5 kW instead of KA=1 with P= 5 kW, the power loss [PV] is
lower, but the total efficiency ηGes is massively too low.
Results for the example "WormGear 1 (DIN 3996, Example 1).Z80":
KA=1; P= 5 kW KA=2; P=2.5 kW
PVLP 0.140 0.070 << (* 1/KA)
PVD+PV0 0.199 0.199 =
PVZ 0.530 0.530 =
PV 0.869 0.799 <
ηz 90.00 90.00 =
ηGes 85.19 75.77 <<
ΘS 76.6 76.6 =
ΘM 80.9 80.9 =
SW 1.386 1.386 =
SH 1.143 1.143 =
Sδ 2.369 2.369 =
SF 2.251 2.251 =
III Worms with enveloping worm wheels 458
ST 1.306 1.306 =
This difference in the results is not logical so therefore, to determine P VLP and ηGes, the power is also
multiplied by KA to achieve the same results.
20.2 Basic data
20.2.1 Axial/transverse module
Here, you can click on Module specific settings in the Calculations > Calculation with normal
module instead of with axial module tab, to work with the normal module mn instead of the axial
module in future calculations.
► Note
This changes the way the tip and root circles(see chapter 20.5.4.2, Calculation with normal module
instead of axial module) are calculated.
20.2.2 Pressure angle at normal section
The normal pressure angle at the reference circle is also the reference profile flank angle. For
standard meshings, the pressure angle is αn = 20°. You can use smaller pressure angles for a larger
number of teeth to achieve higher contact ratios. Larger pressure angles increase the strength and
enable a smaller number of teeth to be used without undercut. In this situation, the contact ratio
decreases and the radial forces increase.
20.2.3 Lead angle at reference diameter
The lead angle on the reference circle in a worm (gear 1) is the complement of the helix angle and is
calculated according to equation 17.1. Lead direction (see Figure 19.3).
(17.1)
Click the button to open the Convert lead angle dialog window, in which you can calculate the
lead angle from other gear values. These options are available here: from center distance, from
reference diameter and from the reference circle and the center distance (x2* is modified). A
larger lead angle produces greater efficiency, whereas you can create self-locking toothing if you use
a smaller lead angle.
III Worms with enveloping worm wheels 459
20.2.4 Center distance
Click the button to calculate the center distance from the values of profile shift coefficient x *,
number of teeth z and lead angle γ. In this case, you do not receive a message telling you that the
calculation has been performed correctly.
20.2.5 Number of teeth
The number of teeth on a worm usually is in the range 1 ≤ z1 ≤ 4.
20.2.6 Facewidth
For more information about the dimensions of gear teeth and wheel flange widths, please refer to
(see Figure 20.2). Enter the width of the worm wheel in the facewidth b2R input field. The facewidths
b2H and b2 of the worm wheel are then calculated using this value.
Figure 20.2: Dimensioning the gear tooth and gear rim width
20.2.7 Profile shift coefficient
In the Worms with enveloping worm wheels calculation module, the profile shift for worm/gear 1 is
set to zero (as defined in the ISO 14521 standard). You can only modify the tooth thickness of the
worm in the input window for the Tooth thickness modification factor xs.
III Worms with enveloping worm wheels 460
► Note
You should use the Crossed helical gears and precision mechanics worms calculation module if
you require a worm whose profile shift coefficient is x1* 0.
20.2.8 Tooth thickness modification factor
This factor should only be used in special cases. The factor xs modifies the tooth thickness with ΔAs
= 2 * xs * mn, as for bevel gears. xs2 = -xs1 always applies, so that the clearance remains unchanged if
you input xs1. For normal applications, the values for xs1 are entered in intervals of -0.1 ≤ xs1 ≤ +0.1.
This factor can be used, for example, if the worm is significantly harder than the gear, which causes
the gear to wear during operation. The gear unit fails when the gear tooth breaks because it has
become increasingly thinner, due to wear. Modifying the worm's tooth thickness with e.g. x s1 = -0.1
will make the worm wheel tooth thicker. This will result in a much longer service life.
20.2.9 Quality for worm gear units
In this input field, you specify the accuracy grade in accordance with the standard shown in brackets.
To change the standard used for this calculation, select Calculation > Settings > General > Input
of quality.
The manufacturing qualities that can be achieved are displayed in the next table.
Manufacturing process Quality according to DIN/ISO
Grinding 2 ... 7
Shaving 5 ... 7
Hobbing (5)6 ... 9
Milling (5)6 ... 9
Shaping (5)6 ... 9
Punching, Sintering 8 ... 12
Table 20.1: Accuracy grades for different manufacturing processes
III Worms with enveloping worm wheels 461
20.2.10 Geometry details
Figure 20.3: Define details of geometry window
Click the Details... button in the Geometry area to display the Define geometry details window, in
which you can change the parameters listed below.
20.2.10.1 Shape of flank
The flank shape is a result of the manufacturing process. ZA, ZN, ZK and ZI worms have very similar
levels of efficiency and flank load capacity. Although ZC and ZH worms (hollow flanks) have better
load capacity in some situations, they do have other major disadvantages.
ZA form: manufactured on lathe with tool (straight flanks), mounted in axial section
ZN-form: manufactured on lathe with tool (straight flanks), mounted in normal section
ZI form: manufactured with hobbing cutter (worm flank is involute)
ZK form: manufactured with grinding wheel (straight flanks), mounted in normal section
ZC, or ZH form: Manufacturing with special tools to generate a hollow flank
For more information, please refer to: Dubbel [23], with figures on pages G136 and S79.
III Worms with enveloping worm wheels 462
20.2.10.2 External diameter and throat radius
You specify values for the external diameter de2 and throat radius rk as specified in DIN 3975-1:2017-
09. According to equation (59) and (67) the following values are suggested for these two dimensions:
with:
da2: Tip diameter
mx: Axial module
a: Center distance
20.2.11 Material and lubrication
Materials
The strength calculation method used for worms according to ISO 14521 is based on empirical
values determined using these materials:
Worm:
▪ Case-hardened steels (especially 16MnCr5), HRC = 58 to 62
▪ Heat treatable steels (especially 42CrMo4), heat- or induction-hardened, HRC = 50 to 56
▪ Nitriding steels (especially 31CrMoV9), gas-nitrided
Worm wheel:
▪ Bronze (GZ-CuSn12, GZ-CuSn12Ni, GZ-CuAl10Ni)
▪ Grey cast iron (GJS40, GC25)
▪ Polyamide (PA-12, cast)
To calculate strength, you require very special materials data, in particular the wear values. The
standard only specifies these values for the most commonly used worm wheel materials (mostly
bronze). This is why the selection of materials in KISSsoft is limited. As defining data for materials
that are not already documented takes a great deal of time and effort, we strongly recommend you
select a material from the list that is closest to the material you actually want to use.
III Worms with enveloping worm wheels 463
Lubricants
Selecting the right lubricant for a worm is extremely important. Synthetic lubricants (polyglycols or
polyalfaolephine) can reduce loss and wear enormously.
20.3 Load
20.3.1 Methods used for strength calculation
The calculations defined in ISO 14521 and DIN 3996:2012 are identical.
However, strength calculation as defined in ISO 14521 includes a number of different methods
(A,B,C,D;). KISSsoft uses the most precise documented method, which is usually Method B. This
calculation method is not suitable for every material (see chapter 20.2.11, Material and lubrication),
because some of the empirical values are missing.
The ISO 14521 standard provides a calculation method for determining:
▪ Efficiency
▪ Wear and safety against wear
▪ Pitting safety
▪ Root safety
▪ Deflection safety
▪ Temperature safety
► Notes:
▪ To calculate strength, you require very special materials data, in particular the wear values. The
standard only specifies these values for the most commonly used worm wheel materials (mostly
bronze). This is why the selection of materials in KISSsoft is limited.
▪ Grease lubrication: Grease lubrication is not mentioned in DIN 3996. In this situation, KISSsoft
performs the calculation as for oil bath lubrication. This assumption is permissible, because the
lubrication type has very little influence on the calculation.
▪ Endurance limit values for tooth root load capacity: The standard provides two different values. If
you enter the smaller value in the database, no decrease in quality due to plastic deformation of
the teeth will be accepted.
III Worms with enveloping worm wheels 464
20.3.2 Service life
The value in the Required service life input field is used together with the speed to calculate the
number of load cycles.
20.3.3 Application factor
The application factor compensates for any uncertainties in loads and impacts, whereby KA ≥ 1.0.
The next table 5ba0bcd9e87 illustrates the values that can be used for this factor. You will find more
detailed comments in ISO 6336.
Operational behavior of Operational behavior of the driven machine
the driving machine
uniform moderate average heavy
shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
Table 20.2: Assignment of operational behavior to application factor
20.3.4 Permissible decrease in quality
Depending on the construction type of the worm wheel, it may experience a decrease in quality over
time due to wear. This value must not sink below the value specified in this input field. A decrease in
quality is linked to the plastic deformation of the material, and therefore a higher material property.
This, in turn, results in a higher safety against plastic deformation in the root.
20.3.5 Power, torque and speed
Click the button next to the power input field (for torque) to calculate the power (torque)
appropriate to maintain a predefined minimum level of safety (see chapter 17.20.6, Required
safeties).
20.3.6 Strength details
Click the Details... button in the Strength area to display the Define details of strength window, in
which you can change the parameters listed below.
III Worms with enveloping worm wheels 465
20.3.6.1 Support of gearing
The calculation method used to ascertain bearing power loss of the integral worm shaft identifies two
different types of bearing.
20.3.6.2 Bearing power loss
If roller bearings are used, the power loss is calculated using the empirical formulae defined in ISO
14521. If plain bearings are used, you must specify the power loss manually.
The empirical formulae defined in ISO 14521 can only be used in a specific range of validity.
KISSsoft checks whether the total power losses are too high.
(PV0 + PVLP + PVD) > 0.2*P
If the power losses are greater than 0.2*P, the individual power losses PV0, PVLP and PVD are each set
to 0.
20.3.6.3 Number of radial sealing rings, worm shaft
To calculate the power loss in sealing, you must enter the number of radial sealing rings on the
integral worm shaft. The sealing gaskets on the worm shaft are not taken into account because their
slow rotation speed means they lose very little power (the calculation formulae are defined in ISO
14521).
20.3.6.4 Permissible tooth thickness decrease
The permissible tooth thickness decrease (on the gear) is needed to calculate the wear safety and
taken into account when calculating the root safety. If this input field contains 0, the permissible tooth
thickness decrease is not checked.
20.3.6.5 Permissible mass decrease
You can limit the permissible mass decrease in kg on the worm wheel (for example, by specifying oil
change intervals). This limiting value is also used to define wear safety. If this input field contains
value 0, the mass decrease is not checked.
► Note
The decrease in mass experienced on the worm is not calculated, because the standard assumes
that the worm is harder than the worm wheel and therefore will not be subject to wear.
III Worms with enveloping worm wheels 466
20.3.6.6 Distances on the integral worm shaft
Figure 20.4: Dimensioning the worm/worm wheel
l1 Distance between the bearings on the integral worm shaft
l11 Distance from bearing 1 to the middle of the worm
You need these values to calculate the deflection safety. The position of the drive has no effect on
the calculation.
20.3.6.6.1 Load spectra with negative elements
Load spectra with negative load bins (T < 0 and/or n < 0) can also be calculated as follows (this is
only applied to bins whose alternating bending factor is YM=1.0).
IMPORTANT:
A load bin is considered to be negative if the non-working flank is placed under load.
Coefficient for torque Coefficient Flank under load Actual load bin
for speed
+ + Working flank (*) evaluated as positive
+ - Working flank (*) evaluated as positive
- + Non-working flank evaluated as negative
III Worms with enveloping worm wheels 467
- - Non-working flank evaluated as negative
(*) Working flank as entered in the Strength tab
Table 20.3: Evaluation of a load bin, depending on the prefix operator
You can select the following under "Details" in the "Strength" section, in the "Rating" tab:
▪ To calculate pitting safety
▪ Evaluate all negative load bins as positive (as up to now)
▪ Consider only positive load bins
▪ Consider only negative load bins
▪ Check both cases and document the less favorable case
▪ To calculate the tooth root safety
▪ Evaluate all negative load bins as positive (as up to now)
▪ For negative load bins, increase root stress by 1/0.7
▪ Increase bending stress for positive load bins by 1/0.7
▪ Check both cases and document the more realistic case
20.4 Tolerances
The structure and functionality of the Tolerances input window (see chapter 17.6, Tolerances) in the
Worms with enveloping worm wheels calculation module is the same as the Tolerances input
window for cylindrical gears. When you enter allowances for worm calculations, we recommend you
click on the Tooth thickness tolerance drop-down list and select either the Worm as defined in
Niemann or Worm wheel as defined in Niemann option. The corresponding data is based on
recommendations in Niemann [10].
20.5 Settings
Click on Calculation >Settings or select the icon to display the window for the Module
specific settings sub-menu. From here, you can access the tabs listed below and input other
calculation parameters in them.
20.5.1 General
You can set general parameters for the calculation in the General tab.
III Worms with enveloping worm wheels 468
20.5.1.1 Power-on time
To calculate the service life, multiply the power-on time with the number of load cycles. The
temperature calculation also takes into account the power-on time when it determines the amount of
heat generated.
Note about calculating temperature:
It is assumed that heat is constantly dissipated, but that, in contrast, heat is only generated during
the specified power-on time. The precondition for this is that the gear unit is only run for a short
period of time (maximum 15 minutes), and is then stopped again. If this is not the case, the power-on
time must be set to 100%.
20.5.1.2 shaft angle
The default value of the shaft angle is set to 90 degrees because this is the default value specified in
the strength calculation method defined in DIN 3996. However, you can calculate the geometry with
shaft angle that is not 90 degrees by using the Crossed helical gears and precision mechanics
worms calculation module (see chapter 21, Crossed helical gears, precision mechanics worms and
crossed helical gear with rack).
20.5.2 Reference gearing
This calculation is based on a standard reference gearing, on which tests have been performed. The
default data corresponds to the reference gearing in ISO 14521. However, if you have the results of
your own tests or empirical values, you can modify this calculation to take advantage of this
expertise. For a more detailed description, please refer to ISO 14521.
20.5.3 Sizings
To dimension the gear unit stage, you select or define different sizing criteria in the Sizings tab.
III Worms with enveloping worm wheels 469
20.5.4 Calculations
Figure 20.5: Calculations tab in the Module specific settings window
20.5.4.1 Always calculate transmittable torque (utilization)
Click on this checkbox to define the value so that exactly the required safety (input in the Sizing
tab) is achieved.
The process is also documented in the main report.
20.5.4.2 Calculation with normal module instead of axial module
The geometry of worm gear pairs is usually calculated with the axial module (or transverse module of
the worm wheel). If you click on this checkbox, all the values used for the reference profile are
calculated with the normal module (tool module). This particularly affects the tip and root circle. In
contrast, the profile shift x* mx (mx for an axial module) remains unchanged.
The formula for the tip circle (mn for the normal module) is then:
da1 = dm1 + 2 mn haP
da2 = d2 + 2 mx x2 + 2 mn haP
For the root circle, the following apply:
III Worms with enveloping worm wheels 470
df1 = dm1 - 2 mn hfP
df2 = d2 + 2 mx x2 - 2 mn hfP
20.5.4.3 Calculation with enhanced formulae (differs from standard)
Alternative calculation methods are used at these points if you select this checkbox:
▪ Effective tooth thickness on the tip (instead of formula (84): calculated according to DIN or
formula (110) according to ISO)
▪ Mesh power loss PVZ with coefficient 1/9.550 instead of 0.1
▪ Radial force and meshing efficiency in accordance with Schlecht [8], where μ zm is the mean
tooth friction number and ϱz is the angle of friction for the average coefficient of friction.
20.5.5 Required safeties
KISSsoft displays an error message to tell you, if the specified required safeties have not been
reached after you completed the calculation. Sizing is always calculated on the basis of the required
safeties for tooth fracture, pitting and wear. If you do not wish to use one or more of these criteria, set
the appropriate required safety to zero. According to ISO 14521, you must ensure the following
safeties:
Root safety 1.1
Pitting safety 1.0
Wear safety 1.1
Deflection safety 1.0
Temperature safety 1.1
III Worms with enveloping worm wheels 471
You can also modify these values if you are familiar with the process.
III Crossed helical gears, precision mechanics worms and crossed helical gear with rack 472
21 Crossed helical gears, precision
mechanics worms and crossed helical
gear with rack
Crossed helical gears are involute cylindrical gears with helical teeth whose shafts have crossed
axes. Usually, the axial crossing angle is Σ = 90°. In contrast to the line contact shown in enveloping
worms, crossed helical gears only contact at one point during generation. As a result, they can only
transmit very small forces, and are primarily used for control purposes.
In precision engineering, a worm wheel is often manufactured in the same way as a helical cylindrical
gear with a cylindrical gear body. This makes it easier to produce and assemble than the "classic"
worm wheel globoid gear. In this situation, the crossed helical gear module is used to calculate the
geometry of a precision mechanics worm wheel in the same way as a helical-toothed cylindrical gear.
In a crossed helical gear where the profile shift coefficient is not zero, the helix angle on Gear 1
(referred to as the "worm" if a small number of teeth is involved)and the helix angle on Gear 2 differ
from each other. Both gears usually have the same hand of gear. In contrast, the total of both helix
angles at the operating pitch circle/spiral is exactly the same as the shaft angle.
The axial crossing angle is usually positive, but can also be negative or positive in some special
cases. However, it must always be smaller than the helix angle on Gear 1. In this situation, gear 2
has the opposite hand of gear to gear 1. In KISSsoft, you must always input values for the helix angle
on Gear 1 and axial crossing angle. The helix angle on Gear 2 is calculated. KISSsoft always uses a
positive value for the helix angle on Gear 1 in its internal calculations. However, the angle on Gear 2
can be either positive (as is usually the case) or negative.
Special cases:
Gear 2 can have internal toothing. In this case, enter a negative number of teeth on Gear 2.
Gear pair with spur gear teeth: Gear 1 cannot be a spur gear. An entry of 0 for the helix angle is not
accepted. In contrast, Gear 2 can have spur gear teeth. In this case, select a negative shaft angle.
For the shaft angle, the following conditions apply:
▪ for external teeth: β1+β2 = Σ (*)
▪ for internal teeth: β1-β2 = Σ (*)
*): Applies if gear 1 and gear 2 have the same hand of gear (either both right or both left). Otherwise,
a negative value for β2 must be entered.
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21.1 Underlying principles of calculation
The method used to calculate crossed helical gears (cylindrical gears with crossed axes) is defined in
Niemann [10]. The current version describes the methods used to calculate and check the geometry
of crossed helical gears for any axial crossing angle. The measures used for checking and
fabrication are determined arithmetically.
Although the method detailed in Niemann [10] is used as an approach for calculating the root and
flank strength and the scuffing safety, the individual equations used are those specified in ISO 6336.
(Niemann uses the equations from an obsolete edition of DIN 3990.)
21.2 Basic data
21.2.1 Normal module
Enter the normal module. However, if you know the pitch, transverse module or diametral pitch
instead of this, click the button to display a dialog window in which you can perform the
conversion. If you want to transfer the diametral pitch instead of the normal module, you can select
Input normal diametral pitch instead of normal module by first selecting Calculation > Settings
> Module specific settings in the General tab.
21.2.2 Pressure angle at normal section
The normal pressure angle at the reference circle is also the reference profile flank angle. For
standard meshings, the pressure angle is αn = 20°. You can use smaller pressure angles for a larger
number of teeth to achieve higher contact ratios. Greater pressure angles increase the strength and
enable a smaller number of teeth to be used without undercut. In this situation, the contact ratio
decreases and the radial forces increase.
21.2.3 Helix angle reference circle gear 1
The center distance, number of teeth, profile shift (x*1, x*2) and shaft angle can be used to calculate
the helix angle of gear 1. It often happens that several helix angles meet the requirements of the
toothing geometry. In this situation, when you click the button, you see an Information window
that lists the possible values. Here, the solution that is closest to the current value is selected
automatically. However, if only one value is suitable for the sizing, it is transferred into the input field
without any messages being displayed. If the sizing function is unable to find any solutions, it
displays a warning message and you must then change either the center distance or the module.
The helix angle value of gear 1 must be entered as a positive value. The hand of gear is set as a
right- or left-hand helix. Gear 2's axial crossing angle and helix angle can be negative.
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21.2.4 Center distance
The center distance is calculated on the basis of the helix angle of gear 1, the axial crossing angle,
the profile shift (x*1, x*2) and the number of teeth.
21.2.5 Facewidth
Because the facewidth must have a minimum value, the input field has a button which you can
use to define the minimum width based on the parameters you have already defined.
21.2.6 Profile shift coefficient
The tool can be adjusted during the manufacturing process. The distance between the production
pitch circle and the tool reference line is called the profile shift. To create a positive profile shift, the
tool is pulled further out of the material, creating a tooth that is thicker at the root and narrower at the
tip. To create a negative profile shift, the tool is pushed further into the material, with the result that
the tooth is narrower and undercutting may occur sooner. In addition to the effect on tooth thickness,
the sliding velocities will also be affected by the profile shift coefficient.
Click the button and KISSsoft will determine whether the profile shift coefficients (see chapter
17.1.8, Profile shift coefficient) are to be taken from measured data or from values given in drawings.
► Note
If one of the two profile shift values appears in gray, this means it will be calculated by KISSsoft. This
is what happens when you select the checkbox for entering the center distance. If you overwrite a
gray field, it will become active and KISSsoft will calculate the value for one of the other gears.
21.2.7 Quality
In this input field, you specify the accuracy grade in accordance with the standard shown in brackets.
To Change the standard used for this calculation, select Calculation > Settings > General > Input
of quality. The accuracy grade according to ISO 1328 (DIN ISO 1328) is very similar to the same
quality in AGMA 2015.
The manufacturing qualities that can be achieved are displayed in the next table.
Manufacturing process Quality according to ISO
Grinding 2 ... 7
Shaving 5 ... 7
Hobbing (5)6 ... 9
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Milling (5)6 ... 9
Shaping (5)6 ... 9
Punching, Sintering 8 ... 12
Table 21.1: Accuracy grades for different manufacturing processes
21.2.8 Geometry details
Click the Details... button in the Geometry area to display the Define geometry details window, in
which you can change the parameters listed below.
Figure 21.1: Geometry details input window
21.2.8.1 Axial crossing angle
The axial crossing angle is usually Σ = 90°, but you can select your own value here.
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21.2.8.2 Internal diameter
The internal diameter is needed to calculate the mass moment of inertia. As defined in ISO or AGMA,
the gear rim thickness does affect the strength. For solid wheels, enter 0. For external wheels with
webs, enter their diameter di. For internal wheels, enter the external diameter of the gear rim.
The internal diameter of the gear rim is required for calculations according to ISO or AGMA. Where
thin gear rings are used, this factor can greatly influence the calculation results. Also see the next
figure.
Figure 21.2: Dimensioning the diameter
21.2.9 Material and lubrication
The materials displayed in the drop-down lists are taken from the materials database. If you cannot
find the material you require in this list, you can either select Own Input from the list or enter the
material in the database (see chapter 9, Database Tool and External Tables) first. Click the
button to display the Material gear 1(2) window, in which you can select a material from the list of
materials available in the database. Select the Own Input option to enter specific material
characteristics. This option corresponds to the Create a new entry window in the database tool.
21.2.10 Load
21.2.10.1 Methods used for strength calculation
As yet, no binding standard has been drawn up for the calculation of crossed helical gears. For this
reason, KISSsoft recommends using ISO 6336 (see chapter 21.2.10.1.3, Strength calculation
according to ISO 6336/Niemann).
You can use one of three different methods to calculate the strength of worms:
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21.2.10.1.1 Strength calculation according to Hirn
The method used to calculate worms as defined by H. Hirn is based on an obsolete edition of
Niemann's machine elements. It calculates the temperature safety, the flank safety, root safety and
deflection safety. Although the material values cannot be compared with the values for worm
calculation as defined in DIN 3996, the safeties are, however, similar.
We do not recommend you to use this obsolete method.
► Note
The calculation method defined in Hirn also selects a material pairing. This material pairing must lie
in the permitted Material and lubrication range. Axial crossing angle Σ = 90° and z1 < 5.
21.2.10.1.2 Strength calculation according to Hoechst
You can use the strength calculation in acc. with Hoechst for worm wheels made from Hostaform ®
(POM), paired with steel worm gears [41]. The permitted load coefficient is c [N/mm 2] See equation
(18.1) ÷ (18.3), is a value that defines the temperature resistance. This method also checks the
worm's permissible contact stress and blocking safety. The decisive value for blocking safety is
maximum load, not continuous load.
(18.1)
(18.2)
(18.3)
where
F2 Circumferential force on the worm wheel
fz Coefficient for number of teeth
b Usable width
mn Normal module
γm Mean lead angle
da1 Tip diameter of worm
III Crossed helical gears, precision mechanics worms and crossed helical gear with rack 478
dm1 Reference diameter of worm
► Note:
Axial crossing angle Σ = 90° and z1 < 5. The calculation method involves a worm made of steel and a
crossed helical gear made of plastic.
21.2.10.1.3 Strength calculation according to ISO 6336/Niemann
You can perform the strength calculation for crossed helical gears with z1 ≥ 5 as defined in Niemann
[10]/ISO 6336. As stated in Niemann, the contact ellipse is calculated using a for the width and b for
the height of the half axes. An effective facewidth of 2a is assumed for flank safety (pitting). The
same value plus twice the module value is used to calculate the strength of the tooth root. This
corresponds to the specifications given in ISO 6336, if the facewidth is greater than the contact width.
Scuffing safety is calculated as defined in Niemann [10]. This method differs from the DIN 3990-4
guideline because of the high sliding velocities of the crossed helical gears. It is more similar to the
method applied to hypoid bevel gears. It supplies a proof of tooth root strength, the flank load
capacity and the scuffing load capacity.
► Note:
If the number of teeth z1 < 5, this calculation supplies tooth root and contact stress safeties that are
too high.
21.2.10.1.4 Strength calculation as defined in VDI 2736
Part 3 of this VDI guideline describes the calculation for a cylindrical worm paired with a
thermoplastic helical gear, i.e. a precision mechanics worm gear unit.
21.2.10.1.5 Static calculation
The static calculation performs a static estimate of the safety against fracture and yield point. The
calculation is performed according to the documented formulae (see chapter 17.2.1.1, Static
calculation).
The calculation in this approach for helical gears returns safeties that tend to be too low, because
gear 2 in a worm gear that is to be mated is more likely to be subjected to shearing.
21.2.10.1.6 Static calculation on shearing
Determining how the worm wheel is subjected to shearing as a helical gear:
τF = Ft2*KA*YE/Aτ
III Crossed helical gears, precision mechanics worms and crossed helical gear with rack 479
Aτ = bmax/5*(4*stda2-stdx2)
dx2 = 2* a-da1
This calculation is performed automatically and is documented in the report under Tooth root load
capacity or Static shearing in tooth root of the gear.
Figure 21.3: Dimensions of the shear cross section.
21.2.10.1.7 Calculating wear on worm gears according to Pech
A calculation for determining the wear on crossed helical gears according to Pech [42] is now
available. This process calculates the plastic deformation, the degree of wear and the overall wear
(in the normal section on the operating pitch diameter) of plastic worm wheels. The following
restrictions apply to this calculation:
▪ Cylindrical worm wheel pair with an axial crossing angle of 90°
▪ Grease lubrication
▪ Calculation without load spectrum
▪ Material of worm: Steel
▪ Material of worm wheel: POM, PEEK, PEEK+30% CF or PA46
▪ Driving gear: Worm
Using KISSsoft, you can also perform calculations for plastic/plastic combinations, but these are
subject to special assumptions and limitations (see below).
The coefficient of friction (COF) taken from the material DAT file has no effect on the calculation (the
III Crossed helical gears, precision mechanics worms and crossed helical gear with rack 480
COF is calculated according to Pech). A (user-defined) COF is used to calculate plastic/plastic
combinations (Select Load > Details).
The entries for the root temperature and flank temperature have no effect on the calculation of
steel/plastic combinations (temperatures are calculated according to Pech). User-defined
temperatures are used for plastic/plastic combinations. The grease temperature for plastic/plastic
combinations is calculated as the mean value of the root temperatures of the two gears.
The flank roughness of the worm wheel has an effect on the calculated coefficient of friction. A
greater level of roughness causes a greater amount of wear.
Click on Module specific settings to input a coefficient for the permitted level of plastic deformation
(Calculation > Settings > Plastic).
If you input your own material into the KISSsoft material database, you must enter additional data in
the material .dat file (for example for PEEK).
-- Type of plastic material
-- Values: 0-not on the list, 1-POM, 2-PEEK, 3-PEEK+30%CF, 4-PA46, 5-PA66,
-- 6-PA6, 7-PA66+GF, 8-PPS, 9-PPS+GF, 10-PA12, 11-PBT, 12-PET
:TABLE FUNCTION MaterialType
INPUT X None TREAT LINEAR
DATA
0
2
END
The table below shows the parameter limits for calculating wear according to Pech.
Number of teeth: Worm wheel 16 = Z2 = 80
Center distance 10 mm = a = 80 mm
Axial module: Worm wheel 0.5 mm = mx = 3 mm
Gear ratio 10 = u = 80
Pressure angle 10° = an = 22°
Profile shift coefficient: Worm wheel -0.2 = x2 = 1.5
Table 21.2: Geometry limit values for calculating wear according to Pech
The progression of the tooth trace deviation over time on the loaded and unloaded flank, according to
Pech, can be seen in the next figure.
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Figure 21.4: Figure: Development of tooth trace deviation on the loaded flank (decrease) and the unloaded flank
(increase) according to Pech.
21.2.10.2 Service life
The system displays the required service life in the input field.
To enter it directly, and perform sizing, click the button. This process uses the minimum safety
value for the tooth root and flank strength to calculate the rating life (in hours) for every gear and for
every load you specify. The rating life is calculated according to ISO 6336-6:2006 using the
Palmgren-Miner Rule. In the range of endurance limit, you can also select a modified form of the S-N
curve (Woehler line) instead of ISO 6336 or DIN 3990. The program displays the system rating life
and the minimum rating life of all the gears used in the configuration. You can also click the
button to size the service life with or without defining a load spectrum (see chapter 17.2.8, Define
load spectrum). For more detailed information about load spectra, see (see chapter 17.2.8, Define
load spectrum).
► Note
The ISO 6336/Niemann method is primarily used to support the service life calculation.
21.2.10.3 Application factor
The application factor compensates for any uncertainties in loads and impacts, whereby KA≥1.0. The
next table 5ba0bcd9e43 illustrates the values that can be used for this factor. You will find more
detailed comments in ISO 6336.
Operational behavior of the driven machine
III Crossed helical gears, precision mechanics worms and crossed helical gear with rack 482
Operational behavior of uniform moderate average heavy
the driving machine shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
Table 21.3: Assignment of operational behavior to application factor
21.2.10.4 Power, torque and speed
Click the button next to the power input field (for torque) to calculate the power (torque)
appropriate to maintain a predefined minimum level of safety (see chapter 17.20.6, Required
safeties). Click the button next to the power input field to apply a load spectra for power, torque
and speed in the Define load spectrum (see chapter 17.2.8, Define load spectrum)window.
21.2.10.5 Strength details
Click on the Details ... button to display the Define details of strength window which is divided into
System data, Pair data and Gear data.
21.2.10.5.1 Profile modification
You can modify the theoretical involute in high load capacity gears by grinding the toothing. You will
find suggestions for sensible modifications (for cylindrical gears) in KISSsoft module Z15 (see
chapter 17.7, Modifications). The type of profile modification has an effect on how the safety against
scuffing is calculated. The load sharing factor XΓ is calculated differently depending on the profile
modification. The main difference is whether the profile has been modified or not. However, the
differences between the versions for high load capacity gears and for smooth meshing are
relatively small. The strength calculation standard presumes that the tip relief C a is properly sized,
but does not provide any concrete guidelines. The load sharing factor XΓ is calculated as follows,
depending on the type of profile modification according to DIN 3990:
III Crossed helical gears, precision mechanics worms and crossed helical gear with rack 483
Figure 21.5: Force distribution factor XΓ for different profile modifications
21.2.10.5.2 Limited life coefficients as defined in ISO 6336
Set the limited life coefficient ZNTto reduce the permitted material stress in accordance with ISO
6336- 2:2006:
(12.14)
(12.15)
As stated in ISO 6336, this value is important for cylindrical gear calculations and is the reason for
the lower safeties for the range of endurance limit, compared with DIN 3990.
1. normal (reduction to 0.85 for 1010 cycles): The permitted material stress in the range of
endurance limit (root and flank) is reduced again. The limited life coefficients Y NTand ZNTare set
to 0.85 for ≥1010 load cycles.
2. are increased if the quality is better (reduced to 0.92): Y NTand ZNTare set to 0.92 for ≥1010 load
cycles (in accordance with ISO 9085).
III Crossed helical gears, precision mechanics worms and crossed helical gear with rack 484
3. with optimum quality and experience (always 1.0): This removes the reduction and therefore
corresponds to DIN 3990. However, this assumes the optimum treatment and monitoring of the
materials.
21.2.10.5.3 Structural factor XwrelT or structural factor Xw (scuffing)
The structural factor takes into account differences in materials and heat treatment at scuffing
temperature. The relative structural factor XwrelT(in DIN 3990 and in ISO TR 13989-2) or structural
factor Xw (in ISO TR 13989-1) is used, depending on which standard is used. However, XwrelT =Xw/XwT
and XwT= 1. This results in XwrelT = Xw. The two factors are identical.
However, the standards do not provide any details about how to proceed when different types of
material have been combined in pairs. You must input this factor yourself, because it is not set
automatically by KISSsoft.
Through hardened steels 1.00
Phosphated steels 1.25
Coppered steels 1.50
Nitrided steels 1.50
Case-hardened steels 1.15 (with low austenite content)
Case-hardened steels 1.00 (with normal austenite content)
Case-hardened steels 0.85 (with high austenite content)
Stainless steels 0.45
Table 21.4: Structural factor as defined in DIN 3990, Part 4
The standard does not provide any details about how to this factor is to be applied when the pinion
and gear are made of different types of material. In this case it is safer to take the lower value for the
pair.
21.2.10.5.4 Number of load cycles
KISSsoft calculates the number of load cycles from the speed and the required service life. If you
want to influence the value, you can define it in the Number of load cycles for gear n window.
Click the button to access this. Here, you can select one of five different calculations for
calculating the number of load cycles.
1. Automatically The number of load cycles is calculated automatically from the rating life, speed,
and number of idler gears.
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2. Number of load cycles Here, you enter the number of load cycles in millions. You must select
this option for all the gears involved in the calculation, to ensure this value is taken into account.
3. Load cycles per revolution Here you enter the number of load cycles per revolution. For a
planetary gear unit with three planets, enter 3 for the sun and 1 for the planets in the input field.
Note:
If the Automatically selection button in the calculation module is selected, KISSsoft will
determine the number of load cycles, taking into account the number of planets, in the
Planetary stage calculation module.
4. Load cycles per minute Here you enter the number of load cycles per minute. This may be
useful, for example, for racks or gear stages where the direction of rotation changes frequently,
but for which no permanent speed has been defined.
5. Effective length of rack The rack length entered here is used to calculate the number of load
cycles for the rack. The rack length must be greater than the gear's perimeter. Otherwise, the
calculation must take into account the fact that not every gear tooth will mesh with another. You
must enter a value here for rack and pinion pairs. Otherwise the values NL(rack) = NL(pinion)/10
are set.
► Note
This calculation method is used for transmissions that only travel over one oscillation angle.
Assume a scenario in which a reduction is present,
𝑧2
𝑖=
𝑧1
and an oscillation angle w in [°] from gear 2, where gear 2 constantly performs forwards and
backwards movements with the angle value w2. The effective endurance is given as the service life.
The two coefficients fNL1 and fNL2, which modify the absolute number of load cycles, NL, are now
calculated. To do this:
▪ a) Set the alternating bending factor of the pinion and gear to 0.7, or calculate it as defined in
ISO 6336-3:2006. In this case, one complete forwards/backwards movement is counted as one
load cycle.
▪ b) Coefficients fNL1 and FNL2 for pinion and gear are defined as follows:
𝑊1,2
𝑅𝑂𝑈𝑁𝐷𝑈𝑃( )
𝑓𝑁𝐿1,2 = 360
𝑊1,2
2∗
360
III Crossed helical gears, precision mechanics worms and crossed helical gear with rack 486
- w2 = oscillation angle gear 2
- w1 = W2*i
- ROUNDUP = round up to a whole number
The value in the counter displays the actual number of loads that occur during a complete cycle
(forward and backward oscillation) on the flanks (not teeth) that are most frequently subjected to
load. By rounding up this number to the next whole number, every rotation recorded is counted
as a load.
Then, to determine the required fNL1,2 factor, the actual number of loads that occur per flank is
divided by the number of loads that would occur per cycle, if rotation were to continue without a
backward rotation at the angle of rotation (1 load for each 360°).
Example calculation for fNL1.2:
Gear 1 rotates through a half cycle at 540° while gear 2 oscillates by 90° (i = 6).
In a complete cycle, the oscillation angle moves forwards once an backwards once.
The actual number of load cycles that occur in a complete cycle on the flanks that are most
frequently subjected to load (only one side of the tooth is taken into consideration) is then:
For Gear 1:
540
𝑅𝑂𝑈𝑁𝐷𝑈𝑃( )=2
360
For Gear 2:
90
𝑅𝑂𝑈𝑁𝐷𝑈𝑃( )=1
360
Without adjusting the coefficients, the number of counted load cycles in a complete cycle would then be:
For Gear 1:
540
2∗( )=3
360
For Gear 2:
90
2∗( ) = 0.5
360
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The coefficients are therefore fNL1 and fNL2:
2
𝑓𝑁𝐿1 = = 0.667
3
1
𝑓𝑁𝐿2 = =2
0.5
▪ c) Then, input coefficients fNL1 and fNL2 in the Load cycles per revolution input field.
The strength calculation can now be performed for the correct number of load cycles, on the basis of
the data entered in steps a through d.
21.2.10.5.5 Optimal tip relief
To calculate safety against micropitting as specified in Method B in ISO/TS 6336-22, you must
specify whether or not the profile modification is to be assumed to be optimal. The same applies to
calculating the safety against scuffing. The software checks whether the effective tip relief (Ca)
roughly corresponds to the optimum tip relief (Ceff). If this check reveals large differences, i.e. Ca <
0.333*Ceff or Ca > 2.5*Ceff, a warning is displayed. In this case, the value you input is ignored and is
documented accordingly in the report.
21.2.10.5.6 Hardening depth, known by its abbreviation "EHT"
You can input the intended hardening depth (for hardness HV400, for nitrided steels, or HV550 for all
other steels). You can also input the hardness HV300. This value is then used to display the
hardening curve as a graphic. The input applies to the depth measured during final machining (after
grinding).
When you input this data, the safety of the hardened surface layer is calculated automatically
according to DNV 41.2 [9]. A minimum value of t400 (nitrided steel) or t550 (all other steels) is used
here. If only the value for HV300 is known, this value is then used. However, the calculation should
then only be seen as an indication. The calculation is performed as described in the "Subsurface
fatigue" section in [9]. The values required to define the CHD hardening depth coefficient YC, as
specified in DNV 41.2, are also needed. The calculation does not use the same approach as the
calculation for the proposal for the recommended hardening depth, but still returns similar results. To
obtain a proposal for a sensible hardening depth, we recommend you call the relevant calculation by
selecting Report > Proposals for hardening depth. A maximum value for the hardening depth is
only used to check the hardening depth at the tooth tip. It is mainly used for documentation purposes.
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21.2.10.5.7 Load spectra with negative elements
Load spectra with negative load bins (T < 0 and/or n < 0) can also be calculated as follows (this is
only applied to bins whose alternating bending factor is YM=1.0).
IMPORTANT:
A load bin is considered to be negative if the non-working flank is placed under load.
Coefficient for torque Coefficient Flank under load Actual load bin
for speed
+ + Working flank (*) evaluated as positive
+ - Working flank (*) evaluated as positive
- + Non-working flank evaluated as negative
- - Non-working flank evaluated as negative
(*) Working flank as entered in the Strength tab
Table 21.5: Evaluation of a load bin, depending on the prefix operator
You can select the following under "Details" in the "Strength" section, in the "Rating" tab:
▪ To calculate pitting safety
▪ Evaluate all negative load bins as positive (as up to now)
▪ Consider only positive load bins
▪ Consider only negative load bins
▪ Check both cases and document the less favorable case
▪ To calculate the tooth root safety
▪ Evaluate all negative load bins as positive (as up to now)
▪ For negative load bins, increase root stress by 1/0.7
▪ Increase bending stress for positive load bins by 1/0.7
▪ Check both cases and document the more realistic case
21.3 Settings
Click on Calculation >Settings or select the icon to display the window for the Module
specific settings sub-menu. From here, you can access the tabs listed below to input other
calculation parameters (the following parameters are not described here: (see chapter 17.20,
Settings)).
III Crossed helical gears, precision mechanics worms and crossed helical gear with rack 489
21.4 Notes
21.4.1 Checking the contact pattern
The collision check shown in the 2D graphic (see chapter 25.2.4, Meshing) can only be used to a
limited extent for crossed helical gears, because it only works for a shaft angle of 90° and does not
supply informative enough results. Some of the flank line modifications are not taken into account,
and meshing is only displayed in the axial section, middle for Gear 1 and in the transverse section for
Gear 2.
A better method for checking meshing is to use a 3D model. A 3D model includes all the
modifications and can be displayed for any axial crossing angle. You can use the "skin model" 3D
model type to simulate a contact situation and then check it exactly using hobbing kinematics. In this
case, click the appropriate function button to gently engage one gear with the other until the contact
between the gear surfaces forms a contact pattern. Then, run the hobbing kinematics. To ensure the
gears do not engage too fully, we recommend you set the number of rotation steps to between 100
and 500 or higher (in Properties).
Figure 21.6: Contact pattern of a worm toothing
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21.5 Crossed helical gear with rack
Click the button next to the field in which you enter the number of teeth to select the crossed
helical gear with rack configuration. Click the button next to the field in which you enter the center
distance to specify the height of the rack.
The number of load cycles on each tooth in the rack can either be input directly or calculated from
the service life, pinion speed and rack length. Otherwise, the operation is identical to that used for a
gear pair.
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22 Beveloid Gears
Beveloid gears, also known as conical gears, are generated by a rack-like tool which is tilted by a
predefined angle (see K. Roth, Zahnradtechnik – Evolventen-Sonderverzahnung [3])
Beveloid gears are primarily used in two particular areas: to generate a shaft angle between two
meshing gears. Alternatively, two beveloid gears with opposing cone angles can be used to generate
backlash-free toothing.
Beveloid gears with a shaft angle can be used to achieve a compact type of gear unit.
Unfortunately, no standards or guidelines have yet been drawn up for the calculation of the complex
geometry, or for strength.
For this reason, the geometry calculation method used in KISSsoft is based on standard technical
literature and publications. The main data used is taken from the publications mentioned in the next
section.
For simplicity's sake, the strength in the mid section is calculated as if for a cylindrical gear pair.
22.1 Underlying principles of calculation
The basic calculation of the geometry and tooth form for a single beveloid gear is based on K.Roth
[3], and on well known standards for cylindrical gears (e.g. DIN 3960, DIN 867, etc.).
Therefore, a beveloid gear is generated using the same process as a cylindrical gear, except that the
profile shift changes along the facewidth. And this therefore changes all the parameters which are
affected by the profile shift.
For helical toothed beveloids, the cutter is not only tilted by a cone angle θ, but also by an additional
helix angle β. In the transverse section, this creates a trapezoidal reference profile with different
pressure angles α on the left and the right side. This has a significant effect on the tooth form,
because it changes the base circles.
The changes to the profile shift across the facewidth mean that beveloid gears often run the risk of
undercut at the root or having teeth with a pointed tip. The profile shift at the toe and heel is
calculated by
The undercut limit and minimum topland are only output in the error message if the values are
exceeded by the data that has just been entered. As the two sizes on the left and right may be
different (in the case of helical gear teeth), the system displays the more unfavorable value in each
case.
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The beveloid pair's meshing conditions are calculated on the basis of the publications by S. J. Tsai:
see [43] and [44]. In this case it is important to note that the parameters are sub-divided into
manufacturing and working parameters ("Manufacturing data and working data" section).
22.2 Basic data
22.2.1 Normal module
You can enter the normal module here.
However, if you know the "Pitch", "Transverse Module" or "Diametral Pitch" instead of this, click on
the conversion button to display a dialog window in which you can perform the conversion. If you
want to transfer the diametral pitch instead of the normal module, you can select Input normal
diametral pitch instead of normal module by selecting Calculation > Settings > General.
22.2.2 Normal pressure angle
This entry relates to the reference profile's flank angle. The normal pressure angle on the beveloid
gear's reference circle is dependent on the cone angle and helix angle. [3]
22.2.3 Helix angle
Here you can enter the helix angle, or else select a spur gear toothing. The helix angle entry only
applies to gear 1. Gear 2 may have a different helix angle value from gear 1, and is calculated. For
gears with total profile shift 0, the following equation applies for determining the second helix angle
from the entered parameters:
22.2.4 Shaft angle
You can specify the shaft angle between the two axes of rotation here.
The shaft angle between any two straight pitches can be determined from the scalar product of the
direction vectors of the two straight pitches. This corresponds to the angle between the two straight
pitches in the plan view along the distance vector between the two straight pitches.
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22.2.5 Number of teeth
The number of teeth defines the transmission ratio of the gears. Only even numbered, positive
values are permitted.
22.2.6 Width
Facewidth of the gears. Please note that, when the width and cone angle are very large, the profile
shifts between the toe and heel may be very different. For this reason, you cannot input just any
value for the width, because this might, for example, create a pointed tooth.
At present, you cannot specify an axial offset. This means the gear pair contact is always in the
middle of the gear.
22.2.7 Cone angle
The specified cone angle corresponds to the manufacturing parameter used to set the misalignment
of the milling cutter to the gear. Both positive and negative cone angles are permitted, however, the
total cone angle must be at least 0.
22.2.8 Profile shift coefficient (center)
The profile shift coefficient is defined in the same way as for a standard cylindrical gear, but the value
relates to the value at the middle of the beveloid gear. When this calculation is performed, the
Results window displays the size of the profile shifts at the toe and heel of the gear.
22.2.9 Quality
The quality achieved when generating the beveloid gear.
22.2.10 Material and lubrication
The entry is the same as the normal entry, as for cylindrical gears.
22.3 Reference profile
In the "Reference profile" tab, you can either input the reference profile for the manufacturing process
in the same way as for a cylindrical gear calculation, or define the tools directly.
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In this case, you must modify the height in the reference profile as follows to calculate the tooth form
in transverse section (see K. Roth [3], section 5.2.6):
Here, the subscript C represents the heights in the transverse section of the beveloid gear
(calculated values) and P represents the heights of the reference profile (input values). You can
check these values in the main report by selecting "Summary / Reference profile / Gears".
22.4 Modifications
The selection options for modifications in the beveloid gear module are limited.
In general, the contact pattern for beveloid gears with a shaft angle that is not 0 improves if negative
crowning is used. To do this, you can input the "Crowning" modification and define a negative value.
22.5 Factors
The face load factor Khβ cannot be calculated automatically for beveloid gears, and must therefore be
set by the user. A value of 1.5 is used by default.
22.6 Dimensioning
As far as we know, no standards or research projects have yet been completed which involve
calculating the load on beveloid gear pairs. For this reason, the calculation of strength is performed
using replacement cylindrical gear toothing in the mid section.
In this case, note that Khβ, in particular, can differ a great deal from the values in the common gear
standards. For this reason, the factor must be entered manually.
Minor differences may occur in the calculated safeties produced during cylindrical gear calculation
and beveloid gear calculation, which are caused by a slight difference in the way the contact ratio is
calculated.
22.7 Manufacturing Data and Working Data
As we are performing the calculation of the beveloid pair according to J. Tsai [43], it is important to
know the difference between "manufacturing data" and "working data".
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Manufacturing data is the data that is decisive for manufacturing. This category includes the values
you input in the 'Basic data' tab. In contrast to this is the working data, which relates to the generation
geometry of the beveloid gears that are in use. An example is the cone angle θ of the angle at which
the tool is tilted during manufacturing. In contrast, working cone angle θw is the angle of the pitch
cone of the beveloid gears in the meshing.
The working data is required to calculate a correct pairing, at which the contact point of the gears is
in the middle of both beveloid gears. For example, if all the other parameters result in the helix angle
value βw from gear 2 at the operating point, this is then converted into a helix angle β for the
manufacturing process.
The working data is also needed to position the two gears relative to each other. To position a gear
pair in a 3D CAD environment, gear 2 is positioned relative to gear 1 as follows:
1. displacement along the Y-axis at rw1
2. rotation around the X-axis with θw1
3. rotation around the negative y-axis with βw1+ βw2
4. rotation around the X-axis with θw2
5. displacement along the Y-axis at rw2
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23 Non-Circular Gears
You can use KISSsoft's non-circular gear module to calculate gears with non-circular gear bodies.
23.1 Input data
Input the geometry, generation and tolerance values in the Basic data tab.
Then, enter the details for generating non-circular intermeshing in the Reference profile tab.
23.1.1 Geometry
Figure 23.1: Basic data tab: entries for a non-circular gear pair
The module is defined from the "Results window" (total length of operating pitch line/[number of
teeth* π]=module).
Figure 23.2: Results window
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To save time in the first phase of the sizing process, we recommend you do not enter the total
number of teeth z. We suggest you perform the calculation with a lower number of teeth (e.g. 2). In
this case, although all the operating pitch lines are calculated completely, only the specified number
of teeth (2) are calculated and displayed.
Initially, start the calculation with a pressure angle in the normal section αn of 20°. Later on you can
change this angle instead of the profile shift or to optimize the tooth form.
23.1.1.1 Generation
The start and end angles φa and φeare important values because they determine the operating pitch
line of gear 1, i.e. the area that will be generated In closed curves the angle φa is 0° and φe is 360°.
The operating pitch lines or the ratio progression are then defined in files. The files must be in either
"dat" or "dxf" format. These files can be stored in any directory. It is important to register these files
correctly, using the button.
Operating pitch lines are also stored in the .Z40 file. As a consequence, when you load a new
calculation, you do not need to access the .dat file. In this case you see a message to tell you the file
cannot be found, and existing data will be used instead.
Figure 23.3: Message
► Note
The progression (ratio or operating pitch line) must be defined from at least the starting angle to the
end angle. To achieve uniform meshing, the curve must have approximately 30° forward motion and
follow-up movement. If the curve has no forward motion and/or follow-up movement, the software
extends it automatically.
23.1.1.1.1 Input format for data in imported files
You can predefine one or two operating pitch lines or the ratio progression. The imported files must
have ".dat" as their file extension.
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A maximum of 7,800 lines can be processed during non-circular gear analysis. Lines that start with #
are comments and are ignored. To predefine the ratio progression, input the angle on gear 1 and the
ratio.
Figure 23.4: Example of ratio progression
To predefine the operating pitch line progression, input the radius and the angle.
Figure 23.5: Example of an operating pitch line
23.1.2 Tolerances
We recommend you enter sufficiently large tooth thickness allowances A sn (e.g. -0.10/-0.12 for
module 2).
23.1.3 Reference profile
You must specify a topping pinion type cutter. The same pinion type cutter is usually defined for both
gear 1 and gear 2.
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Figure 23.6: Reference profile tab: entries for a non-circular gear pair
Problems may arise unless the profile shift coefficient of the pinion type cutter is set to 0. You must
then carefully check exactly how the gears are generated.
23.2 Notes on how to operate KISSsoft
23.2.1 Angle error
When you use an operating pitch line or gear reduction progression to input a closed curve (Gear 1),
it must start at 0° and finish at 360°. For this reason, the rotation of gear 2 must also be 360° (or a
multiple of this). If not, this will result in an error.
Figure 23.7: Minor error for Gear 2. φe is 183.256 instead of 180°
However, this error has no effect because the predefined gear backlash is large enough.
23.2.2 Checking the meshing
A useful way of checking the meshing is to change the number of rotation steps (per 360°) to rotate
the gear in larger or smaller steps. You change the step sizes, as usual, in the Graphics window.
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Figure 23.8: Changing the rotation steps
When you generate gears with allowances, we recommend you click the button to bring the
gears into flank contact with each other.
► Note
If, when you click the "Rotate independently to the right" button, one gear rotates too far against
the other (or not far enough), you must adjust the number of "rotation steps" accordingly!
23.2.3 Improving the tooth form
You can change the tooth form of circular gears quite significantly by changing the profile shift. In the
current version of the program for non-circular gears, we recommend you set the profile shift
coefficient of the pinion type cutter x*0=0. Despite this, you can still modify the tooth form by changing
the pressure angle αn .
23.2.4 Accuracy of the tooth form
Select "Calculations" > "Settings" to predefine the accuracy (and therefore also the size of the file)
for an IGES or DXF export.
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Figure 23.9: Module specific settings
This entry only influences IGES or DXF files.
In the software, the tooth form (each flank) is calculated with 100 points. You will find these results in
the TMP files (and in the report). If you want to modify the number of internally calculated points,
simply change the appropriate entry in the .Z40 file:
Go to a saved .Z40 file and search for the line that contains
ZSnc.AnzPunkteProFlanke=100;
and, for example, replace 100 with 40. If you do so, only 40 points per flank will be calculated.
23.2.5 Exporting individual teeth
Go to a saved .Z40 file and search for the line that contains
ZRnc[0].AusgabeKontur=0, for Gear 1 or
ZRnc[1].AusgabeKontur=0, for Gear 2.
There, change the variable to the required value, e.g. ZRnc[0].AusgabeKontur=3.
The LEFT flank of the x-th tooth space (therefore the 3rd gap in Gear 1, in the example) is always
exported.
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Figure 23.10: Temporary file for exporting teeth (ZRnc[0].AusgabeKontur=3, for Gear 1)
23.2.6 Report
If you have select Detailed in Report settings, this report will also contain a lot of information. If you
want a shorter version, set "Extent of data" to 5 (standard).
Figure 23.11: Report settings with a changed data scope for output to a report
23.2.7 Temporary files
When a calculation is performed, KISSsoft automatically generates temporary files. The directory in
which these files are generated by KISSsoft must be specified in KISS.ini in the "PATH" section. You
will find KISS.ini in the KISSsoft main directory. Before changing the default setting, you must ensure
that you have read and write permissions for the changed directory. You will find more detailed
information in Chapter 2 of the manual, "Setting Up KISSsoft".
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ZF-H1_Rad 1 (Schritt 2).TMP: Unimportant information: contains details about generating
the noncircular gear, flank by flank.
ZF-H1_Rad 2 (Schritt 2).TMP:
ZF-UNRUND-1.TMP: Contains interesting information about operating pitch line
1: defining the contact points on operating pitch line 1,
calculating operating pitch line 2 from operating pitch line 1,
operating pitch line lengths, documentation about the
intermeshing (individual points) of non-circular gear 1 with
X, Y, normal, diameter and angle
ZF-UNRUND-2.TMP: Contains interesting information: documentation about the
intermeshing (individual points) of non-circular gear 2 with
X, Y, normal, diameter and angle
ZF-UNRUND-DAT-1.TMP: Possible further use of the gear teeth (individual points) X,Y
coordinates
ZF-UNRUND-DAT-2.TMP:
ZF-UNRUND-OPLINE-1.TMP: Possible further uses of the operating pitch line (individual
points) x- and y-coordinates
ZF-UNRUND-OPLINE-2.TMP:
Z-WalzKurve-1.TMP: Possible further uses of the operating pitch line r (individual
points), coordinates (*). Has exactly the same format as
the .dat file (see "Import format" section).
Z-WalzKurve-2.TMP:
Z-OpPitchPoints-1.TMP: Possible further use of meshing points on each tooth in r,
coordinates
Z-OpPitchPoints-2.TMP:
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24 Report Menu
24.1 Drawing data
Select Drawing data to display the toothing data you want to add to a drawing. Use the
Z10GEAR1?.RPT file (for Gear 1), and the Z10GEAR2?.RPT file (for Gear 2), etc. (? = d/e/f/i/s for
the required language) to modify the template to your own requirements.
All the angle data for the user-specific Z10GEAR1?.rpt ... Z10GEAR4?.rpt reports is given in
degrees-minutes-seconds, and displayed in brackets after the decimal point.
For example the number 20.3529° is displayed as:
20° 21' 10" (20.3529)
24.2 Manufacturing tolerances
Select the Manufacturing tolerances menu option to generate a report with all the manufacturing
tolerances specified in ISO 1328 (DIN ISO 1328), DIN 3961:1978, AGMA 2000, AGMA 2015 and BS
436 standards.
24.3 Summary
Use the summary function to compare the current toothing with the results of fine sizing.
24.4 Service life
This report shows the most important data that is used to calculate service life either with or without a
load spectrum (see chapter 17.2.8, Define load spectrum). You can also call the service life
calculation by clicking the Sizing button next to the Service life input field. This then displays the
service life that should be achieved if required safeties are used.
24.5 Sizing of torque
The sizing of torque displays the most important data required to calculate the transmittable torque
(or the maximum transmittable power) with or without load spectrum. You can also call the sizing of
III Report Menu 505
torque function directly by clicking the checkbox next to the Torque or Power input fields. You then
see a value for the torque that should be achieved if required safeties are used.
24.6 Proposal for the hardening depth EHT
A wide range of different proposals for the hardening depth EHT as specified in the standards have
been documented. The data specified in the ISO, AGMA and Niemann standards are often very
different, because of the very rough approximations involved. The most accurate calculation, which
uses the shearing stress criterion from the Hertzian law to define the required hardening depth, is
documented in the upper part of the report. You can also specify the safety factor which is to be used
for the calculation (see chapter 17.20.5.12, Safety factor for the calculation of the shear stress at
hardening depth). For the graphical display (see chapter 25.4.4, Surface layer shear stress).
III Graphics Menu 506
25 Graphics Menu
Figure 25.1: Graphics menu in the KISSsoft interface menu bar
In the Graphics menu, you can select various menu options to help you display gear teeth and
functional processes.
► Note
Right-click to display a context menu that contains other operating functions.
The table (see Table 25.1) shows which of the options in the Graphics menu are supported by
particular gear calculation modules, and where you can find the relevant documentation in this
section.
Menu option Options Section
AGMA 925 Temperature in
contact
Lubricant film
thickness
25.1.1
Hertzian
Pressure
Specific thickness
of film
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Evaluation Specific sliding 25.5.11
Flash 25.4.3
temperature
Contact 25.4.2
temperature
Surface layer 25.4.4
shear stress
Theoretical 25.4.6
contact stiffness
S-N curves 25.4.7
(Woehler lines)
Safety factor 25.4.8
curves
Stress curve 25.4.16
Path of contact 25.4.15
(pinion/face gear)
Safety scuffing 25.4.17
Sliding velocity 25.4.17
Oil viscosity 25.4.13
Gaping 25.4.13
Face load 25.4.13
distribution
Tooth flank 25.4.13
fracture
Contact Axis alignment 25.5.1
analysis
Specific sliding 25.5.11
Transmission 25.4.16
error
Transmission 25.5.3
error acceleration
FFT of the 25.5.4
transmission
error
Normal force 25.5.5
curve (line load)
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Normal force 25.5.5
distribution (line
load)
Torque 25.5.6
progression
Stiffness curve 25.5.7
FFT of contact 25.5.8
stiffness
Bearing force 25.5.9
curve
Bearing force 25.5.9
curve in %
Direction of the 25.5.9
bearing forces
Kinematics 25.5.10
Specific sliding 25.5.11
per gear
Specific power 25.5.12
loss
Heat 25.5.13
development
Heat 25.5.13
development
along the tooth
flank
Flash 25.5.15
temperature
Lubricant film 25.5.16
Specific thickness 25.5.16
of film
Safety against 25.5.16
micropitting
Stress curve 25.5.14
Bending stress in 25.4.16
root area
Stress distribution 25.5.14
on tooth
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Wear along the 25.5.17
tooth flank
2D Geometry Meshing 25.2.4
Tooth form 25.2.1
Tool 25.2.2
Manufacture 25.2.3
Profile diagram 25.2.5
Tooth trace 25.2.5
diagram
Flank curvature 25.2.5
radii
Angle of flank 25.2.5
normal
Drawing 25.2.8
Assembly 25.2.8
3D Geometry Tooth system 25.3.1
Tooth form 25.3.2
Graphics list 25.9
Manufacturing 25.2.8
drawing
Table 25.1: Graphics menu in the KISSsoft interface menu bar.
- Single gear, - Cylindrical gear pair, - Pinion with rack, - Planetary gear stage, - Three
gears, - Four gears, - Bevel and hypoid gears, - Face gears, - Worms with double
enveloping worm wheels, - Crossed helical gears and precision mechanics worms, - Splines
(Geometry and Strength)
25.1 AGMA 925
25.1.1 Lubricant film thickness and specific oil film thickness
The lubricant film thickness he according to AGMA 925 is shown over the meshing cycle. Another
figure shows the specific film thickness λ, which is a critical value for evaluating the risk of
micropitting. Expressed in simple terms, λ is the ratio of the lubricant film thickness to the surface
roughness.
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25.2 Geometry 2D
Figure 25.2: Geometry graphics window
You can select a number of different output options from the drop-down list in the Tool bar in the
Geometry graphics window (see Figure 25.2):
25.2.1 Gear tooth forms
Displaying a gear tooth form.
► Note:
Click the Property button above the graphic to specify the number of teeth that are to be displayed.
You can display the gear in transverse section, normal section or axial section. Selecting the "Half
tooth for export" option is also very useful if you want to export the tooth form and then reimport it
into KISSsoft later on.
III Graphics Menu 511
25.2.2 Gear tool
This displays the tool associated with the gear, if one is present.
25.2.3 Manufacturing a gear
Display the pairing: gear with cutter. Here, the gear is shown in blue and the cutter in green.
25.2.4 Meshing
Displays the meshing of two gears.
► Note about face gears:
In KISSsoft, the face gear is calculated by simulating the manufacturing process in different sections.
You can display different sections at the same time. To do this, open the Property browser (PB) in
the Graphic window, and set the property in the section you require to True (see Figure 25.3).
Figure 25.3: Meshing graphics window with Property Browser
The difference between the theory and the effective tooth form means that the tooth has an undercut!
You can see this more clearly in the 2D view.
Collision check:
You can select the collision display option when generating two gears (in the graphical display). In
the graphic, this shows (with squares) the points at which the gears touch or where collisions may
occur.
shown in brown: Contact (between 0.005 * module distance and 0.001 * module penetration)
III Graphics Menu 512
shown in red: Collision (greater than 0.001 * module penetration)
The system identifies and marks collisions in all the meshing teeth. This option is particularly useful
for analyzing the generation of non-involute tooth forms or measured tooth forms (using a 3D
measurement machine) with a theoretical single flank generation check.
This function is also available for cylindrical gears and worm gears (but with restrictions for worm
gears (see chapter 21.4.1, Checking the contact pattern)).
► Note:
If the Make flank contact automatically option is selected, you can only check the tooth meshing
on contact. In this case, collisions are no longer displayed.
25.2.5 Profile and tooth trace diagram
These diagrams are generated by placing two lines diagonally over the tolerance band, as described
in ANSI/AGMA: 2000-A88 (figures 1 and 2).
Figure 25.5: Tooth trace diagram
Figure 25.4: Profile diagram
In the figures shown above, V Τ is the profile tolerance and VψΤ is the tooth alignment tolerance
which correspond to the profile total deviation (Fα) and the tooth helix deviation (Fβ) as detailed in
ISO 1328-1.
Although every company has its own method of creating profile and tooth trace diagrams, the AGMA
standard is recognized as the default standard in the industry. ISO TR 10064-1 (and ISO FDIS
21771) also include a general description of profile and tooth trace diagrams, however without any
explanations about the construction method.
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In KISSsoft the profile and tooth trace modifications are defined in the Modifications tab. The
relevant diagrams are then generated using this data.
Figure 25.6: Modifications tab with modifications
Figure 25.7: Profile diagram for gear 1 according to the predefined modifications
The horizontal axis of the profile diagram shows the profile deviation values and the vertical axis
shows the coordinates along the profile. You can select different values for the left-hand vertical axis
(roll angle or path of contact length) (Calculation > Settings > General). The values for the right-
hand flank are always given as the diameter. You can also specify the tolerance type by clicking on
Calculation > Settings > General. If you select the tolerance band type as specified in AGMA
20000-A88, the diagrams are generated according to the method mentioned above. If you set the
tolerance band type to constant, the tolerance remains constant along the length or the width of the
tooth flank. Click on the "Display profile in the middle of the tolerance band" checkbox to specify
whether the central profile (see below) should usually be displayed.
Description of the specific diameter of the right-hand vertical flank:
▪ dSa: end diameter of the modifications (starting diameter of the modifications at the tip)
▪ dSf: starting diameter of the modifications (starting diameter of the modifications at the root)
▪ dCa: active tip diameter (starting diameter of the modification)
▪ dCf: tip form circle diameter (starting diameter of the modification)
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▪ dCm: center point of the functional profile measured along the path of contact
► Note:
The profile diagram is in the middle of the facewidth. The Twist profile modification is not possible.
Show curves in the diagram:
▪ green curve: Modifications of "1. Tip relief, linear" and "2. Tip relief, arc-like"
▪ blue curve: Reference profile (current function profile used for checking and generated from the
total of the modified curves)
▪ red line: Tolerance curve generated by subtracting the total profile deviation from the reference
profile. The profile deviation values are listed in the main report.
▪ green line (middle): Central profile, which can be entered as the target value for processing
because it lies in the middle between the reference profile and the tolerance curve.
▪ gray lines: Tolerance range, which shows the range (as a crosshatched area) in which the
actual manufacturing profile can lie.
The manufacturing profile (with tolerance) should lie between the tolerance curve and the reference
profile.
You can use the properties to change the colors of the lines or to display or hide the individual
curves.
Figure 25.8: Tooth trace diagram for gear 1 with the predefined modifications
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In the figure, the reference profile is shown in blue and the tolerance line is shown in red. The
horizontal axis shows the coordinates along the tooth trace (facewidth) and the vertical axis shows
the flank allowance as specified in the usual industrial conventions. The value of the total tooth trace
deviation Fb is given in the main report.
The manufacturing tooth trace (with tolerances) should lie between the tolerance curve and the
reference tooth trace.
Flank curvature radii
In this graphic you see the flank curvature radii along the tooth flank. Along with the normal force,
these are critical values for Hertzian pressure.
Angle of flank normal
The normal angle to the flank is shown in this graphic. Every point on the tooth form has a normal.
25.2.6 Drawing
Use this menu to display gears schematically. The gears are shown in transverse and axial section.
This option is primarily used for bevel gears and worms.
25.2.7 Assembly
Use this menu to create a diagram of how gears are assembled. The gear (pair) assembly is shown
in transverse and axial section.
Two views, section and overview, are given for bevel gears with a shaft angle of 90°. For shaft
angles <> 90° only the section of the bevel gear pair is displayed.
25.2.8 Manufacturing drawing
25.2.8.1 General
Manufacturing drawings are designed to display a number of graphics on the same surface, and
therefore create a print-ready image that can be used to manufacture a gear. You can also display
the drawing data report at the same time. Use a control file to tailor the display to suit specific
requirements. The control file is stored in the template directory (usually under KISSDIR\template). It
has the module name and the file extension .grc (e.g. Z012gear1.grc).
You can also save the graphic generated here as a .dxf file in the usual way.
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25.2.8.2 Editing the control file
You can modify the manufacturing drawing to suit your own requirements by making changes to the
control file. The commands used to control the manufacturing drawing are described in the following
table.
papersize: A4 Specifies the required paper format. This refers to the standard terms
used to describe commonly used paper sizes (A3, A4, A5, B4, B5,
papersize: A4 portrait Letter, Legal and Ledger), and also enables you to input your own
dimensions for width and height.
papersize: 297, 210
The default setting is for landscape format. However, you can switch to
portrait format by entering the key word "portrait".
fontsize: 5 Specifies the required font size. The font size influences the size of the
report and the diagram titles.
units: inch The default setting is that input values are assumed to be in mm. The
system can handle these units: inch, mm and cm.
You can now add graphics that have specific properties. The table below gives an overview of the
correct inputs.
draw 2DDiaProfileChart1 "draw" is the key word used to specify that a graphic is to be added.
It is followed by the ID of the graphic you want to insert. The number
at the end is part of the ID, and identifies the gear.
window: 160, 285, 0, 85 "window" identifies the window in which the graphic is displayed.
The values show the limits on the left, right, bottom and top.
scaletofit This optional command forces the graphic to distort so that it fills the
window in every direction. We recommend you do this for diagrams,
but not for geometric figures.
If this term is not used, the original size and shape of the graphic is
retained.
fixedscale 2 This optional command generates a scaled output of the graphic.
The number corresponds to the scale (in this case, 2 for M 2:1, 0.1
for M 1:10, etc.).
You can insert these graphics:
Tooth form 2DGeoToothDrawing
Drawing 2DGeoGearDrawing
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Assembly 2DGeoAssemblyDrawing
Tool 2DGeoToolDrawing
Profile diagram 2DDiaProfileChart
Tooth trace diagram 2DDiaFlankLineChart
Angle of flank normal 2DDiaNormal
Finally, you can now display the report in the required location:
write report1 "write" is the key word used to create a gear data report.
Enter report1 to select the gear data of gear 1, report2 to
select the gear data from gear 2, etc.
topright: 297, 218 Unlike graphics, you must specify an alignment here. You
define this with the first word. The correct commands are
topright:, topleft:, bottomright: and bottomleft:. They represent
the alignment (top right, top left, bottom right and bottom left).
The next two values represent the particular reference point.
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25.3 Geometry 3D
Figure 25.9: Tooth system Graphics window
The gears are displayed in the 3D Parasolid viewer.
You can select a number of different output options from the drop-down list in the Tool bar in the
Geometry 3D (see Figure 25.9) graphics window. You can store the Parasolid viewer graphics in
different file formats such as:
▪ Windows Bitmap (.bmp)
▪ Joint Photographic Experts Group (.jpg, .jpeg)
▪ Portable Network Graphics (.png)
▪ Standard for the Exchange of Product Model Data (.stp, .step)
▪ Parasolid Text File Format (.x_t)
▪ Parasolid Binary File Format (.x_b)
25.3.1 Tooth system
The tooth system displays the assembled system of gears in 3D.
You can display these gears in different views.
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25.3.2 Tooth form
In the Tooth form menu, an individual gear is shown in 3D in the Parasolid viewer.
25.4 Evaluation
25.4.1 Specific sliding
The graphic in the Graphics window evaluation shows the specific sliding of the gears (ratio between
sliding and tangential speed) over the angle of rotation. Different values can be displayed for each
gear: gears without backlash, gears with an upper center distance allowance (for lower tooth
thickness tolerance) and gears with a lower center distance allowance (for upper tooth thickness
tolerance).
When you specify the profile shift (see chapter 17.1.8, Profile shift coefficient), click the button to
see a suggested value for balanced specific sliding.
25.4.2 Contact temperature
The contact temperature is the local temperature on the tooth flank at the moment of contact. It is
displayed over the meshing. Based on the contact temperature values and its locations on the flank,
appropriate action (e.g. profile modification) can be taken to reduce the temperature if necessary.
25.4.3 Flash temperature
The flash temperature graphic is displayed in the Graphic menu bar in the Evaluation graphics
window.
The flash temperature is the increase in local temperature on the tooth flank at the moment of
contact. It is displayed over the meshing. Depending on the values used for the flash temperature,
and its position on the flank, a number of measures (e.g. profile modification) can be implemented to
reduce the temperature.
25.4.4 Surface layer shear stress
The hardening depth graphic is displayed in the Evaluation graphics window.
This calculates the optimum hardening depth (for case hardened or nitrided gears). It shows the
vertical shear stress progression in the depth, relative to the flank surface. This value is displayed
directly in the HV values, because HV or HRC values are always used when specifying hardening
III Graphics Menu 520
depth and hardening measurements. If the materials database already contains values for a
measured hardness curve, the hardening progression is displayed, accompanied by a warning
message if the hardening properties are insufficient.
Proposed values for the recommended hardening depth are displayed in a special report, classified
by calculation method, selected material and heat treatment process.
The various different methods are:
▪ The shearing stress progression in the depth of the gear pair is calculated according to Hertzian
law. The shear stress is multiplied by a safety factor. (Enter this under "Settings". The default
setting is 1.63). This defines the depth of the maximum shear stress (hmax). The program
suggests the value 2*hmax as the hardening depth (EHT).
▪ For each individual gear in accordance with the proposals given in Niemann/Winter, Vol.II [5]
(page 188).
▪ For each individual gear in accordance with the proposals given in AGMA 2101-D04 [45] (pages
32-34).
▪ For each individual gear according to the proposals given in ISO 6336 Part 5 [17] (pages 21-23)
(to avoid pitting and breaking up of the hard surface layer).
25.4.5 Suggested hardening depth
The graphic for the suggested hardening depth is displayed in the Evaluation graphics window.
Suggestions for hardening depths according to ISO 6336, Niemann and AGMA 2001 are displayed
for different hardening processes.
25.4.6 Theoretical contact stiffness
The graphic in the Evaluation graphics window shows meshing stiffness over the angle of rotation.
Contact stiffness is calculated on the basis of the real tooth forms. The calculation takes into account
tooth deformation, gear body deformation, and flattening due to Hertzian pressure. The calculation is
performed according to Weber/Banaschek [19].
For helical toothed gears, the overall stiffness is calculated with the section model (the facewidth is
split into 100 sections and stiffness is added over all sections). See also [21], page 203. The
transmission error is defined according to [5], and the transmission variation in peripheral direction D:
(22.5)
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(22.6)
where (q/c') is replaced by cgam.
► Note:
The theoretical contact stiffness and the contact stiffness of the effective toothing under load can be
quite different.
25.4.7 S-N curve (Woehler lines) for material
The S-N curves (Woehler lines) graphic in the Evaluation graphics window displays the S-N curves
(Woehler lines) for the tooth root and flank. The S-N curves (Woehler lines) are calculated using the
selected calculation method for gears. The individual S-N curves are divided by an appropriate safety
factor. The individual load spectra are also displayed in the same graphic.
If a load spectrum is taken into account when sizing the gears, the graphic also shows the curve for
damage accumulation (not available for plastics).
25.4.8 Safety factor curves
The safety factor curves graphic in the Evaluation graphics window shows the progression of the
safety factors over the service life. The safety factors are displayed for nominal operating conditions
(i.e. without a load spectrum).
25.4.9 Oil viscosity
The graphic shows kinematic viscosity at different oil temperatures.
25.4.10 Gap analysis
The graphic in the Evaluation graphics window shows a gap between the tooth flanks (in the direction
of the path of contact) across the width of the contacting gears.
25.4.11 face load distribution
The graphic in the Evaluation graphics window shows a line load across the width of the contacting
gears.
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25.4.12 Backlash calculation from tooth form
The evaluation graphic includes a circumferential backlash (in °) across the angle of rotation. The
display shows the minimum, average and maximum progressions for the backlash. The actual tooth
form, including tooth trace and profile modifications, is used in this calculation. The crossed helical
gears calculation only covers worm wheels with an axial crossing angle of 90°.
25.4.13 Tooth flank fracture
The graphic shows the material utilization, the material's shearing strength, the equivalent shear
stress and the hardness curve for the selected gear.
25.4.14 Sliding velocity (face gear)
The face gear-sliding velocity graphic in the Evaluation graphics window shows the sliding velocity
for the tip and root of the face gear.
25.4.15 Contact line (face gear)
The "Contact line (face gear)" graphic in the Evaluation graphics window shows the progression of
the contact lines on the pinion and on the face gear.
25.4.16 Stress curve (face gear)
The graphic shows the stress curve (tooth root and flank) over the face gear's facewidth. The
calculation splits the facewidth into individual segments, which can then be sized as rack pairs either
according to ISO 6336, DIN 3990 or AGMA 2001. The calculation assumes a constant line load
(which results in a slightly different torque for each segment due to the different pitch circle).
When you calculate data to represent the contact line and the stress curve, the most important
values are calculated in separate sections and saved to two separate tables. This data is stored in
the Z60-H1.TMP and Z60-H2.TMP files.
25.4.17 Scuffing and sliding velocity (face gear)
The graphic displays the safety against scuffing for face gears. However, due to the very different
sliding velocities and the changing contact stress across the tooth flank, calculating the safety
against scuffing is actually very difficult. Akahori [46] reports massive problems with scuffing at a
higher sliding velocity. For this reason, it is appropriate to think about how to calculate the risk of
scuffing. One sensible option, as described above for stress distribution, is to calculate the safety
against scuffing in separate sections.
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The figure in (see Figure 25.10) shows the progression of scuffing safety as defined by the flash and
integral temperature criterion along the tooth flank. To achieve realistic results from this calculation, it
must be ensured that every section is calculated with the same mass temperature. However, when
you work through the calculation, you will see there are significant changes in safety when the
calculation is performed on the basis of the integral temperature. In particular, this happens as point
E on the path of contact gets closer to the pitch point. If you then use the formulae in DIN 3990 to
convert the flank temperature at point E to the average flank temperature, the results you get will not
be particularly precise. For this reason, we recommend you use the flash temperature as the criterion
when you perform this calculation for face gears.
Figure 25.10: Safety against scuffing Graphics window
25.5 Contact analysis
► Notes:
The usual strength and speed calculations performed on gears assume that an involute tooth form is
being used. However, if you use this program module, you can calculate and evaluate any type of
gear teeth, such as cycloid toothing, just as accurately as involute tooth forms.
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All the graphics can be exported:
▪ 2D diagrams as:
▪ BMP
▪ JPG
▪ PNG
▪ DXF
▪ IGES
▪ TXT
▪ 2D curves as:
▪ TXT
▪ 3D diagrams as:
▪ BMP
▪ JPG
▪ PNG
▪ DAT (the y-axis is only output for the contact analysis if the "Draw data for path of contact"
option is selected in the module-specific settings)
25.5.1 Axis alignment
Display the axis alignment of gear B relative to the axis of gear A. This display is a very useful way of
checking the deviation error of axis and inclination error of axis.
25.5.2 Transmission error
The path of contact under load is used to calculate the transmission error. The diagram shows the
displacement of the contact point (μ) of the second gear on the length of the path of contact or the
angle of rotation (°) of the driven gear.
The amplitude of the transmission error plays a role in how much noise is generated but, despite this,
you should not ignore the pitch (how steep the slopes are), because high acceleration also generates
high additional loads.
25.5.3 Transmission error acceleration
The Transmission error acceleration (second derivative with reference to time) is available as a
graphic.
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III Graphics Menu 526
25.5.4 Amplitude of transmission error
The "Amplitude spectrum of the transmission error" graphic displays the spectroscopic analysis
results for the transmission error by Fourier transformation.
You can compare the amplitudes of the spectra with the harmonic frequencies of the transmission
error in the comment window.
Contact lines on tooth flank
You can examine the contact line along the facewidth in this graphic. All the gear pairs in the
meshing are shown at the same time in an engagement position.
25.5.5 Normal force curve
The normal force curve represents the line load per width for each tooth face in the middle of the
cylindrical gear. In a well arranged profile modification, the normal force should increase steadily
from zero. If you do not have a profile modification, an overlap length in the normal force curve
shows the corner contact.
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Normal force distribution
This graphic shows the normal force curve along the tooth flank and facewidth on a 3D gear.
25.5.6 Torque curve
The default value for torque defined in the main screen is kept constant during the calculation. The
graphic then shows the torque for gear 1 and the torque for gear 2, divided by the ratio. If these two
torque values are different, it means that torque has been lost. The loss is due to friction in the tooth
contact.
Variations in the displayed moment course depend on the level of accuracy you have specified, and
are caused by the accuracy of the iteration.
Single contact stiffness
This graphic shows the individual elements of single tooth contact stiffness. These are the stiffness of
both gears and the single contact stiffness of the gear pair.
As this is a series-connected spring system, the following applies:
25.5.7 Stiffness curve
The stiffness curve shows the local stiffness at the operating point. It is calculated from the torsion
under load at every point of contact. The stiffness value for gears is usually specified per mm
facewidth. To calculate the stiffness of the toothing of two gears, multiply the value you specify (c γ)
with the bearing tooth facewidth.
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25.5.8 Amplitude spectrum of the contact stiffness
The "Amplitude spectrum of the contact stiffness" graphic displays the spectroscopic analysis results
of the contact stiffness by Fourier transform.
You can compare the amplitude of the spectra with the harmonic frequencies of meshing stiffness in
the comment window.
25.5.9 Bearing force curve and direction of the bearing forces
Use the bearing configuration options in the Define face load factor dialog window to calculate the
bearing force curve. In this case, both the bearing distance L and the distance s are used in the
calculation. The value given for the face load factor calculation is used as the distance between the
bearings. The purpose of this graphic is not to display the correct bearing forces, but to represent the
variations in these forces.
Variations in the bearing forces cause vibrations in the shafts and changes in gear case
deformations.
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25.5.10 Kinematics
The effective tooth form and the effective path of contact are used to calculate a wide range of
kinematic values, which are then displayed along the length of path of contact:
▪ specific sliding
▪ sliding coefficients Kg
▪ sliding velocity
▪ variation in ratio
25.5.11 Specific sliding
You can display specific sliding either alongside the meshing cycle, in Kinematics, or alongside the
tooth height. You can also clearly see the area of the tooth flank with contact.
25.5.12 Power loss
This calculates the power loss for a pair of teeth. Power loss is usually greatest at the start and at the
end of the mesh because this is where the highest sliding velocities are generated. However, by
modifying the profile, you can reduce the load at these points so that the maximum value is shifted to
the area between the start of mesh and the operating pitch point and to the area between the end of
mesh and the operating pitch point.
25.5.13 Heat development
Heat development links power loss with specific sliding. If the contact point of a gear moves slowly, it
creates a higher heat value per length than if the contact point moves more quickly.
High temperatures generated on the tooth flank should be in correlation with the tendency to scuffing.
However, this is not directly attributable to temperature.
25.5.14 Stress curve
The effective tooth form is used to calculate and display the exact Hertzian pressure during
generation. The same applies to calculating tooth root stress, as defined in the Obsieger procedure
(see chapter 17.2.6.1.4, Tooth form factors), where the maximum stress in the tooth root area is
shown by the angle of rotation.
Stresses are calculated with KHß = 1.0, KHα= 1.0, KFβ= 1.0, KFα= 1.0; only KA, Kvand K? are taken into
account.
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25.5.15 Flash temperature
The effective local temperature shown in the graphic at each point in the path of contact is defined by
the gear base temperature (the tooth bulk temperature) plus additional local warming (the flash
temperature).
At each point on the path of contact, the calculation uses the following data from the contact analysis
calculation to calculate the flash temperature on the tooth flank:
▪ Sliding velocity
▪ Speed in tangential direction to the pinion and gear
▪ Curvature radii on the tooth flanks
▪ Hertzian Pressure
The coefficient of friction μ is taken from the value input for calculating the path of contact. The bulk
temperature is calculated as specified in ISO TR 6336-22.
The flash temperature is calculated for:
▪ ISO according to ISO TS 6336-22
▪ AGMA according to AGMA 925 with Equation 84
25.5.16 Micropitting (frosting)
Calculation method
The calculation is performed according to ISO TS 6336-22, Method A. All the required data is taken
from the contact analysis.
Lubrication gap thickness h and specific lubricant film thickness λGFP
The ISO TR 6336-22 proposal contains a detailed definition of the calculation used to determine the
progression of the effective lubrication gap thickness h and the effective specific lubrication gap
thickness λGF across the meshing. The lubrication gap can vary significantly depending on local
sliding velocity, load and thermal conditions. The location with the smallest specific lubrication gap
thickness is the decisive factor in evaluating the risk of micropitting.
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Permitted specific lubricant film thickness λGFP
To evaluate the risk of micropitting (frosting), it is vital that you know how large the required smallest
specific lubrication gap thickness λGFmin is to be. The calculation rule states that:
λGFmin >= λGFP must be set to prevent micropitting (frosting), or to ensure safety against frosting Sl =
λGFminP/ λGFP.
If the lubricant's micropitting (frosting) load stage is known, the permitted specific lubricant film
thickness is calculated from test bench data, according to ISO TR 6336-22.
Otherwise, reference values for λGFP can be derived from the appropriate technical literature.
In [47] you will see a diagram that shows the permitted specific lubrication gap thickness λ GFP for
mineral oils, depending on oil viscosity and the micropitting (frosting) damage level SKS.
Figure 25.11: Minimum necessary specific thickness of lubricant film λGFP
The micropitting damage level SKS, determined in accordance with the FVA information sheet [48],
is nowadays also stated in data sheets produced by various lubricant manufacturers. The data in the
diagram applies to mineral oils. Synthetic oils with the same viscosity and frosting damage level
show a lower permitted specific lubrication gap thickness λ GFP [47]. Unfortunately, as no systematic
research has been carried out on their effects, no properly qualified values are available.
Furthermore, you must note that the predefined λGFP values only apply to case-hardened materials.
As specified in ISO TR 6336-22, for other materials, the permitted specific lubrication gap thickness
λGFP can be multiplied by the coefficient Ww.
Ww
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Case hardening steel, with high austenite 1.00
content <= 25%
Case hardening steel, with high austenite 0.95
content >= 25%
Gas-nitrided (HV > 850) 1.50
Induction or flame-hardened 0.65
Through hardening steel 0.50
25.2 table: Material coefficient
It is interesting to note that, at least according to the table shown above, materials with a nitrite
content are more prone to micropitting than case-hardened materials when the same lubrication gap
is used. In contrast, through hardened materials that are not surface hardened are much more
resistant.
You should be aware that the data shown here must be used with caution, because information
about the micropitting process is still incomplete, and even technical publications will sometimes
contain contradictory data.
Safety against micropitting
If the load stage against micropitting as defined in FVA C-GF/8.3/90 [48] is specified for the lubricant,
the minimum required lubricant film thickness λGFP is calculated. This then makes it possible to define
the safety against micropitting Sλ = λGFmin/ λGFP.
25.5.17 Wear
Before you can calculate local wear on the tooth flank, you must first define the material's wear
coefficient kw. This coefficient can be measured using gear testing equipment or by implementing a
simple test procedure (for example pin and disk test rig) to determine the approximate value.
Investigations are currently being carried out to see how the coefficient k w, determined using a
simpler measurement method, can be applied to gears. For exact forecasts, you will also need to
determine the coefficient kwfor the material pairing. For example, POM paired with POM does not
supply the same results as POM paired with steel.
Plastics
You can input the wear factor kw in the polymer data file, for plastics, depending on the temperature
(for example, Z014-100.DAT for POM). The data is input in 10-6 mm3/Nm.
For example:
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Steel
Plewe's investigations have revealed that a rough approximation of the wear coefficients for steel
materials can be defined. See also the calculation of wear coefficients for steel (see chapter
17.1.12.2, Calculation of the wear coefficient kw for steel).
Calculation
Wear is calculated according to the following basic equation:
(δw [mm], kw [mm3/Nm], P: Pressure [N/mm2], V:Velocity [m/s], T:Time[s])
As modified to suit gear conditions, local wear results from:
(i = 1.2)
(δw_i [mm], kw [mm3/Nm], NL: Number of load cycles, w:Line load [N/mm], ζ_i: specific sliding)
This equation also corresponds to the data in [49], Equation 6.1.
The calculation used to determine wear on the tooth flank uses the following data at each point of
contact taken from the calculation of the path of contact:
▪ Specific sliding
▪ Line load
POM against steel (at 23°C), [49] gives a kw value of 1.03 * 10-6 mm3/Nm. Against steel, it gives a kw
value of 3.7*10-6 mm3/Nm.
When you interpret the results, you must note that the increasing wear on the tooth flank changes
local conditions (line load, sliding velocity) to some extent, and therefore also changes the increase
in wear itself.
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25.6 Gear pump
Eleven different diagrams provide detailed documentation about the progressions of the
characteristic values in a gear pump when it is generated. You will find more extensive information
about how to calculate gear pumps in (see chapter 17.11, Gear pump) and in KISSsoft-anl-035-E-
GearPumpInstructions.doc [31] (available on request).
25.7 3D export
Select Graphics > 3D Export to export the geometry of the gears you have just designed to a
specified CAD system. The next section (see chapter 25.8, Settings) provides more detailed
information about which CAD system you should use, and its interface.
► Note:
Before you call this function for the first time, make sure you are using a suitable CAD system. If you
have specified a CAD program that has not yet been installed, you may cause a problem when you
call this function.
25.8 Settings
Click Graphics > Settings to define the background for 3D graphics and select your preferred CAD
system. Here, you can select any of the interfaces for which you have the appropriate licenses.
25.9 Graphics list
The graphics list is where you save the graphics by clicking on as in all the other toothing
modules. The list is attached to the end of the report, unless otherwise specified in the report
template. In the graphics list you can open every graphic with , , and depending on
the graphic type, and then modify, enable or disable its properties, or delete it with .
III Answers to Frequently Asked Questions 535
26 Answers to Frequently Asked Questions
26.1 Answers concerning geometry calculation
26.1.1 Precision engineering
KISSsoft is an ideal tool for calculating the gears for precision engineering.
The reference profile and the geometry are calculated as defined in DIN 54800 etc. The strength
calculation is performed according to ISO 6336, DIN 3990, VDI 2545 or VDI 2736, since no special
strength calculation is available for precision gears. For this reason, "defining required safeties for
gear calculation" (see chapter 26.2.4, Required safeties for cylindrical gear units) is important when
you are interpreting the results.
If gears are manufactured using topping tools, the tip circle can be used to measure the tooth
thickness. In this situation, it is critical that you specify precise value of the addendum in the
reference profile to match the relevant cutter or tool. This is because this value is used to calculate
the tip circle. The tip alteration k*mn is not taken into account in the calculation of the manufactured
tip circle. The following formula is used:
(23.1)
26.1.2 Deep tooth forms or cylindrical gears with a high transverse
contact ratio
Using deep tooth forms is recommended for some specific applications (for example, for spur gears
that should not generate a lot of noise).
In KISSsoft, you can easily calculate all aspects of deep toothed gears. To calculate the geometry,
you must select a profile of a suitable height when you select the reference profile:
Normal profile height: for example mn * (1.25 + 1.0)
For a deep tooth form: for example mn * (1.45 + 1.25)
You must be aware that this type of gear is more prone to errors such as undercut or pointed teeth.
Experience has shown that you must select a value of 20 or higher as the number of pinion teeth to
ensure that you can create a functionally reliable pair of gears. KISSsoft also has very effective and
easy to use strength calculation functionality; as specified in DIN 3990, Part 3, calculation of gears
with transverse contact ratios greater than 2.0 tends to be on the conservative side.
III Answers to Frequently Asked Questions 536
The Geometry Variants calculation (Modules Z04 and Z04a) is very good at sizing optimum
arrangements of deep toothed gear pairs!
See also section 14.16.
26.1.3 Pairing an external gear to an inside gear that has a slightly
different number of teeth
When you pair a pinion (for example, with 39 teeth) with an internal gear (for example, with 40 teeth)
that has a slightly different number of teeth, the teeth may collide ("topping") outside the meshing
area. This effect is checked and an error message is displayed if it occurs.
To size a functioning pairing of this type, select this strategy:
▪ Reference profile: Short cut toothing
▪ Pressure angle: the bigger the better
▪ Total profile shift: select a negative value
▪ Total pinion profile shift: approximately 0.4 to 0.7
26.1.4 Undercut or insufficient effective involute
(this triggers frequent error messages when you calculate the geometry of cylindrical gears.)
An insufficiently effective involute occurs if the tip of the other gear in the pair meshes so deeply with
the root of the first gear that it reaches a point at which the involute has already passed into the root
rounding. These areas are subject to greater wear and tear. Some gear calculation programs do not
check this effect and suffer recurrent problems as a consequence.
To keep a close eye on the undercut and effective involute, you should always work with the
Calculate form circle from tooth form (see chapter 17.20.5.1, Calculate form diameters from tooth
form) option. This function checks the tooth form every time a calculation is performed. It determines
any undercut it discovers and takes it into account in the calculation.
(The tooth form calculation takes into account all aspects of the manufacturing process. In contrast,
geometry calculation according to DIN 3960 uses simplified assumptions.)
26.1.5 Tooth thickness at tip
The tooth thickness at the tip circle is calculated for a zero clearance status. In addition, the
maximum and minimum value is calculated using all tolerances.
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When you check the tooth geometry, the tooth thickness at the tip must usually be at least 0.2 *
module (according to DIN 3960). If this limit is not reached, KISSsoft displays the appropriate
warning message. Select Calculation> Settings > General to change this factor if required.
26.1.6 Special toothing
The term "special toothing" is used to describe toothing with non-involute flanks. The reference
profile (or the normal section through the hobbing cutter or rack-shaped cutter) of special toothing is
not straight (unlike involute toothing). However, the same generating process is used to manufacture
both toothing types. As part of the tooth form calculation, special toothing (cycloid, circular arc teeth)
can either be imported from CAD or defined directly. In addition, you can then generate a suitable
counter gear by clicking Generate tooth form from counter gear.
By simulating the generation process, the tooth form and, from this, the geometry can then be
defined for special toothing. As no standards or documentation are available for strength
calculations, analogies for these tooth form types must be drawn from the calculations used for the
cylindrical gear process. (see chapter 25.5, Contact analysis)
26.1.7 Calculating cylindrical gears manufactured using tools
specified in DIN 3972
Profiles I and II are profiles for the final machining. They can all be handled easily by KISSsoft.
Simply select the tool you require from the selection list (Reference profiles).
Profiles III and IV are used for tools used in pre-machining. However, you should always use a
finished contour to calculation the strength of a gear. These profiles should therefore only be used as
a pre-machining cutter.
The reference profiles are dependent on the module, as defined in the following formulae
Profile III hfP= 1.25 + 0.25 mn-2/3 haP= 1.0 ϱfP= 0.2
Profile IV hfP= 1.25 + 0.60 mn-2/3 haP= 1.0 ϱfP= 0.2
In the Reference profile tab, if the configuration is set to Tool: Hobbing cutter is set, you can click
the Plus button to the right of the hobbing cutter to see a selection list that includes Profiles III and IV
according to DIN 3972. Remember that the data you enter here depends on the module. If you want
to change the module, you must select the correct reference profile again.
Use the recommendations in the standard to select the correct allowances for pre-machining:
Profile III Allowance = +0.5 mn1/3 tan(αn)
Profile IV Allowance = +1.2 mn1/3 tan(αn)
III Answers to Frequently Asked Questions 538
If Pre-machining has been selected (in the Reference profile tab), you can set the appropriate
Grinding allowance for Profile III or IV in the list in the Grinding allowance field.
Click on the + button next to Grinding allowance q to input a tolerance interval for the grinding
allowance qTol (=qmax-qmin). The grinding allowance for pre-machining then lies in the range qmin
... qmax, where qmin = q - qTol/2. qmax = q + qTol/2 applies.
The control measurements (base tangent length etc.) for pre-machining are then calculated with the
following allowances:
Maximum grinding allowance with As.e + qmin*2 / cos(an)
Minimum grinding allowance with As.i + qmax*2 / cos(an)
Note:
If you want customer-specific tolerances to be processed automatically, you can define them in a file
called "GrindingTolerance.dat". The \dat directory has an example of this type of file, which is called
"GrindingToleranceExemple.DAT". When this file is renamed to "GrindingTolerance.dat", its
tolerance values are used in the calculation.
26.1.8 Composites as defined in DIN 58405
DIN 58405 specifies the base tangent length allowances and permitted composite errors for gear
teeth used in precision engineering. In this case, the reference profile specified in DIN 58400
assumes a pressure angle of αn=20°. If you use a working transverse pressure angle that is not 20°,
DIN 58405 Sheet 3, sections 1.2.10 and 1.2.11, state that the permitted composite error and the
permitted rolling deviations must be multiplied with a coefficient L = tan(20°)/tan(abs). This is
because the base tangent length allowances are standardized and the center distance error
increases as the pressure angle is reduced. KISSsoft takes coefficient L into account when
calculating tolerances to comply with DIN 58405, because it is specified in the standard.
However, the tolerances specified in ISO 1328 and DIN 3961 do not include this coefficient because
it is not listed in the standard.
26.1.9 Automatic change of reference profiles
Some calculations have revealed the problem that the reference profile changes automatically when
the center distance changes. In the Reference profiles tab, the factors for the tool tip and dedendums
change automatically. Why?
This is because the "Maintain tip circle when changing profile shift" or "Maintain root circle when
changing profile shift" checkbox has been selected in the General tab, in the module-specific
settings.
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If you change the center distance, the profile shift coefficient also changes. The setting you make
automatically changes the coefficients for the reference profile.
26.1.10 Non-identical (mirrored symmetry) tooth flanks
If the tooth flanks (left, right) are not identical, will this cause an error when the tooth contour is
exported?
The tooth flanks used in the calculation (sizing) are identical.
The export function used in the system not only exports the involute but also the entire tooth form.
This is an approximated curve.
With the export precision (permitted deviation ε ) you can define how closely you want to
approximate the calculated tooth form.
In each case, an approximate curve with the specified level of accuracy is supplied for either half of
the tooth or the whole tooth. You can only use mirror symmetry with approximation accuracy.
This is the error you specified as the permitted deviation.
The smaller the selected deviation, the more detailed the curve.
26.1.11 Internal teeth - differences in the reference profile if you
select different configurations
A gear pair with internal teeth has been calculated in the KISSsoft system. A pinion type cutter is
then to be used to manufacture this internal gear. The tool is manufactured to suit particular
customer requirements and is influenced by the particular tooth form which is used. This must reflect
the reference profile geometry of the internal gear. How can you then determine the pinion type
cutter geometry?
A gear's reference profile is the relevant rack profile. A regular hobbing cutter for an outside gear has
this rack geometry, which makes it easy to define the hobbing cutter profile. However, you must
reverse the gear profile to obtain the hobbing cutter profile (the gear reference profile addendum
becomes the hobbing cutter dedendum, and so on).
If the manufacturing tool is a pinion type cutter, the limited number of teeth on the pinion type cutter
results in a different situation. Generally, the inverse gear reference profile corresponds to that of the
pinion type cutter. However, after this, you must change the cutter addendum in a way that ensures
you can achieve the necessary root diameter on the internal gear.
First of all, you must define the number of teeth on the pinion type cutter. The reference diameter of
the pinion type cutter will already be predefined to some extent, depending on the type of machine
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tool used to manufacture the gear. This reference diameter must be greater than the diameter of the
main shaft of the machine tool that is to be inserted in the pinion type cutter tool. However, if this
diameter is too large in comparison with the size of the pinion type cutter, the shaft diameter will be
too small. This will cause powerful vibrations during the production process and result in a poor
manufacturing quality. To prevent this, you must know the approximate pinion type cutter diameter.
The reference diameter is then divided by the module to determine the number of teeth on the pinion
cutter.
If you want to use the KISSsoft system to design the pinion type cutter geometry, you must first input
the number of teeth on the pinion type cutter. You can start with 0.0 for the profile shift coefficient of
the pinion type cutter. A pinion type cutter's profile shift changes as it is used. Every time the pinion
type cutter is resharpened, the profile shift is reduced slightly. A new pinion type cutter usually has a
positive profile shift (for example +0.2), a worn tool therefore has a negative profile shift.
After you have input the data for a pinion type cutter, you must first check all the entries, i.e. whether
the required root form diameter has been achieved. If not, you must reduce the tip fillet radius of the
pinion type cutter. If that does not help, you must increase the addendum of the tool reference profile.
However, this also changes the active root diameter.
The same problem can also happen with the tip form circle diameter dFa. It often happens that you
cannot generate the entire involute part up to the tooth tip. In this situation, you must either increase
the number of teeth on the pinion cutter tool or reduce the tip diameter of the gear.
If you develop a gear that is manufactured by a pinion type cutter, it is always critically important that
you investigate the production process early on in the development process. This is because not
every gear geometry can be created with this production process.
26.1.12 Effect of profile modifications
Profile modifications are a popular topic of discussion. Where should these modifications start, and
what values should be used to make these modifications?
Linear tip relief is a type of profile modification. It has the following properties: Starting from a
particular point, ever increasing amounts of material are removed from the involute toothing part up
to the tip diameter.
The tooth contact in the modified area is disrupted. This is only a benefit when subject to the relevant
load. This entire area is taken into account when calculating the length of contact to determine the
transverse contact ratio εa . Shouldn't this be different?
If you use profile modifications, you "delete" the real involute. Why is this a good idea?
This is a complex problem that must be taken into consideration when you design profile
modifications. The amount of material removed (tip relief Ca is the reduction of tooth thickness at the
tip due to the profile modification) and must be applied according to the tooth bending.
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For example, if the tooth had infinite stiffness, and you ignored any of the possible effects of
compensating for production errors, the profile modification would simply reduce the transverse
contact ratio. If you did not take this profile modification into account, you would make an error in the
geometry calculation. This is basically correct for a gear that is subject to a lower load. However, you
will usually need to design gears for optimum performance at operating torque and the strain that this
places on the teeth.
If the tip relief Ca is well arranged, the profile modification then compensates for the tooth
deformation, so that the tooth contact across the entire tooth height is not compromised. In this case,
the transverse contact ratio is not reduced. Here you have, when compared to a gear without profile
modification, a changed normal force curve over the meshing.
However, the maximum force (in the operating pitch circle), where only one gear pair is meshing, is
not changed. For this reason, the maximum root and flank strains, which determine the service life of
the gear unit, remain unchanged. This profile modification reduces the normal force at the start and
end of the meshing. This also leads to a significant reduction in the risk of scuffing. The risk of
scuffing is due to contact stress and sliding velocity. Sliding is greatest at the start and end of the
tooth contact, so, by reducing the contact stress in this area, you can also reduce the risk of scuffing.
A profile modification can reduce the influence of tooth strain on stiffness fluctuations across the
meshing, and therefore limit the number of transmission errors. This also lowers the levels of
vibration and noise.
This clearly shows that a profile modification does not reduce the transverse contact ratio, as long as
this has been properly sized, i.e. for the operating torque of the gear unit. However, when lower loads
are involved, gears whose profile has been modified do not mesh as well as gears without profile
modification. This is because the transverse contact ratio has been significantly reduced. In this
case, although the load would increase, it would do so by a comparatively small amount, and can
therefore be ignored.
26.1.13 Number of teeth with common multiples
A gearing with 15:55 teeth has been sized. Different documents state that you should avoid gear
reductions (such as 11:22) that are whole numbers. You will also discover that you should also avoid
using numbers of teeth that are common multiples (in this case the 5 in 3*5 to 11*5). Is that true, and
is it displayed in KISSsoft?
Let's assume we have a gear which has a fault on one of its teeth. In a whole number reduction, this
tooth will always come into contact with the same tooth in the counter gear. The error is then
transmitted to the counter tooth. However, if the tooth with the fault comes into contact with a
different counter tooth in every rotation, this error will be reduced as the gears wear in.
Nowadays, most gears are surface-hardened. Unlike weak gears, they hardly ever wear in. As a
result, this problem is now less critical than it used to be, where it was important that whole number
gear reductions (such as 11:22) were avoided even when hardened gears were used. In contrast,
whole number toothing combinations with common multiples (such as 15:55) do not cause any
issues for surface hardened gears.
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In KISSsoft, you will find notes about whole number combinations with hunting multiples in both fine
sizing and rough sizing under the keyword "hunting". If you see YES for "hunting" in the table, this
means: no common multiple is present.
26.1.14 Allowances for racks
From Release 10/2003 onwards, allowances for racks are defined in conjunction with the paired
gear.
This conforms to DIN 3961.
"The tolerances for the gear teeth on a rack should not be greater than the tolerances for its counter
gear. If the manufacturer does not know the counter gear value, they can set the rack length to the
same value as the counter gear circumference."
26.2 Answers to questions about strength calculation
26.2.1 Differences between different gear calculation programs
You will always discover differences in the results when you compare calculations performed with
different gear calculation programs. Many of these differences are due to the different data entered.
However, even if all the data entered is the same, you will still get different results.
One of the questions our users often ask is whether the results calculated by KISSsoft are correct.
The main calculation process used in the KISSsoft cylindrical gear calculation functions is based on
DIN 3990, ISO 6336, and AGMA. It faithfully follows the procedure described in Method B. However,
as DIN 3990 or ISO 6336 offer various different methods (B, C, D) and sub-methods, it is no surprise
that different calculation programs produce slightly different results. Most programs do not perform
calculations that consistently use Method B. Instead, they partially use Method C or even D, which
are easier to program.
To give our users additional reassurance, we have therefore integrated the FVA program calculation
variant in KISSsoft. This variant supplies exactly the same results as the ST+ FVA program that was
developed by the Technical University in Munich, and which can be used as a reference program.
The minor differences between KISSsoft's calculations according to DIN 3990 and the FVA programs
are due to the slight (permissible) deviations of the FVA program from the standard default process
defined in DIN 3990.
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26.2.2 Difference between cylindrical gear calculation according to
ISO 6336 or DIN 3990
The strength calculation method used in ISO 6336 is virtually the same as that defined in DIN 3990.
The majority of the differences only affect minor details which have very little effect on the safeties
calculated for tooth root, flank and scuffing.
The only significant difference occurs when calculating the service life factors ( ZNT and YNT ). In the
endurance limit range (according to DIN, depending on material type and calculation method 107 to
109 load cycles) this coefficient in ISO 6336 decreases from 1.0 to 0.85 at 10 10 load cycles. Only
with "optimum material treatment and experience" does the coefficient remain 1.0.
As a result, gears in the range of endurance limit supply much smaller safeties (15% lower) when
calculated according to ISO 6336 for root and flank! In the case of optimum material treatment, or for
the number of load cycles in the limited life range, the safeties are practically identical.
26.2.3 Calculation using Methods B or C (DIN 3990, 3991)
Cylindrical Gears:
Calculation using Method B or C is described in DIN 3990. Method B is much more detailed and is
therefore the method we recommend. KISSsoft usually uses Method B. However, we do not consider
Method B to be precise enough to calculate the form factors for internal teeth, which is why we
recommend Method C.
Changing over to using Method C means that most of the calculation is performed according to
Method B and the tooth form factors are only calculated as defined in Method C for the tooth root
strength.
Note: The most precise way of calculating internal teeth is to take the exact tooth form into account
(see "Tooth form factor using graphical method", section 14.3.16.3).
Bevel gears:
Tooth form factors are calculated according to Method C, taken from the standard.
26.2.4 Required safeties for cylindrical gear units
Defining the necessary safeties (for tooth root, flank, scuffing) for gears in a particular application, for
example, in industry standard gear units, vehicles, presses etc., is a very important step in the gear
calculation process.
The (DIN 3990 or ISO 6336) standards provide hardly any information about this. DIN 3990, Part 11
(Industrial Gear Units) has this data:
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Minimum safety for root: 1.4
Minimum safety for flank: 1.0
AGMA 2001 does not specify minimum safeties. The AGMA 6006 guideline (for gear units in wind
power installations) has a note that SFmin = 1.56 is specified for root safety for calculation according
to ISO 6336. In contrast, SFmin = 1.0 is sufficient for calculations according to AGMA. This matches
our findings that calculations performed according to AGMA give much lower root safeties.
Therefore, we recommend a minimum safety of 1.4*1.0/1.56 = 0.90 for industrial gear units
calculated according to AGMA.
Scuffing is calculated according to DIN 3990, Part 4:
Minimum safety for scuffing (integral temperature): 1.8
Minimum safety for scuffing (flash temperature): 2.0
The standards do not specify this value for precision engineering (module under 1.5). Despite this,
according to empirical values, the required safeties are much smaller than for gears with a larger
module (root 0.8; flank 0.6)! The reason for this: The formulae and methods used in strength
calculation are all taken from tests with larger gears and only supply very conservative factors
(values that err on the side of safety) for small modules.
Defining required safeties for gear calculation
You can use the simple method described here to obtain the required safeties:
1. Examine and define the basic settings of the calculation (e.g. application factor, lubricant,
manufacturing quality, processing etc.).
2. Then apply the gear calculation method (without changing the basic settings unless you
absolutely have to!) on a known set of gears. You should select gears that run reliably under
operating conditions and also gears that have failed.
3. You can then use the resulting safeties calculated with these gear sets to define the point up to
which minimum service reliability can be guaranteed.
4. You can then use these parameters to calculate the sizing of new gears. You can, of course,
change these minimum safeties to reflect the results of your own tests and experience.
26.2.5 Insufficient safety against scuffing
You can increase the safety against scuffing by:
▪ Oil selection (higher viscosity at high temperatures)
▪ Tip relief (profile modification)
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▪ Different distribution of the profile shift
The methods used to calculate the safety against scuffing (unlike those used to determine the tooth
root and flank) are still a matter of controversy. For this reason, you should not pay too much
attention to this, especially if the results for safety against scuffing at flash temperature and the
integral temperature process are very different.
26.2.6 Material hardening factor (for strengthening an unhardened
gear)
If you pair a hardened gear with an unhardened gear (e.g. pinion made of 17CrNiMo6 and gear
made of 42CrMo4), you get the positive effect of increased load capability on the flank of the
unhardened gear. This effect is taken into account by the material hardening factor (factor in the
range 1.0 to 1.2). As stated in ISO 6336, the surface roughness of the hardened gear should be low
(polished surface), otherwise the load capability will not increase. On the contrary, the tooth of the
weaker gear may actually be ground off.
26.2.7 Defining the load stage scuffing (oil specification)
In accordance with Niemann [5], page 166, on a test rig the torque on the test gear is gradually
increased until scuffing occurs. This torque level is then entered in the oil specification parameters
(Example: no scuffing at load stage 10. Scuffing at load stage 11. The load stage scuffing of the oil is
therefore 11).
To calculate the scuffing load capacity, you must then enter this load stage (for the oil specification).
In the example described above, this is the value 11 (in accordance with Niemann [5], page 341).
The safety against scuffing calculation determines the safety against scuffing with predefined safeties
greater than 1.0. This creates a necessary reserve, because the gradual increase in torque used in
the test only approximates the effective scuffing torque.
26.2.8 The effect of the face load factor KHß for the tooth trace
deviation fma is due to a manufacturing error.
In the cylindrical gear calculation defined in ISO 6336, when calculating the face load factor K Hß , a
higher value was determined for the tooth trace deviation fma . This was due to a manufacturing error
The value for KHß does not change. Why then, does this value for KHß not change if a higher value is
used for fma?
Before you can calculate KHß , you must input the position of the contact pattern. If the contact
pattern has been defined as "economical" or "optimum", KHß is calculated in accordance with the
formulae in ISO 6336 or DIN 3990. fma has no influence on the calculation of KHß and is therefore
ignored.
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See formulae (53) or (55) in ISO 6336:2006.
The reason for this is that a well designed contact pattern can compensate for manufacturing
variations and variations due to deformation. If a higher value for fma is to be used in the calculation,
this means, in reality, that a good contact pattern can never be present. That is why, in this situation,
you should select the contact pattern position "not verified or inappropriate" when calculating the face
load factor.
26.2.9 Load spectrum with alternating torque
Load bins can also be entered with negative torques.
The problem:
until now, no calculation guidelines have been drawn up to describe how to calculate gears with
alternating load spectra.
The only unambiguous case is when a change in moment takes place, during every cycle (and in
each element in the collective, i.e. load bin). At this point, a load change corresponds to exactly one
double-load with +moment and then with -moment. This instance can be calculated correctly by
entering the load spectrum of the +moments and the alternating bending factor YM for the tooth root.
The flank is also calculated correctly, because the +moments always apply to the same flank.
If, in contrast, the drive runs forwards for a specific period of time and then runs backwards, the
experts agree that the tooth root is not subjected purely to an alternating load (and possibly this is the
only point at which an alternating load change takes place). However, discussions are still raging as
to how this case can be evaluated mathematically. It is even more difficult to define how mixed load
spectra with unequal +moments and -moments for the tooth root are to be handled. For this type of
case, only the +moments are considered for the flank (with the prerequisite that the +moments are
equal to, or greater than, the -moments).
Note about handling load spectra with reversing torque:
A load progression as represented in the figure below, where the tooth is subjected to a load a few
times on the left flank, and then a few times on the right flank, can be converted into a load spectrum
as shown below. This is represented in an example here.
Load progression (example):
▪ 13 loads with 100% of the nominal load (100 Nm) on the left flank, then
▪ 9 loads with 80% of the nominal load (80 Nm) on the right flank, etc.
This results in the following process:
▪ 11 load cycles with 100% load, positive torque, pulsating; then
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▪ 1 load cycle with 100% load on the left and 80% load on the right; then
▪ 7 load cycles with 80% load, negative torque, pulsating; then
▪ 1 load cycle with 80% load on the right and 100% load on the left;
then repeated again from the start.
This can be represented as a load spectrum as follows:
Frequency Torque Left flank load Right flank load
11/20 = 0.55 100 Nm 100% 0%
7/20 = 0.35 80 Nm 0% 100%
2/20 = 0.10 100 Nm 100% 80%
Table 26.1: Load progression shown as a load spectrum
Figure 26.1: Load progression
26.2.10 Strength calculation with several meshings on one gear
How can you take several simultaneous meshing points on a motor pinion into account in the
calculation?
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Figure 26.2: Fourfold meshing
You can solve this problem with a normal cylindrical gear pair calculation (Z12).
Simply divide the power by a factor of 4 (reduce by 25%)
Then, click the Details... button in the Strength area after the reference gear.
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Figure 26.3: Details Strength
Then, click the Plus button after the number of load cycles to perform the change shown below. The
number of load cycles for gear 1 is changed from "Automatically" to 4 load cycles per revolution.
Figure 26.4: Define number of load cycles for gear 1
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26.2.11 Bevel gears: – Determine permitted overloads
Can maximum overloads be taken into account when calculating bevel gears according to ISO
standards?
AGMA norms have definitions that allow for a standard overload of 250%. This overload is defined as
being present for less than 1 second, not more than 4 times in an 8 hour time period. Does the ISO
standard have comparable regulations with regard to overloads (shock)? No references could be
found about this subject in the ISO standard.
ISO 10300 does not give any information about permitted overloads. However, ISO has a different
Woehler curve (for YNT and ZNT factors) than AGMA. Therefore, in principle if ISO 10300 is strictly
adhered to, you must input the total number of load cycle including the overload. The application
factor is 2.5 (which corresponds to 250% overload). After this, you must calculate and check the
safety factors.
If the load only occurs very infrequently, (less than 1000 times during the entire rating life), this can
be handled in a static calculation. KISSsoft has a simplified version of the strength calculation
process, specifically to cover this situation. This is based on the ISO method, but only takes into
account the nominal stress in the tooth root (without stress correction factor YS). Here, please note
that, in this case, you must maintain a minimum safety of 1.5 relative to the material's yield point!
26.2.12 Taking shot peening data into account when calculating
gear strength
You will see a note about shot peening on page 47 of AGMA 2004-B89. This states that shot peening
improves the tooth safety factor by 25%.
If you use KISSsoft to perform calculations according to DIN or ISO, you can achieve the increase in
tooth root strength due to shot peening by inputting the relevant technology factor. To do this, go to
the Factors tab and click on "Z-Y factors..." in the General factors group.
You will find the details of useful entries as specified in Linke, Bureau Veritas/RINA or ISO 6336 in
the manual. If you want to perform the calculation according to AGMA, you do not have the option of
inputting the technology factor. In this case, you must increase the root endurance limit by specifying
the relevant percentage rate directly when you enter the material data. To do this, go to the Basic
data tab and then click the Plus button after the material selection. In the dialog window that is then
displayed, click on "Own input". Input the endurance limit as shown in the figure below.
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Figure 26.5: Material own input
26.2.13 Calculation according to AGMA 421.06 (High Speed Gears)
In the KISSsoft system, you perform calculations as specified by AGMA 421.06 for high speed gear
units in the following way.
AGMA 421 is an old, well-established standard (1968), and has since been replaced by AGMA 6011-
I03 (2003).
(see chapter 17.2.1, Calculation methods)
26.2.14 Comparison of an FEM calculation with the crossed helical
gear calculation
The accepted wisdom is that the differing results in the tooth root stress are primarily due to the lower
value of the "Reference Facewidth" in the KISSSOFT calculation.
The effective contact of crossed helical gears is included in our calculation of the "Reference
Facewidth". This results from the pressure ellipse (flattening of the point of contact). In addition, if
III Answers to Frequently Asked Questions 552
sufficient facewidth is present, 1x module per facewidth is added to each side, as specified in ISO
6336-3.
26.2.15 Determine the equivalent torque (for load spectra)
Some calculation guidelines require you to determine the equivalent torque of a load spectrum and
use it to perform sizing. How can I determine the equivalent torque in KISSsoft?
The fundamental issue here is that the verification of a toothing with equivalent torque must give the
same safeties as the verification with the actual load spectrum. For this reason, you can follow this
procedure:
1. Input the load spectrum and calculate the toothing.
2. Make a note of the lowest root safety and the lowest flank safety for each gear.
3. In the Module specific settings, which you access from Calculation > Settings, input the
safeties you have noted as required safeties in the "Required safeties" tab. At this stage, we
recommend you deselect the "Safeties depending on size" tab.
4. Delete the load spectrum by setting "Individual load".
5. Then click the Sizing button next to the torque input field. This field will then be filled with the
equivalent torque.
6. Now run the calculation to check the data. The safeties you have now defined for the root or flank
of a particular gear must be exactly equal to the previous smallest value (as in step 2). None of the
gears can have a safety that is less than the safeties you recorded in step 2.
26.2.16 Check changes in safeties if the center distance changes
Is it possible to check how the safeties change when gears are mounted with a different center
distance?
Select Calculation > Settings > Module specific settings in the Calculations tab and then click on
Calculation with operating center distance and profile shift according to manufacture. You can
then input the profile shift coefficients and center distance independently of each other. The
calculation then uses the circumferential forces in the operating pitch circle instead of the
circumferential forces in the reference circle.
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26.2.17 Warning: "Notch parameter qs …. outside RANGE (1.0 to
8.0) ..."
The stress correction factor YS Stress correction factor YS is calculated with a formula that complies
with ISO 6336, Part 3 or DIN 3990, Part 3. This formula uses a notch parameter qs , which is also
documented in these standards.
(23.4)
The validity range for the formula for YS in accordance with the standard lies in the range 1.0 ...qs...
8.0. This formula should not be used outside of this range.
If qs < 1, YS(calculated with qs=1), should be rather too large. In this case, the calculation results will
fall in the validity area.
If qs > 8, then YS will be rather larger (than calculated with qs= 8). In this case, the calculation results
fall into the invalid range, and Ys is therefore calculated with the effective qsvalue (>8).
In each case, if qs exceeds, or falls below, the range 1 to 8, a warning is entered in the report. This
report also shows which qsvalue was used further on in the calculation.
► Note:
If you want to change the procedure described here, you can do this either in the setup
(STANDARD.Z12 file, etc.) or in a saved file (.Z12, etc.). To do this, open the file in Notepad and
change this line:
ZS.qsLIMIT=0;
to: ZS.qsLIMIT=1; (qs is not changed)
or to ZS.qsLIMIT=2; (qs<1 is set to qs=1, qs>8 is set to qs=8).
26.2.18 Tooth root stresses in the contact analysis and stress
according to FEM – is there a difference?
An FEM-based approach is now available for calculating stresses in virtual toothing (2D). This is an
additional option, which is generally good. However, this is only if you can trust the TCA stresses
determined by this method – theoretically superfluous?
Calculating tooth root stresses as specified in the ISO or DIN standard only occurs in a cross section
in the tooth root, at the point at which the tangents are exactly 30° to the root contour (60° for internal
toothing). Investigations have shown that the maximum root stress occurs in this cross section, in
standard gear teeth. There are also formulae which can be used to define the rounding radius and
the area of the cross section. These values can then be used to determine bending stress. These
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formulae are based on the assumption that a standard tool is used in a generating procedure.
Changes to the tooth contour, for example due to profile modifications, are ignored. The bending
stress, consisting of nominal stress (YF coefficient) and the stress correction factor (YS) as specified
in the standard, is determined on the basis of measurements taken on a few gears, and is therefore
approximated. In special toothings, for example those with deep tooth forms, there may be a
significant difference between the theoretical bending stress and the effective bending stress.
The calculation for helical gear teeth, as specified in the standard, is performed with virtualspur
gears. The FEM calculation with virtual spur gears therefore uses the same approach as the
standard, the only difference being that the exact tooth form is used in the FE calculation. The
restriction to the cross section at the 30° tangent and also the formulae for YF and YS no longer
apply in this case. The application of the load at the single tooth contact point is treated in the same
way. This enables the exact difference between the stress calculated as specified in the standard
and in FEM to be determined. As already described above, this is a particularly good approach for
special gear teeth or gear teeth with substantial profile modifications in the root area.
The KISSsoft contact analysis (TCA) procedure determines load distribution across the facewidth
and then uses this data to calculate the force applied at each individual tooth contact point in every
segment across the facewidth. The formulae in the standard are then used to determine tooth root
stress in the individual segments. However, KISSsoft's "graphical method" offers a considerable
enhancement in functionality compared to the standard. The graphical method applies the stress
calculation process using the standard's formulae to all the cross sections in the 30° tangent range
(not just at the 30° point), and therefore calculates the cross section (diameter) at the point on the
tooth at which the maximum tooth root stress is found (also using the formulae in the standard for the
relevant cross section).
The tooth root stress in the TCA result is therefore more accurate than the one calculated using the
standard. Despite this, the difference between the root stress according to FEM using the exact tooth
form, or the stress calculated using the formulas for YF and YS according to the standard is not
taken into account. The FEM calculation can therefore be used to investigate whether the root stress
for a specific toothing is very different from the root stress calculated as specified in the standard. If it
is, the stress determined using the TCA method can be multiplied by the coefficient (stress according
to FEM/stress as specified in the standard) of the 2D FEM results in KISSsoft to achieve the most
accurate results.
26.3 Abbreviations used in gear calculation
Abb. in Abb. in
standards etc. KISSsoft
a a Center distance (mm)
ad a.d Reference center distance (mm)
Aa A.a Center distance allowance (mm)
Ase As.e Tooth thickness allowance at the normal section (mm)
αen alf.en Load direction angle (degrees)
III Answers to Frequently Asked Questions 555
αn alf.n Pressure angle at normal section (degrees)
αPro alf.Pro Protuberance angle (degrees)
αt alf.t Pressure angle on the reference circle (degrees)
αwt alf.wt Working pressure angle (degrees)
b b Facewidth (mm)
BM B.M Thermal contact coefficient (N/mm/s.5/K)
β beta Helix angle at reference circle (degree)
βb beta.b Base helix angle (degree)
c c Tip clearance (mm)
c' c' Singular tooth stiffness (N/(mm*μm))
cγ c.g Meshing stiffness (N/(mm*μm))
d d Reference diameter (mm)
da d.a Tip diameter (mm)
db d.b Base diameter (mm)
df d.f Root diameter (mm)
df(xE) d.f(x.E) Root circle with profile shift for Ase (mm)
di d.i Internal diameter gear body (mm)
dNa d.Na Tip active circle diameter (mm)
dNf d.Nf Active root diameter(mm)
dFf(0) d.Ff(0) Root form circle (mm)
dsh d.sh External diameter of integral pinion shaft (mm)
dw d.w Operating pitch diameter (mm)
DM D.M Theoretical ball/pin diameter (mm)
D.M eff Effective ball/pin diameter (mm)
efn e.fn Normal gap width on the root cylinder (mm)
ηtot eta.tot Total efficiency
εα eps.a Transverse contact ratio
εβ eps.b Overlap ratio
εγ eps.g Total contact ratio
ff f.f Profile form deviation (mm)
fHβ f.Hb Tooth trace helix slope deviation (mm)
III Answers to Frequently Asked Questions 556
fma f.ma Tooth trace deviation due to manufacturing tolerances (mm)
fpe f.pe Single pitch deviation (mm)
fsh f.sh Tooth trace deviation due to deformation of the shafts (mm)
Fa F.a Axial force (N)
Fβy F.by Actual tooth trace deviation (mm)
Fn F.n Normal force (N)
Fr F.r Radial force (N)
Ft F.t Nominal circumferential force in the reference circle (N)
Fase.d Tip chamfer (mm)
gα g.a Length of path of contact (mm)
Γ Gamma Gamma coordinates (point of highest temperature)
h h Tooth height (mm)
haP h.aP Addendum reference profile (in module)
hF h.F Bending moment arm (mm)
hfP h.fP Dedendum reference profile (in module)
hk h.k Protuberance height (in module)
ha ha Chordal height (mm)
H H Service life in hours
I I AGMA: Geometry factor for pitting resistance
Impulse Impulse Gear driving (+) / driven (-)
jn j.n Normal backlash (mm)
jt j.t Rotational backlash (transverse section) (mm)
jtSys j.tSys Backlash of the entire system (mm); for planetary stages
k k Number of teeth spanned
k * mn k * m.n Tip alteration (mm)
KA K.A Application factor
KBα K.Ba Transverse coefficient - scuffing
KBβ K.Bb Width factor - scuffing
KBγ K.Bg Helical load factor - scuffing
Kf K.f AGMA: Stress correction factor
KFα K.Fa Transverse coefficient - tooth root
III Answers to Frequently Asked Questions 557
KFβ K.Fb Width factor - tooth root
KHα K.Ha Transverse load factor - flank
KHβ K.Hb Width factor - flank
KHβbe K.Hbbe Bearing application factor
KV K.V Dynamic factor
Kwb K.wb Alternating bending coefficient
kw K.w Wear coefficient (mm3/Nm)
l l Bearing distance l on integral pinion shaft (mm)
mn m.n Normal module (mm)
mRed m.Red Reduced mass (kg/mm)
mt m.t Transverse module (mm)
MdK M.dK Diametral measurement over two balls without backlash (mm)
MdKeff M.dKeff Effective diametral measurement over two balls (mm)
MdReff M.dReff Effective diametral roller mass (mm)
MrK M.rK Radial measurement over one ball without backlash (mm)
MrKeff M.rKeff Effective radial measurement over one ball (mm)
μm mu.m Mean coefficient of friction (as defined in Niemann)
μm my.m Mean coefficient of friction
μm my.my Coefficient of friction
n n Speed (RpM)
νE1 n.E1 Resonance speed (min-1)
N N Resonance ratio
NL N.L Number of load cycles (in millions)
ν100 nu.100 Kinematic nominal viscosity of oil at 100 degrees (mm2/s)
ν40 nu.40 Kinematic nominal viscosity of oil at 40 degrees (mm2/s)
pbt p.bt Base circle pitch (mm)
pet p.et Transverse pitch on path of contact (mm)
pt p.t Pitch on reference circle (mm)
P P Nominal power (kW)
PV Z P.VZ Gear power loss due to tooth load (kW)
PV Ztot P.VZtot Total power loss (kW)
III Answers to Frequently Asked Questions 558
PWaelzL P.WaelzL Meshing power (kW)
RZ R.Z Average total height (mm)
ϱF ro.F Tooth root radius (mm)
ϱfP ro.fP Root radius reference profile (in module)
ϱOil ro.Oil Specific oil density at 15 degrees (kg/dm3)
s s Distance of integral pinion shaft (mm)
san s.an Normal tooth thickness on the tip cylinder (mm)
sFn s.Fn Tooth root thickness (mm)
smn s.mn Normal tooth thickness chord, without backlash (mm)
s.mn e/i Effective normal tooth thickness chord with clearance (mm) (e:
upper, i: lower)
SB S.B Safety factor for scuffing (flash temperature)
SF S.F Safety for tooth root stress
SH S.H Safety for pressure at single tooth contact
SHw S.Hw Safety factor for contact stress on operating pitch circle
SSint S.Sint Safety factor for scuffing (integral temperature)
SSL S.SL Safety for transmitted torque (integral temperature)
σF sig.F (Effective) tooth root stress (N/mm2)
σF0 sig.F0 Nominal tooth root stress (N/mm2)
σFlim sig.Flim Endurance limit tooth root stress (N/mm2)
σFP sig.FP Permissible tooth root stress (N/mm2)
σH sig.H Contact stress on operating pitch circle (N/mm2)
σH0 sig.H0 Nominal contact stress on the pitch circle (N/mm2)
σHB/D sig.HB/D Single tooth contact point contact stress (N/mm2)
σHlim sig.Hlim Endurance limit Hertzian pressure (N/mm2)
σHP sig.HP Permissible contact stress (N/mm2)
σs sig.s Yield point (N/mm2)
Σ xi Total x.i Total profile shift
T T Torque (Nm)
θB the.B Highest contact temperature (oC)
θint the.int Integral flank temperature (oC)
θm the.m Tooth bulk temperature (oC)
III Answers to Frequently Asked Questions 559
θM-C the.M-C Tooth bulk temperature (oC)
θOil the.Oil Oil temperature (oC)
θs the.s Scuffing temperature (oC)
θSint the.Sint Scuffing integral temperature (oC)
u u Gear ratio
v v Circumferential speed reference circle (m/s)
vga v.ga Maximum sliding velocity on tip (m/s)
Vqual Accuracy grade
w w Nominal circumferential force reference circle per mm (N/mm)
Wk W.k Base tangent length (no backlash) (mm)
W.k e/i Effective base tangent length (mm) (e: upper, i: lower)
x x Profile shift coefficient
xE x.E Profile shift coefficient at manufacturing for Ase
Xαβ X.alfbet Angle factor
XB X.B Geometry factor
XBE X.BE Geometry factor
XCa X.Ca Tip relief factor
Xe X.e Contact ratio factor
XΓ X.Gam Mesh load factor
XM X.M Flash factor
XQ X.Q Meshing factor
XS X.S Lubrication factor (scuffing)
XWrelT X.WrelT Relative structural factor (scuffing)
ya y.a Running-in value (μm)
yb y.b Running-in value (μm)
Y Y AGMA: Tooth form factor
Yb Y.b Helical load factor
Y drel Y.drel Notch sensitivity factor
Ye Y.e Contact ratio factor
YF Y.F Tooth form factor
Y NT Y.NT Limited life coefficient
III Answers to Frequently Asked Questions 560
YR Y.R Surface factor
YS Y.S Stress correction factor
Y st Y.st Stress correction factor test gear
YX Y.X Size factor (tooth root)
z z Number of teeth
zn z.n Substitute number of teeth
Zβ Z.b Helix angle factor
ZB/D Z.B/D Single contact point factor
ZE Z.E Elasticity factor (N1/2/mm)
Zε Z.e Contact ratio factor
ZH Z.H Zone factor
ZL Z.L Lubricant factor
ZNT Z.NT Limited life coefficient
ZR Z.R Roughness factor
ZV Z.V Speed factor
ZW Z.W Material hardening factor
ZX Z.X Size factor (flank)
ζw zet.W Wear sliding coefficient according to Niemann
ζa zet.a Specific sliding at the tip
ζf zet.f Specific sliding at the root
IV
Shafts and Bearings
Chapter 27 - 33
IV Defining Shafts 562
27 Defining Shafts
This program consists of a base package and different expert add-ins. The following calculations are
available:
▪ Deformation and force, torque and stress curves
▪ Eigenfrequencies (bending, torsion and axial movements)
▪ Buckling loads
▪ Static and fatigue strength
▪ Rolling bearing calculation
▪ Plain bearing calculation (hydrodynamic)
▪ Necessary width modification of pinions
Base package
In this module, you can input and correct geometry and material data, shaft specifications, the
drawing number, the support, boundary conditions and external forces and torques (simplified input
for couplings, spur and bevel gears, worms, worm gears, belt pulleys etc.).
A shaft with the machine elements mounted on it (for example, gears or bearings) is defined in the
graphical Shaft Editor.
The properties required to define a shaft in this Editor are:
▪ Any dimensions (cylindrical and conical), axially symmetric cross section, solid and hollow
shafts, beams (H-, I- or L-profile etc.)
▪ Integrated drawing tool that enables simple modifications to be made to the shaft contour
(diameter, lengths). You can change any of these elements simply by clicking on them with the
mouse.
▪ Definition of notch geometries for the automatic calculation of notch factors.
The following notch geometries are available here:
▪ Radius
▪ Chamfer
▪ Relief groove
▪ Interference fit
▪ Longitudinal key way
▪ Circumferential key way
▪ Square key way
▪ V-notch
▪ Spline
IV Defining Shafts 563
▪ Cross hole
▪ You can enter these values for force and torque in any spatial positions, however, the following
values are already predefined:
▪ Cylindrical gear
▪ Bevel gear
▪ Worm
▪ Worm wheel
▪ Coupling
▪ Pulley/V-belt
▪ Centrical force
▪ Eccentric force
▪ External masses with moment of inertia (additional mass)
▪ Power loss
▪ Calculation of:
▪ Shaft weight
▪ Moment of inertia
▪ Axial force
▪ Static twisting of the shaft due to torsion
▪ Clear representation of geometry data and the calculated bearing and peripheral forces both on
screen and on paper.
27.1 Input window
The KISSsoft system offers a range of different input windows in which you can calculate shafts. The
Shaft Editor (see chapter 27.1.1, Shaft editor) displays the shaft system as a graphic. The Element
Tree (see chapter 27.1.2, Element Tree) illustrates the structure of the shaft system in a tree
structure. The Element editor (see chapter 27.1.4, Element Editor) is where you input parameters for
an element.
27.1.1 Shaft editor
The Shaft editor displays the shaft system as a graphic. Enter elements in the Element box here. If
your system has several shafts, the new element is always added to the active shaft. A shaft
becomes active when one of its elements is selected. If no element has been selected, the last shaft
is the active one.
You can select options in the context menu to save the graphic as a picture file, and print it, in the
Shaft editor. Each of the different elements also has interactive context menus.
IV Defining Shafts 564
27.1.2 Element Tree
The Element Tree illustrates the structure of the shaft system in a tree structure. Shafts are at the
highest level. The connecting elements in systems with several shafts are also shown here. Each
shaft groups its main elements by Outer contour (see chapter 27.2.2, Outer contour), Inner contour
(see chapter 27.2.3, Inner contour), by Strength (see chapter 27.2.2.1, Defining sub-elements), by
Bearings (see chapter 27.2.5, Bearings) and by Cross sections (see chapter 27.2.7, Cross sections).
The sub-elements of the cylinder and conus main elements are located on a another sub-level.
You can select, copy, insert and delete elements via the Element Tree. You can select options in a
context menu to display the actions that are available for each element. Special actions are available,
depending on the element type. You can also size shafts, rolling bearings and cross sections. You
can also import/export outer and inner contours to DXF. (see chapter 27.2.2.2, Importing the shaft
geometry)/ (see chapter 27.2.2.3, Export shaft geometry).
27.1.3 Element List
The Element List contains groups of elements in table format. You can edit the parameter listed in
the table directly in the Element List. Using the context menu, you can insert elements quickly and
easily.
27.1.4 Element Editor
In the Element Editor, you can edit any of the selected element's parameters.
27.2 Element overview
27.2.1 The shaft element
To add a new shaft, click on the can of the appropriate icon in the Element box (see chapter 27.1.1,
Shaft editor). You will also find the Add shaft option in the Element tree context menu (see chapter
27.1.2, Element Tree). A new entry is displayed at the end of the Element Tree. Click on the element
you require in the Element Tree and enter parameters for the shaft in the Element editor (see chapter
27.1.4, Element Editor).
27.2.1.1 Drawing number
In the Drawing number input field, you can enter a string of any characters apart from ";"
(semicolons). The drawing number you enter here does not affect the calculation.
IV Defining Shafts 565
27.2.1.2 Position
The Position input field is where you enter the Y coordinate of the starting point of the shaft with
regard to the global coordinates system.
► Note
Global coordinates are indicated by upper case letters. Lower case letters indicate a shaft's local
coordinates system.
27.2.1.3 Temperature
The shaft may undergo thermal expansion if the shaft's temperature is not the same as the reference
temperature (see chapter 27.3.6, Reference temperature). In addition to the thermal expansion of the
shaft, the thermal expansion of the gear case can also be taken into account by the housing
temperature (see chapter 27.3.7, Housing temperature).
27.2.1.4 Ambient density
Bodies placed in hydrostatic fluids become buoyant. The value here is the same as the weight of the
displaced medium, and is defined by the volume and the density of the displaced medium. KISSsoft
takes this buoyancy effect into account if you enter the appropriate ambient density value. The
default setting is for air density. The table below lists technical values for other media.
Medium Air Water Oil
Density ϱ 1.2 998 772
Table 27.1: Densities [kg/m3] of a few important fluids where ϑ = 20oC and p = 1016 mbar
► Note
If a shaft is operated in different ambient media, as is the case for input shafts in ships, for example,
you can combine two individual shafts, each of which has different ambient density data, by using the
Connections element in the Element Tree, and then calculate them as a single shaft.
27.2.1.5 Speed
Shaft speed around its longitudinal axis [rpm]. If you click the checkbox to the right of the input field,
you can change the speed independently of the other shafts. However, if this checkbox is not active,
the value is taken from the Speed input field (see chapter 27.3.4, Speed) in the Basic data input
window.
IV Defining Shafts 566
27.2.1.6 Direction of rotation
The sense of rotation can influence the way loads are distributed along the shaft, for example, as the
result of helical gear teeth, and therefore affect the rating life of the bearing. Click the checkbox to the
right of the Speed input field to display the drop-down entries and select the one you require.
However, if this checkbox is not active, the value is taken from the Shaft rotation input field (see
chapter 27.3.5, Direction of rotation) input field in the Basic data input window.
27.2.1.7 Material
You can select a shaft material from this selection list and therefore assign a specific material to each
individual shaft. If you use this function together with the Connections element in the Element Tree,
you can generate shafts made of different materials.
27.2.1.8 Base size
The Raw dimension input field is decisive for strength calculation. However, if you select the Pre-
machined to actual diameter option in the State during heat treatment drop-down list, in the
Strength input window, the setting for the raw measure value has no effect on the calculation. In
contrast, if the selection is set to Raw diameter, the largest rounded shaft diameter is selected, and
the strength calculation is performed with this value. Click the checkbox to the right of the input field
to specify your own diameter for the blank before it is turned.
27.2.1.9 Hardening depth (FKM)
The hardening depth input field is required for estimating the infinite life strength of surface-treated
parts. Hardening depth is used to define the position of the transition surface layer relative to the
core. It varies depending on which surface treatment process has been used. This input is not
required for the main calculation. You will find another description of this calculation in the "Estimate
the fatigue strength of surface treated parts" section.
27.2.1.10 Surface factor
In this selection list, you can define if an additional surface factor should be applied. Here, you can
select either Rollers or Shot peening.
27.2.1.11 State during heat treatment
To define the technological size coefficient K1,deff, select one of these three options:
IV Defining Shafts 567
▪ Pre-machined to actual diameter. The raw diameter has no influence on the technological size
coefficient. The value K1,deff is recalculated for each cross section based on the actual diameter
size.
▪ Raw diameter. K1,deff is determined once from the raw diameter and applied to all cross sections.
▪ Pre-turned to actual diameter (shoulders K1 from d)
► Note
You can also set a value in the Base size field in the Element editor for the relevant shaft. To do
this, input the dimension of the raw material that was used to generate the final material properties
during the last heat treatment. If this involves a solid shaft, enter the external diameter of the blank
part. For a pipe, enter the wall thickness and, for a cast part, enter the greatest wall thickness.
27.2.1.12 Heat treatment of hollow shafts in the full state
If you do not input the raw diameter for a "heat treatment state", and you are investigating a hollow
shaft (di > 0.1*da), you can use this option to specify
whether the coefficients are determined using the solid shaft or hollow shaft. This option is only valid
for the FKM and DIN calculation methods.
Table 1.2.3 in the 6th Edition of the FKM Guideline shows data for both a hollow shaft and a solid
shaft, and also methods for Case 1 and Case 2. Case 1 is for parts made of treated steel, case
hardening steel etc., Case 2 is for parts made of unalloyed steel, normally annealed through
hardening steel, etc. KISSsoft automatically calculates values for these 2 cases when you input the
material.
According to DIN 743-2, the shaft diameter deff is used for factor K2 and K3. If a solid shaft is
involved, the diameter is used for coefficient K1. If a hollow shaft is involved, the wall thickness s or
2x the wall thickness s is used for deff, according to FKM.
27.2.1.13 Material properties
Select an entry in the Material characteristic values drop-down list to specify how KISSsoft is to
define the material characteristic values that are relevant to strength:
1. with reference diameter Values are taken from the database (in the case of the reference
diameter) and multiplied by K1
2. Rp, Rm as stated in database, sW for reference diameter The values Rp and Rm are
determined according to size (excluding K1), and the fatigue strength σW is determined for the
reference diameter entered in the database and then it is multiplied by K1.
IV Defining Shafts 568
3. Rp, Rm as stated in the database, σW constant The values Rp and Rm are determined
according to size, and the fatigue strength σW is taken from the database without being
influenced by the geometric size factor. The size factor K1 is not taken into account here.
4. Rp, RM according to the database, σW is calculated from Rm The values Rp and Rm are taken
from the database, and σW is determined from the tensile strength Rm according to the standard.
The material's data, used to calculate the shaft strength, is derived from the values in the database
as follows:
▪ Fatigue limit factors (for tension/compression, bending, etc.) are taken directly from the material
database. There, these values are defined for every calculation method. If data for these
materials has been specified in the calculation method, it is these values that are used.
▪ Tensile strength values are stored in the database according to their diameter as defined in the
specific EN standard. The raw diameter is used to fetch the tensile strength value from the
database and use it in the calculation. This method of defining the effective tensile strength is
very reliable and can be used for every calculation method. It has the effect that the same
values are used for each calculation method.
When you specify a calculation method, you can decide to use the material database on the
basis of the requirements given in the relevant standard. Then, the real tensile strength is
defined using the thickness factor taken from the base tensile strength of the sample diameter
(normally 10 mm), according to the standard (which must be FKM or DIN. If you use Hänchen,
this triggers an error message).
▪ The yield point or strain limits are taken either from the database or from the standard, in the
same way as for the tensile strength.
27.2.1.14 Own data for S-N curve (Woehler line)
Click the Own data S-N curve (Woehler line) checkbox to define your own S-N curve (Woehler
line). You can also enter values for the sustainable damage or Miner total here. If this option is not
selected, the S-N curve (Woehler line) according to DIN 743 or FKM is used.
27.2.1.15 Taking the results into account in the report
If this option is selected, the corresponding shaft is output in the main shaft report, along with all its
elements (outer/inner contour, force elements, bearing). However, this is only valid for inputs and
does not affect the results of the calculation.
IV Defining Shafts 569
27.2.2 Outer contour
You can use (hollow) cylinders, (hollow) cones and beams to define the shaft geometry. You can
either use the Element box or select "Add" in the context menu to add elements to the Element Tree.
If you have selected a contour element in the Shaft editor or Element Tree, select "Insert before" in
the context menu to insert a new element to the left of it or select "Insert after" to insert a new
element to the right of it. By default, the new element is inserted to the right.
Possible profiles for beams are:
Rectangular profile Double T profile
H profile Rectangular profile (hollow)
IV Defining Shafts 570
L profile
27.2.2.1 Defining sub-elements
Before you can define a sub-element, first select the main element to which you want to add this sub-
element in the Element Tree. Then, right-click to select the sub-element you require. The inserted
sub-element is now displayed in the Shaft editor, and its associated notch factors are determined in
the strength calculation.
Entering sub-elements:
▪ Radius right/left
Input values:
▪ Radius: Size of the radius
▪ Surface roughness: Radius surface
▪ Chamfer right/left
Input values:
▪ Length: Chamfer length
▪ Angle: Chamfer angle
▪ Relief groove right/left
Input values:
▪ Relief groove form: Select the relief groove form as defined in DIN 509 or the FKM
Guideline.
▪ Series (DIN 509): (Selection: Series 1, radii as defined in DIN 250. Series 2, special radius.)
▪ Stress (DIN 509): (with conventional stress; with increased fatigue strength)
▪ relief groove length: Length of the relief groove in axial direction
▪ Transition radius: Radius between the end of the relief groove and the next element
IV Defining Shafts 571
▪ Depth of recess: Recess depth
▪ Surface roughness: Recess surface
▪ Interference fit
Input values:
▪ Length of Interference fit: Interference fit length
▪ Type of interference fit: (Selection: Slight interference fit, interference fit and interference fit
with end relief.)
▪ Reference measure: this specifies the measurement from the left-hand end of the selected
element up to the start of the interference fit
▪ Key way
Input values:
▪ Length: Key way length
▪ Standard: Standards used for keys
▪ Key way width: Width of the key way (can be entered if "Own Input" is selected)
▪ Key way depth: Depth of the key way (can be entered if "Own Input" is selected)
▪ Number of keys: (i > 2 not permitted according to standard)
▪ Manufacturing process: (Selection: end milling cutter, side milling cutter, combined with
interference fit (FKM))
▪ Surface roughness: Keyway surface
▪ Reference measure: this specifies the measurement from the left end of the selected
element up to the start of the keyway
▪ Circumferential groove
Input values:
▪ Depth: Depth of the circumferential groove
▪ Rounding in the groove bottom: Radius of the circumferential groove
▪ Surface roughness: Surface of circumferential groove
▪ Reference measure: this specifies the measurement from the left end of the selected
element up to the middle of the circumferential groove
▪ Square groove
Input values:
▪ Width: Width of the square groove
▪ Depth: Depth of the square groove
▪ Radius: Radius of the square groove
▪ Surface roughness: Surface of the square groove
▪ Reference measure: this specifies the measurement from the left end of the selected
element up to the middle of the square groove
IV Defining Shafts 572
▪ V-notch
Input values:
▪ Depth: Depth of the V-notch
▪ Surface roughness: Surface of the V-notch
▪ Reference measure: this specifies the measurement from the left end of the selected
element up to the middle of the V-notch
▪ Spline
Input values:
▪ Standard: Standard series of spline (click the button to select the required size from a
list)
▪ Tip circle: you can either select this from a list of standards or input your own value
▪ Root circle: you can either select this from a list of standards or input your own value
▪ Number of teeth: you can either select this from a list of standards or input your own value
▪ Module: you can either select this from a list of standards or input your own value
▪ Surface quality: Spline surface quality
▪ Length: Spline length
▪ Reference measure: this specifies the measurement from the left end of the selected
element up to the start of the spline
▪ Spline shaft
Input values:
▪ Tip circle: Tip circle of the spline shaft
▪ Root circle: Root circle of the spline shaft
▪ Number of keys: Number of keys
▪ Straight-sided splines root rounding: (Selection: Shape A, Shape B and Shape C)
▪ Length: Length of the spline shaft
▪ Reference measure: this specifies the measurement from the left end of the selected
element up to the start of the spline shaft (straight-sided spline)
▪ Surface quality: Spline shaft surface
▪ Cross hole
Input values:
▪ Bore diameter: Diameter of bore
▪ Surface roughness: Cross hole surface
▪ Reference measure: this specifies the measurement from the left end of the selected
element up to the position of the cross hole
▪ Thread
Input values:
▪ Label: Thread label
IV Defining Shafts 573
▪ Thread depth: Thread depth
▪ Rounding: Rounding in the notch bottom of the thread
▪ Length: Thread length
▪ Reference measure: this specifies the measurement from the left-hand end of the selected
element up to the start of the thread
▪ Surface roughness: Thread surface
▪ General notch effect
Input values:
▪ Width: Width of the overall sub-element
▪ Notch factor bending/ torsion/tension-compression/shearing force: you can enter the notch
factors directly here.
▪ Surface roughness: Surface of the overall sub-element
▪ Reference measure: this specifies the measurement from the left end of the selected
element up to the middle of the overall sub-element
You can enable the "Conical shoulder" notch type directly in the Strength calculation (see chapter
28.5.14, Cross-section types).
27.2.2.2 Importing the shaft geometry
Right-click on "outside" or "inner contour" in the Element Tree to open a context menu. Click Import
to import a .ktx or a .dxf file.
Reading (importing) a ktx file:
In KISSsoft, go to the Shaft calculation Element Tree and right-click on the Outer contour element to
display the context menu. Select the Import option in it. Select the required .ktx file and click on
Open. The shaft contour is now imported into KISSsoft.
Reading (importing) a dxf file:
The outside and inner contour of the shaft (if present) should be output individually by the CAD
system.
► Note:
You can use the default value ALL for the layer name, so that all layers are imported. You can also
import the contours as variants in different layers. To do this, enter the layer name in the appropriate
input field. If you don't know the exact layer designation, you can input an invalid name as a test (for
example, xxx). If you then try to import this file, the resulting error message will list the valid layer
names.
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▪ The shaft contour is displayed with a centerline in a CAD system. Use the X-Y plane as the
coordinates system (the X-axis is the rotational axis) to ensure the contour is interpreted
correctly after it has been imported and so that the shaft is drawn in KISSsoft in the Y-Z plane
(the Y-axis is the rotational axis). Save the shaft geometry as a .dxf file.
▪ In KISSsoft, go to the Shaft calculation Element Tree and right-click on the Outer contour
element to display a context menu in which you select the Import option. Select the .dxf file you
require, and click Open.
▪ This opens another dialog, in which you can define the layer, the point of origin (X/Y) and the
angle of the symmetry axis. After you have input this data, click OK to close this dialog. The
shaft contour is then imported with these details.
27.2.2.3 Export shaft geometry
Right-click on "outside" or "inner contour" in the Element Tree to open a context menu. If you select
Export, you can create either a .ktx or .dxf file.
27.2.3 Inner contour
The inner contour is built up from left to the right, in the same way as the outer contour. For example,
if you want to generate a shaft with an axial hole from the right-hand side, you must first input data
for an inside cylinder starting from the left-hand side with a diameter of 0 that extends up to the point
where the bore begins.
27.2.4 Forces
27.2.4.1 Forces
You can add forces to any place on the shaft, even outside of the shaft! Different methods are
available for defining force-transmitting elements (such as gears) or even individual forces. In most
force elements, the direction of the torque is defined by setting them as "driving" or "driven". "Driving"
means that the shaft is the driving element or that the moment is counter to the sense of rotation,
(see chapter 27.3.5, Direction of rotation).
Comments about some of the elements:
▪ Cylindrical gear
Position of contact: If you enter the position of contact with the other gear, forces are applied at
this point. Instead of simply entering the reference diameter, you get a more accurate result if
you enter the operating pitch diameter and the operating pressure angle instead of the nominal
pressure angle.
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Click the Convert button to calculate these values.
If the meshing type is set to "Multiple contact", you can model several meshings on the same
cylindrical gear element. You must then define the position, the active operating pitch diameter
and the length of load application for each meshing. The resulting working transverse pressure
angle, and the helix angle, are then determined automatically from this data.
By default, the center point for load application is the center of the gear. This can be changed by
defining the load application position offset δyF, according to the following formulae:
original starting position of gear load application: L0 = middle of the gear - (gear width/2)
Original final position of the load application on the gear: R0 = middle of the gear + (gear
width/2)
* If δyF > 0
New starting position, load application on the gear: L1 = L0 + 2 * δyF
New final position, load application on the gear: R1 = R0
* If δyF < 0
New starting position, load application on the gear: L1 = L0
New final position, load application on the gear: R1 = R0 + 2 * δyF
The calculations shown above are only valid if the relevant setting is enabled in the Module
specific settings. Use the same process for all the gear elements.
▪ Bevel gear
Position of contact: refer to the data for cylindrical gears.
The bevel gear's position can be converted using the bevel gear data. The reference point for
positioning is the middle of the bevel gear width on the pitch cone. The position of the bevel gear
can be converted using the position of the axis crossing point on the shaft and other bevel gear
data.
The formulae in ISO 23509:2016 Annex D are used to determine the axial and radial forces for
bevel gears in the shaft calculation.
An additional force component due to friction is taken into account when calculating hypoid
gears. The corresponding coefficient of friction μ can be defined in the module-specific settings.
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▪ Face gear
The pitch angle for face gears is always set to 90° (this input cannot be changed).
▪ Worm
This is usually a driving element. Its efficiency is included in the calculation of force components.
Position of contact: refer to the data for cylindrical gears.
If the worm data is read from a Z80 file, select the "Calculation with enhanced formulae (differs
from standard)" checkbox in the Calculations tab, in "Module specific settings", in the worm
gear calculation. This ensures that the radial forces in the shaft calculation match up with the
radial forces in the worm gear calculation (see chapter 20.5.4.3, Calculation with enhanced
formulae (differs from standard)).
▪ Worm wheel
This is usually a driven element. Its efficiency is included in the calculation of force components.
Position of contact: refer to the data for cylindrical gears.
▪ Rope sheave
Direction of rope sheave: Input the direction of the resulting belt forces as shown in (see Figure
27.4)
The direction of the helix angles and the positions of the elements are defined in Figure (see Figure
27.1).
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Figure 27.1: Defining the direction of force elements.
Eccentric force
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Figure 27.2: Cartesian/polar coordinates for eccentric force
You can enter values for eccentric force either in Cartesian or polar coordinates (see Figure 27.2).
You can change the coordinates system in the Drawings/Settings screen in the Shaft Editor.
Transferring data from gear calculation
In the Element Editor, you can import the data used to define spur and bevel gears from a gear
calculation file. Select the element you require in the Element Tree and then click on the Read data
from file checkbox. Then select the gear number (1 to 4). The data relevant to these gear pairs is
then imported directly. In this situation, the data at the pitch point is used instead of the data at the
reference circle.
Important: If the Read data from file option in this input window remains selected, data will be
reimported from the gear calculation every time you call the shaft calculation function. If you then
change the gear data later on, the new data will automatically be transferred with it! However, if you
only want to import this data once, deactivate this option again once you have imported your data.
27.2.4.2 Coupling
A coupling transmits torque and can also be subject to radial and axial forces. From the torque (or
the specified power and speed) you can calculate the circumferential force to
(24.2)
Ft = Circumferential force
Mt = Torque
d = Effective diameter
Calculating radial force for a coupling:
(24.3)
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Ft = Circumferential force
K2 = Radial force factor
Define the direction of the force in the input window. You are also prompted to enter the mass of the
coupling so it can be included in the calculation as a gravitational force.
Calculating axial force for a coupling:
(24.4)
Ft = Circumferential force
K3 = Axial force factor
Axial force acts along the center line of the shaft.
27.2.4.3 Masses
Masses placed on the shaft are used as moments of inertia to determine the critical speeds. They
are to be considered as a gravitational force.
27.2.4.4 Magnetic force
The axial force of the magnetic force is shown in the following equation:
In this case,
F*A = axial force factor
T = torque (with sign)
k = groove lead
k= -1 = groove lead, right
k= +1 = groove lead, left
k= 0 = groove lead, straight
This figure is the schematic display for an armature with a groove lead (left).
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Figure 27.3: Figure: Armature with groove lead (left)
27.2.5 Bearings
In addition to calculating the shaft, you can export rolling bearings, plain bearings and general
bearings as separate rolling bearing or plain bearing calculation files (File > Export).
27.2.5.1 Support
A support is a generic boundary condition for the associated shaft. You can configure this boundary
condition to suit your own requirements. You can model all six degrees of freedom as non-locating,
elastic or rigid. You can also input the stiffness or clearance as required for all degrees of freedom.
The next table lists the different templates that are also available for commonly used bearing types:
Support selection list ux uy uz rx ry rz
Own Own Own Own Own Own
Own Input
definition definition definition definition definition definition
non- non- non- non-
Non-locating bearing fixed fixed
locating locating locating locating
Fixed bearing adjusted on non- non- non-
fixed fixed fixed
both sides <-> locating locating locating
Fixed bearing adjusted on non- non- non-
fixed right fixed
right side -> locating locating locating
Fixed bearing adjusted on left non- non- non-
fixed left fixed
side <- locating locating locating
Axial bearing adjusted on non- non- non- non- non-
fixed
both sides <-> locating locating locating locating locating
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Axial bearing, adjusted on non- non- non- non- non-
right
right side -> locating locating locating locating locating
Axial bearing adjusted on left non- non- non- non- non-
left
side <- locating locating locating locating locating
Fixed fixed fixed fixed fixed fixed fixed
ux, uy, uz: Displacement in x-, y- and z-direction
rx, ry, rz: Rotation about x-, y- and z-direction
27.2.5.2 Rolling bearings
In addition to a general support, you can also select a specific rolling bearing. If you do so, the
bearing data is taken from the rolling bearing database.
If a suitable entry is present in the bearings database, the bearing stiffness value is taken from there.
Alternatively, you can enter the values directly in the Element editor. You also have the option of
defining the radial and axial stiffness, and the tilting stiffness, in a file (for example "W05-
Stiffness.dat" in the "dat" directory), and then using these values to calculate the local operating
stiffness of the bearing. The file should include the bearing clearance in the position contact-load
curve, which is why the value input for clearance is set to 0 when the file is imported.
A pretension force, applied on the outer ring, can be used to define the pretension force on the
bearing, instead of using the offset. This is only taken into account for bearings with inner geometry,
and only if the relevant bearing can accept an axial pretension force. The pretension force is then
transformed internally to an equivalent axial offset of the outer ring. For bearings with inner geometry,
you can also specify a rotation around the x and z axis of the outer ring. This could then be used, for
example, to model the housing deformation, so you can enter the FEM results directly.
Pd = do – di – 2 * Dw
Here, Pd is the diametral pitch bearing clearance, do is the outside raceway diameter, di is the
internal raceway diameter and Dw is the rolling element diameter. Similar definitions are used for
other bearing types, which vary depending on which particular type is involved.
The rolling bearings can be modeled as radial or thrust bearings, each with different mountings,
(refer to the next table):
Rolling bearing selection list ux uy uz rx ry rz
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non- non- non- non-
Non-locating bearing fixed fixed
locating locating locating locating
Fixed bearing adjusted on both sides non- non- non-
fixed fixed fixed
<-> locating locating locating
non- non- non-
Fixed bearing adjusted on right side -> fixed right fixed
locating locating locating
non- non- non-
Fixed bearing adjusted on left side <- fixed left fixed
locating locating locating
Axial bearing adjusted on both sides non- non- non- non- non-
fixed
<-> locating locating locating locating locating
non- non- non- non- non-
Axial bearing, adjusted on right side -> right
locating locating locating locating locating
non- non- non- non- non-
Axial bearing adjusted on left side <- left
locating locating locating locating locating
27.2.5.3 Plain bearings
Hydrodynamic plain journal bearings (see chapter 31, Hydrodynamic Plain Journal Bearings) can be
represented with the plain journal bearing element. In addition to entering the nominal width B, the
attitude angle β and the diametral clearance Pd, you can also input the radial stiffness cr. This affects
the shaft after the available clearance has been fully used. You can also enter a damping rate dr to
evaluate the forced vibrations (see chapter 28.8, Forced vibrations).
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The plain bearing is implemented as a non-locating bearing which can transmit radial forces but no
tilting moments. If a particular configuration results in tilting moments, which the plain bearing must
be able to transmit in practice, you must add in a support to ensure the modeling is correct.
27.2.5.4 Pure thrust bearing
If a bearing is defined as a pure thrust bearing (left/right/both side layout) no radial forces can be
transferred to it. Any radial forces created by the pressure of the outer ring on the housing and the
corresponding coefficients of friction will be ignored.
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27.2.6 Connection elements
A number of coaxial shafts can be connected by two different connection elements: "General
connection", "Connecting rolling bearing" or "Connecting plain bearing".
The connecting element between these shafts defines the shaft's degree of freedom at the
connection point for the three relative displacements along the x-, y- and z-axis, and three relative
rotations around the x, y and z axis.
27.2.6.1 General connection
A general connection is similar to a support. It is a generic connection for the associated shaft that
can be configured to suit your own requirements. You can model all six degrees of freedom as non-
locating, elastic or rigid. You can also input the stiffness or clearance as required for all degrees of
freedom.
The "Joint" and "Stiff connection" templates are available for typical bearing types.
Joint: All displacements are prohibited, but all rotations are permitted.
Stiff connection: All degrees of freedom (3 displacements and 3 rotations) are prohibited.
27.2.6.2 Connecting rolling bearing
A rolling bearing can be used to connect two shafts. The data you input is the same as that for a
rolling bearing for a single shaft, but with the addition of inputs for the internal and external shaft.
The bearing inner ring is assumed to be fixed on the inside shaft, and the bearing outer ring is
assumed to be fixed on the outside shaft. The type of the bearing (fixed bearing, placed on left/right
side, etc.) defines how the axial forces are transmitted from the shaft through the bearing.
As connection elements are able to transfer not only forces but moments, we strongly recommend
that the bearing calculation is performed with internal geometry as defined in ISO/TS 16281.
27.2.7 Cross sections
You will find more examples of cross sections and the strength calculation in the "Calculating Shafts"
chapter 28, especially in (see chapter 28.5.12, Cross sections).
27.2.7.1 Free cross section (single notch)
You can use free cross sections to input notch effects, no matter what the actual definition of the
shaft geometry.
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27.2.7.2 Free cross section (multiple notches)
Use this type of cross section to input stress results from a FE calculation at a specific point on the
shaft. This is then used to determine a notch factor which can be used to run a nominal stress-based
proof according to DIN 743. The standard's application limits also apply to this type of calculation.
You will find a more detailed description in (see chapter 28.5.6.4, Calculation of multiple notches
according to DIN 743).
27.2.7.3 Limited cross section
You should define the restricted cross section as the preferred cross section type in shaft
calculations. The notch effect is determined automatically according to the geometry data input at
this position in this cross section. If you make changes to the shaft geometry, you do not need to
modify the cross section manually. The changes are transferred automatically. However, if you are
working with restricted cross sections, you must input shaft geometry in detail.
27.2.7.4 Documentation point
You can use a documentation point to document the equivalent stress, displacement, rotation, force
and moment at any position on the shaft in the editor and in the report.
27.3 Basic data
The Basic data input window is where you enter the basic settings for the shaft calculation. The
relevant parameters are described below.
27.3.1 Position of shaft axis in space
The position of the shaft axis in space is defined accordingly (see Figure 27.4).
The weight of the shaft (in a horizontal position) is considered a gravitational force in the Z-Y plane
when calculating the deflection. However, if the shaft is positioned vertically, the resulting axial force
is, for example, included in rolling bearing calculations. If a shaft is positioned at an angle, the
relevant components are distributed correctly on the Z-Y plane and on the axial force.
Alternatively, you can use the 3-coordinate format to enter the shaft mass direction vector.
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Figure 27.4: Defining the position of the shaft and the position of contact.
27.3.2 Number of eigenfrequencies
Defines the number of eigenfrequencies that KISSsoft is to determine (see chapter 28.2,
Eigenfrequencies).
27.3.3 Number of buckling cases
Defines the number of buckling cases that KISSsoft is to determine (see chapter 28.3, Buckling).
27.3.4 Speed
Enter the speed in revolutions per minute (rpm). Click the button to display the Define speed
window. This is where you define the speed and the sense of rotation for all the shafts.
The shaft speed used for the calculation can also be found in the corresponding report: select
"Report" > "Shaft speeds".
► Note
If you change the speed, the effective torques and power change accordingly.
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27.3.5 Direction of rotation
The shaft axis runs along the positive y-direction (left to right in the graphical Shaft Editor). In the
Shaft Editor, the z-axis points vertically upwards and the x-axis points towards the user. A right-hand
rotation of the shaft around the positive Y-axis direction is specified as "clockwise".
The next figure shows the direction of these coordinates and the positive direction of forces and
moments. Note that weight has an effect in the negative z-direction if the shaft is positioned
horizontally (see chapter 27.3.1, Position of shaft axis in space).
In most force elements, the direction of the torque is defined by setting them as "driving" or "driven".
If you enter a "driving" value, this means either that the shaft drives (an external application) or that
the moment runs counter to the sense of rotation (i.e. the shaft loses power). If you enter a "driven"
value, this means either that the shaft is driven from outside (e.g. by a motor) or that the moment
runs in the same direction as the sense of rotation (i.e. the shaft is supplied with power).
27.3.6 Reference temperature
The reference temperature is the temperature used in the drawing data or to check the part.
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27.3.7 Housing temperature
When used together with the thermal expansion coefficient, the housing temperature causes a
general displacement of all the bearing points. It also affects the operating clearance of rolling
bearings.
It is assumed that the bearing's outer ring and the housing or the outer ring have the same
temperature and that the bearing's inner ring and the inner shaft also have the same temperature.
► Note
Take the axial stiffness of the bearings into account if you want to examine the influence of thermal
expansions. Otherwise, the load peaks will be too high.
Reference point housing
Reference point for the displacement of bearing points due to the thermal expansion of the housing.
For example, if yθ = 0, this means all thermal expansion is considered relative to the global frame of
reference.
The magnitude of the thermal expansion which is applied on the bearing outer ring is given by ΔL,
where
is the housing temperature
is the reference temperature
is the coefficient of thermal expansion of the housing material
is the global axial coordinates of the bearing (relative to the global frame of reference, not the
shaft)
is the housing temperature thermal reference point used to perform the calculation
For example, if yθ = 0, this means all thermal expansion is considered relative to the global frame of
reference.
27.3.8 Lubricant temperature
The Lubricant temperature changes the lubricant's viscosity. This value is used to determine the
extended bearing rating life (aISO) and the moment of friction.
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27.3.9 Load spectra
If the loads defined in the Shaft Editor have been assigned a load spectrum, this can be taken into
account when calculating deformation. Deformation can also be calculated either for the nominal load
or for any element of the load spectrum.
To take load spectra into account, select Load spectra and then click on the Consider load spectra
option. However, if you only want to perform the calculation for a single load bin, select Consider
only one load bin of the load spectra. Enter the appropriate element number in the input field to
the right of the drop-down list.
If the Consider load spectra option is selected, the following modifications are made if the definition
of the load spectra is inconsistent:
▪ if the frequency H = 0 is set, this is set to the value 10 ^-10
▪ if the speed factor nfact = 0, this is set to 10^-5 and the torque/load factor is set to 10^-10
▪ if the torque/load factor is set to Tfact = 0, this is set to 10^-10
27.3.9.1 Load spectrum with negative bins
Load spectra with negative load spectrum elements (T < 0 and/or n < 0) are handled as follows:
Coefficient for torque Coefficient for Shaft direction of rotation Force element
speed
+ + - -
+ - C D
- + - D
- - C -
- = unchanged
C = shaft direction of rotation changes clockwise/counterclockwise
D = driving/driven changes
27.3.10 Gears
If the calculation includes gears, they can be considered in a number of different ways:
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▪ Gears are only load applications: The masses and stiffnesses of the gears are not taken into
account.
▪ Consider gears as masses: The gear is handled as a mass in the bending calculation. The
mass results from the difference between the operating pitch circle and the external shaft
diameter as well as the gear width (same specific weight as the shaft).
▪ Consider gears as mass and as stiffness: The gear is handled as part of the shaft contour (for
example, integral pinion shaft).
▪ Consider gears mounted by interference fit with stiffness according to ISO 6336-1 (with dw
instead of dr): The shaft is stiffened at the mid diameter dm, with dm = (d1+d2)/2, d1 = shaft
diameter, d2 = the gear's operating pitch circle. The reference diameter is used to calculate the
gear's weight. The mean diameter is used in all the other calculations (IXX, Izz, Ip, WXX, Wzz, Wp).
► Note
If gears have been mounted on shafts by interference fit, it is usually hardly possible to assess the
extent to which the gear stiffens the shaft. You cannot use KISSsoft to solve this problem. However,
you can estimate the influence the interference fit has: It is sufficient to perform the calculation for
Gear as mass and for Gear as mass and stiffness and note the difference in the diagrams of
bending. If the difference is small, the interference fit has no influence. However, if the difference is
significant, you must enter more precise information. To do this, you must integrate a part of the gear
in the shaft contour in the graphical shaft input.
If multiple identical gear elements are defined at the same position, for a gear with multiple contacts
(such as a sun wheel in a planetary system), the weight is only taken into consideration once.
27.3.11 Rolling bearings
If the calculation includes rolling bearings, they can be considered in a number of different ways:
▪ Stiffness: not calculated. Service life: ISO 281, with manufacturer's notes: Calculation using
the classic method (as described in manufacturers' catalogs). In this calculation of the way
bearings with a contact angle (e.g. taper roller bearings) react, the bearing reaction is
determined at the place where the direction force intersects with the shaft's symmetry axis.
In this way, the interdependency between the axial and radial forces, such as exists in taper
roller bearings, is included in the calculation. Rolling bearings primarily place constraints on the
degree of freedom of movement found in displacement and/or rotation, which is why they are
modeled in this way when you select this option. You can input displacement or torsional
stiffness (if no values are input, the bearing is assumed to have infinite stiffness). This means
the calculation is not affected by the type or size of the bearing.
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▪ Stiffness: ISO/TS 16281. Service life: ISO 281, with manufacturer's notes: If you select this
option, the shaft's bending lines are affected by the finite bearing stiffness which is calculated
based on the bearing’s geometry. However, the rating life is calculated based on the forces,
according to the manufacturer catalog (i.e. tilting moments are ignored in the rating life
calculation).
▪ Stiffness: ISO/TS 16281. Service life: ISO/TS 16281: Both the shaft bending lines and the rating
life of the bearing are based on the inner geometry of the bearings according to ISO/TR 16281.
27.3.12 Tolerance field
The definition of the bearing clearance class does not yet provide a definitive statement about
bearing clearance because only a range of values has been defined for the bearing clearance class.
The Minimum and Maximum options define the upper and lower limits of the range, whereas the
Mean value is the arithmetical average of the Maximum and Minimum for (radial) bearing
clearance.
The Operating bearing clearance is defined using the selected bearing clearance class (e.g. "C0"),
the selected tolerance (e.g. "mean value") and the working conditions, i.e. speed and temperature.
For every rolling bearing, the calculation of operating clearance is described below. Starting from the
next figure (see Figure 27.5), the following variables are introduced in the calculation:
Figure 27.5: Diameters used to calculate bearing clearance
▪ Internal and external diameter of the shaft.
▪ Internal and external diameter of the hub. If the bearing is a connecting element, then
these values represent the internal and external diameter of the external shaft. For simplicity's
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sake, the term "housing" is used here to mean either the housing or the external shaft (if
present).
▪ Internal and external diameter of the bearing, and for the diameter of the
internal and external outer raceway.
All diameter values represent actual diameters, i.e. they take the allowance for each part into
account. The calculation steps are as follows:
▪ The ring race allowance is taken from the corresponding table (e.g. for tolerance "PN"), for the
inner ring ΑΒi and the outer ring ΑΒo.
▪ The allowance for the shaft Aw and housing An are calculated from the user-defined data (e.g.
"k6").
▪ The interference is calculated on the inner ring Uwi and on the outer ring Uwo.
▪ According to DIN 7190, the interference is reduced by the value 0.4*(RzA + RzB). In this case,
RzA and RzB are the surface roughness of the contact bodies (A: rolling bearing ring, B:
shaft/hub). It is assumed that the roughness of the rolling bearing rings is much less than the
roughness of the shaft/hub. For this reason, the roughness of the rolling bearing rings is not
taken into account (RzA = 0).
▪
▪ The effect of temperature is taken into account,
▪
where αs,αh, αb is the thermal expansion coefficient of the shaft, housing and bearing, ΤsΤhΤR
are the shaft, housing and reference temperatures and dnom, Dnom is the nominal diameter of
the bearing as defined in the catalog.
▪ An interference fit calculation is performed for the inner ring if condition A applies and for
the outer ring if condition B applies, taking into account the operating speed as well.
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▪ The pressure generated in the interference fit changes the operating diameter of the bearing
races, and therefore also causes a change, ΔPd, to the nominal bearing clearance.
► Note
The selection you make in the Tolerance field has no effect on the general behavior of the bearings.
27.3.13 Modified rating life according ISO 281
Enables the state of the lubricant to be taken into account when calculating the rating life as a
modified service life Lmn. This requires the Lubrication and Contamination selection lists and the
Lubricant temperature input field to be configured accordingly.
27.3.14 Consider weight
This defines how the shaft's own weight is taken into account in the section dimension calculation.
Depending on the orientation of the shaft arrangement (see chapter 27.3.1, Position of shaft axis in
space), you will see additional axial and shear forces which may have an influence on the diagrams
of bending and/or axial displacement.
► Note
In a global coordinates system, gravitational forces act on the shafts in the negative, z-direction.
27.3.15 Consider gyroscopic effect
When calculating the eigenfrequencies, you can also take into account the gyroscopic effect of shafts
that have weights attached to one end and either rotate forwards or backwards around the
longitudinal axis.
Whereas, in situations that are not technically critical, the eigenfrequency sinks when the speed
increases in a counter direction, the eigenfrequency increases when the speed is in the same
direction.
27.3.16 Housing material
The housing material value is only used to calculate the thermal expansion of the housing. The
materials available for housings are identical to those used for shafts.
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27.3.17 Lubrication
The choice of lubricant only affects the bearing life calculation. Click the button to enter your own
data with Own input for the lubricant parameters.
27.3.18 Contamination
As defined in ISO 281, contamination coefficient ec depends on the type of oil filter, the bearing size,
and the viscosity of the lubricant. This value varies within the range 0 (high level of contamination)
and 1 (ideal). Select the Own Input option and then click the button to specify your own ec
values.
Click on the Enter contamination in each bearing separately checkbox, displayed in the dialog
that you display by selecting Calculation > Settings > Rolling bearings, to specify whether the
value for contamination is to be applied globally in the basic data (for every bearing) or individually,
for each bearing.
► Note
Click the button to enter your own values. You can define new values for the Housing and
Lubrication that are based on existing data. However, these values are only data used in the
calculation file and are not stored permanently in the database.
27.4 Module specific settings
27.4.1 Non-linear shaft
Click this option to perform a calculation using geometric non-linear beam elements. This can result
in either a deflection or a displacement in the axial direction because the arc length remains
constant. In most applications where shafts are used, this non-linear model is irrelevant.
► Example
A shaft, which is fixed to its mounting on both sides, is subjected to centrical force. The linear beam
model does not allow for an elongation of the beam because it ignores axial displacement during
shear and moment loads. If you click on the Non-linear shaft field, you can select a calculation
method that takes into account the bending effect on the shaft and therefore the elongation of the
beam. This results in axial forces.
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27.4.2 Consider deformation due to shearing and shear correction
factor
If this checkbox has not been selected, the shaft is modeled to be infinitely stiff. In this case,
shearing forces have no effect on the diagrams of bending. This is a suitable ?? for all shafts whose
length is significantly greater than their cross section. If this is not the case, you can enable
Consider deformation due to shearing. The associated shear correction factor κ can be modified
in the Module specific settings.
(24.1)
where
A’ shear section
A Cross-sectional area
The shear correction coefficient κ ≥ 1 includes the irregular distribution of stress across the cross
section and applies to the entire shaft system. κ = 1.1 applies for circular-shaped cross sections, and
κ = 1.2 applies for rectangular-shaped cross sections.
► Note
The value input here must correspond to the shear correction factor specified in the valid definition
in KISSsoft, as shown in the equation above. Some sources also use the reciprocal value for the
formula symbol.
27.4.3 Activating offset of the load application center point
This enables the gear load elements to define their load application center point offsets, as described
in the relevant section of the manual (see chapter 27.2.4.1, Forces).
27.4.4 Using the 2013 solver
The new solver is used by default for shaft calculations. However, you can use the previous "2013
solver" instead. The new solver is more stable, which is why we recommend it.
The new solver is based on the finite differences (FD) method, with which the equations for the
elastic deformation are approximated numerically in a grid (see chapter 27.4.7, Node density). In
addition, the cylindrical elements of a linear shaft's contours are calculated with the precise analytical
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formulae in the transfer matrix method [50], and conical elements are calculated with the FD method.
For non-linear shafts, the FD method is applied for the entire shaft contour.
27.4.5 Saving temporary results in CSV format with .tmp file
extension
Results are saved to temporary files (in the TMPDIR). The naming convention is W010-
H3_bin_x.tmp, where "x" is the load spectrum's number. For example, the W010-H3_bin_1.tmp,
W010-H3_bin_2.tmp and W010-H3_bin_3.tmp files are created for a load spectrum with 3 stages.
1. For rolling bearings
a. General results of the rolling bearing (displacement, tilting, reaction force)
b. Results for each rolling body
c. Results for each slice, if a roller bearing is selected
d. The stiffness matrix
2. For shafts
a. Data for the bending lines
27.4.6 Standard radius at shoulders
To calculate the notch effect on shoulders, you require a radius. This can be input as an auxiliary
element. If no radius has been defined, the system uses the standard radius defined for calculating
the notch effect.
Generally, we recommend you define radii for each shoulder.
27.4.7 Node density
The user can influence how many nodes are used to calculate a beam. If you are performing a linear
calculation, this has no effect on the result, apart from line moments which are distributed across the
existing nodes. The beam elements supply the exact solution in the linear model independently of the
length.
Reasons for influencing the density of nodes are, on one hand, to speed up calculations (for
example, in series calculations in KISSsys) and, on the other hand, to ensure the accuracy of the
display of the bending lines and the corresponding report.
The density of the nodes affects the accuracy of non-linear beam elements. For this reason, the
maximum distance between two nodes for non-linear calculations, when compared with a linear
calculation, is halved, no matter what value is predefined.
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The node density affects only the elements that are modeled with the finite differences method.
Elements that are modeled with the transfer matrix method, are not grid-dependent (see chapter
27.4.4, Using the 2013 solver).
27.4.8 Iterative calculation of load distribution
If this checkbox is selected, the load distribution is calculated iteratively for the selected gear in the
"Tooth trace modification" tab. The initial gear is replaced by a specified number of identical gears.
The number of gears is set in the "Number of slices" field. The load on each replacement gear is set
according to the current load distribution, and the load on each gear is adjusted iteratively until the
quadratic mean value (or "root mean square" - RMS) of the error in the line load difference between
two sequential calculations is less than 1%.
You will find details of how KHβ is calculated in (see chapter 28.6, Tooth trace modification)
Note: In the case of bevel gears, the checkbox must be selected, so that the effect of the changeable
operating pitch circle of the gear can be taken into account. Otherwise, the bevel gear is handled as
a cylindrical gear whose pitch circle dw equals the pitch circle in the middle section.
27.4.9 Input different numbers of load cycles for bending and torsion
(for limited life calculations)
Every time a shaft rotates, the bending load cycle changes. For this reason, the number of bending
load cycles is calculated using the rating life and the speed. The number of torsional load cycles is
often very much lower, because not every rotation causes a torsional load cycle. For example, a gear
unit may be started in the morning and run throughout the day with a constant torque, resulting in
exactly one torsional load cycle per day. In contrast, a shaft running at 1000 rpm for 8 hours would
be subject to 8000 bending load cycles in the same space of time. As a consequence, in this
example, the ratio between the number of bending load cycles and torsion would be 8000: 1. You
can enter this ratio here.
27.4.10 Save user defined bearings in calculation file
If this option is enabled, the data from all user-defined rolling bearings is saved together with the
calculation file. As a result, this calculation can still be performed if this file is opened on a computer
whose database does not contain these rolling bearings. If this data is present both in the file and in
the database, the data in the database is used and updated in the file when the file is saved.
27.4.11 Read user-defined rolling bearings from calculation file
If this option is also enabled, the data from all user-defined rolling bearings stored in the calculation
file is used and given priority over the data in the database. If the database contains bearings with
identical IDs, this data is ignored.
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27.4.12 Entering contamination in each bearing separately
If this option is selected, and Modified rating life according to ISO 281 has been selected in the
Basic data tab, you can enter a value for contamination for each rolling bearing, in the Lubrication
sub-tab, in the Element Editor. Otherwise, the contamination is defined globally in the Basic data tab
and applies to all the rolling bearings.
27.4.13 Axial clearance
The axial clearance for the rolling bearing calculation according to ISO 281 can be defined here. The
clearance applies to both directions. As a result, a bearing that is fixed on both sides may deviate
either to the right or to the left by this value. This clearance is not used in the calculation if the
bearing stiffness from the internal bearing geometry according to ISO/TS 16281 is taken into
account.
27.4.14 Failure probability
The value n=10% is used as standard for the failure probability, in the rolling bearing service life
calculation. The valid input range is 0.05% < n < 10%.
27.4.15 Required service life
Preset required rating life for rolling bearings. However, this value does not actually affect the rolling
bearing calculation. However, if the calculated bearing rating life is less than the required rating life,
KISSsoft displays a warning message.
27.4.16 Maximum life modification factor
Defines an upper limit for the life modification factor aISO::
The default value, as defined in ISO 281, is aISO,max = 50.
27.4.17 Display critical bearings
The Shaft Editor displays critical rolling bearings with colors to identify their rating life. The color
"orange" is used for critical bearings with a rating life which is less than the required rating life. The
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color "red" is used for bearings with a minimum rating life which is much less than the required rating
life. The color "green" is used for bearings whose rating life is longer than the required rating life.
The rating life value used to determine the bearing colors depends on which bearing calculation
method has been selected, and whether the user has requested the Modified rating life to be
calculated.
Nominal service time Modified rating life
(basic rating life) requested
requested
Rolling bearings, classic (without contact Lnh Lnmh
angle)
Rolling bearing, classic (contact angle
considered)
Rolling bearing stiffness calculated from inner
geometry
Rolling bearing rating life acc. to ISO/TS 16281 Lnrh Lnmrh
Table 27.2: Table: Lifetime value used for the bearing colors, based on the calculation settings
27.4.18 Housing surface roughness
The housing's surface roughness value is used to calculate the nominal operating clearance for
rolling bearings. The pressure is calculated for a housing with an infinitely large external diameter.
Additional shafts can be defined here if different roughnesses are required for different bearings or if
the external diameter must be defined.
27.4.19 Calculation method for friction
Select the method for calculating friction from this list. These methods are described in more detail in
the Rolling Bearings section (see chapter 29.4, Moment of friction), in the Moment of Friction chapter.
27.4.20 Grease lifetime
In this list, you can select whether an estimated grease lifetime is to be calculated. These methods
are described in more detail in the Grease lifetime section (see chapter 29.5, Grease lifetime), in the
Rolling Bearings chapter.
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27.4.21 Oil level
If you select the calculation method described in the SKF catalog 2018 or the Schaeffler catalog
2017 (INA, FAG) to calculate friction, the oil level has an effect on the moment of friction which is
determined by the amount of oil lost in the process. This is described in greater detail in the Moment
of Friction chapter. (see chapter 29.4, Moment of friction).
You input the oil level with reference to the left-hand end of the first shaft (but only if Oil bath
lubrication has been specified). The position of the shaft is then used to define a separate oil level
for each bearing (h and H) which is then taken into account when calculating the loss. The oil level is
displayed in the Shaft Editor, so you can check it.
27.4.22 Type of oil lubrication
The type of oil lubrication used is important if you are using the calculation method described in SKF
catalog 2018 to calculate friction. The method differentiates between oil bath and oil injection
lubrication (see chapter 29.4, Moment of friction).
27.4.23 Moment of friction, seals
Defines how the moment of friction is to be defined for seals:
▪ SKF main catalog according to selected calculation method
▪ According to SKF main catalog 4000/IV T DE:1994
You will find values from the SKF catalog for the seal types used in your bearings
integrated in the KISSsoft software. If the KISSsoft system finds a familiar seal label in the
bearing label, it calculates the moment of friction for a grinding seal using the coefficients
listed in the catalog. Otherwise, the moment of friction is set to zero.
▪ According to SKF main catalog 17000/1 EN:2018
You will find values from the SKF catalog for the seal types used in your bearings
integrated in the KISSsoft software. If the KISSsoft system finds a familiar seal label in the
bearing label, it calculates the moment of friction for a grinding seal using the coefficients
listed in the catalog. Otherwise, the moment of friction is set to zero.
In KISSsoft, the diameter of the mating surface is calculated with the formula ds = d + (D -
d) * 0.2
▪ according to ISO/TR 13593:1999 Viton Mseal, this diameter is calculated with the formula: Mseal =
3,736*10^-3*dsh; Mseal in Nm, dsh Shaft diameter in mm
▪ according to ISO/TR 13593:1999 Buna N Mseal this diameter is calculated with the formula: Mseal =
2,429*10^-3*dsh; Mseal in Nm, dsh Shaft diameter in mm
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27.4.24 Bearing manufacturer
Only bearings made by the selected bearing manufacturers are available in the selection list.
27.4.25 Show coordinates system
This option toggles the coordination system in the Shaft Editor on and off.
27.4.26 Show automatic dimensioning
This option toggles the mass line in the Shaft Editor on and off.
27.4.27 Equivalent stress for sizings
Defines the equivalent stress used to size a shaft for strength.
27.4.28 Maximum deflection for sizings
Defines the maximum permitted deflection for sizing a shaft for deflection.
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28 Calculating Shafts
Once you have finished defining the shafts, either click the button in the tool bar or press F5 to
calculate all the shaft-specific values. The results are then made available as graphics and tables,
and in different reports.
28.1 Deflection and bearing forces, distribution of
force and torque
The stress, displacement and tilting calculation are based on the Finite Difference Method (FDM).
You can use this calculation to:
▪ Calculate the diagrams of bending, course of transverse force and torque diagram in the XY and
ZY plane (the shaft rotational axis is always Y), with or without taking the dead weight into
account.
▪ Calculate the axial force taking into account the weight (depending on the length of the shaft).
▪ Display all essential values as graphics: course of deflection, shearing force, bending moment in
different levels, torsional moment and static equivalent stress (VM).
▪ Calculate the forces and moments in bearings (and ends of shafts) for an unlimited number and
any type of bearing.
▪ The utilization and damage of a rolling bearing is calculated as follows:
The utilization of a rolling bearing is calculated as follows: in this case Lreq is the required rolling
bearing service life, Pref is the equivalent load which corresponds to Lreq, L is the achieved
service life and k is a coefficient that depends on the type of rolling bearing (k = 3 for ball
bearings, k = 10/3 for roller bearings).
▪ Bearing clearance is always considered. If the bearing calculation method according to inner
geometry is selected, then the bearing stiffness at the operating point and the static safety are
also reported. 2 static safeties - S0r and S0r - are calculated.
S0w is calculated as
where pmax is the maximum Hertzian pressure on the ring race. For ball bearings p0 = 4200
IV Calculating Shafts 603
N/mm2 and n = 3. For roller bearings p0 = 4000 N/mm2 and n = 2.
S0r is calculated with the following formula
where C0 is the basic static load rating of the bearing, and P0r is the equivalent nominal load
(i.e. tilting moments are ignored), which causes the same maximum surface pressure. The same
calculations are available for standalone bearing calculations with internal geometry.
▪ The relative displacement and torsion of the inner ring to the outer ring is calculated and
recorded.
Note:
the calculation assumes that the inner ring of the bearing is connected to the shaft. If a hollow
shaft is connected to the inside of a rolling bearing, the bearing displacement and rotation are
documented with the reversed prefix operator.
▪ Calculate the inclination of the diagrams of bending in bearings, e.g. when calculating cylindrical
roller bearings. The progression of the angle of inclination can also be displayed on screen and
printed out.
▪ The diagrams of bending can be calculated with or without taking shear deformation into
account.
Figure 28.1: Displacement graphic displaying the bending lines in the plane α = 63.53°
► Note
Although the data about equivalent stress gives an initial indication of the static strength of a shaft, it
cannot be used to calculate infinite life strength. To do this, you must perform the actual strength
IV Calculating Shafts 604
calculation. However, this equivalent stress data is useful for beams, because the load they are
subjected to is usually only a static load. If the moment of resistance in torsion has not been defined
for beams, torsional stress is not included in the equivalent stress calculation. Despite this, you can
still perform the calculation.
28.1.1 Calculating force on bearings with a contact angle
Bearings with a contact angle must be handled as a special case when you calculate shafts and
bearings. The effective active bearing center used to calculate the bearing reactions is determined at
the point at which the compression force line of action intersects with the shaft centerline. In the
rolling bearing catalogs, this is described as the axial force resulting from the oblique position of the
bearing housing. You can use this to define the data (radial and axial loads) required to calculate the
rating life.
It is more difficult to calculate the load progression in the shaft, and this is also not documented
clearly in the technical literature. Here, two modeling types are possible:
▪ Approach 2: In bearings that have a contact angle, the effective bearing force line of action
passes through the pressure center point. For this reason, you can calculate the bearing forces
because, for calculation purposes, the bearing can be considered as being at the pressure
center point. This matches the procedures used to define the rolling bearing load.
▪ Approach 1: However, you cannot introduce the bearing force on the shaft outside the bearing
width. This is why KISSsoft places the bearing force in the center of the bearing. At the same
time, the eccentric load application creates an additional bending moment which equals the
product of the distance of the bearing- and pressure center point, times the radial force. This is
also the approach used in KISSsoft.
Both approaches return the same progression of bending moment between the pressure centers.
There is, however, a difference in the area of the pressure/bearing centers.
In real life, the load is not necessarily applied to the center of the bearing but to the entire area of the
bearing. Therefore, the bending moment can be placed precisely on the shaft shoulder. However,
this then causes a problem in the strength calculation if the load application acts directly on the proof
point (i. e. when the proof point lies between the bearing center and the shaft shoulder).
The calculation of the diagrams of bending produces a difference in that, in approach 1, the
deflection is zero in the pressure center and, in approach 2, it is at the bearing position. Here,
approach 2 is certainly more precise, especially when large contact angles, where the pressure
center lies outside the bearing width, are involved. Only approach 2 enables the calculation to
include cases in which the pressure center point lies outside the shaft.
IV Calculating Shafts 605
As often happens in such cases, the reality lies somewhere between the two approaches. More
precise calculations can only be performed using time-consuming FEM calculations which take into
account the properties of the bearing housing.
Approach 2 is more precise and convenient for shaft calculations (because it allows for pressure
center points being outside the shaft), which is why this variant has been included in KISSsoft
shaft calculation functions.
Notes about the strength calculation: Any strength verification based on the nominal stress concept
(DIN 743, FKM, etc. ), has limited validity, in the force application zone (e. g. internal bearing ring on
the shaft shoulder) when the local stress distribution does not correspond to the estimated nominal
stress. In practice, the results calculated on these points must be interpreted with caution.
In KISSsoft, the additional internal axial force that is present in the case of bearings with a contact
angle is calculated as Fr * 0.5/Y, as described in "Die Wälzlagerpraxis" and different bearing product
catalogs. (FAG as here, NSK with a factor value of 0.6 instead of 0.5, SKF for taper roller bearings,
as here, and for angular contact ball bearings with a factor value of 1.14 (Catalog 2004 as a function
of Fa/C)). If factor Y is not present in the bearing database, no additional axial force is taken into
consideration. Consequently, the calculation process is the same as the KISSsoft bearing
calculation.
28.2 Eigenfrequencies
Click on Graphic > Shaft > Eigenfrequencies to display the results of the eigenfrequencies
calculation for the modeled shaft system. The calculation is based on a one-dimensional Finite
Element Method (FEM) which takes into account the support type and its stiffnesses.
The calculation enables you to:
▪ calculation of any number of eigenfrequencies
▪ display natural modes
▪ takes into account the gyroscopic effect large spinning masses. The critical speeds (bending
mode) are calculated for forwards and backwards whirl. During synchronous forwards whirl, an
unbalance increases the bending oscillations, because the angular speed of the rotating shaft
and angular speed of the shaft's peripheral center point are the same. However, synchronous
backwards whirl is, in most cases, not technically important.
▪ For beam profiles, the critical bending mode (eigenfrequencies) is calculated in both main
planes.
▪ Gears can automatically be handled like masses. In this situation, KISSsoft takes into account
the mass and the moments of inertia of the gear located on the shaft.
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28.2.1 Bending critical speed
The calculation of critical speeds takes into account any masses located on the shaft. However,
applied forces have no effect on the calculation. For this reason, additional masses must be modeled
as masses and not as loading forces.
The nodal points of the bending eigenmodes (vibration on plane x-z) are also documented in the
report: select "Report" > "Nodal points".
28.2.2 Torsion critical speed
▪ Calculation of the critical rotating eigenfrequencies of shafts.
▪ Calculation of any number of eigenfrequencies.
▪ Graphical display of natural oscillation.
28.3 Buckling
Use this function to calculate the buckling load for shafts and beams. All boundary conditions,
bearings and effective axial forces (point or line loads) are taken into account in the calculation. Only
the axial forces you specify are used to calculate the buckling load. This function calculates the factor
by which all these forces have to be multiplied to create a situation under which buckling occurs. This
factor therefore corresponds to the safety against buckling.
28.4 Rough sizing of shafts
The rough sizing of shafts is based on equivalent stress. A number of options affect the behavior of
this functionality:
1. Equivalent stress: the maximum equivalent stress to which the shaft material is subjected.
2. Change only cylinder diameters: If this option is selected, the length of the cylinders that form
the outer contour is retained and only their diameter is changed. Otherwise, KISSsoft sets both
the length and diameter of the cylinders. In this case, the inner contour is deleted.
3. Do not delete cross sections A-A etc.: If this option is selected, the user-defined cross sections
for the strength calculation (A-A, B-B etc.) are deleted, and KISSsoft attempts to find the most
critical cross sections in the new design.
4. Consider bearings in sizing: If this option is selected, rolling bearings are sized according to
their required rating life.
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5. Match shaft diameter to bearing bore: If this option is selected, KISSsoft rounds up the final
cylinder diameter to match the bearing's internal diameter.
6. Take bearing type from model: If this option is selected, existing bearings are retained.
Otherwise, you can replace the bearings in the model with a specific bearing type as required.
7. Move bearing if needed: When a bearing is being sized, it may happen that a larger, wider
bearing is selected, and this covers the neighboring cylinder. If this option is selected, the
bearing is moved so that it does not cover the cylinder.
Once the calculation has finished, the old shaft contour is displayed so you can compare the old and
new data more easily.
28.5 Strength
To enter values for the strength calculation, click on the Strength tab in the Shaft calculation
module user interface.
In KISSsoft, you can use these methods to calculate shaft and axle strength:
▪ Hänchen & Decker
▪ DIN 743:2012-12
Load capacity of shafts and axes [51] including FVA proposed update concerning fatigue
strength and tensile strength []
▪ FKM Guideline (2012)
Analytical strength verification of steel, cast iron and aluminum materials in mechanical engineering,
6th Edition 2012
▪ AGMA 6101-F19/AGMA 6001-F19
Design and Selection of Components for Enclosed Gear Drives
▪ No strength calculation
In this case, strength verification is not performed. However, all the other results (diagrams of
bending, equilibrium of forces, bearing reactions etc.) will still be calculated.
A static proof and proof of fatigue strength can be applied in each case. The proof according to FKM,
DIN and AGMA can also be performed using a load spectrum.
Some of the shaft-specific data for the strength calculation can be defined for a particular shaft in the
Element editor.
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28.5.1 Calculation method
You can select the calculation method you prefer for strength verification from this list.
28.5.1.1 Hänchen & Decker
Strength calculation according to R. Hänchen and H. K. Decker [52] is an old, but well established
method. If insufficient notch factor data is present, the equations produced by TÜV in Munich,
Germany, are used: they are derived from known test results.
Material values
As shown in Figures 52, 56, 60 in accordance with [52] for construction, heat treated and case
hardened steels. The empirical formula used is in accordance with Hänchen [52], page 37
You can input the material data in the database (see chapter 9, Database Tool and External Tables).
Calculation of equivalent stress
In the case of bending and torsion, KISSsoft calculates the equivalent stress value σV according to
the hypothesis of the largest distortion energy (see [52], section 3.2.5.).
Calculation of safety against fatigue failure
▪ Maximum load according to [52], Equation (4a). Operating factor as defined in [52] Table 1
(page 24).
▪ Design bending fatigue limit under reversed bending according to [52], Equation (42a).
▪ Safety margin for fatigue fracture according to [52], Equation (46).
▪ Required safety against fatigue failure according to [52], Figure 156, depending on the
frequency of the maximum load.
▪ The result of the calculation is the ratio of the required safety margin to the calculated safety
margin, expressed as a percentage.
Important formulae
A)= Equivalent stress (infinite life strength)
(25.1)
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(25.2)
(25.3)
A1) Equivalent stress (strength against overload failure and deformation) (τt = 0)
(25.4)
(25.5)
(25.6)
B) Calculation of the safety against fatigue failure:
(25.7)
(25.8)
α0 a.0 Stress ratio factor
A A Cross section area (cm3)
bd b.d Thickness number
bkb b.kb Notch factor (bending)
bo b.o Surface number
f f Total load factor
Fq F.q Shearing force (N)
Fz F.z Tension/Compression force (N)
Mb M.b Bending moment (Nm)
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Mt M.t Torque (Nm)
σb s.b Bending stress (N/mm2)
σbW s.bW Fatigue strength under reversed bending stresses (N/mm2)
σbWG s.bWG Deformation strength under reversed bending stresses (N/mm2)
σv s.v Equivalent stress (N/mm2)
SD S.D Safety against fatigue failure
τq t.q Shear stress (force) (N/mm2)
τt t.t Torsional stress (N/mm2)
Wb W.b Axial moment of resistance (cm3)
Wt W.t Polar moment of resistance (cm3)
Stress ratio factor
Values for the stress ratio factor are displayed in the next table (see Table 28.1).
Bending alternating alternating static static static static
Torsion pulsating alternating pulsating alternating static static
Structural 0.7 0.88 1.45 1.6 1.0 1.0
steel
Case 0.77 0.96 1.14 1.6 1.0 1.0
hardening
steel
Through 0.63 0.79 1.00 1.6 1.0 1.0
hardening
steel
Table 28.1: Stress ratio factor α0 according to Hänchen, p. 28 [52] or Niemann, I, p. 76 [6]
28.5.1.2 DIN 743 (2012)
The German DIN 743 standard [51] uses the most up to date information to calculate shafts and
includes the following points:
▪ Consistent distinction between the different load classifications (tension/compression, bending,
torsion) and between mean stress and stress amplitude.
▪ Surface factor: The influence on the strength is documented when using thermal methods
(nitriding, case hardening) and mechanical processes (shot peening, rolling).
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▪ Notch factors: Data for construction elements other than the usual notch factors is mentioned in
all the specialist literature. This data, such as relief grooves, interference fit with relief groove or
square notches (recesses for snap rings) is widely used nowadays but has only been poorly
documented until now. All notch factors are documented for tension/compression, for bending
and for torsion.
▪ Materials: it includes an extensive list of materials, and also instructions about how to derive
estimated values for undocumented steels.
▪ Limited life: the calculation of load strength according to the "Miner extended" method is
described in Part 4 of the standard.
The critical limitations of the DIN 743 standard are:
▪ Shearing load (shearing forces) is not included. This is not a disadvantage except for shafts with
a very short distance between bearings.
▪ It only applies to steels and operating temperatures between -40oC and +150oC.
▪ As defined in the standard, the minimum safety margins for deformation and fatigue failure are
defined as stated in 1.2. However, these safety factors only cover the lack of precision in the
calculation method, and do not cover the problems encountered in load assumptions or the
consequences if the material fails. The required safety factors must therefore be checked or
agreed by both the customer and contractor.
28.5.1.3 FKM Guideline, 2012 Edition
The FKM guideline (FKM: Forschungskuratorium Maschinenbau e.V., Frankfurt (Board of Research
in Mechanical Engineering)) is based on the former GDR standards and includes the latest
knowledge on workshop theory. It will probably form the basis of a new VDI guideline. The FKM
Guideline is long (running to approximately 175 pages plus 400 pages of commentaries), and
includes not only the classic range of endurance limit calculation, but also fatigue strength
calculations and rating life calculations, taking into account load spectra. It also provides calculation
approaches for special problems such as operating temperatures above 100°C.
The calculation is performed according to the 6th edition (2012) of the FKM Guideline, using the
solutions proposed by Haibach.
Fatigue strength
The service strength coefficient KBK,S is determined according to chapter 2.4 of the guideline. The
number of cycles at knee point ND is 106.
KBK,S is greater than 1.0 if the number of load cycles is less than ND. Above ND, KBK,S usually equals
1.0.
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Normal calculations with a given load (without load spectrum) are referred to as an "individual load".
This is calculated in accordance with section 2.4 of the guideline. Three different processes can be
used for load spectra. See (see chapter 28.5.2, Type of calculation).
28.5.1.4 AGMA 6101-F19/AGMA 6001-F19
AGMA 6101-F19/ 6001-F19 [51] describes how to calculate a closed gear unit. Calculations are
described for shafts, interference fits, keys, bearings, housings and bolts in this AGMA standard.
▪ It distinguishes between the different load classifications (tension/compression, bending, torsion
and shearing) and between mean stress and stress amplitude.
▪ Notch factors: the few notch factors given here are only for bending. The same ones are used
for the other loads.
▪ Materials: it includes an extensive list of materials, and also instructions about how to derive
estimated values for undocumented steels. The permitted values are converted from the core
hardness value entered by the user.
▪ In KISSsoft, load spectra are not taken into consideration when the AGMA method is applied (as
it is not described adequately).
The critical limitations of the AGMA standard are:
▪ Only for cylindrical steel shafts, but could maybe also be used for other materials.
▪ The only notch types defined in detail are shoulder, circumferential groove and cross hole.
▪ According to the standard, the set minimum safeties against peak load and fatigue are 1.0.
However, these safety factors only cover the lack of precision in the calculation method, and do
not cover the problems encountered in load assumptions or the consequences if the material
fails. The required safety factors must therefore be checked or agreed by both the customer and
contractor.
28.5.2 Type of calculation
You can perform a safety analysis using one of these four different methods:
▪ Static. Calculates the safety against yield safety.
▪ Infinite life strength. Calculates the safety against the infinite life strength (in the horizontal
section of the S-N curve (Woehler lines), no load spectrum used)
▪ Limited life. Calculates the safety against fatigue for a given number of cycles. Here, a constant
load is used (no load spectra). The calculation method according to AGMA only defines a one-
step load spectrum. A one-step load spectrum is handled separately in the FKM method.
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According to the methods defined in DIN 743 and FKM, the S-N curve (Woehler lines) runs
horizontally after it reaches the number of load cycles limit ND (10^6).
▪ Miner consequent/elementary/extended. These methods differ in the way they calculate the
inclination of the S-N curve (Woehler lines) above the number of breakpoint cycles.
Figure 28.2: Miner hypotheses
▪ Legend:
▪ 1) Miner elementary following FKM
▪ 2) Miner extended in acc. with DIN 743-4:2012
▪ 3) Miner consequent following FKM guideline
▪ 4) Miner original according to Haibach
▪ 5) Miner elementary according to Haibach
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▪ The gray fields are the fractions that are ignored.
► Note
The calculation methods according to Miner are only available if you have selected the Consider
load spectra option in the Load spectra drop-down list in the Basic data input window. Load
spectra (see chapter 17.2.8, Define load spectrum) can be defined in the KISSSOFT database tool.
You then only need to select them in the calculation.
28.5.3 Rating life
The required rating life in number of revolutions is calculated from the required rating life in hours.
28.5.4 Strength parameters according to Hänchen and Decker
28.5.4.1 Frequency of load
This value refers to the load value you entered previously (such as torque). If a load applies to the
whole rating life of the shaft, the frequency is 100%, otherwise it is correspondingly lower.
28.5.4.2 Notch factors
▪ Thickness number: according to [52], Image 120.
▪ Surface number: as stated in [52], Figure 119, Definition of the associated machining process in
[52], Table 4.
▪ The following curves have been pre-programmed:
▪ Coarsely cut out Curve with bo = 0, 50 at 150 kp/mm2
Milled/finely turned Curve with bo = 0, 70 at 150 kp/mm2
Ground Curve with bo = 0, 94 at 150 kp/mm2
Polished Curve with bo = 0, 97 at 150 kp/mm2
▪ Shoulder notch effect coefficient during bending according to [52], Figure 131.
▪ Wheel seat with key: proposed values after consulting with TÜV, Munich. Only very few details
given in [52], section 6.4.
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▪ Interference fit: Proposed values after consulting with TÜV, Munich. Details given in [52], section
6.4.
▪ Bearings are handled as weak interference fits. Only very few details given in [52], section 6.4.
▪ Shaft-hub connections (multi-wedge toothing): Stress concentration factor and section modulus
according to [52], section 8.5. Conversion of the stress concentration factor into the notch effect
coefficient according to [52], section 5.6, Formula (36) and (37b) or (37c) with the radius for the
substituting notch according to [52], Figure 112.
▪ Thread: Diameter quotient according to [52], Figure 123. Conversion into notch effect coefficient
as shown above.
28.5.4.3 Safety against deformation/fracture
KISSsoft calculates the required safety margin for fatigue fracture, depending on the frequency of the
maximum load, using Hänchen's definitions. If the frequency is 100%, the specified safety is 2.0. At
0%, it is 1.0. However, the safety does not follow a linear progression between these two extremes.
The required safety against overload failure is 3.5 to 5.0, depending on the type of application or
guideline involved. The required safety against deformation (yield point) is usually 2.0 to 3.5.
28.5.5 Strength parameters according to FKM
28.5.5.1 Temperature duration
The FKM guideline takes into account thermal creep in various materials. Constant high
temperatures will reduce the shaft's strength and therefore also reduce its safeties.
Part temperatures in the range from -40°C - +500°C are taken into consideration according to the
FKM Guideline. For temperatures above 100°C (or above 60 degrees C, for fine grain steels),
temperature factors (for the tensile strength, yield point, and resistance to change) are used to take
the reduction in strength into account.
► Note
You can define the shaft temperature in the Element Editor. To do this, click on the shaft you
require, in the Element Tree, and then enter the appropriate value in the Temperature field.
28.5.5.2 Protective layer thickness, Aluminum
If you selected aluminum as the shaft's material, enter the value for the thickness of the aluminum
oxide layer in this field.
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28.5.5.3 Enter safeties
If this option is selected, you can enter the required safeties on the right-hand side. Alternatively,
click the button to display the Define safeties dialog window in which you can specify safeties as
defined in FKM.
The safety factors for the static strength calculation, jm (for overload failure) and jp (for deformation),
are determined in accordance with section 1.5 of the guideline, and the safety factor for fatigue
resistance, jD, is determined in accordance with Part 2.5 of the guideline. You will find detailed
comments in the Guideline.
Steel jm = 2.0 jp = 1.5 jF = 1.5 jF = 1.5
GS, GJS -not checked jm = 2.8 jp = 2.1 jG*jF = 2.6 jG*jF = 2.6
-non-destruction-tested jm = 2.5 jp = 1.9 jG*jF = 2.4 jG*jF = 2.4
GJL, GJM -not checked jm = 3.3 jp = 2.6 jG*jF = 3.1 jG*jF = 3.1
-non-destruction-tested jm = 3.0 jp = 2.4 jG*jF = 2.9 jG*jF = 2.9
jm, jp: The values apply for - severe damage as the result of failure
- high probability of load occurrence
If only minor damage results from the fracture, the safety factors can be reduced by about 15%.
Provided the probability of the same load occurring again is low, the safety factors can be reduced by
about 10%.
jG*jF: The values apply for - severe damage as the result of failure
- irregular inspection
If only minor damage results from the fracture, the safety factors can be reduced by about 15%.
Provided inspections are carried out regularly, safety factors can be reduced by about 10%.
28.5.5.4 Stress case
The stress case can identify four scenarios for the development of the stress ratio σa/σm with
continued increase in load, starting from the operating point.
28.5.5.5 Estimation of the infinite life strength for surface-treated parts (section
5.5)
This calculation should only be used for surface-treated rolled steel. The surface treatments include
the following treatment methods applied to the materials:
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▪ case-hardened
▪ nitrided, gas-nitrided, nitro-carburated
▪ induction hardened
▪ rolling
▪ shot peening
These types of treatment can be defined either when you input the material, or when you input the
surface factor for the shaft in the Element Editor.
This process is based on the concept of a local infinite life strength. Two points on the part are
considered. The first point is on the part's surface, and the second point is at the transition point
between the hard surface layer and the core. The resulting stresses are converted into main stresses
σ1 and σ2. Only the largest main stress σ1 is then used for subsequent calculation.
You can also input a hardening depth for this calculation in the Element Editor. The hardening depth
is then used to calculate the distance from the component's surface to the transition point between
the hard surface layer and the core.
The Strength tab is where you define whether the constant Kf is to be calculated according to
formulae 4.3.2 and 4.3.3 or taken from Table 4.3.1. You also have the option of inputting the core
hardness when you specify the material. Alternatively, this can also be estimated from the tensile
strength.
This approach is used to calculate the internal stress, which is included in the calculation of mean
stress sensitivity. In this case, the degree of utilization for the point on the component's surface is
calculated first, followed by the degree of utilization at the transition point between the hard surface
layer and the core. The greater of the two degrees of utilization is then used for the proof. Both
degrees of utilization should be < 1.
The results are only displayed in the report if this calculation method has been selected for rolled
steel with the predefined treatment types.
28.5.6 Strength parameters according to DIN
28.5.6.1 Stress case
The stress case can identify two scenarios for the development of the stress ratio σ a/σm with
continued increase in load, starting from the operating point.
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28.5.6.2 Calculation with experimental data
Use this option to define a Haigh diagram which has been determined from experimental data. If you
input a file name (e.g. WMAT-001.dat) in the Experimental data field for module-specific material
data as defined in DIN 743, a selection list appears in the Strength tab.
▪ Do not take into account: the data is ignored.
▪ Use in DIN 743 (KFσ according to DIN 743): the data is imported from the file which was defined
for the materials under Experimental data, and the KFσ coefficient is defined according to DIN
743.
▪ Use in DIN 743 (KFσ=1): the data is imported from the file which was defined for the materials
under Experimental data, and the KFσ coefficient is always set to 1.
Instructions about how to define the data can be requested from KISSsoft. The measured Haigh
diagram is not interpreted exactly as described in DIN 743. The overall influence coefficient divides
the Haigh diagram into x- and y-coordinates so that the results are much lower.
The influence of mean stress as defined in DIN 743 increases as the notches become sharper, and
should not decrease. This modification ensures that this influence always increases.
If the comparative medium stress is σmv <0, the line of the Wöhler diagram is extended into the
negative area of the Haigh diagram, and the curve is then broken in the negative area by
compression yield point σDk. For more information, see also the description in DIN 743-1, p. 21.
28.5.6.3 Safety against fatigue/deformation
Enter the required safeties for endurance/yield in these input fields. A warning is displayed if these
values are not achieved for one or more of the specified cross sections.
28.5.6.4 Calculation of multiple notches according to DIN 743
The procedure for creating the model in an FE program (modeling guideline) and for defining a notch
factor from the stresses (evaluation guideline) is described in FVA research project No. 700 I
"Berechnung von Mehrfachkerben nach DIN 743 durch Einbindung von FEM-Ergebnissen".
The methods defined here are limited to notches with component surfaces that are not subject to
force. You will still have to use a notch effect coefficient determined by experimentation to calculate
critical failure points with fretting fatigue over time in the contact zone (e.g. interference fits or key
connections).
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Figure 28.3: Local notch stresses in a general case
Two different methods are described: Method A: (a comprehensive calculation method for multiple
notches) and Method B (a simplified method involving multiple notches).
KISSsoft does not use Method B.
Method A:
Method A takes into account all the effects that affect strength for multiple notches.
The stresses at the critical proof point are defined at the point where the equivalent stress amplitude
is greatest on the component surface. The von Mises stress (VM) is then applied to these values to
calculate the equivalent stress amplitude.
Figure 28.4: Components of local notch stress
The FE analysis usually supplies a spatial stress tensor in the global coordinate system, which still
has to be transformed into the plane stress tensor.
The notch factor is defined as a quotient of the local stress peaks at the notch root and of the
nominal stress in the notch cross section.
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Figure 28.5: Stress curve for tension/compression, bending and torsional stress
To define the notch factor, the local stress components are separated into primary and secondary
stresses. A load type's primary stress is the nominal stress associated with the base load case.
You must define the stress gradient before you can determine the theoretical stress concentration
factors. This requires the stress values that occur at a neighboring node in the interior of the
component.
The notch factor is determined using the equations in the next table (Method A). The notch factor can
also have values that are less than 1. The secondary stresses are ignored in Method B.
Figure 28.6: Table 4 - Calculating the notch factor for components (Method A)
The notch effect coefficient β is calculated separately for each component present in the local stress
amplitude. The stress gradient required to do this is not defined separately.
Special case: interference fit (mean stress without base load case):
If mean stress without a base load case is included in the calculation as nominal stress, it can be
handled in the same way as mean stress. Firstly, the equivalent stress is calculated from the
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resulting local stresses. Then, the relevant notch factor can be used to determine the nominal mean
stress.
The safety verification is then performed component by component, because the notch factor was
also evaluated individually for each component.
The component safeties are calculated as follows:
Figure 28.7: Table 5 - Calculating the part's fatigue limit
The mean stress sensitivity is also calculated here. Adjust the mean stress sensitivity of the ranges in
DIN 743 to ensure this additional calculation does not return unexpected results. The safety is
determined using the formulae for combined load and phase equivalence in the plane stress state.
Method B:
In Method B, the mechanical stress is simplified when determining the notch factor. This method is
not suitable for a superimposed dynamic load.
The equivalent stress (VM) is calculated from the primary and secondary stress.
This method can only be used to a limited amount for a combined load. Limits:
σa2/σa1 < 0.2 and τa2/σa1 < 0.2
Defining the notch factor using the notch stresses for the load cases (tension/compression, bending,
or torsion amplitude) from an FE analysis.
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Figure 28.8: Table: Table 7 - Calculating the notch factor with equivalent stress (Method B)
The supporting effect and notch effect coefficient are defined in the same way as specified in the
formulae in DIN 743.
Mean stresses that are not subject to base load (interference fit) are not included in the simplified
Method B.
The safety verification is performed in the same way as in DIN 743.
28.5.7 Strength parameters according to AGMA
28.5.7.1 Coefficients used to determine fatigue strength
The following coefficients are required to calculate the modified fatigue strength σf:
Surface finish coefficient ka
You can set the surface finish for each individual element in a list. Coefficient ka is then determined
from the list entry, using the method shown in Figure 4, AGMA 6101-F09.
Size factor kb
The size factor kb is determined on the basis of the shaft diameter, using the method shown in
Figure 5, AGMA 6101-F09.
Reliability coefficient kc
The Strength tab is where you define the reliability (default 0.99%). This value is used to determine
reliability coefficient kc, using the method shown in Figure 6, AGMA 6101.
Temperature coefficient kd
The coefficient kd=1 is set for temperatures between -30°C and 120°C. The entries for the shaft can
be modified if the shaft temperature lies outside this range.
Life factor ke
This coefficient is determined on the basis of stresses σe and σu and the number of load cycles NL.
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Surface processing coefficient kf
For key ways, this coefficient is taken directly from Table 2 in AGMA 6101-F09.
For straight-side or normal splines, a Kt coefficient of 2.0 is assumed.
If a combination of a key and an interference fit is present, a kf coefficient of 0.33 to 0.4 is specified.
In KISSsoft, the default kf value is 0.33.
The notch effect type of the circumferential groove is used for V-notches and threads. It has a fixed
ratio of h/r = 20.
The system takes an individual Kt coefficient from the diagrams for the shoulder, circumferential
groove and cross hole (Figures 8 to 10, AGMA 6101-F09) and uses them, together with coefficient q
(Figure 7, AGMA 6101-F09) to calculate coefficient kf.
Miscellaneous effects coefficient kg
This coefficient can be used to take into account, for example, heat treatments, residual stresses
(shot peening, cold rolled, etc.), corrosion, and surface coatings.
The default value set for this coefficient is kg=1, however, it can be overwritten with the values
entered for the shaft.
28.5.7.2 Calculating the Safeties
Load spectra are not taken into consideration when the AGMA method is applied.
To calculate the fatigue safety FSf, the average stress and the amplitude are determined using the
von Mises stress.
These values, together with the modified fatigue strength and the tensile strength, are required later
to determine the fatigue safety.
The total stress is determined using the von Mises stress to calculate peak load safety. The peak
load safety coefficient is calculated using the total stress, the tensile strength, a coefficient for the
yield point, and a peak load coefficient.
The peak load coefficient can be defined individually in the Strength tab for all loads
(tension/compression, bending, torsion, thrust). In the KISSsoft system, the default setting for the
peak load coefficient is 1.0. As specified in the standard, the setting for this coefficient is 2.0 for
cylindrical gears with straight and helical flanks, bevel gears, and double helical gearings. For worm
gears, the setting for this coefficient is 3.0. The following rules apply to multi-level gear units with a
cylindrical or globoid worm gear stage that are connected to a non-worm gear stage (cylindrical gear-
, angled-, or bevel gear stage):
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▪ Fp = 2.0, if the stages are to withstand 200% of the current load
▪ Fp = 3.0, if the stages are to withstand 300% of the current load
The yield point coefficient can be also defined in the Strength tab. In the KISSsoft system, the
default setting for the yield point coefficient is 0.75. (As specified in the standard, it is 0.66 to 0.8).
According to the standard, the resultant safety factors for fatigue FSf and peak load FSp must be >=
1.
28.5.8 Stress
This is where you define how the stresses calculated by KISSsoft (e.g. the bending moment) are to
be converted into mean stresses and stress amplitude. You can select usual loads (alternating,
pulsating, static load) from the list. For special cases, open the Stress selection list and select the
Own Input option. Then, enter a suitable value in the Stress ratio field (see chapter 28.5.9, Stress
ratio). Rotating shafts normally have alternating bending and pulsating or static torsion.
28.5.9 Stress ratio
You must also enter the stress ratio, because KISSsoft requires this value to split the load on the
corresponding cross-section into mean load and load amplitude.
Maximum stress per load cycle: σo
Minimum stress per load cycle: σu
Stress ratio R = σu/σo
Mean stress: σm = (σo + σu)/2
= (σo + R . σo)/2
= σo . (1 + R)/2
Stress amplitude: σa = (σo - σu)/2
= (σo - R . σo)/2
= σo . (1 - R)/2
For:
Pure alternating stress (σu = - σo) R=-1
Pulsating stress (σu = 0) R=0
Static stress (σu = σo) R=1
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Normally valid for rotating shafts or axes:
Bending and shearing force: R = -1
Torsion and tension/compression: R = 0 (ev. R = 0 to 1)
► Note
In contrast to the calculation according to DIN or FKM, where there is a clear differentiation between
the mean stress and amplitude stress, when a strength calculation in accordance with Hänchen (see
chapter 28.5.1.1, Hänchen & Decker) is performed, the loads that are entered are converted into a
comparative stress that is then compared with the fatigue limit for bending. For this reason, if you
select this method, the stress ratio only affects the value of the stress ratio factor α0.
28.5.10 Load factor for static analysis
The static calculation normally uses the greatest possible load. The maximum load factor covers the
difference between the load value you specified and the peak value.
Maximum stress: σmax = σo . fmax
You can specify individual factors for every type of stress (bending, tension/compression, etc.).
The load factor is not used if the forces or power ratings are specified in free cross sections.
► Example
Electric motor with a permanent torque 100 Nm, starting torque 170 Nm. When you specify the shaft
data, enter 100 Nm and set the maximum load factor to 1.7.
28.5.11 Load factor endurance calculation
If necessary, the mean stresses and the stress amplitudes can be multiplied by a load factor. As the
DIN 743 standard does not include this factor, you should generally predefine it as 1.0. Using a factor
> 1 is a good idea if you specify the nominal torque in a shaft calculation without taking into account
the increases in torque due to the vibrations caused when the shaft rotates.
The load factor is not used if the forces or power ratings are specified in free cross sections.
The calculation according to Hänchen includes the following information:
The total load factor f according to Hänchen [52], p. 24:
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(25.9)
fun Uncertainty in maximum load (1.0 or 1.2 to 1.4)
fbetr Operational approach (shocks) (1.0 to 3.0)
fleb Importance of part (1.0 or 1.2 to 1.5)
► Note:
The Hänchen method uses only one load factor, which is the larger of the two values entered for
bending and torsion.
28.5.12 Cross sections
The yield safety and safety for fatigue fracture are determined at specific cross sections along a shaft
that are defined by you. In the Element Tree, you will see Cross sections at group level. In the
context menu, you can either add a Free cross section or a Limited cross section.
28.5.12.1 Surface roughness
If you enter a value for surface roughness as defined in ISO 1302, the corresponding surface
roughness, RZ , is displayed in the selection list. This value, RZ , is then used in the calculation. In the
calculation according to DIN or FKM, surface roughness has already been included in the notch
factor in some cases. In these cases, the surface factor is always 1.0, no matter what value you input
as the surface roughness.
28.5.13 Sizing
You can select the Sizing option in the context menu for the Cross section entry in the Element
Tree, to make it easier for you to define the cross sections that need to be recalculated.
In this sizing process, KISSsoft automatically finds cross sections (shaft shoulders, interference fits in
bearings, key-grooves and other notch effects) which have been defined in the graphical shaft
input, and in which a notch effect occurs. It displays the cross sections that have the lowest safeties.
You must check these cross sections carefully.
► Note
It is essential that you check the model for other notch effects that KISSsoft might not be able to find,
for example threads or cross holes.
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28.5.14 Cross-section types
▪ Shoulder
▪ Shoulder with relief groove
FKM Shape B FKM Shape D
DIN 509 Shape E DIN 509 Shape F
According to FKM, these shapes are handled like shape B.
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DIN 509 Shape G DIN 509 Shape H
According to FKM, these shapes are handled like shape D.
▪ Shoulder with interference fit
In Hänchen+ Decker and not possible.
AGMA 2101:
In DIN 743: The notch factor is calculated like a shoulder, but with the ratio
d/(1.1*D). The maximum transmission for D/d ~ 1.1 and for r/(D/d) ~2.
This condition is only applied if D/d = 1.1, otherwise the notch effect of
the shoulder is used.
In the FKM guideline: The notch effect coefficient is determined for the fit H7/n6. The notch
effect coefficient is also calculated for a shoulder and then used, in the
worst case, in subsequent calculations.
Notch factors are documented in the different methods. The notch factors calculated in
FKM are usually significantly larger than in DIN.
▪ Shoulder with conical transition
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▪ Shaft grooves
With the following variants:
▪ Thread
Notch factors for threads are not supplied separately in the specialist literature. For this reason,
notch factors for threads are handled like those for V-notches.
▪ Interference fit
Interference fit (Tight interference fit, Slight interference fit, Interference fit with relief grooves).
Only notch factors for the tight interference fit are defined in DIN 743, which is why the FKM
Guideline is used to define the factors for the other types of interference fit.
Defining notch effect coefficients for different types of interference fit:
Slight interference fit:
According to FKM and DIN 743: The notch effect coefficients for bending and
tension/compression are defined according to Kogaev, Figure 5.3-11. Formula
5.3.16 is used to define torsion. Formula βq = 1+(βt-1)/2, an assumption according
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to Prof. Haibach, is used to define shearing force.
Interference fit:
According to FKM: The notch effect coefficients for bending are calculated as
shown in Figure 2 of Table 5.3.1. The values for torsion are calculated from the
value for bending.
According to DIN 743: The notch effect coefficients for bending and torsion are
taken from Table 1, case 2, in DIN 743-2.
Interference fit with exceptions:
According to FKM and DIN 743: The notch effect coefficients for "Interference fit
with exceptions" are determined according to Table 5.3.1, Figure 3, in the FKM
Guideline for bending. The value for torsion is determined from the value for
bending with the formula from the FKM Guideline.
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Top: Interference fit with relief grooves.
Bottom: Interference fit with end relief.
Key
In every method, the moment of resistance for bending is determined from shaft diameter d. As
described by Hänchen, the moment of resistance for torsion is calculated from the incorporated circle
d - t. According to FKM, DIN and AGMA, it is calculated from the outer shaft diameter d.
Notch factors are documented in the different methods. However, Hänchen provides very little
information about this that can be used to extrapolate values for steel of higher strength (with the
appropriate comment about the calculation). In contrast, these values are well documented in the
DIN standard and the FKM Guideline (in the tables for Interference fit with key). Two different
production methods for keys are described in AGMA 6101 (side milling cutter or keyway cutter). This
standard also distinguishes between 2 different hardness ranges.
The program includes tables for cross sections with keys. The data is imported from a data file which
includes the DIN 6885.1 (corresponds to ISO/R 773), DIN 6885.2 and DIN 6885.3 standards. You
can also specify other standards.
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▪ Splines and straight-sided splines
Straight-sided spline shapes
To calculate groove meshings or straight-sided splines, you must first enter the tip and root
diameter data. All other values are used purely for documentation purposes.
To calculate the moments of resistance:
In Hänchen & Decker and FKM: From the mean value (da/2 + df/2)
In DIN 743 and AGMA 6101: From the root circle
Notch factors are documented in the different methods.
An exception to this is the calculation according to FKM, where the root diameter of
straight-sided splines (in this case: d) is used to calculate the notch radius.
▪ Cross hole
▪ Smooth shaft
If you select Smooth shaft the notch factor is set to 1. You should select this for the cross
section with the maximum stress.
▪ Input your own notch factors (see chapter 28.5.12, Cross sections)
▪ Intersecting notch effects (see chapter 33.1, Intersecting notch effects)
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28.5.15 General entries
28.5.15.1 Thickness factors from the shaft diameter
You can derive material values that depend on the diameter either from the effective shaft diameter
(d or D) or from the thickness of the raw material. The choice based on the effective shaft diameter
gives more reliable safety results, but can only be used if the shaft is through hardened before it is
turned.
However, if you select Pre-machined to actual diameter (for shoulders K1 from d), the material
data for shoulders is derived from the smaller diameter (d). If you select Pre-machined to actual
diameter, it is derived from the larger diameter (D). Although deriving these values from D gives
slightly lower strength values, the results are therefore somewhat safer. The standard does not
comment on this.
28.5.16 Thermally safe operating speed
The definition of the thermally safe operating speed is described in DIN 732 [53]. The calculation of
the thermally safe operating speed is based on the thermal balance in the bearing. The thermally
safe operating speed is derived from the thermal reference speed, using the speed ratio. The result
of this calculation is the speed that will be reached by the bearing running at the permitted
temperature in an actual situation. In order to define the thermally safe operating speed, you must
first define the thermal reference speed for each case.
The thermal reference speed is defined in DIN ISO 15312 [54]. The thermal reference speed is the
bearing-specific speed calculated under a given set of nominal operating conditions, such that
equilibrium is achieved between heat development (friction) and heat dissipation (through bearing
contact and lubricant).
You can enter the values for the calculation in the special "Thermally safe operating speed" tab and
in the relevant rolling bearing in the Element Editor.
The calculation is also available for use in the rolling bearing calculation module [W050], where the
calculation process and the values you enter are described in more detail. (see chapter 29.3,
Thermally safe operating speed)
28.6 Tooth trace modification
For various purposes, it is important that you know how much a specific point in the shaft cross
section moves in a particular direction due to elastic deformation (bending and torsion). An example
of this is calculating the gaping between the two halves of a coupling that are mounted on each end
of the same shaft. In this situation, the displacement of a point on the shaft cross section is
calculated in the axial direction.
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The most important application of this calculation is to determine shaft deformation in the meshing
area. The deformation for the pitch point is calculated along the facewidth. In this situation, the
displacement of the pitch point due to bending and torsion is calculated only in the direction of the
normal to the flank. A displacement parallel to the flank only results in a very minimal change in
sliding velocity and can therefore be ignored.
In the Tooth trace modification tab, you can directly select the toothing currently present on the
shaft. The data you have already input is used to define the necessary defaults for the calculation
(Facewidth from and to, Coordinates meshing point, Direction of the normal to the tooth flank in the
pitch point) which are displayed in the user interface. Therefore, assuming that the counter gear has
infinite stiffness, the progress of the pitch point displacement due to deformation can be determined
along the facewidth.
► Note:
during the tooth trace modification calculation, any gear load application offset for the gear selected
for the particular calculation (Calculation A or B) is temporarily deactivated. This means the gear load
application offset of gear A is disabled when Calculation A is performed, but is re-enabled when
Calculation B is performed.
To display this deformation, also called gaping, click Graphics > Tooth trace modification >
Deformation.
This shows the deformation in the pitch point. It also shows a proposed value for an optimum tooth
trace modification. This modification would achieve a homogeneous load distribution along the
facewidth.
You can input the tooth contact stiffness cγ in another input field. For steel gears, the tooth contact
stiffness per mm facewidth is approximately 20 N/mm/°. The values of cγ are calculated precisely
and documented in the cylindrical gear calculation. This stiffness can then be used to calculate the
load distribution along the facewidth. Click Graphics > Tooth trace modification > Load
distribution to see the result.
Calculating the load distribution coefficient KHβ for gear calculations
The results window also shows the load distribution coefficient KHβ, calculated according to ISO
6336, with the equation KHβ = wmax/wm from the average line load (wm) and the maximum line load
(wmax). This calculation enables the face load factor to be estimated with significantly more
accuracy, similar to Method B in ISO 6336. The procedure is basically similar to Annex E of ISO
6336. However, you must be aware that the shaft of the counter gear used here is assumed to have
infinite stiffness. This is permitted if the shaft of the counter gear has much greater stiffness.
Manufacturing allowances are also only included if, for example, they have been defined by inputting
an angular deviation of the shaft (bearing offset) as part of the shaft data.
The normalized displacement of the gear body determined from an FE (Finite Element) calculation
can also be taken into account as a displacement or stiffness matrix. To do this, select the Take
additional displacement matrix into account option in the cylindrical gear force element. You will
IV Calculating Shafts 635
find the deviation.dat file, which contains an example of a displacement matrix, in the dat directory.
The stiffness matrix can be calculated in the gear body deformation module (K16), or imported from
another FE program.
► Note:
If KHβ is to be determined while taking into account the deformation of the two shafts: The
deformation components of two shafts can be combined in the cylindrical gear calculation in the
Contact analysis tab.
Sizing the tooth trace modification
This calculation module has been designed to enable you to define the best possible tooth trace
modification both quickly and accurately. To do this, you can input a modification consisting of
flankline crowning or end relief and flank angle deviation. You can specify the flank angle deviation
either as a positive or negative number, depending on the required progression. The modification
input here is then also displayed in the "Deformation" graphic. In the "Load distribution" graphic you
can then clearly see the improved load distribution achieved by this calculation. Click Graphic >
Tooth trace modification > Tooth trace diagram to call the graphic for creating the modification
(gear drawing).
Figure 28.9: Determining gaping in the meshing point
28.7 Campbell diagram
Call this function from the Calculations > Campbell diagram menu option. In the relevant tab, you
can select the shaft to be analyzed, the range of shaft speeds, the number of calculation steps with
which the speed is calculated, and the number of resonance curves (forwards whirl) to be displayed.
The Campbell diagram shows the eigenfrequencies in a wider range of shaft speeds, which enables
you to follow the forward and backwards whirl associated with the eigenmodes. To calculate the
Campbell diagram, set the number of eigenfrequencies in the Basic data tab. The gyroscopic effect
IV Calculating Shafts 636
causes large changes in the eigenfrequencies. You can take it into consideration by clicking selecting
the Consider gyroscopic effect option in the Basic data tab.
In normal cases, the backwards whirl drops in frequency, while the forwards whirl increases in
frequency. In the case of forwards whirl, as shaft speed increases, the gyroscopic effect increasingly
affects the spring stiffness and increases the eigenfrequencies. The effect is reversed for backward
rotation, so increasing shaft spin speed reduces the effective stiffness, and thus reduces the
eigenfrequencies. The eigenfrequencies are also affected by the stiffness of the bearings.
28.8 Forced vibrations
Use this module to calculate forced vibrations for the shafts defined in KISSsoft. The dynamic
excitation of an unbalance mass is used to dynamically excite the shaft.
28.8.1 Calculation procedure
The first step in the calculation procedure is to enter this special calculation by selecting Calculation
> Forced response. Select the shaft whose speed will be changed during the calculation, the
relevant speed range and the number of calculation steps, here. Another input is the material
(structural) damping for torsional, axial and bending vibrations. Note that the viscous damping of
bearings must be defined separately for each bearing. To ensure that the calculation can be
performed, at least one unbalance mass in a shaft must be specified ("Additional mass" element,
"Mass", "Eccentricity" and "Angular position of the eccentric mass" input fields).
Note that results of completed calculations can only be requested at predefined documentation
points. The documentation points in this case are used as measurement probes for the dynamic
response of the shafts. Note that the resulting responses from different dynamic forces are added in
the time domain, and the final result is given based on the maximum value found during this
operation.
Apart from the calculation for a range of speeds of the reference shaft, there is also an option for
performing a calculation for a specific running speed of the reference shaft and determining the
dynamic response results along its length.
28.8.2 Results
Once the calculation is finished, you can display the results by selecting Graphics > Shafts >
Forced response.
IV Rolling Bearings (Classic Analysis) 637
29 Rolling Bearings (Classic Analysis)
Manufacturer catalogs (such as SKF) include fairly comprehensive methods for verifying the rating
life and static load capacity of rolling bearings. Specialized technical literature is also available to
help you resolve more detailed problems [2].
KISSsoft includes data from well-known bearing manufacturers. to which you can add your own
information.
The calculation module is integrated in the Shafts Module and can also be started separately by
clicking Shafts and Bearings > Rolling bearing ISO 281, ISO 76.
29.1 Selecting the type of rolling bearing
29.1.1 Properties of the most important bearing types
Selecting the most suitable type of rolling bearing is sometimes no easy matter. The table below
presents an overview of the critical properties of the most important types of rolling bearing:
▪ Deep groove ball bearing (DIN 625):
The single row radial deep groove ball bearing is the most commonly used, because it is both
extremely versatile and also the most inexpensive form of rolling bearing, because of its simple
design. This bearing can withstand relatively high radial and axial forces in both directions.
▪ Single row angular contact ball bearing and four-point contact bearing (DIN 628):
Each ring of a self-holding single row angular contact ball bearing has one lower shoulder and
one higher shoulder. The grooves on the higher shoulder are positioned so that the contact
angle is normally α = 40°. The higher number of balls in this configuration means it can
withstand not only radial forces but also larger axial forces in one direction (towards the higher
shoulder) than deep groove ball bearings. Axial reaction forces due to the angle of the groove
are generated when the bearing is subjected to a radial load. You must take this into account
when sizing the bearing. Because of their one-sided axial loading capacity, these types of
bearings are usually installed in pairs in which the second bearing is mounted in the opposite
direction. The axial load that acts on the bearing in the case of an O- or X-arrangement is
calculated and displayed in the mask.
▪ Double row angular contact ball bearing (DIN 628):
The double row angular contact ball bearing corresponds to a pair of mirror image compounded
single row angular contact ball bearings (back-to-back arrangement) with α = 25° or 35°, and
can therefore withstand radial and high axial forces in both directions.
IV Rolling Bearings (Classic Analysis) 638
Use: To support the shortest possible bending-resistant shaft that is subject to strong radial and
axial forces: integral worm shafts, shafts with helical gears and bevel gears.
▪ Double row self-aligning ball bearing (DIN 630):
The self-aligning ball bearing is a double row bearing with a cylindrical or conical bore (bevel
1:12). It can compensate for shaft displacement and misalignment (up to approximately 4 °
angular deviation) thanks to its hollow sphere raceway in the outer ring. It can be subjected to
radial loads and axial loads in both directions.
Use: bearings which are inevitably subject to mounting inaccuracies and bending of the shaft,
e.g. transmissions, conveyors, agricultural machinery, etc.
▪ Cylindrical roller bearing (DIN 5412):
Cylindrical roller bearings can support larger radial loads than ball bearings of the same size
(point contact area!) because the contact between the rollers and the races is made along a line.
Demountable cylindrical roller bearings can only support small axial forces (if at all) and require
accurately aligned bearings.
The different construction types can be identified by the rim arrangement: construction types N
and NU have an unconfined outer and inner ring and can be used as non-locating bearings,
construction type NJ can be used as a step bearing and construction types NUP and NJ can be
used as a guide bearing for axial shaft support in both directions.
Use: in gear units, electric motors, for axles of rail vehicles, for rollers in a rolling mill. In general,
suitable for bearing applications that are subject to large radial loads.
▪ Needle roller bearing (DIN 617):
Needle roller bearings are a special type of cylindrical roller bearing in which a cage separates
the needle rollers to keep them at a specific distance from, and parallel to, each other. The
bearing is supplied with or without an inner ring, and is only suitable for radial forces. Its
significant features are: small overall diameter, high degree of rigidity in the radial direction and
a relative insensitivity to uneven loading.
Use: Predominantly used at low to medium speeds and when oscillatory motion is present, e.g.
as connecting rod bearings, rocker-shaft bearings, swivel arm bearings, jointed cross-shaft axle
bearings (vehicles), spindle bearings, etc.
▪ Taper roller bearing (DIN 720):
The ring raceways in taper roller bearings are cone-shaped shells which must converge into one
point due to the action of kinematic forces. The bearings with α = 15°(30°) can support high
loads both in the radial and axial directions. The detachable outer ring makes them easy to
IV Rolling Bearings (Classic Analysis) 639
assemble and dismantle. Taper roller bearings are installed in mirror image pairs. The bearing
clearance can be set and adjusted as required. Due to the angle of the race, a radial force
produces an axial reaction force.
Use: hub bearings of vehicles, cable pulley bearings, spindle bearings in machine tools, shaft
bearings in worms and bevel gears.
Calculation: the axial force that you must specify when calculating dynamic equivalent loads is
defined in several theories (see, for example, page 296 of FAG Wälzlager Catalog WL 41520DE
(1995)). The axial force acting on the bearing is displayed in the screen. The bearing forces that
include the contact angle can be calculated directly.
▪ Barrel-shaped bearings (DIN 635), toroidal roller bearings (CARB), and double row self-
aligning ball bearings (DIN 635):
Spherical raceways in the outer ring and barrel-shaped rollers (toroidal-shaped for CARB
bearings), as in double row self-aligning ball bearings, enable barrel-shaped, toroidal roller
(CARB) and double row self-aligning roller bearings with a cylindrical or conical bore (1:12) to
compensate for misalignment and for the angular dislocation of the shaft (oscillating angle 0.5°
to 2°) Barrel roller bearings (single row self-aligning roller bearings) are suitable for high radial
loads, but can only withstand low axial forces. In contrast, double row self-aligning roller
bearings (α = 10°) can be used for the highest radial and axial forces. Toroidal roller bearings
(CARB) have an extensive range of uses in many load applications. Toroidal roller bearings
combine the angular flexibility of double row self-aligning roller bearings with the axial
displacement options of cylindrical roller bearings.
Use: for heavy wheels and cable pulleys, propelling shafts, rudder posts, crank shafts, and other
heavily loaded bearings. Toroidal bearing: paper making machinery, blowers and, generally, in
planetary gear units.
29.1.2 Comparing types
Selecting the most suitable type of rolling bearing is sometimes no easy matter. The table below
gives an overview of the most important properties. The rolling bearing you select for specific
operating conditions has often already been determined by its properties and properties. You can
use this information to select the bearing you require for frequently occurring working cases and for
specialized requirements. However, results may overlap, and therefore the cost factor may be
decisive.
IV Rolling Bearings (Classic Analysis) 640
In addition to the specified rolling bearing types, some hybrid bearings (with ceramic rolling bodies)
have been included, for some types. The special properties of these bearings are described in the
"Hybrid bearing" section.
Radial bearing:
Features a b c d e f g h i j k l m n
Radial load capability ⊗ ⊗ ⊗ Ø ⊗ + + + + + + + + +
Axial load capability ⊕ ⊗ ⊗ ⊗ Ø - ⊕ ⊕ - ⊕ ⊕ + ⊕ ⊗
Inside position - - - - - + Ø - + Ø - - - -
adjustment
Mounting position ⊕ ⊕ ⊕ - ⊕ - - ⊕ - ⊕ ⊕ ⊕ ⊕ ⊕
adjustment
Dismountable bearings - - ⊕ ⊕ - + + + + ⊕ - + - -
Alignment error Ø - - - + Ø Ø Ø - Ø - Ø + +
adjustment
Increased precision ⊕ ⊕ ⊕ Ø - ⊗ ⊕ ⊕ + - - ⊗ - -
High speed running + + ⊕ Ø ⊗ + ⊗ ⊗ + - - ⊕ ⊕ ⊕
Quiet running + ⊗ Ø Ø Ø ⊕ Ø Ø ⊕ - - Ø Ø Ø
Conical bore - - - - + ⊗ - - + - - - + +
Seal on one/both sides ⊕ - ⊕ - ⊕ - - - - - ⊕ - - ⊗
High stiffness ⊗ ⊕ ⊕ ⊗ Ø ⊕ ⊕ ⊕ + + + + ⊕ ⊕
Low friction + ⊕ ⊗ ⊕ + ⊕ ⊕ ⊕ + - - ⊕ ⊗ ⊕
Fixed bearing ⊕ + ⊕ ⊕ ⊗ - ⊗ ⊕ - ⊗ ⊗ + ⊕ ⊕
Non-locating bearing ⊗ ⊗ ⊗ - ⊗ + ⊗ Ø + ⊗ ⊗ Ø ⊗ ⊗
+ very good ⊕ good ⊗ normal/possible Ø with restrictions- not suitable/no longer relevant
a Deep groove ball bearing
b Angular contact ball bearing (single row)
c Angular contact ball bearing (double row)
d Four-point contact bearing
e Double row self-aligning ball bearing
f Cylindrical roller bearing NU, N
g Cylindrical roller bearing NJ
h Cylindrical roller bearing NUP, NJ+HJ
IV Rolling Bearings (Classic Analysis) 641
i Cylindrical roller bearing NN
j Cylindrical roller bearing NCF, NJ23VH
k Cylindrical roller bearing NNC, NNF
l Taper roller bearing
m Barrel roller bearing
n Double row self-aligning roller bearing
not listed here: Needle roller bearing, needle cage
Thrust bearing:
Features o p q r s t
Radial load capability - - Ø - - Ø
Axial load capability ⊗ ⊗ ⊗ ⊗ ⊗ +
Inside position adjustment - - - - - -
Mounting position adjustment - - - - - -
Dismountable bearings + + - + + +
Alignment error adjustment ⊕ ⊕ Ø - - +
Increased precision ⊗ - + + ⊕ -
High speed running ⊕ Ø ⊗ + Ø Ø
Quiet running Ø - Ø Ø - -
Conical bore - - - - - -
Seal on one/both sides - - - - - -
High stiffness ⊕ ⊕ ⊗ + ⊕ ⊗
Low friction ⊗ Ø ⊕ ⊕ - -
Fixed bearing ⊕ ⊕ + + ⊗ ⊗
Non-locating bearing - - - - - -
+ very good ⊕ good ⊗ normal/possible Ø with restrictions- not suitable/no longer relevant
o Deep groove thrust ball bearing (one-sided)
p Deep groove thrust ball bearing (double direction)
q Axial angular contact ball bearing (one-sided)
r Axial angular contact ball bearing (double direction)
s Cylindrical roller thrust bearing
IV Rolling Bearings (Classic Analysis) 642
t Axial spherical roller bearings
not listed here: Thrust needle cages, angular contact thrust roller bearings, cross roller bearings
29.1.3 Hybrid bearings
In a hybrid bearing, the race is made of rolling bearing steel, and the rolling bodies are made of a
ceramic material (silicon nitrite, Si3N4).
Hybrid bearings are included in the databases of standard rolling bearings. The rolling bearing
database has a particular setting which identifies hybrid bearings.
The calculation basis is the same as for standard types of rolling bearing.
However, the thermal reference speed and thermally safe operating speed cannot be determined,
because hybrid bearings are not covered by the standards.
The moment of friction for these bearings cannot be determined because the calculation methods
used in rolling bearing catalogs do not cover hybrid bearings.
The most important benefits of hybrid bearings are:
▪ higher stiffness
▪ suitability for use at higher speeds
▪ reduced inertia and centrifugal forces in the bearing
▪ reduced frictional heat
▪ lower energy consumption
▪ longer bearing life and grease lifetime
29.2 Load capacity of rolling bearings
We distinguish between the dynamic load capacity of the rotating bearing and the static load capacity
in idleness (at standstill), at very slow speed or if very small oscillations are present, relative to the
working state, but not to the effect of the load.
29.2.1 Dynamic load capacity
The dynamic load capacity is a property of the entire bearing. ISO 281 describes a number of various
properties of a rolling bearing that occur if the bearing experiences specific mechanical loading under
IV Rolling Bearings (Classic Analysis) 643
specific conditions at specific speeds. This data is then used to calculate the number of operating
hours (this is usually based on a failure probability of 10%).
29.2.2 Static load capacity
The static load capacity includes properties that a rolling bearing must display in order to withstand
certain mechanical loading situations in idleness (at standstill), at very low speeds (n < 20 rpm) or
during oscillatory motion.
Plastic deformation (indentation) occurs between the rolling bodies and the races when the bearing is
subjected to a moderate static stress due to the weight of the shaft and the other elements. This
value gradually increases as the stress increases. However, the plastic deformation must not be so
great that it influences the operational properties of the bearing in its rotational movement. As defined
in ISO 76, the static characteristic value S0 = C0/P0 is a safety factor against detrimental plastic
deformation which is a measure of the sufficient static load capacity.
The static load number, which is used to determine the bearing size, can be determined by taking
into account the safety margin which depends on the operating conditions:
S0 > 2 for shocks and impacts as well as exacting requirements for smooth
operation and for axial spherical roller bearings
S0 = 1 for normal operation and low noise requirements
S0 = 0.5...0.8 for smooth and non-impact operation with few requirements (non-loaded
bearing with adjusting or swivel motion)
29.2.3 Rolling bearing calculation with internal geometry
The rolling bearing reference rating life calculation is based on ISO/TS 16281.
The additional results of this calculation are the maximum Hertzian pressure on the inner and outer
ring (right and left ring for a thrust bearing), the static safety, the reference and modified reference
rating life in hours, the stiffness matrix at the operating point, and the load distribution or pressure
curve on each rolling element.
For more detailed information, see (see chapter 30, Rolling Bearings (Internal Geometry)).
If the rolling bearing inner geometry is provided by the manufacturer, then it is used in the calculation.
If it is unknown, then KISSsoft runs an approximation method that tries to determine the internal
geometry using the rolling bearing load ratings (the static load rating C0 and dynamic load rating C)
provided by the manufacturer. This procedure is based on ISO 76 and ISO 281, and normally
produces quite useful results.
IV Rolling Bearings (Classic Analysis) 644
If individual values such as the number of rolling bodies are known, only the remaining values are
approximated.
If the inner geometry you enter in the database is either insufficient or incorrect, this data is then
ignored, and the inner geometry is approximated. A note is then printed in the report, stating that an
approximation of the inner geometry has been used.
Internal geometry cannot always be taken into account when calculating bearing types (see chapter
9.5.37.2, Rolling bearing Internal geometry).
29.3 Thermally safe operating speed
The method for defining the thermally safe operating speed is described in DIN 732 [53], based on
the heat levels in the bearing. The thermally safe operating speed is derived from the thermal
reference speed, using the speed ratio. The result of this calculation is the speed that will be reached
by the bearing running at the permitted temperature in an actual situation. This thermally safe
operating speed may differ greatly from other operating speed limits, depending on lubrication type,
because the reference conditions only apply to quite specific cases. Before you can determine the
thermally safe operating speed, you must first define the thermal reference speed for each case.
► Note:
Calculations cannot be performed for barrel roller bearings (single row self-aligning roller bearings),
angular contact thrust roller bearings, cross roller bearings, and all hybrid bearings, because none of
the relevant standards have values for them.
29.3.1 Thermal reference speed
The thermal reference speed is defined in DIN ISO 15312 [7]. The thermal reference speed is the
bearing-specific speed calculated under a given set of nominal operating conditions, such that
equilibrium is achieved between heat development (friction) and heat dissipation (through bearing
contact and lubricant). Mechanical or kinematic criteria are not taken into account for this speed. The
reference values (temperatures, load, viscosity of the lubrication, reference face of the bearing,. . . )
are fixed so that the reference speed using oil- or grease-lubricated bearings will result in identical
values.
29.3.1.1 Dissipated Heat Flows
The heat flow Qr is calculated from the reference heat flow density qr that is specific to a rolling
bearing (for heat flow dissipated through bearing contact and lubricant), and from heat dissipation via
the reference surface Asr.
Qr = 10-6 * qr * Asr
qr, Asr are defined under reference conditions according to DIN ISO 15312.
IV Rolling Bearings (Classic Analysis) 645
29.3.1.2 f0r and f1r coefficients
The coefficients f0r and f1r used to define the thermal reference speed are different, depending on
which bearing type/series (also lubrication type for f0r) is used. They are shown in Table A.1 of the
standard. Not all bearing variants are listed in the table.
The following values have been assumed for bearings and bearing types for which no data has been
defined in the standard:
f0r (tabular value) f1r
Ball bearing 1.7 0.00015
Roller bearing 3 0.0003
Thrust ball bearing 1.7 0.00015
Thrust roller bearing 3.5 0.0015
29.3.1.3 Calculating the thermal reference speed
The dissipating heat flows and the friction power are set as equal values so that the energy balance
of the bearing is correct. The equation for the energy balance is:
NFr = 103 * Qr
NFr: Friction power [W]
Qr: dissipated heat flow: [kW]
The subsequent equation becomes:
(π *nθr)/30 * (10-7 *f0r * (νr*nθr)2/3 *dm3 + f1r *P1r *dm) = qr *ASr
nθr: thermal nominal speed [rpm]
f0r: Coefficient from Table A.1, DIN ISO 15312 [-]
r: Reference viscosity [mm2/s]
dm: average rolling bearing diameter [mm]
f1r: Coefficient from Table A.1, DIN ISO 15312 [-]
P1r: Reference load [N]
qr: Rolling bearing-specific reference heat flow density (bearing contact, lubricant) [kW/m 2]
ASr: Heat-transferring reference surface [mm2]
nθr can be determined using this equation.
IV Rolling Bearings (Classic Analysis) 646
29.3.2 Process for calculating thermally safe operating speed (DIN
732-2)
As, when calculating the thermal reference speed, this calculation is based on the thermal balance in
the bearing. Dissipating heat flow:
Q = QS + QL + QE
QS: Dissipating heat flow from the bearing contacts
QL: Heat flow dissipated by lubrication (only when there is circulatory lubrication) (the lubrication's
density ϱ = 0.91 kg/dm3 and the specific heat capacity of the lubricant, cL = 1.88 KJ/(kg *K) are
predefined).
QE: additional heat flows (assumed for the calculation QE = 0).
29.3.2.1 Friction coefficients f0 and f1
Coefficients f0 and f1 and the dynamic equivalent load P1 are only needed to define the load and
lubrication parameters. These values differ depending on the specific bearing type/model, lubrication
type, or load direction. They are listed in Table A.1 in the standard. Not all bearing variants are listed
in the table. The values for various types of lubrication below have been defined (and incorporated in
KISSsoft). They are based on the notes about f0 in Table A.1 in the standard.
▪ Oil, bath lubrication, bearing in oil mist: f0 = 0.5 * f0 (tabular value)
▪ Oil, bath lubrication, oil level up to middle bearing: f0 = 2.0 * f0 (tabular value)
▪ Oil, bath lubrication, oil level up to middle of the lowest rolling element: f0 = 1.0 * f0 (tabular
value)
▪ Oil, circulatory lubrication: f0 = 2.0 * f0 (tabular value)
▪ Grease, run-in bearing: f0 = 1.0 * f0 (tabular value)
▪ Grease, newly greased: f0 = 2.0 * f0 (tabular value)
The following values have been assumed for bearings and bearing types for which no data has been
defined in the standard:
P1 f0 (tabular value) f1
Ball bearing 3.3*Fa - 0.1*Fr 1.7 0.0007*(P0/C0)^0.5
(P1 <= Fr) where P1 = Fr
Roller bearing Fr 3 0.0003
Thrust ball bearing Fa 1.7 0.0007*(P0/C0)^0.5
Thrust roller bearing Fa 3.5 0.0015
IV Rolling Bearings (Classic Analysis) 647
29.3.2.2 Calculating the thermally safe operating speed limit
The thermally safe operating speed is derived from the thermal reference speed, using the speed
ratio. nθ = fn * nθr
The load and lubrication parameters must be calculated before the speed ratio can be iterated from
this equation:
KL * fn5/3 + KP * fn = 1
Load parameter KL:
KL = 10-6 * (π/30) * nθr*10-7 * (f0r * n2/3 * nθr2/3 * dm3)/Q
Lubricant film parameter KP:
KP = 10-6 * (π/30) * nθr*(f1 * P1 * dm)/Q
nθr: thermal nominal speed [rpm]
f0: Coefficient of friction from Table A.1, DIN 732 [-]
f1: Coefficient of friction from Table A.1, DIN 732 [-]
n: Lubricant viscosity [mm2/s]
dm: average rolling bearing diameter [mm]
P1: Reference load [N]
Q: Total dissipated heat flows [kW]
29.4 Moment of friction
In a rolling bearing, the friction between individual components has a decisive influence on heat
development and therefore the operating temperature. The appropriate heat value can be estimated
from the moment of friction of the rolling bearing. Select Calculation > Settings to display the
Settings tab. In it, you can select this calculation method.
You can only perform this calculation by clicking the Modified service life according to ISO 281
option in the Strength tab (to display it, select Basic data > Strength).
29.4.1 Calculation according to SKF Catalog 1994
The prerequisite for calculating the moment of friction is that the bearing rotating surfaces must be
separated by a lubricant film. The total bearing moment of friction results from the sum:
(27.1)
IV Rolling Bearings (Classic Analysis) 648
M0: load-independent friction moment
M0 is determined by the hydrodynamic losses in the lubricant. It is especially high in quickly rotating,
lightly loaded bearings. The value M0 depends upon the quantity and viscosity of the lubricant, as
well as the rolling speed.
M1: load-dependent friction moment
M1 is determined by the elastic deformation and partial sliding in the surfaces in contact, especially
due to slowly rotating, heavily loaded bearings. The value M1 depends on the bearing type (bearing-
dependent exponents for the calculation), the decisive load for the moment of friction and the mean
bearing diameter
For axially loaded cylindrical roller bearings, an additional axial load-dependent moment of friction,
M2 , is added to the formula.
(27.2)
M2: axial load-dependent friction moment
M2 depends on a coefficient for cylindrical roller bearings, the axial loading and the bearing's mean
diameter.
For sealed rolling bearings, an additional axial load-dependent moment of friction, M3 is added to the
formula.
(27.3)
M3: Moment of friction for grinding seals
The moment of friction for grinding seals depends on the bearing type, the bearing size, the diameter
of the seal-lip mating surface, and the layout of the seal. As the type of seal, the diameter of the seal-
lip mating surface, and the seal layout, differ from one manufacturer to another, it is difficult to define
a generally applicable moment of friction.
Select Calculation > Settings to display the Settings tab. In it, you can choose different options for
determining this reference size:
▪ according to SKF main catalog in selected calculation method
▪ according to the Hauptkatalog (main catalog) 4000/IV T DE: 1994:
You will find values for the seal types used in your bearings in the SKF catalog, which is
integrated in the KISSsoft software. If the KISSsoft system finds a familiar seal label in the
bearing label, it calculates the moment of friction for a grinding seal using the coefficients
listed in the catalog. Otherwise, the moment of friction is set to zero.
IV Rolling Bearings (Classic Analysis) 649
Example of a seal label in the name of a rolling bearing:
SKF: 623-2RS: this means that the bearing has a RS1-type seal on both sides. The
KISSsoft system then searches for names with "-2RS1" in them. If this label is present, the
coefficients from the SKF catalog are applied and the moment of friction for grinding seals
is calculated.
▪ according to ISO/TR 13593:1999 Viton Msea calculated with the formula: Msea = 3,736*10^-3*dsh;
Msea in Nm, dsh Shaft diameter in mm
▪ according to ISO/TR 13593:1999 Buna N Msea calculated with the formula: Msea = 2,429*10^-
3*dsh; Msea in Nm, dsh Shaft diameter in mm
Coefficients f0, f1 (see chapter 29.3.2.1, Friction coefficients f0 and f1) and P1 (values that depend
on the bearing type and bearing load) used for the calculation have been taken from ISO 15312. The
formulae, exponents and coefficients have been taken from the SKF Catalog, 1994 Edition.
29.4.2 Calculation according to SKF Catalog 2018
As this calculation has to take into consideration a myriad of factors and influences, it is only
performed if selected as an option in the modified rating life calculation. However, this calculation can
also be performed without these default values. The calculation of the total moment of friction
according to the 2018 SKF catalog is determined by a combination of rolling and sliding friction in the
roller contacts (between rolling bodies and cage, the bearing surface, the lubricant, and the sliding
friction from grinding seals caused in sealed bearings). The calculation of the moment of friction
depends on various coefficients:
▪ Rating (load)
▪ Type of bearing
▪ Bearing size
▪ Operating speed
▪ Lubricant properties
▪ Lubricant quantities
▪ Seals
The following working conditions must be present for the calculation to be performed:
▪ Grease or oil lubrication (oil bath, oil mist, or oil injection process)
▪ Load equal or greater than minimum load
▪ Load constant in size and direction
▪ Nominal operating clearance
IV Rolling Bearings (Classic Analysis) 650
If the load is less than the minimum load, the calculation continues using the minimum load. If a
minimum load value has been entered in the database, this value is used. If not, the software will
determine this value. In the case of radial bearings, the minimum load is converted into a minimum
radial force. In thrust bearings, the minimum axial force is defined by the software. The value for the
minimum load is not used here.
The formula for the total moment of friction is:
M = Mrr + Msl + Mseal + Mdrag
Mrr: Rolling moment of friction
The rolling moment of friction depends on the bearing type, mean diameter, radial and axial loading,
rotation speed, and lubricant viscosity. The design coefficients required to calculate the rolling
moment of friction are defined using the rolling bearing's series. The design coefficients and
coefficients used in the calculation are taken from the SKF Catalog 2018.
Coefficients used for rolling friction:
▪ ish: Lubricant film thickness factor
In a lubricant flow, the lubricant is exposed to shear forces caused by the movement of the
rolling bodies. This produces heat and therefore reduces the rolling moment of friction.
▪ rs: Lubricant displacement factor
The constant rolling action squeezes excess lubricant away from the contact zone of the rolling
body. This reduces the lubricant film thickness and therefore reduces the rolling moment of
friction.
Assumptions have been made for bearing types and bearing series for which no design coefficients
have been defined in the catalog, so that the rolling moment of friction can still be calculated despite
their absence.
Msl: Sliding moment of friction
The sliding moment of friction depends on the bearing type, mean diameter, radial and axial loading
and lubricant viscosity. The design coefficients required to calculate the sliding moment of friction are
defined using the rolling bearing's series. You will find the factors used for this calculation in the SKF
2018 catalog.
Mseal: Moment of friction for grinding seals
The moment of friction for grinding seals depends on the bearing type, bearing size, diameter of the
seal-lip mating surface, and the seal type. As the type of seal, the diameter of the seal-lip mating
surface, and the seal layout, differ from one manufacturer to another, it is difficult to define a
generally applicable moment of friction.
Select Calculation > Settings to display the Settings tab. In it, you can choose different options for
determining this reference size:
▪ according to SKF main catalog in selected calculation method
IV Rolling Bearings (Classic Analysis) 651
▪ PUB BU/P1 17000/1 EN: October 2018
You will find values for the seal types used in your bearings in the SKF catalog, which is
integrated in the KISSsoft software. If the KISSsoft system finds a familiar seal label in the
bearing label, it calculates the moment of friction for a grinding seal using the coefficients
listed in the catalog. Otherwise, the moment of friction is set to zero.
Example of a seal label in the name of a rolling bearing:
SKF: 623-2RS: this means that the bearing has a RS1-type seal on both sides. The
KISSsoft system then searches for names with "-2RS1" in them. If this label is present, the
coefficients from the SKF catalog are applied and the moment of friction for grinding seals
is calculated.
In KISSsoft, the diameter of the seal-lip mating surface is calculated with:
ds = d + (D - d) * 0.2
▪ according to ISO/TR 13593:1999 Viton Msea calculated with the formula: Msea = 3.736*10^-3*dsh;
Msea in Nm, dsh Shaft diameter in mm
▪ according to ISO/TR 13593:1999 Buna N Msea calculated with the formula: Msea = 2.429*10^-
3*dsh; Msea in Nm, dsh Shaft diameter in mm
Mdrag: Moment of friction caused by lubrication losses
This moment of friction is caused by flow, splash or injection losses during oil bath lubrication. To
calculate this moment, you must also input the oil level depth (h Oil), which you can specify by
selecting Calculation > Settings. You will find a more detailed description of this entry in the Oil
level and lubrication type section (see chapter 29.11). The design coefficients KZ and KL for rolling
bearings with a cage are also applied to toroidal roller bearings (CARB).
29.4.3 Calculation according to Schaeffler 2017 (INA, FAG)
To define the total moment of friction, the speed, load, lubrication type, lubrication method and
viscosity of the lubricant at operating temperature must be known.
Formula used for the total moment of friction:
(27.1)
M0: speed-independent (load-independent) moment of friction
M0 is determined by the hydrodynamic losses in the lubricant. It is especially high in quickly rotating,
lightly loaded bearings. The value M0 depends upon the quantity and viscosity of the lubricant, as
well as the rolling speed.
M1: load-dependent friction moment
IV Rolling Bearings (Classic Analysis) 652
M1 is determined by the elastic deformation and partial sliding in the surfaces in contact, especially
due to slowly rotating, heavily loaded bearings. The value M1 depends on the bearing type (bearing-
dependent exponents for the calculation), the decisive load for the moment of friction and the mean
bearing diameter
For axially loaded cylindrical roller bearings, an additional axial load-dependent moment of friction,
M2 , is added to the formula.
(27.2)
M2: axial load-dependent friction moment
M2 depends on a coefficient, kB for cylindrical roller bearings, the axial loading and the bearing's
mean diameter.
For bearings with a TB design (better axial load capacity achieved using new calculation and
production methods), bearing factor f2 is displayed in a special diagram in the main catalog.
Coefficients f0, f1 (see chapter 29.3.2.1, Friction coefficients f0 and f1) and P1 (values that depend
on the bearing type and bearing load) used for the calculation have been taken from DIN ISO 15312.
The formulae, exponents and coefficients have been taken from the Schaeffler Catalog, 2017
Edition.
29.5 Grease lifetime
Grease lifetime is the length of time that a bearing remains adequately lubricated without having to
be regreased. If the grease lifetime is reached without regreasing, it can be expected that the bearing
will fail.
By its very nature, the grease lifetime is very application-specific. However, there are approaches
which can be used to estimate its approximate value. In the KISSsoft system, methods from the
Schaeffler (INA/FAG) and SKF catalogs can be used to calculate a guide value. Select Calculation
> Settings to display the Settings tab. In it, you can select the appropriate method. The calculation is
performed when you select the Enhanced service life calculation (see chapter 29.7.1, Modified rating
life calculation according to the Supplement to DIN ISO 281 (2007)) and select a grease as the
lubricant in it.
29.5.1 Calculation according to Schaeffler 2018 (INA, FAG)
According to the Schaeffler catalog 2018 (INA, FAG), a guide value for the grease lifetime can be
determined on the basis of a speed-dependent base grease lifetime. This guide value can then be
adjusted to suit the particular application and environment in which the bearing is working:
𝑡𝑓 𝑔 = 𝑡𝑓 ∗ 𝐾𝑇 ∗ 𝐾𝑃 ∗ 𝐾𝑅 ∗ 𝐾𝑈
IV Rolling Bearings (Classic Analysis) 653
tf: base grease lifetime
KT: correction factor for increased temperature
KP: correction factor for increased load
KR: correction factor for oscillating mode
KU: Correction factor for environmental influences
The lower guide value of the order of magnitude specified in the relevant diagram is used as the
reference for the base grease lifetime tf.
The correction factor KT for increased lubricant temperature is used above the lubricant-specific
operating temperature. In oscillating mode, the correction factor KR is assumed to be 1.
29.5.2 Calculation according to SKF Catalog 2018
The SKF catalog 2018 states that a guide value for the grease lifetime can be determined on the
basis of a speed- and load-dependent base grease lifetime. Like the Schaeffler approach, this can
then be adjusted by a number of factors, depending on how the bearing is used and its environment.
In the KISSsoft system, the lubrication lifetime is determined as the guide value for the lubrication
interval and a modification, KS, is applied for vertical shafts and a modification, KT, is applied for
lubricant temperatures greater than 70°C. The catalog lists a number of additional influencing factors
and provides qualitative descriptions for them. These factors must then be evaluated and taken into
account on an application-specific basis.
𝑡𝑓 𝑔 = 𝐾𝑇 ∗ 𝐾𝑆 . ..
tf: base grease lifetime
KT: correction factor for increased temperature
KS: Correction factor for a vertical shaft
29.6 Maximum Speeds
Rolling bearings are reliable and can be expected to reach their calculated rating life as long as the
maximum speed (speed limit) is not exceeded. This depends on the type, size and lubrication.
A warning message is displayed if the maximum permissible speed is exceeded.
The permitted maximum speed can be much lower, depending on the lubrication type used (see
chapter 29.3, Thermally safe operating speed).
IV Rolling Bearings (Classic Analysis) 654
29.7 Rating life
The nominal rating life is calculated using the formulae given in ISO 281, and corresponds to the
formulae that can also be found in the manufacturers' catalogs. Usually the rating life is calculated at
90% (10% probability of failure), in hours. The label used here is L10h (h: hours. 10: probability of
failure).
29.7.1 Modified rating life calculation according to the Supplement to
DIN ISO 281 (2007)
ISO 281 includes the regulations for "modified rating life" which take into account the influence of
load, lubricant conditions, materials specifications, type, material internal stresses and environmental
factors.
The life modification factor: aISO can be defined as follows:
(27.3)
aISO: Life modification factor from diagram [-]
ec: Contamination characteristic value [-]
Cu: fatigue load limit [N]
P: Dynamic equivalent load [N]
κ: viscosity ratio = nu/nu1
nu1: reference viscosity diagram [mm2/2]
n u: VT diagram for the lubricant [mm2/2]
The fatigue load limit Cu is specified by the bearing manufacturers. If none of these values are
known, you can calculate them with the approximate formula as defined in ISO 281.
The contamination factor ec (between 0 and 1) is taken directly from the degree of cleanliness.
29.7.2 Rating life calculation with load spectra
The load spectrum on the bearing has these values:
k: number of elements in the load spectrum
qi: Frequency (load bin i) (%)
IV Rolling Bearings (Classic Analysis) 655
ni: Speed (load bin i) (rpm)
Fri: Radial force (load bin i) (N)
Fai: Axial force (load bin i) (N)
You can take this load spectrum data from the shaft calculation, in which case you may obtain
different load spectra for radial and axial forces. Alternatively, you can select a load spectrum from
the database. For bearing forces, the important factor here is the torque factor (not the load factor)
and a negative prefix operator will only affect the axial force.
Achievable rating life with simple calculation approach:
You calculate the rating life by defining an equivalent design load and the average speed. You can
then use the usual formulae to calculate the rating life.
(27.4)
(27.5)
nm: average speed
p: exponent in the rating life formula (3.0 or 10/3)
Pi: dynamic equivalent load (load bin i)
Pm: average dynamic equivalent load
Achievable rating life with the modified rating life calculation:
When the modified rating life calculation is used, the rating life is calculated separately for every
equivalent load bin. The result is then used to determine the total service life:
(27.6)
Lhnai: service life (load spectrum bin i) in the case of speed ni and load Fri, Fai
Lhna: Total rating life
IV Rolling Bearings (Classic Analysis) 656
29.8 Failure probability
Normally, the failure probability is assumed to be 10%. This means there is a 90% probability that the
nominal rating life will be achieved. In this case, the coefficient a1 is equal to 1.0. If the failure
probability value has to be lower, this coefficient must also be lower (at 1%, a1 = 0.21).
To define the failure probability, select Calculation > Settings.
29.9 Bearing with radial and/or axial force
For every bearing, you can specify whether it is subject to a radial or axial force. If the bearing is
subject to axial force, you must also specify whether the force is applied in both directions (<>), in the
direction of the y-axis (− >) or in the opposite direction (> −).
29.10 Calculating axial forces on bearings in face-to-
face or back-to-back arrangements
Because of the inclination of the raceways in the bearing, a radial load generates axial reaction
forces in taper roller bearings, angular contact spindle ball bearings and angular contact ball
bearings. This data must be taken into account when the equivalent design load is analyzed.
Axial reaction forces are calculated in accordance with SKF (rolling bearing catalog) which exactly
match the values defined in FAG.
For bearings in a back-to-back arrangement, left bearing A, right bearing B, outer axial force in A-B
direction, the following data applies:
Condition Formula
IV Rolling Bearings (Classic Analysis) 657
FrA,FrB Radial force on bearing A, B
Y A,Y B Y coefficient of bearing A, B
Fa External axial force
FaA,FaB Axial force on bearing A, B
For all other cases (face-to-face arrangement or axial force in the other direction), simply reverse the
formula.
These calculated internal tension values are displayed in the main window. If the actual internal
forces are higher, for example, due to the use of spring packages, you can change the value
manually.
29.11 Oil level and lubrication type
To input the oil level and lubrication type, select Calculation > Settings. These entries are required
to define the moment of friction due to lubrication losses. The value h is given in the shaft calculation
and results in the following formula for every bearing:
IV Rolling Bearings (Classic Analysis) 658
Figure 29.1: Oil level in the bearing
Two different types of lubrication can be defined:
▪ Oil bath lubrication
▪ Oil injection lubrication
If you select the Oil injection lubrication (spray lubrication) option, the value determined for the flow
loss-dependent moment of friction for oil bath lubrication is multiplied by 2.
IV Rolling Bearings (Internal Geometry) 659
30 Rolling Bearings (Internal Geometry)
In addition to the classic bearing calculation (see (see chapter 29, Rolling Bearings (Classic
Analysis))), KISSsoft also provides a calculation according to ISO/TS 16281. Here, the internal
bearing geometry (number of rolling elements, rolling body diameter, etc.) is used to calculate the
bearing load and the service life.
This method is integrated in the Shaft calculation and is also available as a separate KISSsoft
module. Unless otherwise indicated, the separate KISSsoft module is described below. The module
is designed to be used by bearing experts, or users who know the internal geometry of their
bearings.
Notes:
EHL lubricant film thickness
The minimum EHL lubricant film thickness is calculated for rolling bearings with a known internal
geometry, using the methodology described in [55]. The effect of pressure on viscosity is taken into
account using the Barus’ equation, as documented in the same reference.
Spin to roll ratio
The spin to roll ratio of ball bearings is calculated on the basis of the equations in [55]. The
assumption of "outer raceway (ring) control" is used, meaning that no spin of the ball is present on
the outer raceway (ring). It is a well-known fact that this assumption primarily applies for lightly
loaded high speed bearings. Ball gyroscopic motions and cage effects are not considered any further
than that.
30.1 Bearing data tab
30.1.1 File interface
Use this module to link to a shaft calculation file. This means bearing information is automatically
transferred from the shaft calculation file without you having to reenter the data. The user must input
the:
▪ File name: name of the shaft calculation file (extension .W10), from which the selected bearing
data will be extracted.
▪ Element type: Here, you select whether the bearing is a rolling bearing that belongs to a shaft,
or a connecting rolling bearing
▪ Shaft no.: if the bearing belongs to a shaft, the user must input the shaft number here. The
program then runs through the shafts Element Tree from top to bottom 5ba0bcd6a1d96.
IV Rolling Bearings (Internal Geometry) 660
▪ Bearing no.: number of the selected bearing, either on the corresponding shaft or from the list of
connecting elements. The program runs through the shafts Elements tree from top to bottom
5ba0bcd6a1d96.
▪ Data exchange: determines how data is exchanged between the shaft file and this module. In
each case, the geometry of the selected bearing is transferred from the shaft file.
▪ Bearing load: the information transferred from the shaft file is the applied force and torque
of the bearing as well as the lubricating conditions
▪ Bearing displacement: the information transferred from the shaft file is the displacement
and rotation of the inner ring of the bearing as well as the lubricating conditions
▪ Own Input: only the bearing geometry is transferred. You can specify your own load and
lubrication conditions.
30.1.2 Bearing data
This is where the geometry of the bearing is defined (see chapter 29.2.3, Rolling bearing calculation
with internal geometry). In addition to the geometry data, you can also enter the basic dynamic load
rating. If you do not know this value, the rating is calculated using the current geometry data as
specified in ISO 281. If you require a modified rating life (see chapter 29.7.1, Modified rating life
calculation according to the Supplement to DIN ISO 281 (2007)), input the fatigue load limit Cu. If Cu
is not known, it is also calculated on the basis of ISO 281.
Note for the shaft calculation: In this module, the effect of surface hardness on the static capacity
can be taken into account by entering the Vickers hardness. You will find the formulae for this in [56].
The hardness value of every bearing calculated with their inner geometry is predefined as HV 660 for
the shaft calculation.
30.1.2.1 User-defined roller profile
A logarithmic profile as specified in ISO 16281 is usually used for roller bearings. However, a user-
defined roller profile can be used instead, if required. The expected structure of this file is as follows:
-- this line is a comment
DATA
1 -0.45 0.000581256
2 -0.41 0.000390587
3 -0.37 0.000277616
4 -0.33 0.000200197
IV Rolling Bearings (Internal Geometry) 661
...
...
21 0.33 0.000200197
22 0.37 0.000277616
23 0.41 0.000390587
24 0.45 0.000581256
END
Notes:
▪ Lines that start with "--" are comments and are ignored.
▪ The profile function definition starts with the keyword "DATA" and ends with the keyword "END".
▪ Each line must have three columns. The first column is the index. It is only included as a
reference source for the user. Its values have no effect, and are ignored. The second column is
the non-dimensional position x/Lwe for which the profile is defined in mm/mm. The values in this
column should range between -0.5 and +0.5. The third column is the non-dimensional profile
f/Dw, in mm/mm. The values in this column cannot exceed 0.5.
▪ If the profile is not defined over the entire rolling body width, the value is
extrapolated quadratically for these areas.
▪ To save space, the data represented by "..." has been omitted.
Figure 30.1: Coordinate frame used to define the user-defined roller profile
30.1.2.2 Bearing ring deformations
The inside/outer rings are usually assumed to be rigid (non-deformable). To take ring deformations
into account, click on the plus button next to the bearing type definition. The expected structure for
both files is as follows:
IV Rolling Bearings (Internal Geometry) 662
-- this line is a comment
DATA
0 0 0.00E+00 0.00E+00 5.00E-03
1 8 0.00E+00 6.96E-04 4.95E-03
2 16 0.00E+00 1.38E-03 4.81E-03
3 24 0.00E+00 2.03E-03 4.57E-03
...
...
41 328 0.00E+00 -2.65E-03 4.24E-03
42.336 0.00E+00 -2.03E-03 4.57E-03
43.344 0.00E+00 -1.38E-03 4.81E-03
44.352 0.00E+00 -6.96E-04 4.95E-03
45.360 0.00E+00 -1.23E-18 5.00E-03
END
Notes:
▪ Lines that start with "--" are comments and are ignored.
▪ The ring deformation definition starts with the keyword "DATA" and ends with the keyword
"END".
▪ Each row must have 5 or 8 columns. The first column is the index. It is only included as a
reference source for the user. Its values have no effect, and are ignored. The second column is
the angle φ, which sets the deformation. The next three columns are the X, Y, and Z
components of the ring deformation, all defined in mm. If 8 columns are used, the last 3 columns
represent the x, y and z components of the rim tilting, in "rad".
Row 5 columns 8 columns
1 Index Index
2 φ (°) φ (°)
IV Rolling Bearings (Internal Geometry) 663
3 ux (mm) ux (mm)
4 uy (mm) uy (mm)
5 uz (mm) uz (mm)
6 - rx (rad)
7 - ry (rad)
8 - rz (rad)
▪ To save space, the data represented by "..." has been omitted.
Figure 30.2: Coordinate frame for this module (W051), which defines the axial (x) and radial directions (y, z). For the
sake of clarity, the coordinate frame of the shaft module (W010) is also displayed.
Note for the shaft calculation:
Ring deformations can only be processed in bearing calculation module W051, not in shaft
calculation module W010.
30.2 Rating (load) tab
Define the bearing's working conditions in this window.
30.2.1 Rating (load)
Four combinations of data can be entered here:
▪ (A) Force and Tilting moment
▪ (B) Force and Tilting
IV Rolling Bearings (Internal Geometry) 664
▪ (C) Displacement and Tilting moment
▪ (D) Displacement and Tilting
Speed: the speed of the inner ring relative to the outer ring. The outer ring is always assumed to be
fixed (non-rotating).
Oscillating angle: the oscillating angle for partially rotating bearings. The rating life in million
oscillation cycles is determined according to [2].
Note for the shaft calculation: The default setting for the shaft calculation process is combination D.
Note: A complete oscillation is
30.2.2 Modified rating life calculation in accordance with ISO 281
The effect of lubrication, filtration and contamination on bearing rating life can be taken into account
here.
Lubricant: the lubricant used
Operating temperature: the temperature of the lubricant
Contamination: the class of the contamination
30.3 Tab Elastic Rings
The calculation according to ISO/TS 16281 assumes that the bearing rings are rigid. However, in
many cases, the elasticity of the ring must be considered, to achieve realistic results. A typical
application is the bearing which supports the planet gear in a planetary system. The ring is thin
relative to its diameter, and therefore its elasticity cannot be neglected. The effect of the ring
elasticity is that it typically increases the load zone and changes the load distribution within it, by
“sharing” the maximum load to the neighboring rolling bodies. The calculation is based on the
transfer matrix method [50].
30.3.1 Basic data
This calculation requires the ring geometry. Unless "Own Input" is selected, the ring is assumed to
be cylindrical, with a rectangular cross section.
IV Rolling Bearings (Internal Geometry) 665
a. del,i is the internal diameter of the inner ring. The inside ring race diameter (di) is assumed to be
the external diameter of the inner ring.
b. del,o is the external diameter of the outer ring. The external ring race diameter (do) is assumed to
be the internal diameter of the outer ring.
c. Bi is the inner ring width.
d. Bo is the external ring width, which is usually not equal to Bi (for example, taper roller bearing).
If you have selected Own Input, the ring is no longer assumed to have a rectangular cross section,
and you then need to input the geometric properties of its surface.
a. Ai is the cross section area of the (inner) ring.
b. is the area moment of inertia (surface Si) around the x axis, for an arc length li equal to the ring
thickness ti. This is used to calculate the local bending of the ring in the transverse plane (normal to
the radial plane).
Jyi is the area moment of inertia of a surface (surface Ai) around the y axis.
d. Jzi is the area moment of inertia (surface Ai) around the z axis.
IV Rolling Bearings (Internal Geometry) 666
e. Jpi is the polar area moment of inertia (surface Ai) around the local XL axis (normal to surface Ai).
f. Rci is the centroid radius of surface Si. It is essentially the radius of the center of gravity of surface
Si on the plane yz.
You can then determine the same variables for the outer ring by replacing each "i" subscript with "o".
30.3.2 Details
This is where you define the boundary conditions which are applied on the elastic ring. The definition
of boundary conditions must be complete, in the sense that the elastic ring solution should not be ill-
conditioned (i.e. a certain degree of freedom (DOF) is free).
30.3.2.1 General boundary conditions
The following boundary conditions are available. These conditions act on predefined angular
positions around the ring perimeter. Unless otherwise specified, all the coordinates refer to the global
coordinates system.
a. Force: localized force and moment vector.
b. Distributed force: a force and moment loading which is applied on a given arc length starting at
angle f1 and finishes at angle f2 (constant load distribution is assumed). Since this is a distributed
load, its components (X/Y/Z and RX/RY/RZ) are assumed to be constant relative to the local ring
coordinates (XL/YL/ZL).
c. Elastic support: a spring support with constant spring stiffness.
d. Fixed support: a fixed support (on the ring mean line M) which blocks the corresponding DOF. A
numerical value different than 0 in any component, means that this DOF is fixed. Example: (X, Y, Z,
RX, RY, RZ) = (1, 1, 0, 1, 0, 0) means that ux, uy and rx are fixed, and the remaining degrees of
freedom (DOFs) are free.
e. Fixed support (left): a fixed support which blocks all DOFs, but the support is defined on the left
side (L) instead of on the ring mean line. A practical modeling case is a ring which is fixed on the
shaft (or housing) with bolts.
f. Fixed support (right): similar to "Fixed support (left)", but the support is on the right side (R).
g. Deformation: Deformation: a given deformation and tilting value which is determined for the ring.
IV Rolling Bearings (Internal Geometry) 667
30.3.2.2 Gear contacts
A gear contact is internally identical to a general boundary condition for the "force" (a cylindrical gear
is assumed). You must enter the following data:
a. αpos: the angular contact of the meshing point. This corresponds to "αpos" for a gear load element
in the shaft calculation
b. mn: normal module
c. αn: nominal pressure angle
d. β: nominal helix angle (+: right-hand gear, -: left-hand gear)
e. a: center distance between gear and counter gear
f. z: number of teeth on the gear
g. zc: number of teeth on the counter gear
h. T/P (selection): select the torque or the power input
i. T/P (value): the numerical value of the load (+: driving gear, -: driven gear)
j. n: the gear's speed around the ring's global X-axis (+: clockwise, -: counterclockwise)
30.4 Graphics
The following graphics are provided:
1. Load distribution
This shows the load distribution over the rolling bearings (balls/rollers). For thrust bearings, the
magnitude of the reaction force is used for the plot.
2. Deformation (elastic rings)
Shows the radial and axial deformation of the inner and outer ring.
3. Stress distribution on raceway
Shows the stress distribution on the inner and outer raceways.
4. Pressure curve
This shows how the pressure develops along the length of each roller, or at every contact point in a
ball bearing.
5. Pressure curve for each rolling body
This graphic shows the pressure curve on each roller element along the roller profile.
6. Stiffness curve
IV Rolling Bearings (Internal Geometry) 668
This shows the force-displacement curve of the bearing. Both radial and axial stiffness are shown.
30.5 Fine sizing
After you have loaded the "Roller bearing ISO/TS 16281" module, click on the Fine sizing option
to open a window in which you can perform fine sizing on the internal geometry of rolling bearings. In
the same way as for fine sizing gears (see chapter 17.17, Fine sizing), you can vary the geometry
parameters to generate a multitude of different bearing variants. The type you selected in the bearing
data now determines which specific input parameters (for example, number of rolling bodies, radial
clearance, osculation etc.) are available. Any existing bearing data for the bearing type is transferred
directly to the fine sizing function.
You need a certain amount of experience before you can use the fine sizing function effectively. This
is because the process may generate bearing variants whose internal geometry does not match
either the currently applicable standards or roller bearings that have actually been manufactured. The
system does check some of the parameters you input, and displays warning messages when it
encounters implausible data.
You input the external dimensions of the roller bearing in the upper third of the first tab in the window.
The middle third is where you input the parameters for the internal bearing geometry (according to
the bearing type). In each case, the number of variants for the parameters are determined from the
start values, the final values and the intervals (for example: if between 11 and 15 rolling bodies are
involved, and the interval is set to two rolling bodies, the program calculates exactly three variants, if
all the other intervals are set to zero).
The lower third of this tab is where you define the boundary conditions that each of the rolling bearing
variants the system generates has to fulfill. You can set the density of the rolling bodies to a number
between 0% and 100% (if you set it to 100%, the bearing will have so many rolling bodies of this type
that they will touch each other along the whole length of the operating pitch circle). The minimum wall
thicknesses you enter here apply to the inner and outer ring races. Any bearing variants that fail to
meet the boundary conditions are ignored in the rest of the calculation.
Now, click on the "Calculate" button in the bottom area of the window to generate the bearing
variants. The system now calculates the detailed inner geometry and the load rating and rating life. In
this case, the load data is taken from the "Rating" tab in the "Rolling bearing ISO/TS 16281" module.
A progress bar shows you how the calculation is progressing.
The bearing variants determined here are then displayed in a table in the "Results" tab in the Fine
sizing window. These results can also be output in the report. The bearing variants are also
displayed as a graphic in the "Graphic" tab (in a similar way to the results of the Gear fine sizing
function (see chapter 17.17.6, Graphics)). Here you can display the values of different parameters
along the horizontal and vertical axes. You can also use a color scale to make the results easier to
understand.
IV Hydrodynamic Plain Journal Bearings 669
31 Hydrodynamic Plain Journal Bearings
Niemann [6] provides a very accurate method for calculating plain radial bearings that can run at high
speeds. This also produces good results for oval-clearance or tilting pad plain bearings.
ISO 7902 [57] or DIN 31652 include a very good and detailed method for calculating stationary
hydrodynamic plain radial bearings that are to run at low to medium speeds. For those running at
high speeds, use the equally excellent DIN 31657 [58].
31.1 Calculation methods
You can use one of these four methods to calculate oil-lubricated, hydrodynamic plain journal
bearings:
▪ a) According to G. Niemann, Maschinenelemente I, 1981, [6].
This method is very suitable for quickly rotating bearings. This also produces quite good results
for special construction types such as tilting pad or oval-clearance plain bearings.
This method calculates the power loss, oil flow, oil temperature, and minimum lubricant gap
thickness, according to [6] and [59]. This calculation can only be used for pressure-lubricated
bearings (circulatory lubrication) when the service reliability is also tested.
▪ b) According to ISO 7902, Parts 1 to 3, 1998, 2013 [57].
This method is very suitable for slowly rotating bearings. It also determines the oil consumption,
the oil flow and the entire heat balance.
Complete calculation according to ISO 7902, Parts 1 to 3 (1998 and 2013 Editions) for pressure-
less and pressure-lubricated bearings. This takes into account the way in which lubricant is
applied (lubrication holes, lubrication groove, lubrication glands). It calculates all the operating
data as defined in ISO 7902, including the operating temperature, minimum lubrication gap
width, power loss, oil flow etc. It also checks service reliability.
▪ c) According to DIN 31652, Parts 1 to 3, 2015, [60].
This method is very suitable for slowly rotating bearings. It also determines the oil consumption,
the oil flow and the entire heat balance.
Calculation according to DIN 31652, Parts 1 to 3 (2015 Edition) for pressure-less and pressure-
lubricated bearings. This takes into account the way in which lubricant is applied (lubrication
holes, lubrication groove, lubrication glands). It calculates all the operating data according to
DIN 31652, including the operating temperature, minimum lubrication gap width, power loss, oil
flow etc. It also checks service reliability.
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▪ d) According to DIN 31657, Part 1-4, 1996, [58].
This method is very suitable for quickly rotating bearings. It also determines the oil consumption,
the oil flow and the entire heat balance. The calculation is suitable for multi-lobed plain bearings
and tilting pad plain bearings.
Complete calculation according to DIN 31657, Parts 1 to 4 (1996 Edition) for pressure-lubricated
bearings. It calculates all the operating data according to DIN 31657, including the operating
temperature, minimum lubrication gap width, power loss, oil flow etc. It also checks service
reliability.
31.2 Module specific entries
Calculating the lubricant volume-specific heat c.
The lubricant's volume-specific heat can be calculated in two ways:
▪ Take into account dependence on temperature
▪ Simplified assumption (as in ISO 7902/DIN 31657): 1.8·106 J/(m3·K)
If the Take into account dependence on temperature option has been selected, the specific heat
capacity of the lubricant can also be specified, if it is known. For example, you must overwrite this
value if you want to perform a calculation for a water-lubricated plain bearing, otherwise you will get
incorrect results.
Run calculation with critical Reynolds number
If this option has been selected, the calculation which checks for the critical Reynolds number
(laminar to turbulent transition) continues even if an error message is output. Otherwise, the
calculation is interrupted.
31.3 Coefficients of thermal expansion
To calculate the clearance, you need the coefficients of thermal expansion of the shaft and hub.
These are the thermal expansion coefficients for the most important materials:
Steel 11.5 10-6/°C
Cast iron 11.0 10-6/°C
White metal 18.0 10-6/°C
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Composite bronze 18.0 10-6/°C
31.4 Average surface pressure
You will find the permitted values in:
▪ Niemann, Volume I, Table 15/1, [6]
▪ ISO 7902, Part 3, Table 2, [57]
▪ DIN 31657, Part 4, Table 1, [58]
Permitted maximum values for the surface pressure, depending on operating temperature (ISO
7902/DIN 31652):
▪ Pb and Sn alloys: 5 (15) N/mm2
▪ Cu Pb alloys: 7 (20) N/mm2
▪ Cu-Sn alloys: 7 (25) N/mm2
▪ Al Sn alloys: 7 (18) N/mm2
▪ Al Zn alloys: 7 (20) N/mm2
the values shown in brackets were recorded under special working conditions.
Permitted maximum values for the surface pressure, depending on operating temperature (DIN
31657):
▪ Lead alloys: 16 to 25 N/mm2
▪ Tin alloys: 25 to 40 N/mm2
▪ Copper alloys (bronzes): 25 to 50 N/mm2
31.5 Geometries according to DIN 31657
Different load cases and arrangements of the multi-lobed plain bearings, as shown in DIN 31657-2
and as are present in the tables.
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Figure 31.1: Arrangements of multi-lobed plain bearings
1) Z=2;Ω=150°;φP,1=180°;h*0,max=3,5;B/D=0.75
2) Z=2;Ω=150°;φP,1=240°;h*0,max=3,5;B/D=0.75
3) Z=2;Ω=150°;φP,1=270°;h*0,max=1,3,5;B/D=0.5,0.75,1
4) Z=2;Ω=150°;φP,1=300°;h*0,max=3,5;B/D=0.75
5) Z=3;Ω=100°;φP,1=240°;h*0,max=3,5;B/D=0.75
6) Z=3;Ω=100°;φP,1=300°;h*0,max=1,3,5;B/D=0.5,0.75,1
7) Z=4;Ω=70°;φP,1=270°;h*0,max=3,5;B/D=0.75
8) Z=4;Ω=70°;φP,1=270°;h*0,max=1,2,3,4,5;B/D=0.5,0.75,1
Different load cases and arrangements of the tilting pad plain bearings, as shown in DIN 31657-3
and as are present in the tables.
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Figure 31.2: Arrangements of tilting pad plain bearings
1) Z=4;Ω=80°;φF,1=45°; ΔRB/CR=2,3,5;B/D=0.5,0.75,1
2) Z=4;Ω=80°;φF,1=0°; ΔRB/CR=3;B/D=0.75
3) Z=4;Ω=60°;φF,1=45°; ΔRB/CR=2,3,5;B/D=0.5,0.75
4) Z=4;Ω=60°;φF,1=0°; ΔRB/CR=3;B/D=0.5
5) Z=5;Ω=60°;φF,1=36°; ΔRB/CR=2,3,5;B/D=0.5,0.75
6) Z=5;Ω=60°;φF,1=0°; ΔRB/CR=3;B/D=0.5
7) Z=5;Ω=45°;φF,1=36°; ΔRB/CR=2,3,5;B/D=0.5
8) Z=5;Ω=45°;φF,1=0°; ΔRB/CR=3;B/D=0.5
IV Hydrodynamic Plain Journal Bearings 674
31.6 Stiffness
To calculate the stiffness of the plain bearing, the maximum force at the narrowest point (operating
point) is determined.
This maximum force can then be used to calculate the stiffness at the narrowest point. The diametral
clearance (eccentricity) is also produced as a result of the plain bearing calculation.
The results for the stiffness cr, the diametral clearance Pd and the misalignment angle β are listed in
the report. These results can then be entered in the shaft calculation to determine the stiffness of the
plain bearing.
31.7 Lubrication arrangement
The different lubrication arrangements are shown in the next three figures.
Figure 31.3: 1: One lubrication hole, opposite to load direction. 2: One lubrication hole, positioned at 90° to the load
direction. 3: Two lubrication holes, positioned at 90° to the load direction.
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Figure 31.4: 4: Lubrication groove (ring groove). 5: Lubrication groove (ring groove). 6: Lubrication pocket opposite to
load direction.
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Figure 31.5: 7: One lubrication pocket positioned at 90° to the load direction. 8: Two lubrication pockets positioned at
90° to the load direction. 9: From one bearing edge across the entire perimeter of the bearing (only Draft DIN 31652)
31.8 Heat transfer coefficient
If the heat transfer coefficient value is not known, you can take 15 to 20 (W/m2k) as a guide value.
31.9 Heat transfer surface
If the values of the heat transfer surface are not known, you can take 10 * d * b to 20 * d * b as a
guide value. This value is only needed if heat is lost due to convection.
d: Bearing diameter
b: Bearing width
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31.10 Oil temperatures
Oil exit temperature:
▪ Normally approximately 60°C
▪ Upper limit for usual mineral oils: 70° to 90°C
Oil inlet temperature:
▪ With the usual cooler: 10°C lower than the output temperature
▪ With a very efficient cooler: 20°C lower than the output temperature
31.11 Mixture factor
The mixture factor that is used for the calculation according to DIN 31657 should lie between 0.4 and
0.6.
If the mixture factor M=0, this would mean that there is no mixture in the lubrication pockets, or that
the exiting lubrication flow rate Q2 flows entirely into the next lubrication gap.
If the mixture factor M=1, this would mean complete mixture in the lubrication pockets.
31.12 Sizing the bearing clearance
Bearing clearance = d_bore - d_shaft
In general, a larger bearing clearance makes the bearing more stable and allows it to cool more
effectively. However, it also results in reduced load capacity.
▪ Suggestion according to Niemann
Proposal for metal bearings in mechanical engineering according to Niemann, Volume I, Table
15/2, [6].
The following values should be applied for other materials:
Cast iron bearing 0.001 * d
Light metal bearing 0.0013 * d
Sintered bearing 0.0015 * d
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Plastic bearing 0.003 * d
d : Bearing diameter
▪ Proposal according to ISO 7902
Proposal for metal bearings in mechanical engineering according to ISO 7902, Part 3, Table 4,
[57].
In this sizing method, you can either use the proposal according to ISO 7902 or calculate the
clearance from a predefined output temperature (only where the lubricant is used to dissipate
the heat).
▪ Proposal according to DIN 31652
Proposal for metal bearings in mechanical engineering according to ISO 7902, Part 3, Table 4,
[57], as the DIN standard does not contain a proposed value.
In this sizing method, you can either use the proposal according to ISO 7902 or calculate the
clearance from a predefined output temperature (only where the lubricant is used to dissipate
the heat).
▪ Proposal according to DIN 31657
Proposal for plain bearings in mechanical engineering according to DIN 31657, Part 4, [58].
In this sizing method you can either use the proposal according to DIN 31657 or calculate the
clearance from the entered output temperature.
▪ Proposal according to K. Spiegel
Proposal for clearance according to K. Spiegel: Goettner equation
Relative bearing clearance = (2.5+50.0/D)/1000.0 "with d [mm]"
Bearing clearance in mm: (2.5+50.0/D)/1000.0*D
31.13 Sommerfeld number
You must calculate the Sommerfeld number because it is an important characteristic value for plain
bearings.
A Sommerfeld number > 1 occurs in heavily loaded bearings at the
limit for b/d: 0 < b/d ≤ 2
A Sommerfeld number < 1 occurs in quickly rotating bearings at
the limit for b/d: 0.5 < d/b ≤ 2
d: Bearing diameter
b: Bearing width
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31.14 Bearing width
Reference value for bearing width as defined in Niemann, Volume I, Table 15/1, [6]
Normal range: b/d = 1 to 2
Reference value for bearing width according to ISO 7902, [57]
Normal range: b/d = 0.125 to 1
Reference value for bearing width according to DIN 31652, [60]
Normal range: b/d = 0.01 to 5
Reference value for bearing width according to DIN 31657, [57]
Normal range: b/d <= 0.8, b/d = 0.8 is assumed for the calculation of Qp
d: Bearing diameter
b: Bearing width
31.15 Permissible lubricant film thickness
The suggested value is taken from ISO 7902, Part 3, Table 1, [57] or DIN 31652, Part 3, Table 1,
[60].
The values in this table are all empirical values. They assume that the average roughness height is <
4μ, there is a small form error and that the lubricant is to be filtered appropriately.
The proposed value according to Niemann is taken for DIN 31657, because no value is present in
this standard.
A value is determined according to the diameter, in the case of the proposed value according to
Niemann.
IV Hydrodynamic Plain Thrust Bearings 680
32 Hydrodynamic Plain Thrust Bearings
The DIN standard has two different methods for calculating hydrodynamic plain thrust bearings,
according to type.
▪ Calculation of pad thrust bearings according to DIN 31653 [61]: This standard applies to
bearings that have fixed sunken surfaces for lubrication (see Figure 32.1) which are separated
from the rotating disks by a film of lubricant.
▪ Calculation of tilting-pad thrust bearings according to ISO 12130, DIN 31654 [62]: This standard
applies to bearings that have fixed sunken surfaces for lubrication (see Figure 32.2) which are
separated from the rotating disks by a film of lubricant.
If you do not consider the influence of the center of pressure on the tilting-pad thrust bearings, the
same calculation procedure is described in both standards, which is why it is described here only
once. However, any significant variations to these two standards will get a special mention here.
Figure 32.1: Pad thrust bearings as described in DIN 31653
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Figure 32.2: Tilting-pad thrust bearings according to ISO 12130, DIN 31654
32.1 Calculation
Essentially, both calculation procedures are based on the equation used to ascertain the thermal
balance in the bearing. You can use either convection or circulatory lubrication in this calculation.
▪ Non-pressure-lubricated (self-lubricating) bearings dissipate heat out to the surrounding
environment by convection. According to the standard, the coefficient of thermal expansion kA
lies between 15 . . and 20 W/(m2*K). In the program, the default value is 20W/(m2*K), but you
can change this as required.
▪ Pressure-lubricated bearings mainly dissipate heat through the lubricant. In this case, you must
define a mixture factor M, which must lie between 0 and 1. Experience shows that this usually
lies between 0.4 and 0.6. The default setting is 0.5, but this can be changed.
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Figure 32.3: Segment lubricant and heat levels
These calculations provide values for the friction power, the lowest lubricant film thickness and the
operating temperature. They also calculate the lubricant flow rate for circulatory lubrication.
The bearing force (in idleness) is only used to determine the lowest admissible lubricant film
thickness, and is otherwise irrelevant. The load coefficient, friction coefficient and lubrication flow
rates are calculated according to the formulae (not the diagrams or tables) provided in DIN
31653/31654 Part 2. The hmin/Cwed ratio for tilting-pad thrust bearings is calculated from the
support position of the tilting-pad aF*. The formula for this is given in ISO 12130 Part 2 or in DIN
31654 Part 2.
32.2 Sizings
You can also calculate the bearing force (nominal load), but before you can do this, you must enter
all the other input values. The bearing force is then calculated using the value you specified for the
lowest lubricant film thickness, hlim.
The lowest possible lubricant film thickness hlim can be calculated according to DIN 31653 or 31654.
This lowest possible lubricant film thickness is calculated depending on sliding velocity, average
diameter and loading, according to the formula.
For convection:
If you do not know the value for the heat transfer surface, you can use a formula for approximation as
defined in the standard:
A = (15 to 20) * B * L * Z
Click the button next to the surface value input field to calculate this value using the formula A =
15 *B *L *Z.
For circulatory lubrication:
Experience shows that the exit temperature is between 10 and 30 K higher than the entry
temperature. Click the button next to the exit temperature to calculate a default value with a 10 K
temperature difference.
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32.3 Calculation of volume-specific heat
In the dialog you see by selecting Calculations > Settings, there are two methods you can use to
calculate volume-specific heat:
▪ Take into account dependence on temperature
▪ Simplified assumption (as in ISO 7902): 1.8*106J/(m3*K)
32.4 Limiting values in the calculation
The standards only apply to laminar flow in the lubrication gap. For this to happen, the Reynold
number must lie below the critical value of 600.
These results are also checked for highest permissible bearing temperature, Tlim, the smallest
possible lubricant film thickness, hlim, and the specific bearing load. These limiting values are
defined in DIN 31653/ISO 12130/DIN 31654 Part 3.
IV Answers to Frequently Asked Questions 684
33 Answers to Frequently Asked Questions
33.1 Intersecting notch effects
If at all possible, notch effects, for example in a shoulder with an interference fit, should not be
overlapped when the shaft is designed. However, if this does happen, in the worst case scenario, the
FKM Guideline should be applied to calculate the overall notch effect coefficient Kf:
from part notch effect coefficients Kf1 and Kf2 . In KISSsoft, this situation can be resolved by selecting
Own input for the notch effect (see chapter 28.5.14, Cross-section types) of a free cross section
(see chapter 27.2.7.1, Free cross section (single notch)).
The overall notch effect coefficient can then be calculated as follows:
1. Two cross sections (for example, A-A and B-B) are defined with the same Y-coordinate.
2. Cross section A-A is calculated by selecting notch type Kf1 (for example, shoulder). The notch
factors are displayed directly in the Elements Editor (see chapter 27.1.4, Element Editor).
3. The process described in 2. is then repeated for cross section B-B.
4. The resulting notch factors for both these notches are noted down, and the notch factors Kf are
calculated according to the formula given above.
5. Now, both cross sections (A-A and B-B) are deleted, and a new free cross section C-C with the
same Y-coordinate is added. Open the Element Editor and select Own Input for the notch
effect. Then, enter the overall notch effect coefficients calculated in point 4.
33.2 Notch effects on hollow shafts
All the notch factors described in the standards have been determined for solid shafts. No data is
available for hollow shafts. KISSsoft calculates the nominal stresses for hollow shafts using the
section modulus and taking into account the internal diameter.
33.2.1 Notches on the outer contour
For "small" internal diameters, the error due to calculating notch effect values for solid shafts is
relatively small. You can then use the results as approximations. However, when "large" internal
diameters are involved, you must correct the notch effect values.
IV Answers to Frequently Asked Questions 685
According to the FKM Guideline 2012, 6th Edition, you cannot accurately calculate the notch effect
values for a round shaft that has a longitudinal bore for bending and tension/compression using the
notch effect coefficients for a round solid shaft. You should use the notch effect coefficient for a
round solid shaft for torsion and round shafts that have a circumferential notch, shoulder or conus.
Use the nominal stress value for a round shaft that has a longitudinal bore.
33.2.2 Notches on the inner contour
You cannot use these calculation methods to determine the notch factors of notches on the inner
contour.
33.3 Fatigue Limits for New Materials
If you want to add a new material to the database, you must enter its infinite life strengths, and also
the yield point and tensile strength.
Hänchen gives
an approximation of the bending fatigue limit, and also other approximations from different sources.
For the tension/compression fatigue limit, this states
, and for the torsion fatigue limit it states
According to DIN 743, the following approximations can be made:
For through hardened steels (there can be different values for other material types), the FKM
Guideline proposes:
IV Answers to Frequently Asked Questions 686
33.4 Taking double helical gearings into account in
the shaft calculation
In the shaft analysis process, when you input cylindrical gear data in Hand of gear, you can select
double helical gearing from the selection list. A gear with this characteristic always has an axial
force 0 N. When double helical gearings are transferred from the gear calculation (the Read data
from file checkbox is selected), the total width (= left side + gap + right side) is also transferred, as
is the total power. The shaft calculation then takes both the gap and the effective gear teeth into
account. This generally results in a very useful model.
If you require a more precise model, input the two halves of the gear individually, one angled to the
right and the other angled to the left. Unfortunately, you cannot do this by transferring the data
directly from the gear calculation.
V
Connections
Chapter 34 - 49
V Cylindrical Interference Fit 688
34 Cylindrical Interference Fit
▪ This calculation includes the entire DIN 7190-1 standard (elastic range) with longitudinal, radial
and oil interference fits.
▪ Load in circumferential and axial directions.
▪ Load with bending moment and radial force.
▪ Calculate the maximum torque for a non-slipping fit. If slip occurs in the fit, micro gliding will
cause corrosion due to friction.
▪ Influence of centrifugal force.
▪ Verification of an elastic-plastic loaded interference fit as specified in DIN 7190-1 with
predefined interference (stresses and strains are calculated only for the purely elastic case)
▪ Analysis of hubs with multiple interference fits
▪ Display stress curves (equivalent, tangential and radial stresses)
▪ Display tolerance fields:
▪ only take into account allowances
▪ take into account temperature and centrifugal force (without pressure)
▪ take into account temperature, centrifugal force and pressure
You can calculate the safety of the interference fit against sliding and the safety of the shaft material
and the hub against fracture and yield point. The calculation also takes into account the effect of
centrifugal force on the expansion of the interference fit and on the stresses in the shaft and hub. The
tolerance system specified in DIN 7151 (e.g. with diameter input 60 H7/f6) has been implemented to
make it easier to input data. You can either enter the tolerance manually, or use an automatic option
to calculate the tolerance pairing on the basis of the required safety against sliding and the permitted
material stress. Input values for surface roughness with qualities as defined in ISO 1302.
Calculating the pressure: For elastic materials according to the theory of mechanics, for thick
cylinders under internal pressure and thick cylinders under external pressure (e.g. [63], page 399, or
[6]).
V Cylindrical Interference Fit 689
Figure 34.1: Basic data: cylindrical interference fit
Influence of speed: In accordance with the theory of the cylinder in rotation ([23], page 219).
Amount of embedding: According to DIN 7190-1.
Equivalent stress:
you can change the hypothesis of equivalent stress by selecting Calculations > Settings. The
Settings chapter provides more information about this function.
Bending moment and radial force: this takes into account the effect of a bending moment and a radial
force on the pressure. The additional amount of pressure is calculated as follows:
(32.1)
So that there is no gaping, this additional pressure must also be lower than the minimum pressure on
the connection ((pb + pr) < pmin).
These formulae have been taken from the technical literature according to Prof. Hartmann,
"Berechnung und Auslegung elastischer Pressverbindungen", pages 6 to 7.
Other values:
Dismounting force According to [6], page 363.
Transmission without slip According to [64], Equations, sections 2.93 to 2.110.
V Cylindrical Interference Fit 690
Micro sliding: If the torque of an interference fit is increased continuously until it exceeds the micro
sliding limiting value, local slip will occur at the position at which the torque is applied. As torque
decreases continuously in the interference fit, the slip occurs only in one part of the interference fit
length, even if the torque then increases again. This effect is called micro gliding (one-sided
movement of the shaft, back and forth in the hub). It can cause friction rust. Further explanations and
details about this calculation are given in "Welle-Nabe-Verbindungen" (Shaft-Hub Connections), by
Kollmann [64].
Comment about the calculation as defined by Kollmann:
To limit torque for micro sliding, use equation 2.110, with k, use equation 2.107 and with ιr, use
equation 2.93.
Mounting: You will find details about mounting in the report. The temperature difference for mounting
is calculated in such a way that, even if the maximum interference is reached (worst case scenario)
there will still be enough clearance in the joint. Define mounting clearance under Settings. Here the
values for mounting the shaft at ambient temperature and for a deeply cooled shaft (shaft at
approximately -150°) are calculated.
Verification of an elastic-plastic loaded interference fit according to DIN 7190-1:
Prerequisites: EI = EA, nyI = nyA, n = 0, diI = 0
If all the prerequisites are fulfilled, as defined in DIN 7190-1, you can calculate the plasticity diameter
DPA of the external component that is to be mounted (diameter at which the plastic range ends). The
corresponding compacting pressure, and the ratio between the ring surface qpA and the overall
cross section qA are also calculated. (Experiential limit according to DIN 7190-1 for heavily loaded
interference fits in mechanical engineering qpA/qA <= 0.3)
34.1 Inputting Tolerances
Tolerances according to ISO/DIN:
To enter tolerances in the same way as, for example 60 H7/f6, you must:
▪ Enter 60 (mm) as the "Diameter of joint".
▪ Enter H7 and f6 in the Tolerances fields. Here, the first field is where you enter the value for the
wheel or hub and the second is where you enter the value for the shaft.
▪ The program checks automatically to see whether the tolerances you specified actually exist,
and if you entered the data in the correct format!
Define own tolerances
V Cylindrical Interference Fit 691
Figure 34.2: Tolerance values
Click the button next to the Tolerances field to display the current allowances. You can then
change them as required.
34.2 Coefficients of friction
Tables 32.2 and 32.4 contain coefficient of friction values as defined in DIN 7190-1.
Materials Coefficients of friction
dry lubricated
νll νrl νll νrl
E 335 0.11 0.08 0.08 0.07
GE 300 0.11 0.08 0.08 0.07
S 235JRG2 0.10 0.09 0.07 0.06
EN-GJL-250 0.12 0.11 0.06 0.05
EN-GJS-600-3 0.10 0.09 0.06 0.05
EN-AB-44000 and 0.07 0.06 0.05 0.04
following
CB495K 0.07 0.06 - -
TiAl6V4 - - 0.05 -
νll: in axial direction - loosening
νrl: in axial direction - slipping
Table 34.1: Coefficients of friction for longitudinal fits under continuous stress as defined in DIN 7190-1.
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Material pairs, Lubrication, Joining Coefficients of friction
νr,νrl,νu
Steel-steel pairing:
Oil pressure connection, normally joined with mineral oil 0.12
Oil pressure connection with degreased contact surfaces 0.18
joined with glycerin
Shrink fit normally after warming the 0.14
External component up to 300°C in electrical oven
Shrink fit with degreased contact surfaces after 0.20
Heating up to 300°C in electrical oven
Steel-cast iron pairing:
Oil pressure connection, normally joined with mineral oil 0.10
Oil pressure connection with degreased contact surfaces 0.16
Steel-MgAl pairing, dry 0.10 to 0.15
Steel-CuZn pairing, dry 0.17 to 0.25
νr: Slipping
νrl: in axial direction - slipping
νu: in circumferential direction
Table 34.2: Coefficients of friction for radial interference fits in the longitudinal and peripheral direction subjected to
slipping as defined in DIN 7190-1.
V Cylindrical Interference Fit 693
34.3 Variable external diameter of the hub
Figure 34.3: Variable external diameter
In the case of an external stepped hub diameter, the individual diameters and lengths are used to
determine a single equivalent diameter. These values are then used to calculate the stiffness of the
external component.
34.4 Convert external pressure with multiple
interference fit
The effect of outside pressure on the first hub can be taken into account for a multiple interference fit.
This pressure is defined through a series of sequential interference fits, as shown in the following
figure, and is calculated by the software (no direct user input).
Figure 34.4: Multiple interference fit
V Cylindrical Interference Fit 694
The following notes apply to this calculation:
▪ The first two elements are the original shaft and hub (the first two lines in the table correspond to
the first interference fit on the shaft), and are simply shown in the table for the sake of
completeness. The values users can edit are the external diameter tolerances of the hub.
▪ The external diameter of each ring is also used as the internal diameter of the next ring.
▪ When a new ring is added, the following default values are used:
▪ External diameter = internal diameter + 50 mm
▪ The Material and Surface roughness are the same as for the original hub
▪ The operating temperature is the same as for the original hub
▪ The fit (tolerance) class of the inner diameter is the same as the fit (tolerance) class of the
shaft (for example, s6)
▪ The fit (tolerance) class of the external diameter is the same as the fit (tolerance) class of
the hub (for example, H7)
The pressure on the hub is calculated for the following three cases of tolerance values of all the
elements:
▪ The average tolerance at each contact surface
▪ The worst case, i.e. the maximum oversize at each contact surface
▪ The best case, i.e. the minimum oversize at each contact surface
V Cylindrical Interference Fit 695
34.5 Materials
Figure 34.5: Materials screen: Cylindrical interference fit
The selection list contains materials from the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the material data used
in the calculation which you can specify to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
V Cylindrical Interference Fit 696
34.6 Settings
Figure 34.6: Settings: cylindrical interference fit
▪ Select equivalent stress
According to [6], with the modification of shape hypothesis:
▪ According to [64], S.13, with the shear stress hypothesis:
σv = max(|σ σrr|,|σ σrr|)
▪ Shaft/hub assembly temperature
The press-on force can be calculated from the assembly temperatures.
▪ Coefficient of friction coefficient (press on)
Here you can define the ratio μe/μa, i.e. the ratio of the coefficient of friction for press on to the
axial coefficient of friction. The default value is 1.3.
Only values for forcing off are given in DIN 7190-1. Niemann Volume I (1981 edition), Table 18/3
p. 363, also gives values for press on.
▪ Coefficient of friction coefficient (press off)
Here you can define the ratio μII/μa ratio, i.e. the ratio of the coefficient of friction for press off to
the axial coefficient of friction. The default value is 1.6.
V Cylindrical Interference Fit 697
Only values for forcing off are given in DIN 7190-1. Niemann Volume I (1981 edition), Table 18/3
p. 363, also gives values for press on.
▪ Calculate the joining temperature
You can define the joint clearance either by using the diameter at join DF (adjusted for warming)
or as a constant clearance value, from which you can then calculate the joining temperature of
the external part.
You can also define the shaft temperature for joining. This temperature and the mounting
clearance are then used to calculate the joining temperature of the hub. The joining temperature
of the hub is only output in the report if the shaft temperature during joining lies between -273 °C
and 20 °C.
▪ Required safeties
In the Settings, you can input the required safeties against slipping, yield point and fracture. The
required safeties define the values the system searches for during sizing. The required safeties
against plastic deformation are used to define the plasticity diameter that must be set when an
interference fit is placed under plastic-elastic stress.
▪ Calculate material strength with wall thickness as raw diameter
If you set this flag, the strength of the hub material is determined using the wall thickness
instead of the raw diameter.
▪ Allow calculation of elastic-plastic loaded interference fits
If you set this flag, the calculation is also performed for elastic-plastic stress (according to DIN
7190-1), otherwise, only elastic stress is included.
▪ For negative interference during operation, continue the calculation and document the
allowances
If there is a negative allowance during operation, an error message is displayed. This usually
interrupts the calculation, because this value would mean that the fit was no longer an
interference fit. Set this flag to force the calculation to continue despite the error message so
that you can display allowances for higher operating temperatures. Only the section with the
allowances calculated for operation is then displayed in the report.
34.7 Sizings
▪ Tolerance according to ISO/DIN
V Cylindrical Interference Fit 698
Figure 34.7: Display of possible tolerance pairings
KISSsoft has a very convenient sizing function that you can use for suitable tolerance pairs.
Standardized tolerance pairs are stored in the M01-001.dat file. Click the button next to the
Tolerances field in the main window to start the sizing process.
Based on the nominal required safety (which you can change in Settings), you can determine all
the tolerance pairs which fulfill the requirements (sufficient safety against sliding, sufficient
safety against fracture and yield point) and display these pairs in a list.
▪ Torque, axial force, joint diameter, and length of interference fit
KISSsoft can size the maximum transmittable torque, the transmittable axial force, the required
length, and the diameter (according to the required safety values you entered in Settings).
V Conical Interference Fit 699
35 Conical Interference Fit
Use this module to calculate the service reliability of a conical interference fit. Defining the mounting
conditions.
The calculation methods are:
- Method as defined by Kollmann [64], Verification and sizing.
- Method as defined in DIN 7190-2 (2017)
Figure 35.1: Basic data: Conical interference fit
Cone angle: The cone angle is the angle β between the flank of the cone and its axis. The opening
angle α of the cone is twice the size of the angle of taper.
Calculating the conical interference fit:
▪ All known investigations focus on external and internal components made of materials that have
the same Young's modulus. (Kollmann)
▪ If you select the method described in DIN 7190-2, and the shaft and hub are made of different
materials, the material with the higher Young's modulus should be used for the shaft material.
▪ Conical interference fits must always have a stop at the upper end. For this reason, the program
only deals with this situation.
V Conical Interference Fit 700
▪ Conical interference fits are normally clamped axially with a bolt. You must check the joint
carefully by measuring the length. Simply tightening it with a torque wrench is not accurate
enough. Conical interference fits are only joined by pressing them on in exceptional
circumstances.
▪ To perform the calculation according to Kollmann, without clamping using a bolt, a special
coefficient of friction is used in the longitudinal direction. The coefficient of friction is calculated
according to a series of articles in Antriebstechnik 12 (1973), issued by the company Voith.
Adhesive coefficient for slipping in the longitudinal direction: Coefficient of friction (for slipping in axial
direction) as detailed in investigations by Galle (see Kollmann [64], Table 2.20):
Material pairing Previous Coefficient for stiction
Rating (load)
Ck60/16MnCr5 - 0.299
42CrMo4/16MnCr5 - 0.269
31CrMoV9/31CrMoV9 - 0.247
Ck60/16MnCr5 U 0.407
42CrMo4/16MnCr5 U 0.297
31CrMoV9/16MnCr5 U 0.375
31CrMoV9/31CrMoV9 U 0.468
Ck60/16MnCr5 W 0.357
42CrMo4/16MnCr5 W 0.472
31CrMoV9/31CrMoV9 W 0.387
Load classifications:
- none
U Circumferential bending load
W Fatigue torsion load
No adhesive coefficients for other combinations of materials are available, so you will have to
estimate them.
V Conical Interference Fit 701
Adhesive coefficients for radial interference fits in longitudinal and circumferential direction of sliding:
Coefficient of friction as described in DIN 7190 [65], Table 4 (see chapter 34.2, Coefficients of
friction).
35.1 Calculation
Sizing according to Kollmann:
If you select this method, the maximum angular deviation γmax, the pressing distance for mounting af
and the joining force, can be sized using the required safeties and the specified load and geometry.
Verification according to Kollmann:
The transmittable torque is also calculated if no angular deviation, or maximum angular deviation is
present.
You can also input the pressing distance for mounting af or the mounting pressing force Ffmin.
The safeties against the yield point and against sliding are also calculated in the verification process.
The safeties defined by Kollmann include the required safeties, which you can define in the Settings
tab. To display it, select Calculation > Settings.
According to DIN 7190-2:
In this calculation method, the sliding moment, joining force, and axial force are calculated for the
state at which all the elements are already joined, from the input torque, mounting without force and
all the geometry data. The safety against sliding is calculated in this way. If different external hub
diameters or different internal shaft diameters are present, these can also be defined as slices (max.
7). The values are calculated for each individual slice and then added together. The maximum value
is used for the pressure in the joint.
The safety against sliding SR for a central load application should have a value of SRmin > 1.3.
Furthermore, if you have defined your own joining force at mounting pFA to calculate the effective
equivalent stresses, the maximum equivalent stress is then compared with the yield point of that
particular material in order to define the safety. The maximum equivalent stresses appear every time
for the inner diameter of the hub or shaft when a hollow shaft is being used.
V Conical Interference Fit 702
The required safety against the yield point SP (plastic flow) should have a value of SPmin > 1.3 to
ensure that the elements are not affected by plastic deformation when they are assembled and
disassembled.
35.2 Application factor
You define the application factor here in the same way as in the cylindrical gear calculation:
Operational behavior of Operational behavior of the driven machine
the driving machine
uniform moderate average heavy
shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
35.1 table: Application factor as used in calculations according to DIN 6892. You will find more detailed comments in
DIN 3990, DIN 3991 and ISO 6336.
35.3 Axial spanning with nut
Figure 35.2: Axial spanning of nut
V Conical Interference Fit 703
Axial spanning (tightening the nut) produces relative axial displacements which are applied to the
individual parts. This causes transversal strain and therefore increases the compacting pressure on
the active surface. The values required for this calculation are shown in the diagram below.
35.4 Variable external diameter of the hub
Figure 35.3: Variable outside diameter
V Conical Interference Fit 704
In the case of a stepped external diameter, a single equivalent diameter is determined from the
diameters and lengths. This value is then used to calculate the stiffness of the external component.
35.5 Conicity
Figure 35.4: Conicity
This additional input dialog gives two methods for defining the conus:
▪ Conicity:
you define conicity as follows:
x = l/(D0-D1); Here, x is the value that must be input.
▪ Morse tapers:
Morse tapers are defined in DIN 228 and have a conicity of between 1:19.212 and 1:20.02.
V Conical Interference Fit 705
35.6 Materials
Figure 35.5: Materials screen for Conical interference fit
The selection list contains materials from the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the material data used
in the calculation which you can specify to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
V Conical Interference Fit 706
35.7 Settings
Figure 35.6: Settings: Conical interference fit
If you selected Calculate material strength with wall thickness as raw diameter, the strength of
the hub material is calculated using the wall thickness instead of the raw diameter.
If you select the Consider pressure at both diameters (Kollmann) flag, the pressure at both the
large and small cone diameters is taken into account, otherwise only the pressure at the largest
diameter is used. However, this only applies to the method described by Kollmann. In DIN 7190-2,
the average diameter is used for the calculation.
Enter the required safeties for slipping and yield point under Settings. The required safeties define
the values the system searches for during sizing.
In the method defined by Kollmann, the default value set for required safety against sliding is 1.0 and
the default value for required safety against the yield point is set to 2.0.
DIN 7190-2 recommends that safety against the yield point is set to 1.2, to ensure that the elements
are not affected by plastic flow when they are disassembled hydraulically.
If load is applied centrally, DIN 7190-2 recommends a safety against sliding of at least 1.2.
35.8 Sizings
KISSsoft can size the maximum transmittable torque, the permitted cone angle (for self-locking) and
the length of interference fit for transmitting the maximum torque.
The torque and the length of interference fit are sized using the defined required safeties.
In a verification according to Kollmann, you can size the pressing distance for mounting or the
mounting pressing force using the required safety against sliding.
V Conical Interference Fit 707
As specified in DIN 7190-2, the sizings are calculated using the required safety against sliding, apart
from the joining pressure, which is sized using the required safety against yield point.
V Clamped Connections 708
36 Clamped Connections
Clamped connections are only used to transfer low or medium torque (small fluctuations).
Figure 36.1: Basic data: Clamped connections
There are two different configurations of clamped connections that can be calculated:
▪ Split hub
In the case of a split hub, it is assumed that pressure is distributed uniformly across the whole
joint. The pressure can be equal, cosine-shaped surface pressure or linear contact.
▪ Slotted hub
We recommend you use as narrow a fit as possible (hubs are also subject to bending) to ensure
that the pressure is mostly of a linear nature. The calculation is performed for the least practical
case of linear pressure.
Calculations of safety against sliding and surface pressure are described in literature by Roloff Matek
[66]. The calculation of bending is performed as specified by Decker [67].
36.1 Calculations
Split hub:
Depending on the type of surface pressure, an additional factor for surface pressure and safety
against sliding is used to calculate a shared hub:
V Clamped Connections 709
▪ K = 1; uniform surface pressure
▪ K= π^2/8; cosine-form surface pressure
▪ K = π/2 linear contact
In KISSsoft you can select the type you require from a selection list.
Formula for surface pressure:
Formula for safety against sliding:
Formula for calculating bending:
Slotted hub:
Formula for surface pressure:
Formula for safety against sliding:
Formula for calculating bending:
V Clamped Connections 710
Description of codes:
pF: Surface pressure [N/mm2]
KA: Application factor
T: Nominal torque [N]
SH: Safety against sliding
K: Correction factor surface pressure
l: Joint width [mm]
D: Diameter of joint [mm]
lS: Distance bolt to shaft center [mm]
l1: Distance normal force to center of rotation [mm]
l2: Distance clamp load to center of rotation [mm]
μ: Coefficient of friction
σB: Bending stress [N/mm2]
Fkl: Clamp load per bolt [N]
i: Number of bolts
Wb: Moment of resistance [mm3]
36.2 Sizings
In these calculations, you can size the torque, the clamp load per bolt, and the number of bolts, to
suit a predefined required safety value.
V Clamped Connections 711
36.3 Settings
Figure 36.2: Settings Clamped connections
The required safety against sticking, SSH, is used to size the torque, the clamp load per bolt, and the
number of bolts.
If the hub material is gray cast iron, this coefficient multiplied by the tensile strength is used to
calculate the permitted pressure.
(pzul =pFact*Rm) (default value ~ 0.35 for an interference fit)
For all other materials, this coefficient multiplied by the yield point is used to calculate the permitted
pressure.
(pzul =pFact*Rp) (default value ~ 0.35 for an interference fit)
V Clamped Connections 712
36.4 Materials
Figure 36.3: Materials: clamped connections
The selection list contains materials from the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the material data used
in the calculation which you can specify to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
V Keys 713
37 Keys
Keys are by far the most commonly used shaft-hub connections. In particular, they help to transmit
the torque. Their geometry has long been standardized according to DIN 6885 [68]. However, to
ensure adequate safety levels are achieved when transmitting torque, you always had to contact
secondary sources of technical literature [6]. The DIN standard 6892 [69] documents the different
calculation methods that can be used for feather key connections.
You must perform two checks for keys:
1. Check the torque transmission by monitoring surface pressure on the shaft, hub and key.
2. Check the endurance limit of the shaft due to the notch effect caused by the key way. This effect
is already described in DIN 743 [51]. We recommend you use this standard to analyze the shaft
strength rather than DIN 6892.
Special characteristics of calculations according to DIN 6892:
▪ Key connections are mainly used with light interference fits. The calculation takes into account
the decrease in torque on the key due to the interference fit.
▪ The calculation proves the nominal torque as well as the actual pitch torque over the entire
operating period. The endurance limit calculation based on the nominal torque also includes the
number of load changes, which experience has shown to have a significant and damaging effect
on the key.
▪ The type of load has a considerable effect on the service reliability of keys. This effect is taken
into account by using a wide range of load distribution coefficients.
▪ The permissible pressure values are derived from the yield point. As a result, you can derive this
for common and more unusual materials according to the standard. The hardness influence
coefficient is used to take the surface treatment into account.
Calculation Method B as defined in DIN 6892 recommends you use a differentiated calculation to
prove the service reliability of key connections. Method C has been greatly simplified.
37.1 Main window
For keys as defined in
▪ DIN 6885.1 (ISO/R 773, VSM 15161) Standard
▪ DIN 6885.1 Form G, H, J
V Keys 714
▪ DIN 6885.2
▪ DIN 6885.3
▪ ANSI B17.1 Square
▪ ANSI B17.1 Rectangular
▪ Own Input
you can calculate the load on shaft, hub and key (surface pressure) and the key (shearing) to
determine the safeties.
The following calculation methods are available: DIN 6892 B/C [69].
The calculation takes into account the tolerances of the key radii and the direction of force. You can
also enter your own value for the number of keys and the application factor.
Explanatory information about the figure (see Figure 37.1):
→ Application or removal of torque
o Start of key
Fu Center of force application point on hub
Figure 37.1: Key: load introduction
▪ Supporting key length: The supporting key length is defined according to DIN 6892:
Helical key form (A, E, C according to DIN 6885) ltr = leff - b
Straight key form (B, D, F, G, H, J according to DIN 6885)ltr = leff
▪ leff Actual key length
V Keys 715
ltr Supporting key length
b Key width
▪ Frictional torque
Key connections are usually combined with a light interference fit. The calculation takes into
account the decrease in torque on the key due to the interference fit. This effect is only relevant
if you are performing the calculation as defined in DIN 6892 B.
▪ Frequency of load peak
To determine the safety regarding the maximum torque, you must enter the approximate
number of load peaks. This effect is only relevant if you are performing the calculation as
defined in DIN 6892 B.
37.1.1 Additional inputs for DIN 6892 Method B
If you select the calculation method specified in with DIN 6892 B, you can enter the following data:
▪ Chamfer on shaft
▪ Chamfer on hub
▪ Small external diameter of hub D1
▪ Large hub external diameter D2
▪ Width c to external diameter D2
▪ Distance a0 (see Figure 37.1)
▪ Torque curve: indication of whether this is alternating torque.
If alternating torque is present, you can also define the backwards torque here. If this backwards
torque is greater than the minimum effective frictional torque (TmaxR > TRmin*q; q=0.8), the load
direction changing factor fw is set to 1.
If (TmaxR > TRmin*q und Tmax > TRmin*q; q=0.8), the maximum torque is therefore also greater than
the minimum effective frictional torque. In this case, the frequency of the changes in load
direction is taken into account when defining the load direction changing factor (from diagram.
fw<1)
V Keys 716
Figure 37.2: Load direction changing coefficient for alternating load, Figure 6, DIN 6892
▪ To perform the calculation with the equivalent torsional moment, use coefficient q=0.5. The
formula is the same as the one used for the maximum torsional moment, therefore (TeqR >
TRmin*q; q=0.5).
▪ Frequency of the changes in load direction
In this situation you input the number of torque changes throughout the entire service life
(but only if alternating torque is present).
V Keys 717
Figure 37.3: Load peak coefficient, Figure 7, DIN 6892
▪ Green line: ductile material
▪ Blue line: brittle material
37.2 Application factor
You define the application factor here in the same way as in the cylindrical gear calculation:
Operational behavior of Operational behavior of the driven machine
the driving machine
uniform moderate average heavy
shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
V Keys 718
37.1 table: Suggestions for the application factor in calculations according to DIN 6892. You will find more detailed
comments in DIN 3990, DIN 3991 and ISO 6336.
Suggestions for the application factor from other sources: (see Table 37.2), (see Table 37.3)
Type of characteristic Type of working
Machine Operational behavior Shocks Factor
Turbine, blower Uniformly rotating movements Slight 1.0. . . 1.1
Internal combustion engine Reciprocating movements Medium 1.2. . . 1.5
Presses, saw frames Reciprocating, impacting strong 1.6. . . 2.0
movements
Hammers, stone crushers Impacting movements Very heavy 2.1. . . 3.0
37.2 table: Application factor according to Roloff/Matek [70].
surfaces pressed surfaces sliding surfaces sliding against
together against each other each other under load
without load
constant load 1.0 2.0 6.0
Pulsating load, 1.5 3.0 9.0
average shocks
Alternating load, 3.0 6.0 18.0
average shocks
Pulsating load, 2.0 4.0 12.0
heavy shocks
Alternating load, 6.0 8.0 36.0
heavy shocks
37.3 table: Application factor that takes into account the load behavior as described by Professor Spinnler [71].
37.3 Contact coefficient
Contact coefficient as defined in DIN 6892 [69]:
Kν=1/(i* )
=1 for one spring
= 0.75 for two springs, to calculate the equivalent surface pressure
= 0.9 for two springs, to calculate the maximum surface pressure
More than two springs is unusual.
V Keys 719
KISSsoft calculates the contact coefficient on the basis of the number of springs.
37.4 Own inputs
If you set the Own input flag, you can enter your own data for the keys' geometry, that differs from
the values specified in DIN 6885.
► Note
If you already know the upper and lower allowance, you must enter the mean value for the chamfer
and the two groove depths. The value for the peak incline a is only to be defined for key forms G, H,
and J, according to the DIN 6885.1 standard.
37.5 Permissible pressure
The permitted values are calculated on the basis of the yield point (or fracture in the case of brittle
materials).
37.6 Materials
The selection list contains materials from the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the material data used
in the calculation which you can specify to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
37.7 Settings
▪ Calculation method
Here you can select either DIN 6892 Method B or Method C. The default setting is Method B,
because Method C has been greatly simplified.
▪ Support factors for shaft, hub and key
The support factors given in DIN 6892 differ according to the materials and parts involved. The
factors vary within a specific range. The minimum values are used in KISSsoft, and these values
can be overwritten here.
V Keys 720
▪ Take pressure on key into account
When sizing the transmittable torque ( button) you can also take the permitted pressure on
the key into account.
▪ Calculate material strength with wall thickness as raw diameter
When the strength values for the hub are being set, either the external diameter (hub was turned
from solid) or the wall thickness of the hub (hub was heat treated as a ring) is used.
▪ Symmetrical arrangement of 2 keys
In the key arrangement graphic, the default setting is for 2 keys to be displayed, offset by 120°
from each other. You can use this option to arrange the 2 keys symmetrically.
37.8 Sizings
During the sizing process, the required value is defined such that the required safety (specified in the
dialog you see by selecting Calculations > Settings) is only just achieved. To view the results in the
lower part of the main window, run the calculation after the sizing process is complete.
Possible sizings:
▪ transmittable torque
▪ necessary length of key way in shaft and hub
The "Keys" tutorial has been created specially to describe how you verify these keys.
V Straight-sided splines 721
38 Straight-sided splines
Straight-sided spline shaft connections are often used for adjustable, form-closed shaft-hub
connections. Main areas of use: Vehicle gear trains, machine tools.
KISSsoft calculates the load on the shaft and hub (surface pressure) for straight-sided splines. This
calculation, along with defining the safeties, is performed as described in classic technical literature
([6]). The calculation defined by Niemann forms the basis of DIN 6892 (key calculation).
38.1 Standard profiles
You can select one of these standards from the selection list:
▪ DIN ISO 14 (light series)
▪ DIN ISO 14 (medium series)
▪ DIN 5464 (heavy, for vehicles)
▪ DIN 5471 (for machine tools)
▪ DIN 5472 (for machine tools)
▪ Own Input
In a splined shaft connection, after you select a standard, the program displays the corresponding
external and internal diameters, and the number of splines, along with their width.
Own Input: select the Own input option to define your own splined shaft profile.
V Straight-sided splines 722
38.2 Application factor
The application factor is defined in the same way as in the key calculation:
Operational behavior of Operational behavior of the driven machine
the driving machine
uniform moderate average heavy
shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
38.1 table: Application factor according to DIN 6892
V Straight-sided splines 723
38.3 Torque curve/Number of changes of load
direction
When you select the torque curve, you can select one of two positions:
1. No alternating torque
2. With alternating torque
If you select item 2), the calculation not only defines the frequency of change of load direction, as
defined in DIN 6892, Figure 7, but also the frequency of change of load direction coefficient fw. In the
case of item 1), the coefficient will be set to 1.0.
38.4 Occurring contact stress
This formula is used to calculate occurrences of contact stress. The formula is used both for the
equivalent load and for the maximum load:
p(eq,max)=kφβ(eq,max) * k1 * T * 2000/(dm * ltr * h * z)
kφβ: Share factor ltr: supporting length
k1: Length factor h: spline height
T: Torque z: Number of splines
dm: average diameter
38.5 Length factor
A length factor, k1 is multiplied by the loading that takes into account how the load is distributed
across the supporting length as a consequence of the twist between the shaft and hub. The length
factor depends on the equivalent diameter derived from the bearing length, the small and the large
external hub diameter and the width c to the external diameter. In addition, the distance a0 is used to
define the length factor. This factor is shown in a diagram in Niemann.
V Straight-sided splines 724
Figure 38.1: Straight-sided splines: load introduction
38.6 Share factor
A share factor of kφβis taken into account to calculate the occurring contact stress. This is then
multiplied by the load. Interim sizes not shown in the table are interpolated linearly.
Form-closure spline connection with involute flank
connection Tolerance fields according to DIN 5480
H5/IT4 H7/IT7 H8/IT8 H9/IT9 H11/IT11 Maximum
value
kφβeq 1.1 1.3 1.5 2 4 z/2
kφβmax 1 1.1 1.3 1.7 3 z/2
38.2 table: Share factor according to Niemann
38.7 Permissible pressure
The permitted values are calculated on the basis of the yield point (or fracture in the case of brittle
materials). For continuous stress with Teq:
- for ductile materials:
peq=fs * fH * Rp
- for brittle materials:
peq=fs * Rm
V Straight-sided splines 725
Structural Material fs
steel
Shaft Structural steel, through hardening steel, case-hardened steel, GJS, GS 1.2
GJL 1.0
Hub Structural steel, through hardening steel, case-hardened steel, GJS, GS 1.5
GJL 2.0
Table 38.3: Notch factor according to DIN 6892
KISSsoft always uses the minimum value for the notch factor fs.
A notch factor of fs takes into account the supporting effect that occurs when bodies are subjected to
pressure.
The hardness influence coefficient fH is calculated from the surface to core hardness ratio for surface
hardened parts.
The hardness influence coefficient for case-hardened steel is 1.15. Otherwise, it is set to 1.0. The
values used for this coefficient are defined in DIN 6892.
For calculation with peak torque:
pmax=fL * peq
fL is the load peak coefficient, which depends on the material type and the number of load peaks.
This coefficient is shown in a diagram in DIN 6892.
38.8 Materials
The selection list contains materials from the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the material data used
in the calculation which you can specify to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
38.9 Settings
In Settings you can specify the required safety for the connection. The required safety defines the
values the system searches for during sizing.
The support factors for the shaft and the hub in DIN 6892 differ according to the materials and parts
involved. The factors vary within a specific range. The minimum values are used in KISSsoft, and
these values can be overwritten here.
V Straight-sided splines 726
If you selected Calculate material strength with wall thickness as raw diameter, the strength of
the hub material is calculated using the wall thickness instead of the raw diameter.
38.10 Sizings
During the sizing process, the required value is defined such that the required safety (specified in the
dialog you see by selecting Calculations > Settings) is only just achieved. To display the results in
the lower part of the main window, run the calculation after the sizing process is complete. Possible
sizings:
▪ transmittable nominal torque Tn
▪ transmittable maximum torque Tmax
▪ supporting length ltr
V Splines (Strength) 727
39 Splines (Strength)
Splines are spur gear meshings that have a shortened tooth height and a large pressure angle
(usually 30°). In KISSsoft, you can use one of two different calculation modules to calculate splines.
The geometry and tolerances required for manufacture, and the strength calculation, are described in
the Splines chapter (Geometry and Strength) (Z09a (see chapter 40, Splines (Geometry and
Strength))) under Connections.
For splines, you must calculate the load on shaft and hub (surface pressure). You can also add
additional standards. Toothing data is defined in the database and therefore you can make the use of
in-house profiles mandatory. You can also use the KISSsoft Spline (geometry and strength) module,
Z09a, to calculate the manufacturing mass and the tolerances. This calculation, along with defining
the safeties, is performed as described in classic technical literature ([6]).
39.1 Standard profiles
You can choose one of these standards from the selection list:
▪ DIN 5480
▪ DIN 5481
▪ DIN 5482
▪ ISO 4156
▪ ANSI B92.1
▪ ANSI B92.2M
▪ Own input (tip diameter of shaft and hub, module, number of teeth, profile shift coefficient)
For splines, the corresponding values are displayed in the list after the norm selection.
da1: Tip diameter of the shaft z: Number of teeth
da2: Tip diameter of the hub x: Profile shift coefficient
m: Module
V Splines (Strength) 728
Own Input: Select the Own Input option to enter your own data for the spline. The critical factor here
is that the tip diameter of the shaft is greater than the tip diameter of the hub. If not, an error
message is displayed.
39.2 Application factor
The application factor is defined in the same way as in the key calculation:
Operational behavior of Operational behavior of the driven machine
the driving machine
uniform moderate average heavy
shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
39.1 table: Application factor according to DIN 6892
V Splines (Strength) 729
39.3 Torque curve/Number of changes of load
direction
When you select the torque curve, you can select one of two positions:
1. No alternating torque
2. With alternating torque
If you select item 2), the calculation not only defines the frequency of change of load direction, as
defined in DIN 6892, Figure 7, but also the frequency of change of load direction coefficient fw. In the
case of item 1), the coefficient will be set to 1.0.
39.4 Occurring contact stress
This formula is used to calculate occurrences of contact stress. The formula is used both for the
equivalent load and for the maximum load:
p(eq,max)=kφβ(eq,max) * k1 * T * 2000/(dm * ltr * h * z)
kφβ: Share factor ltr: supporting length
k1: Length factor h: spline height
T: Torque z: Number of splines
dm: average diameter
If pmax < peq, pmax = peq is set.
39.5 Length factor
A length factor, k1 is multiplied by the loading that takes into account how the load is distributed
across the supporting length as a consequence of the twist between the shaft and hub. The length
factor depends on the equivalent diameter derived from the bearing length, the small and the large
external hub diameter and the width c to the external diameter. In addition, the distance a0 is used to
define the length factor. This factor is shown in a diagram in Niemann.
V Splines (Strength) 730
Figure 37.2: Splines: load introduction
► Note:
The recommended values for kl given by Niemann apply to splined joints which are only subject to
torsion. Any additional stress caused by bending or shearing forces can create a large number of
high local loads. More precise methods must be used to investigate these cases.
39.6 Share factor
If you are working with DIN profiles, the "Manufacturing quality according to DIN" can be used
directly as a "Tolerance field according to DIN 5480" to define the value of kφβ according to the table
shown below.
If you are working with ISO and ANSI profiles, the specified manufacturing quality +4 (see
"Tolerances" section) is taken and used as the "Tolerance field according to DIN 5480". This value is
then used to determine kφβ.
Form-closure spline connection with involute flank
connection Tolerance fields according to DIN 5480
H5/IT4 H7/IT7 H8/IT8 H9/IT9 H11/IT11 Maximum
value
kφβeq 1.1 1.3 1.5 2 4 z/2
kφβmax 1 1.1 1.3 1.7 3 z/2
Table 39.2: Share factor according to Niemann
V Splines (Strength) 731
► Note:
The recommended values for kφβ according to Niemann apply to splined joints which are only subject
to torsion. Any additional strain caused by bending or shearing forces can create a large number of
high local loads. More precise methods must be used to investigate these cases.
39.7 Permissible pressure
The permitted values are calculated on the basis of the yield point (or fracture in the case of brittle
materials). For continuous stress with Teq:
- for ductile materials:
peq=fs * fH * Rp
- for brittle materials:
peq=fs * Rm
Structural Material fs
steel
Shaft Structural steel, through hardening steel, case-hardened steel, GJS, GS 1.2
GJL 1.0
Hub Structural steel, through hardening steel, case-hardened steel, GJS, GS 1.5
GJL 2.0
Table 39.3: Notch factor according to DIN 6892
KISSsoft always uses the minimum value for the notch factor fs.
A notch factor of fs takes into account the supporting effect that occurs when bodies are subjected to
pressure.
The hardness influence coefficient fH is calculated from the surface to core hardness ratio for surface
hardened parts.
The hardness influence coefficient for case-hardened steel is 1.15. Otherwise, it is set to 1.0. The
values used for this coefficient are defined in DIN 6892.
For calculation with peak torque:
pmax=fL * peq
fL is the load peak coefficient, which depends on the material type and the number of load peaks.
This coefficient is shown in a diagram in DIN 6892.
V Splines (Strength) 732
39.8 Materials
The selection list contains materials from the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the material data used
in the calculation which you can specify to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
39.9 Settings
In Settings you can specify the required safety for the connection. The required safety defines the
values the system searches for during sizing.
The support factors for the shaft and the hub in DIN 6892 differ according to the materials and parts
involved. The factors vary within a specific range. The minimum values are used in KISSsoft, and
these values can be overwritten here.
If you selected Calculate material strength with wall thickness as raw diameter, the strength of
the hub material is calculated using the wall thickness instead of the raw diameter.
39.10 Sizings
During the sizing process, the required value is defined such that the required safety (specified in the
dialog you see by selecting Calculations > Settings) is only just achieved. To display the results in
the lower part of the main window, run the calculation after the sizing process is complete.
Possible sizings:
▪ transmittable nominal torque Tn
▪ transmittable maximum torque Tmax
▪ supporting length ltr
V Splines (Geometry and Strength) 733
40 Splines (Geometry and Strength)
You can calculate the geometry and the control measurement values of splines and hubs according
to DIN 5480 (1986 Edition), ISO 4156, ANSI B92.1 or ANSI B92.2M. Strength calculations according
to Niemann, DIN 5466 and AGMA 6123-C16 are also included.
The geometry profiles according to DIN 5481 (2019) and DIN 5482 (1973) are saved in files.
When you open the file for the profile you require, the KISSsoft screens are filled with all the
necessary geometry settings.
40.1 Underlying principles of calculation
40.1.1 General
Involute short cut teeth are often used for couplings. Teeth with a very large pressure angle αn = 30°
are very common and, to increase strength, they have a tooth height that is half the size of normal
cylindrical gears. Couplings with teeth as defined in DIN 5480 are very widespread, and are precisely
described with regard to geometry and tolerance calculation. The strength calculation is performed in
accordance with the usual methods described in technical literature [72], [52].
► Note
The moment of inertia is calculated as follows: The value di = 0 is used as the internal diameter of the
shaft, and the rounded up result of di = df + 4mn is used as the external diameter of the hub. The
moment of inertia is then determined for the cylinder between di and (da + df)/2.
40.1.2 Calculation of spline connections as described in DIN 5480
with diameter centering
Diameter centered connections are centered in the outside or inside diameters. The pinion center
root diameter with the shaft tip diameter is used for outside centering. The pinion center root
diameter with the pinion center tip diameter is used for inside centering. Here, the gear toothing is
only used for rotational synchronization. The connection must therefore have sufficient backlash to
prevent the center holes from intersecting. Due to the small tolerances of the centering diameter,
diameter-centered connections require increased manufacturing effort to limit the central
displacement. This is why they are only used in exceptional circumstances.
To calculate diameter-centered connections:
V Splines (Geometry and Strength) 734
1. In the Connections > Splines (Geometry and Strength) calculation module, open the
Reference profile input window by clicking on its tab. Here, select the DIN 5480 Major
diameter fit option in the Reference profile drop-down in the Shaft and Hub area.
2. Click the Tolerances tab to open the Tolerances input window. Check that no flag has been set
in the checkbox to the right of Tip diameter deviation (upper/lower) and Root diameter
deviation (upper/lower) input fields, for Shaft or for Hub. The program then prompts values
from the DIN 5480 recommendations as tolerances. For the tip circle, the following apply:
▪ for outside centering, H6 for the shaft tip diameter and H11 for the hub tip diameter
▪ for inside centering, h11 for the shaft tip diameter and H7 for the hub tip diameter
For the root circle, the following apply:
▪ for outside centering h14 for the shaft root diameter and H7 for the hub root diameter
▪ for inside centering, h6 for the shaft root diameter and H14 for the hub root diameter
9H/9e is recommended for the tooth thickness allowances.
40.1.3 Calculating spline connections according to DIN 5480 with
flank centering
In flank-centered connections, the flanks are used for centering and rotational synchronization. The
nominal lengths of the root diameter used for the shaft and the hub in flank-centered connections are
the "theoretical root diameter" calculated with hfP = 0.55*m. All reference profiles without the note
Major diameter fit or Minor diameter fit are for flank-centered splined joints.
The allowances that apply where cutting manufacturing processes are involved cover the appropriate
greatest possible dedendum (hfP=0.65*m) and the root diameter allowances. The tolerance field for
the root diameter of the tooth space is 9H. For the hub root diameter it is 11a.
The following values apply for flank-centered splines:
▪ Hub tip diameter da2 with tolerance field H11
▪ Shaft tip diameter da1 with tolerance field h11
▪ Allowance for the hub root diameter df2, calculated with Adf2 = (0.2*m+1.73*(Ae+TG)).
▪ Allowance for the hub root diameter df1, calculated for machining: with Adf1 = -
(0.2*m+(1.73*As+TG)). For cold roll forming: with Adf1 = -0.76*m.
This process for calculating root circle tolerances according to the base standard, DIN 5480-1, Table
5, is described below.
V Splines (Geometry and Strength) 735
Select Calculations > Settings > General to display a dialog in which you can select whether root
circle tolerances are to be calculated according to the manufacturing process (DIN 5480-16, 4.3.1) or
according to the base standard (DIN 5480-1, Table 5).
When the root circle tolerances are calculated according to the basic standard DIN 5480-1 (table 5),
the root form circle diameter is calculated as specified by the formulae on page 13:
Shaft root form circle: dFf1 = |da2| - 2*cFmin
Hub root form circle: dFf2 = -(da1 + 2*cFmin);
cFmin comes from Table 4 in the DIN 5480-1 standard.
If either the reference diameter or the module lie outside of the defined range, the adjacent edge
value in the table is used as cFmin.
The tolerance band calculated for the root diameter is also used here.
40.2 Basic data
40.2.1 Geometry standards
The complete standard and preference sequences are also available for most of the standards in this
list. Use the database tool (see chapter 9, Database Tool and External Tables) to add your own
standards to the list or extend existing guidelines. For example, the DIN 5480 preference sequence
is stored in the M02C-001.dat file in the dat folder in your KISSsoft installation directory. Each line
corresponds to an entry in the Define profile list and uses the following syntax:
da1 da2 mn z x*
where
da1 Tip diameter, shaft
da2 Tip diameter, hub
mn Normal module
z Number of teeth
x* Profile shift coefficient shaft
V Splines (Geometry and Strength) 736
► Example:
Figure 40.1: Example entry in M02C- 001.dat
The entry highlighted in the figure (see Figure 40.1) represents da1 = 5.5mm, da2 = 4.62mm, mn =
0.5mm, z = 10 and x* = 0.
► Note
You can only edit the Normal module, Number of teeth and Profile shift coefficient input fields if you
first selected Own input in the drop-down list for geometry standards.
40.2.2 Normal module
Enter the normal module. However, if you know the pitch, transverse module or diametral pitch
instead of this, click on the button to open a dialog window, in which you can perform the
conversion.
40.2.3 Pressure angle at normal section an
The normal pressure angle at the reference circle is also the flank angle of the reference profile. For
splines the pressure angle is usually αn = 30°.
40.2.4 Number of teeth
For internal toothed gears, you must enter the number of teeth as a negative value as stated in DIN
3960. The shaft and the hub must have the same number of teeth, but different prefix operators.
40.2.5 Profile shift coefficient
The tool can be adjusted during the manufacturing process. The distance between the production
pitch circle and the tool reference line is called the profile shift. To create a positive profile shift, the
tool is pulled further out of the material, creating a tooth that is thicker at the root and narrower at the
V Splines (Geometry and Strength) 737
tip. To create a negative profile shift, the tool is pushed further into the material, with the result that
the tooth is narrower and undercutting may occur sooner. For pinion and gear factors:
Click the button and KISSsoft will determine whether the profile shift coefficients are to be taken
from measured data or from values given in drawings.
The following options are available here:
▪ Base tangent length
Enter the base tangent length (span) and the number of teeth spanned here. This option cannot
be used for (internal) helical gear teeth because their base tangent length cannot be measured.
▪ Measurement over balls
To do this, enter this dimension and the diameter of the ball. In a gear with helical gear teeth
and an odd number of teeth, the measurement over balls is not the same as the measurement
over two pins. See Measurement over pins.
▪ Measurement over 2 pins
To do this, enter this dimension and the diameter of the pin. You must also enter a minimum
span for helical gear teeth and gears with an odd number of teeth, so the measurement can be
performed. The measurement over pins cannot be measured in internal helix gears.
▪ Tip circle
This is a rather imprecise calculation because the tip diameter does not always depend solely
on the profile shift.
▪ Tooth thickness at reference circle
Here, you specify the tooth thickness. You can also enter the arc length or chordal length, and
specify whether the value is in transverse or normal section.
► Note
The profile shift coefficient of the shaft and hub must be the same value.
40.2.6 Quality and tolerances
The manufacturing qualities that can be achieved are displayed in the next table.
Manufacturing process Quality according to DIN/ISO
Grinding 2 ... 7
Shaving 5 ... 7
V Splines (Geometry and Strength) 738
Hobbing (5)6 ... 9
Milling (5)6 ... 9
Shaping (5)6 ... 9
Punching, Sintering 8 ... 12
Table 40.1: Accuracy grades for different manufacturing processes
Tolerances for splines
As a comparison, we have calculated an example for the tolerances specified in DIN 5480, ISO 4156
and ANSI B92.1 (spline) and for the tolerances given in ISO 1328 (cylindrical gear pair) with
accuracy grade 6 (external) and accuracy grade 7 (internal).
The results for the ISO 4156 accuracy grade are 3 to 4 accuracy grades higher than the same results
for the DIN 5480 accuracy grade.
ANSI B92.1 returns the same results as ISO 4156.
This is all very confusing, because all other gears (cylindrical gears with straight or helical teeth,
bevel gears, worms, etc.) return accuracy grades that are mostly very similar for DIN, ISO and AGMA
tolerance results.
40.2.7 Niemann geometry data
This is geometry data that is only used to calculate strength as specified by Niemann:
▪ Diameter of shaft bore dΙ
▪ Large outside diameter of hub D
If you perform the calculation as defined in Niemann, you must also enter additional values.
Depending on the position of the load, you can enter the value a0. If a shouldered hub is present,
you must also enter the small hub external diameter D and the width of the center part c (with D).
The following diagram shows how to define these values:
V Splines (Geometry and Strength) 739
Figure 40.2: Niemann parameter definition
40.2.8 Geometry details
To open the Define geometry details window, click the Details... button in the upper right-hand part
of the Geometry area. Here, you can change the values for the shaft and hub drawing numbers.
40.2.9 Define details of strength
The strength calculation is then performed either according to Niemann [6], DIN 5466 or AGMA
6123-C16. As DIN 5466 is still being developed, it is not described in any further detail here. To
perform the calculation according to DIN 5466 and Niemann, you must enter additional data (see
chapter 39, Splines (Strength)).
40.2.9.1 Application factor
The application factor compensates for any uncertainties in loads and impacts, whereby K A ≥1.0. The
next table (see Table 40.2) illustrates the values that can be used for this factor. You will find more
details in ISO 6336, DIN 3990 and DIN 3991.
Operational behavior of Operational behavior of the driven machine
the driving machine
uniform moderate average heavy
shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
V Splines (Geometry and Strength) 740
40.2 table: Assignment of operational behavior to application factor
40.2.9.2 Strength method as defined by Niemann
40.2.9.2.1 Type of loading/Number of changes of load direction
If you open the Type of loading list, you can then select one of the two items shown in it:
1. No alternating torque
2. With alternating torque
If you select item 2), the calculation not only defines the frequency of change of load direction
NW, as defined in DIN 6892, Figure 7, but also the frequency of change of load direction coefficient
fw. In the case of item 1), the coefficient will be set to 1.0. This data is only used for calculations as
described in Niemann.
peq=fw * pzul
Figure 40.3: Graphic as described in DIN 6892 Figure 7: Load direction changing coefficient for alternating load
V Splines (Geometry and Strength) 741
40.2.9.2.2 Number of load peaks
fL is the Load peak coefficient, which depends on the material type and the Number of load peaks
NL. This coefficient is shown in a diagram in DIN 6892. This value is needed for calculations as
described in Niemann.
For calculation with peak torque:
pmax=fL * pzul
Figure 40.4: Graphic as described in Niemann (DIN 6892 Figure 8): Load peak coefficient
▪ Green line: ductile material
▪ Blue line: brittle material
40.2.9.2.3 Support factors
The support factors for the shaft and the hub in DIN 6892 differ according to the materials and parts
involved. The factors vary within a specific range. The minimum values are used in KISSsoft, and
these values can be overwritten in this window.
V Splines (Geometry and Strength) 742
40.2.9.3 Geometries according to DIN 5466
40.2.9.3.1 Resulting shearing force
Shearing forces vertical to the shaft axis cause flank contact on both sides of the opposing side of
the contact point.
40.2.9.3.2 Stress ratio R
Stress ratios are the ratios between under and over stress with regard to a particular type of load,
such as torque. Here R = -1 and defines a pure alternating stress ratio, R = 0 defines a pure
pulsating stress ratio.
40.2.9.3.3 Width and circumferential factor
Click on the checkbox to the right of the input field for one of these factors to enter a value for that
factor. Otherwise, this value is calculated automatically and may vary within the range [3, 5]. As
these are multiplied together to define the load increase, you can achieve safeties of up to 20 times
smaller than is possible with the calculation method defined in Niemann.
40.2.9.4 Strength method AGMA 6123-B06
This standard is intended to be used to size a closed planetary gear unit. However, it also includes a
part in which the spline is calculated (section 10.4).
This calculation method calculates a permissible torque for contact stress and a permissible torque
for scuffing and wear resistance.
It can be used to calculate both the permitted shearing stress, ssA, and the permitted contact stress,
scA, from the material's core hardness (HRC value).
The calculated permitted torques are then compared with the maximum torque, Tmax, (Tn*KA), to
define a safety.
Select Calculation > Settings to display the Settings tab. In it, you can define the required safeties.
These are then used to determine the safety factors and calculate the sizings.
Additional entries for this calculation method can include defining the misalignment type (aligned;
misaligned, uncrowned; misaligned, crowned) and the misalignment angle.
You can use these values to define the face load factor Km.
V Splines (Geometry and Strength) 743
► Note:
The prerequisite for calculating shearing stress is that the load is carried by half the number of teeth.
The prerequisite for performing a calculation against scuffing and wear resistance is that the load
(wear) is carried by all the teeth.
If a thinner rim which runs at a faster speed is used, it must be checked for fracture. AGMA 6123 has
a calculation for doing this. This calculation is split into three parts: the radial component, the tensile
stress and the centrifugal ring stress.
These components can then be used to calculate the overall tensile stress on the ring, which is then
compared with the permitted stress (converted from the core hardness) which corresponds to the
safety against rim fracture.
► Note:
A prerequisite for calculating the rim's safety against fracture is that the load is carried by half the
teeth.
The formulae for the individual calculations are listed at the end of the calculation report.
40.2.10 Materials
The materials displayed in the drop-down lists are taken from the materials database. If you cannot
find the material you require in this list, you can either select Own input from the list or enter the
material in the database (see chapter 9, Database Tool and External Tables) first. Click the
button to display the Material hub/shaft window, in which you can select your material from a list of
materials that are available in the database. Select the Own Input option to enter specific material
characteristics. This option corresponds to the Create a new entry window in the database tool.
40.3 Tolerances
40.3.1 Tooth thickness tolerance
Select one of the options from the Tooth thickness tolerance drop-down list.
The allowances for "Actual" (smax, smin, emax, emin) correspond to the individual measurements
(base tangent length or measurement over pins measured on the gear teeth). The allowances for
"Effective" (svmax, svmin, evmax, evmin) correspond to the measurement with gauges (all teeth
checked together). The gear backlash of a spline connection is therefore derived from the "Effective"
allowances. The effective allowances include not only the tooth thickness allowances of individual
teeth but also a pitch and form error component. The "Effective" allowances are therefore theoretical
values, and are smaller (the tooth is thicker) than for the "Actual" allowances.
V Splines (Geometry and Strength) 744
► Note
According to the standard, the allowances for tooth thickness (smax, smin) are predefined for the
shaft. In contrast, for the hub, the allowances apply to the tooth space (emax, emin).
If the tooth thickness tolerance has been set to your own input, you can input svmax for the shaft
(maximum "Effective" allowance) to calculate svmin because the relationship applies in this case:
svmin – smin = svmax – smax
In addition, you can then use the flag to predefine the individual measurement allowances for
"Actual". However, if this flag is not set, the difference svmax–smax (pitch and form error
component), and the tolerance interval smax-smin are set according to the standard for the selected
accuracy grade.
The same also applies to the hub.
Note
The circumferential backlash and normal backlash are calculated using the formulae for gear pairs,
where jt.act, jn.act are the values for "Actual" and jt.eff, jn.eff are the values for "Effective". In the
case of radial clearance, we have to consider that all the teeth can have contact when they are
moved. The first gear pair to make contact is the one whose direction of movement most closely
matches the normal angle to the flank. The radial clearance therefore corresponds to the normal
clearance in transverse section (jr = jt * Cos(alfa)). The function also checks whether the tip
clearance is so small that it also restricts the radial clearance.
40.3.1.1 DIN 5480
Unlike ISO 4156 or ANSI 92.1, DIN 5480 has the special feature that sveffmin = svmax always
applies to the shaft and eveffmax = svmin to the hub. For this reason, sveffmin and eveffmax are not
displayed.
► Note
The tolerance widths in the specified values for gauges are larger because of Taylor's formula [73].
40.3.1.2 ANSI 92.1 and ISO 4156/ANSI 92.2M
If you have selected Own Input and then entered your own tooth thickness tolerance value, you
must take the following points into account:
You must enter the tooth thickness allowance sv for the Effective tooth thickness for the overall
measurement (caliber) to suit the tolerance system that you are using to calculate cylindrical gears.
The Actual tooth thickness s for single measurements is defined using these equations.
V Splines (Geometry and Strength) 745
(38.1)
(38.2)
These equations apply to the shaft tooth thickness or to the tooth space of the hub.
40.3.2 Effective/Actual
Click the button to display the Convert total deviation of tooth thickness Effective(Actual) for
shaft window. In it, you can convert the effective/actual tooth thickness allowance. Here, you can
enter values either for the base tangent length, measurement over balls or pins, or the tooth
thickness.
Note that the tooth thickness allowances do not always have a direct effect on the root diameter's
allowances. The different standards have different rules for defining the root diameter.
40.3.3 Shaft/hub: diameter of ball/pin
The implemented DIN 5480, Part 1, contains an extract of the measuring roller diameter as specified
in DIN 3977 that must be used here. You can decide whether to extend the list of available roller
diameters in the Z0Rollen.dat file in the dat folder in your KISSsoft installation directory.
40.4 Gauges
Spline connections are often checked using gauges.
Go gauges are always fully toothed (teeth all around the perimeter) and are used to test the effective
tolerance limit. For hubs this is the min. effective tooth space and for shafts this is the max. effective
tooth thickness.
No-go gauges are always toothed by sector (depending on the number of teeth of the test piece, 2 to
7 teeth located opposite each other) and are used to test the actual tolerance limit. For hubs, this is
the max. actual tooth space and for shafts, this is the min. actual tooth thickness. The externally
located flanks of each sector are given sufficient clearance (flank relief, see 1 in the Figure), as they
cannot be measured exactly.
V Splines (Geometry and Strength) 746
Figure 40.5: Displaying gauges
KISSsoft can calculate all the gauge allowances detailed in ISO 4156 and DIN 5480-15. To do this,
go to "Report" and click on the "Construction of gauges" option. The system does not automatically
calculate the gauge dimensions for profiles that comply with ANSI.
DIN 5480-15 is limited to the pressure angle of 30°. The pressure angles 37.5° and 45° are defined
in ISO 4156. DIN 5480-15 has data for a module range of 0.5 to 10 mm and a maximum number of
100 teeth on the sample. No information is provided in the report for sizes that exceed the data in
DIN 5480-15.
According to DIN 5480-15, a calculated allowance coefficient AF1 should be entered for the
measuring rollers, if the measuring rollers do not exactly match the specified dimension. Then the
distance AF1 is calculated as a multiplication coefficient on the mean value of the allowances of the
two measuring rollers, enabling the tolerance for the distance over rollers to be determined. As this
value is not known, this calculation is not performed in KISSsoft.
40.5 Tooth form
If you want to generate the tooth forms of a splined joint, you can select the data you require from the
six different tolerance fields (actual, effective) and the three different diameter tolerances displayed in
the Tooth form tab.
The default settings here are the average allowance for tooth thicknesses and diameter. After the
calculation has been performed, the resulting diameter and tooth thickness are output in the tooth
form report.
V Splines (Geometry and Strength) 747
► Note
To ensure the selected diameter tolerance is applied to the root diameter, set the flag next to the root
diameter allowance in the Reference profile tab. If you do not set this flag, only the tooth thickness
tolerance will be included in the calculation of the root diameter.
If this flag is not set, the calculation uses a default tolerance for the root diameter as defined in the
standard. In other words, the diameter tolerance you selected will not be used to calculate the root
diameter.
V Polygons 748
41 Polygons
You use polygon connections to create shaft-hub connections that can withstand very heavy loads.
In particular, the low notch effect present in this connection does not reduce shaft strength.
For polygon shafts, you must calculate the load on the shaft and hub (surface pressure). You can
also add additional standards.
You can use one of these two methods to calculate the load on the shaft and hub (surface pressure)
and to define the safeties:
▪ Niemann, Volume I (4th Edition) [6].
▪ DIN 32711-2 (P3G-Profile) [74]/ DIN 32712-2 (P4C-Profile) [75]
The calculation according to DIN only takes into account the static load. In the method according to
Niemann, the influence of alternating torque or an additional calculation with load peaks can also be
taken into account.
41.1 Standard profiles
You can select one of these standards from the selection list:
▪ DIN 32711-1 (P3G profile)
▪ DIN 32712-1 (P4C profile)
Figure 41.1: Profiles
V Polygons 749
In a P3G profile, which varies according to which standard you select, the list displays the diameter
of mean circle, d1, the diameter of outer circle, d2, the diameter of inner circle, d3, the eccentricity e
and the factor y.
In a P4C profile, the diameter of outer circle d2, the inner circle diameter d3, the eccentricity e and
the factor y are displayed in the list.
41.2 Application factor
The application factor is defined in the same way as in the key calculation:
Operational behavior of Operational behavior of the driven machine
the driving machine
uniform moderate average heavy
shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
41.1 table: Application factor according to DIN 6892
41.3 Torque curve/Number of changes of load
direction
This influence can only be made to apply using the Niemann calculation method.
When you select the torque curve, you can select one of two positions:
1. No alternating torque
2. With alternating torque
If you select item 2), the calculation not only defines the frequency of change of load direction, as
defined in DIN 6892, Figure 7, but also the frequency of change of load direction coefficient fw. In the
case of item 1), the coefficient will be set to 1.0.
41.4 Occurring contact stress
Method according to Niemann:
V Polygons 750
This formula is used to calculate occurrences of contact stress. The formula is used both for the
equivalent load and for the maximum load:
Profile P3G:
p(eq,max)=T * 1000/(ltr* d1 * (0.75 * π * e + 0.05 * d1))
Projected area = ltr * n * 2 * e; (n = 3)
d1: Mean circle diameter T: Torque
ltr: supporting length e: Eccentricity
Profile P4C:
er = (d2 - d3) / 4; dr = d3 + 2 * e
p(eq,max)=T * 1000/(ltr* (π *dr* er + 0.05 * d2^2))
Projected area = ltr * n * 2 * er; (n = 4)
d2: Diameter of outer circle T: Torque
ltr: supporting length e: Eccentricity
dr: mathematically theoretical diameter er: mathematical eccentricity
d3: Diameter of inner circle
Method according to DIN:
The following formula is used to calculate the occurrence of contact stress:
Profile P3G:
p=T * 1000/(ltr* d1 * (0.75 * π * e + 0.05 * d1))
d1: Mean circle diameter T: Torque
ltr: supporting length e: Eccentricity
Profile P4C:
er = (d2 - d3) / 4; dr = d3 + 2 * e
p=T * 1000/(ltr*dr (π * er + 0.05 * dr))
V Polygons 751
d2: Diameter of outer circle T: Torque
ltr: supporting length e: Eccentricity
dr: mathematically theoretical diameter er: mathematical eccentricity
d3: Diameter of inner circle
41.5 Permissible pressure
Method according to Niemann:
The permitted values are calculated on the basis of the yield point (or fracture in the case of brittle
materials). For continuous stress with Teq:
- for ductile materials:
peq=fs * fH * Rp
- for brittle materials:
peq=fs * Rm
Structural Material fs
steel
Shaft Structural steel, through hardening steel, case-hardened steel, GJS, GS 1.2
GJL 1.0
Hub Structural steel, through hardening steel, case-hardened steel, GJS, GS 1.5
GJL 2.0
Table 41.2: Notch factor according to DIN 6892
KISSsoft always uses the minimum value for the notch factor fs.
A notch factor of fs takes into account the supporting effect that occurs when bodies are subjected to
pressure.
The hardness influence coefficient fH is calculated from the surface to core hardness ratio for surface
hardened parts.
The hardness influence coefficient for case-hardened steel is 1.15. Otherwise, it is set to 1.0. The
values used for this coefficient are defined in DIN 6892.
For calculation with peak torque:
pmax=fL * peq
fL is the load peak coefficient, which depends on the material type and the number of load peaks.
This coefficient is shown in a diagram in DIN 6892.
V Polygons 752
Method according to DIN:
The permissible surface pressure on the shaft or hub for polygon profiles P3G and P4C is:
pzul = 0.9 * Rp0.2
41.6 Materials
The selection list contains materials from the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the material data used
in the calculation which you can specify to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
41.7 Settings
In Settings you can specify the required safety for the connection. The required safety defines the
values the system searches for during sizing.
The support factors for the shaft and the hub in DIN 6892 differ according to the materials and parts
involved. The factors vary within a specific range. The minimum values are used in KISSsoft, and
these values can be overwritten here.
If you selected Calculate material strength with wall thickness as raw diameter, the strength of
the hub material is calculated using the wall thickness instead of the raw diameter.
41.8 Sizings
During the sizing process, the required value is defined such that the required safety (specified in the
dialog you see by selecting Calculations > Settings) is only just achieved. To display the results in
the lower part of the main window, run the calculation after the sizing process is complete. Possible
sizings:
▪ Transmittable nominal torque Tn
▪ Transmittable maximum torque Tmax(only for Niemann)
▪ Supporting length ltr
V Polygons 753
41.9 Graphics
The polygon form is defined using the formulae in the relevant DIN standard (32711-1/32712-1) and
is displayed as a graphic which can be exported either as a picture file or as a DXF file.
Polygon curve equation (profile P3G, DIN 32711-1):
Polygon curve equation (profile P4C, DIN 32712-1):
V Woodruff Keys 754
42 Woodruff Keys
Connections that use Woodruff keys are no longer commonly used, because the deep keyway in
these keys causes too great a notch effect. However, this connection still widely used in precision
mechanics.
For Woodruff keys, you calculate the load on the shaft and hub (surface pressure). You can also add
additional standards. The calculation of the load placed on the shaft and hub (surface pressure),
together with determining the safeties, is performed as described in classic technical literature ([6].
The calculation defined by Niemann forms the basis of DIN 6892 (key calculation).
42.1 Standard profiles
You can select one of these standards from the selection list:
▪ DIN 6888, series A (high hub groove)
▪ DIN 6888, series B (low hub groove)
▪ Own Input
After you select the standard for calculating the Woodruff key, a list of corresponding values is
displayed.
b: Width d: Diameter
h: Height t1: Shaft groove depth
V Woodruff Keys 755
Figure 42.1: Woodruff key with circumferential and normal forces for the calculation as defined in Niemann
Own Input: Select the Own input option to define your own Woodruff keys.
42.2 Application factor
The application factor is defined in the same way as in the key calculation:
Operational behavior of Operational behavior of the driven machine
the driving machine
uniform moderate average heavy
shocks shocks shocks
uniform 1.00 1.25 1.50 1.75
light shocks 1.10 1.35 1.60 1.85
moderate shocks 1.25 1.50 1.75 2.00
heavy shocks 1.50 1.75 2.00 2.25
42.1 table: Application factor according to DIN 6892
42.3 Torque curve/Number of changes of load
direction
When you select the torque curve, you can select one of two positions:
1. No alternating torque
2. With alternating torque
V Woodruff Keys 756
If you select item 2), the calculation not only defines the frequency of change of load direction, as
defined in DIN 6892, Figure 7, but also the frequency of change of load direction coefficient fw. In the
case of item 1), the coefficient will be set to 1.0.
42.4 Occurring contact stress
This formula is used to calculate occurrences of contact stress. The formula is used both for the
equivalent load and for the maximum load:
p(eq,max)=kφβ(eq,max) * k1 * T * 2000/(d * ltr * htw * z)
kφβ: Share factor ltr: supporting length
k1: Length factor htw: supporting height (shaft)
T: Torque z: Number of Woodruff Keys
d: Shaft diameter
42.5 Length factor
A length factor, k1 is multiplied by the loading that takes into account how the load is distributed
across the supporting length as a consequence of the twist between the shaft and hub. The length
factor depends on the equivalent diameter derived from the bearing length, the small and the large
external hub diameter and the width c to the external diameter. In addition, the distance a0 is used to
define the length factor. This factor is shown in a diagram in Niemann.
Figure 42.2: Woodruff key: load introduction
V Woodruff Keys 757
42.6 Share factor
A share factor of kφβ is taken into account in the calculation of the occurring contact stress. This is
then multiplied by the load. Intermediate sizes not shown in the table are interpolated linearly.
Form-closure spline connection with involute flank
connection Tolerance fields according to DIN
H5/IT4 H7/IT7 H8/IT8 H9/IT9 H11/IT11 Maximum
value
kφβeq 1.1 1.3 1.5 2 4 z/2
kφβmax 1 1.1 1.3 1.7 3 z/2
Table 42.2: Share factor according to Niemann
42.7 Permissible pressure
The permitted values are calculated on the basis of the yield point (or fracture in the case of brittle
materials). For continuous stress with Teq:
- for ductile materials:
peq=fs * fH * Rp
- for brittle materials:
peq=fs * Rm
Structural Material fs
steel
Keys Structural steel, bright steel, through hardening steel, case-hardened steel 1,1
Shaft Structural steel, through hardening steel, case-hardened steel, GJS, GS 1.2
GJL 1.0
Hub Structural steel, through hardening steel, case-hardened steel, GJS, GS 1.5
GJL 2.0
Table 42.3: Notch factor according to DIN 6892
KISSsoft always uses the minimum value for the notch factor fs.
A notch factor of fs takes into account the supporting effect that occurs when bodies are subjected to
pressure.
The hardness influence coefficient fH is calculated from the surface to core hardness ratio for surface
hardened parts.
V Woodruff Keys 758
The hardness influence coefficient for case-hardened steel is 1.15. Otherwise, it is set to 1.0. The
values used for this coefficient are defined in DIN 6892.
For calculation with peak torque:
pmax=fL * peq
fL is the load peak coefficient, which depends on the material type and the number of load peaks.
This coefficient is shown in a diagram in DIN 6892.
42.8 Materials
The selection list contains materials from the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the material data used
in the calculation which you can specify to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
42.9 Settings
In Settings you can specify the required safety for the connection. The required safety defines the
values the system searches for during sizing.
The support factors for the shaft, the hub and the Woodruff key in DIN 6892 differ according to the
materials and parts involved. The factors vary within a specific range. The minimum values are used
in KISSsoft, and these values can be overwritten here.
If the Take pressure on key into account flag is set, the values of the Woodruff key are included in
sizings. Otherwise, the sizing procedure will be carried out using the values for shaft and hub.
If you selected Calculate material strength with wall thickness as raw diameter, the strength of
the hub material is calculated using the wall thickness instead of the raw diameter.
42.10 Sizings
During the sizing process, the required value is defined such that the required safety (specified in the
dialog you see by selecting Calculations > Settings) is only just achieved. To display the results in
the lower part of the main window, run the calculation after the sizing process is complete.
Possible sizings:
V Woodruff Keys 759
▪ transmittable nominal torque Tn
V Bolts and Pins 760
43 Bolts and Pins
Figure 43.1: Basic data for bolts and pins
Five types of calculation have been created to categorize bolt/pin connections, depending on where
they are used:
▪ Cross pin under torque
The surface pressure of the shaft and hub, and the shearing of the pin, are checked in cross pin
connections where large forces are involved.
▪ Longitudinal pin under torque
Longitudinal pin connections are subject to surface pressure in the shaft and hub and shearing
on the pin.
▪ Guide pin under bending force
Guide pin connections are subject to bending stress due to a moment and to shearing force
caused by transverse forces. The shearing force, surface pressure and bending of the pin, and
the surface pressure on the part, are calculated in this case.
▪ Bolt connection under shearing action (in double shear)
The bolt is subject to bending and shear stress and to surface pressure in this arrangement. You
can use different calculation methods, depending on the fit of the rod/bolt and fork/bolt
connections. Experience shows that the decisive value in sizing non-sliding surfaces is the
bending stress. In sliding surfaces, it is the surface pressure.
V Bolts and Pins 761
▪ Bolts in a circular arrangement (in single shear)
In this arrangement, the effective torque is distributed uniformly across the individual bolts/pins,
and the shaft and hub are therefore subject to surface pressure from the individual bolts/pins,
creating a shearing force. The maximum shear stress (calculated as specified in Roloff Matek
[66], page 254) and the minimum safety for the bolts are also output.
The load placed on the bolts, shaft and hub (or part), together with determining the safeties, is
calculated as described in classic technical literature (Niemann, Maschinenelemente I, 4th edition,
2005 [6]),
apart from bolts in a circular layout.
The cross-sectional area and moment of resistance to bending in the spiral and slotted spring pins
(bushes) is calculated according to Decker [67]. In those configurations where the bolts, spiral and
slotted spring pins (bushes) are only subjected to shearing, the permitted shearing force specified in
the relevant DIN EN standard can be applied to the pins.
43.1 Influence factors
When calculating individual connections you must include a number of influencing factors which are
defined depending on the load, stress, type, etc.:
▪ Application factor
▪ Dynamic factor:
fixed load: Cd = 1; pulsating load: Cd = 0.7; alternating load: Cd = 0.5;
for slotted spring pins and spiral pins (bushes)
Fixed load: Cd = 1; pulsating load: Cd = 0.75; alternating load: Cd = 0.375;
▪ Reduction factors for full/slotted spring pin
Full pin: Ck = 1; slotted spring pin (bending, shear): Ck = 0.7; slotted spring pin pressure: Ckp =
0.8;
Since the permissible stress values in the literature are very low, other material factors have been
added to obtain the values in the table.
V Bolts and Pins 762
43.2 Materials
Figure 43.2: Material screen: Bolts and Pins
The selection list contains materials from the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the material data used
in the calculation which you can specify to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
V Bolts and Pins 763
43.3 Settings
Figure 43.3: Settings for bolts and pins
In this subwindow, you can view and change the materials factors and required safeties for each
calculation.
This factor is multiplied by the tensile strength Rm for all parts/bolts and pins apart from split spring
pins and spiral pins (bushes) to calculate the permitted value.
In the case of split spring pins and spiral pins (bushes), the permitted values are taken directly from
the file and do not depend on tensile strength Rm.
43.4 Permitted values
Parts/Full pins/Bolts/Split spring pins
Select Calculation > Settings to display the Settings tab. In it, for each part/bolt and pin, depending
on the load, the coefficient you find is multiplied by the tensile strength Rm to define the permitted
value.
Split spring pins and spiral pins (bushes)
The permitted values for split spring pins and spiral pins (bushes), are imported from a file.
V Bolts and Pins 764
The permitted values for transverse force, for configurations that are only subject to shearing, can be
taken from the relevant DIN EN standard for the pins.
These values for the minimum safety against shearing are displayed in the standards for a case
involving double shear. If the calculation involves single shear, the minimum shearing force (double
shear) used in the standard can be halved. This was described in the old standard (e.g. DIN
1481:1978).
The permitted values for shear and bending stress under different loads can be taken from the
technical documentation provided by Decker:
Bending stress: σb = 380N/mm2
Shear stress: τ = 160N/mm2
Surface pressure: p = 208N/mm2
Half the permitted values from other arrangements are used for the arrangement "Longitudinal pin
under torque". (Recommendation according to Decker)
43.5 Sizings
Click the buttons next to diameter and load to size the values that are beside them to suit the
required safeties.
V Bolts 765
44 Bolts
KISSsoft calculates bolted joints according to VDI 2230 (2015). In addition to providing tables with
standard values, the program also has a range of options that enable you to enter your own
definitions for most of the constraint values (such as geometry and material data). Although the VDI
2230 standard does not have iteration functionality, i.e. it can be calculated manually, the flexible
input and modification options give you a user-friendly software solution at your fingertips. However,
you must be familiar with VDI 2230 before you can interpret the results and enter the required values
correctly in the program.
VDI 2230 compares the assembly pretension force (FM/FMzul) with the minimum and maximum
required assembly pretension force (FMmax and FMmin). FMzul is based on the permitted load on
the bolt. FMmax and FMmin describe the minimum necessary pretension forces that ensure the
connection will function correctly.
The minimum necessary mounting pretension force, FMmin, is calculated from the operating force
FA and the resilience of the parts and the bolt, the embedding loss FZ, the thermal forces Fvth and
the required clamp load FKerf. FMmax can be calculated while taking into consideration the scatter
of the tightening technique (tightening factor αA) from FMmin.
(42.1)
(42.2)
The maximum required mounting pretension force FMmax must be less than the permitted
pretension of the bolt FMzul. A similar comparison to this comparison is the one between the
minimum required mounting pretension force FMmin and the minimum pretension force achieved by
tightening FM/αA:
(42.3)
44.1 Special features in KISSsoft
In VDI 2230, the values for pretension force FM when utilizing 90% of the yield point, and for the
tightening torque, are listed in Tables A1 to A4. These values are rounded (rounding error <= 1%). In
contrast, KISSsoft uses the equations on which the tables are based to calculate the values. The
results are therefore more general than the ones that use the values given in the tables and might
therefore also differ from them slightly.
V Bolts 766
44.2 Inputs for Basic data
The entries you make in the Basic Data tab form part of the operating and bolt data, and include the
type of bolting, washers or extension sleeves, and tightening technique.
44.2.1 Operating data
Enter operating data in the Basic data tab. In this tab, you can select one of these bolting
configurations:
1. Bolted joint under axial load (single bolt)
2. Bolted joint under axial load and shearing force (single bolt)
3. Flange connection with torque and forces (multiple bolts)
4. Multi-bolted joint with any bolt position
5. Proof for bolts with FEM results
VDI 2230 assumes that the operating forces that will affect the bolted joint are already known. You
can enter external forces and torques, depending on which configuration you select in KISSsoft. In
configurations with several bolts, KISSsoft uses the values input for the entire joint to calculate the
axial force and the pretension force for an individual bolt.
For a bolted connection under shear load, this shear load is received by the friction force between
the bolted parts. The friction force is determined by the coefficient of friction and the pretension force.
The torsional moment is then applied at the location of the friction radius. This radius is determined
from the dimensions of the clamped parts (connecting solids).
Figure 44.1: Bolting configurations: 1/2, 3 and 4
V Bolts 767
44.2.1.1 Bolted joint under axial load and shearing force (single bolt)
In the second configuration, the required clamp load for axial load transmission is calculated from the
shearing force FQ, the torque MT, the coefficient of friction μT, the average friction radius ra and the
number of force transmitting parting lines qT:
(42.5)
(42.6)
FKQ Clamp load required to transmit a shearing force and/or a torque through friction grip
FKP Clamp load required to guarantee sealing (required when internal pressure is present)
μT Interface coefficient of static friction (when shearing force or torques are present), → (see
Figure 44.2).
ra The friction radius resulting from the dimensions of the clamped parts to which the
torsional moment is applied.
44.2.1.2 Bolted joint under axial load (single bolt)
The occurring axial forces FAmax and FAmin are entered directly. The necessary clamp load FKerf is
defined in accordance with
(42.4)
based on the required clamp load for axial load transmission FKQ and the sealing function FKP are
calculated. FKA is present to prevent gaping in the required clamp load and is calculated by the
program.
44.2.1.3 Flange connection with torque and forces (multiple bolts)
The forces on the single bolt in the case of flanged joints (with stress from torque and/or shearing
force and/or bending moment and/or axial force) are calculated according to [76], and also partially
according to [70], for example, 8.4:
(42.7)
V Bolts 768
(42.8)
(42.9)
(42.10)
(42.11)
dt Pitch circle diameter
n Number of bolts
μT Coefficient of friction between the bolted parts, (see Figure 44.2)
FQ Shearing force on configuration
FAmax Axial force on configuration (maximum)
FAmin Axial force on configuration (minimum)
FBo Upper operating force on the bolt that is subject to the greatest stress
FBu Lower operating force on the bolt that is subject to the greatest stress
FKP Configuration sealing load
MB Bending moment on configuration
MT Torque on configuration
FKerf Required clamp load
FKQ Required clamp load (e.g. for friction grip)
FKP Clamp load required to ensure sealing (at internal pressure)
FKA Clamp load required to prevent gaping under eccentric load
If you select a flanged joint configuration, we strongly recommend that you define the geometry of the
clamped parts as individual annulus segments.
Experience shows that the results of VDI 2230 are usually very conservative for flanged connections.
To achieve realistic results, you should increase the coefficient of friction between the parts.
V Bolts 769
Figure 44.2: Interface coefficients of static friction according to [1]
44.2.1.4 Multi-bolted joint with any bolt position
In a multi-bolted joint you can define bolts in any position. They are then affected by shearing force, a
bending moment in two directions, and a torsional moment. The load distribution on the bolts is
calculated on the assumption that rigid plates are connected by springs at the bolt positions. Forces
which do not affect the centroid point must be moved to the centroid point so they can be entered.
You can represent different bolt diameters by entering a coefficient.
V Bolts 770
Enter coefficient = 1 for the bolt for which you want to calculate the proof. The proof is always
performed for the bolt specified in the Basic data tab. For all the other bolts in the arrangement, set
a coefficient that is either greater than or less than 1. The coefficient represents the diameter of the
larger or smaller bolt compared to the bolt for which the proof has been performed. For example,
enter coefficient = 2 for a bolt whose diameter is twice the size.
If the bolt for which the proof is to be performed is determined automatically, you might need to run
the calculation a second time after you have determined which bolt is subjected to the greatest load.
In the second calculation, the reference diameter in the Basic data tab, and the coefficients in the
Position of bolt tab, may need to be modified so that a coefficient = 1 can be set for the bolt that is
subjected to the greatest load.
Figure 44.3: Definitions of forces and moments in KISSsoft
Once you have entered the operating data in the Basic data tab, you can define the bolt positions in
the Position of bolt tab. You can either enter the bolt positions in a table or import them from a file.
The resulting axial forces, and also the clamp loads required to transmit shearing force, are also
displayed in the table.
You can also define an additional Factor for thrust bolts, in which it is assumed that compression is
transmitted directly via the plates. The neutral axis can be moved by the Factor for thrust bolts. In
[66], under the keyword "Multi-bolted Plate Joint", for example, an average pressure point of 1/4 plate
height is assumed.
V Bolts 771
If the bolt number was not defined manually, the bolt with the highest axial force is automatically
selected for the calculation. In this case, to ensure that the calculation results are on the safe side,
the maximum required clamp load is used for all bolts.
If the Use maximum required clamp load option is not selected, the required clamp load on the
particular bolt is used for the calculation.
When you calculate the required clamp load, you can also take into account the algebraic prefix
operator set for the shearing forces. Shearing forces caused by torsion and shearing force are then
added at specific points and subtracted at other points. You should only include the prefix operator if
you know the direction of the shearing force and if this force is constant. The default setting is that all
the shearing force values are added together, no matter which direction of force is involved.
Click the button in the table (above, on the right) in the "Position of bolt" tab to display this
window, in which you can enter different configurations. The selected number of bolts is then
automatically inserted at regular intervals in the selected configuration.
Possible configurations are:
▪ line (values for: starting point, end point, number of bolts)
▪ circle (values for: center point, radius, number of bolts)
▪ circle segment (values for: radius, starting angle, end angle, number of bolts)
Figure 44.4: Position sizing options
V Bolts 772
44.2.1.5 Proof for bolts with FEM results
The following behavior can be taken into account in an FEM calculation (instead of a calculation
according to VDI 2230 Sheet 1):
▪ Non-linear material behavior (for example, plasticity or yield)
▪ Non-linear boundary conditions (for example, load dependency of the contact surfaces),
▪ Geometric non-linear behavior (for example, significant deformation occurs when the tightening
process is simulated)
As specified in VDI 2230 Sheet 2, Multi bolted joints, the FEM modeling is subdivided into 4 model
classes:
Model class I:
The bore is not represented. The interface is either completely integrated or connected by a rigid
coupling and a reference node for every bolt.
Model class II:
The bolt is represented as a beam or a spring element (with the ideal translational and rotational
degrees of freedom for each section). Interface with contact definition.
Model class III:
The bolt is shown in 3D as a cylinder with large cylinders at its ends. The interface and support areas
are assigned contact definitions in the FEM calculation. The cylinder has the same core diameter as
the thread.
Model class IV:
The bolt is modeled with the exact thread geometry. The assembly and working states are treated
separately.
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A proof according to VDI 2230 Sheet 1 with FEM results is really only a sensible idea for model
classes II and III. Model class I does not supply informative enough results to create a proof
according to VDI 2230 Sheet 1. If you are using model class IV, you already have all the necessary
results and should use a different method from the one in VDI 2230 Sheet 1 for the proof.
You can select these model classes directly from the list in the Results from FEM calculation tab.
List items model class II and model class III:
The main difference in the modeling is that bolt resilience can only be defined in model class III.
In these list items, the "Bolted joint under axial and shearing force" configuration is required for
calculating the amount of embedding.
In KISSsoft, the FEM results are embedded in the calculation as follows, according to VDI 2230
Sheet 1:
R0, according to VDI 2230 Sheet 1
R1
R2 You can input the clamp load for the sealing function FKP directly in the basic data, if it has
already been determined in the FEM calculation. The lifting force FKab can be determined
directly in the FEM calculation and entered here. If the results are not defined, they can be
determined according to VDI 2230 Sheet 1. The axial load transmission FKQ is determined
as specified in VDI 2230 Sheet 1.
R3 In model classes II and III, the resilience of the plates is taken from the results of the FEM
calculation. In model class III, the bolt resilience is also taken from the results of the FEM
calculation. In model class II, bolt resilience is derived as specified in VDI 2230 Sheet 1.
The amounts of embedding are estimated according to VDI 2230 Sheet 1.
R4 Amounts of embedding are defined according to VDI 2230 Sheet 1, Fv'th is input directly
from the FEM calculation, as the result.
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R5 Fv'th can be input directly as a result from FEM, and Fkerf, φen, Famax, Fz can be taken
from VDI 2230 Sheet 1 > determination of FMmin.
R6 Fmmax = αA*FMmin.
R7 In KISSsoft, assembly stress is calculated according to VDI 2230 Sheet 1. This would take
an exceptional amount of time and effort if an FEM calculation were used instead.
R8 FV'th is included in the calculation of Fsmax (total bolt load). If FV'th > 0 it is set to 0, as
specified in R8/1, VDI 2230 Sheet 1.
All other σz, τmax, σredB are calculated according to VDI 2230 Sheet 1.
R9 FSA, MSA as input from the FEM results. You can specify the upper and lower limit. Proof
of dynamic strength according to VDI 2230 Sheet 1 (R9/2). The permitted values are
defined according to VDI 2230 Sheet 1.
The effects of temperature are included directly in the FEM results.
R10 pBmax can be derived from the FEM results if model class III is being used, otherwise it is
calculated according to VDI 2230 Sheet 1.
You should only calculate the values for permissible surface pressure pGmax directly in
FEM if these values are not already available.
R11 The minimum length of engagement cannot be represented realistically in model classes I
to III. It would take a great deal of time and effort to model this in model class IV. The
calculation is performed according to VDI 2230 Sheet 1.
R12 The calculation In KISSsoft is performed according to VDI 2230 Sheet 1. The values you
need to input here are determined from the FEM calculation.
R13 Not applied.
List item model class III (only forces and moments, without resiliences):
The main difference between this and the other methods is that the calculation is performed without
defining the resiliences.
When this list item is used, the load application factor is permanently set to n=1.
The FEM results needed to create a proof according to VDI 2230 Sheet 1 are grouped in the
summary of the calculation steps below:
R0 The geometry must be defined according to VDI 2230 in FEM. In KISSsoft, set this to
"Plates" for clamped parts.
R1 Tightening factor according to VDI 2230 Sheet 1
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R2 to R6 Determined in the FEM model. The results are: FM, FM/α (may be different, because this
is a real value), FKP, FSmax, FKR.
FKQ which is determined with the values FQ, Mt and ra, is used to calculate safety
against sliding.
R7 Mounting conditions:
FMzul = FMtab at 90% load, otherwise σredMzul =ν*Rp0.2. With FM value for calculating
σredM from FE.
R8 Working conditions:
FSmax is the result in the FEM calculation.
σz, τmax, σredB are calculated according to VDI 2230 Sheet 1.
SF = Rp0.2/σzmax
R9 FSA and MSA values from the FEM results. You can specify the upper and lower limit.
Proof of dynamic strength according to VDI 2230 Sheet 1 (R9/2). The permitted values
are defined according to VDI 2230 Sheet 1.
The effects of temperature are included directly in the FEM results.
σAbo = FSA,o/As + MSA,o/Ws; σAbu = FSA,u/As + MSA,u/Ws
SD = σAS/σab
σAS calculated according to the formulae in VDI 2230 Sheet 1.
R10 Input values: permissible surface pressure pGzul (under head and nut).
Mounting: pMmax = FMzul/Apmin
Operation: pBmax/Apmin
SP = pGzul/PM,Bmax
R11 Minimum length of engagement is not calculated.
R12 FKR is an input value. FKerf is calculated according to VDI 2230 Sheet 1. FKQ interim
results are calculated from input values FQ, Mt and ra.
SG = FKR/FKerf
R13 Not applied.
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44.2.2 Bolt data
A bolt's type, geometry, surface roughnesses and strength class can all be defined as bolt data.
Bolt type: You can use the following standard bolt descriptions from the database to define the bolt
type:
DIN EN ISO 4762 Hexagon socket head cap screw
DIN 912 Standard thread M1.6 to M64
DIN 7984 Hexagon socket head cap screw with low head
Standard thread M3.0 to M24.0
DIN EN ISO 4014 Hexagon headed screws with shank (formerly DIN 931 T1)
DIN EN 24014 Standard thread M1.6 to M64
DIN EN ISO 4017 Hexagon headed screw without shank (formerly DIN 933)
DIN EN 24017 Standard thread M1.6 to M64
DIN EN ISO 1207 Slotted cheese head screw
DIN 84 Standard thread M1.0 to M10
DIN EN ISO 8765 Hexagon headed screw with shank
Fine thread M8.0 to M64
DIN EN ISO 8676 Hexagon headed screw without shank
Fine thread M8.0 to M64
DIN EN 1662 Hexagon headed screw with flange, light series form F
Standard thread M5.0 to M16
DIN EN 1662 Hexagon headed screw with flange, light series form U
Standard thread M5.0 to M16
DIN EN 1665 Hexagon headed screw with flange, heavy series form F
Standard thread M5.0 to M20
DIN EN 1665 Hexagon headed screw with flange, heavy series form U
Standard thread M5.0 to M20
ASME B18.2.1 Square bolts, UNC thread, 0.25 to 1.5in
ASME B18.2.1 Hex bolts, UNC thread, 0.25 to 4in
ASME B18.2.1 Heavy hex bolts, UNC thread, 0.5 to 3in
ASME B18.2.1 Hex cap screws, UNC thread, 0.25 to 3in
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ASME B18.2.1 Heavy hex screws, UNC thread, 0.5 to 3in
Reference diameter: You can either input your own value for the nominal diameter or click the
button to calculate an approximate value after you input the operating data. This sizing function
usually leads to bolt diameters that are too large. We therefore recommend you input a value that is
1 or 2 standard sizes less than the system's proposed value.
Bolt length: You can input any bolt length if you are inputting your own bolt geometry. Otherwise,
after you input the bolt length, the system sets it to the next standard length.
Surface roughness of thread/head bearing area: The surface roughnesses influence the amount
of embedding and therefore also the preload loss of the bolted joint.
Strength class: After the entry for standard strength grades you can click the Define... button to
define your own strength values. The shearing strength ratios are set according to Table 5.5/2 in VDI
2230 Sheet 1 (2015), according to strength class. The values can be overwritten.
Own definition of bolt geometry: To define your own bolt geometry, you must set the Bolt type
selection list to Own input. This activates the button, which you can click to input your own bolt
geometry values.
Figure 44.5: Bolt geometry
▪ General tab: If you are using a bolt with a bore, input the bolt head dimensions as well as the
bore diameter.
▪ Thread tab: Data from the standard, the size of the thread, the pitch, and the thread length. This
is where you define the factors used to calculate the flank diameter d2 and the core diameter d3
(d2 = d - d2factor*P; d3 = d - d3factor*P).
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▪ Bolt shank tab: Data about individual bolt cross sections. Click on the button to add a new
cross section or click on the button to remove the selected cross section. Click on the
button to delete all the cross sections.
44.2.3 Type of bolted joint
To define the type of bolting, select either Nut or Blind hole. This corresponds to the difference
between through-bolt and single-bolted tapped thread connections as defined in VDI. Click on the
appropriate Define... button to display a dialog in which you input additional data about the nut or
blind hole.
Blind hole
The counter bore depth ts describes a milled groove without thread, which is primarily used to
elongate the clamp length (see Figure 44.5).
Nut
In the nut definition screen, you can either select a standard for the geometry or define the
dimensions yourself by selecting Own Input.
For example, when calculating the length of engagement, you can either define the hardness from
the strength class (as specified in DIN EN ISO 898-2) or define the shearing strength directly from
the material.
The Own Input option is also available in both variants. However, when you input the strength class,
you must also define the ratio of the shearing strength to tensile strength (τBM/Rm).
The system then converts the hardness value you enter here into tensile strength as part of the
hardness conversion process. The tensile strength Rm is then multiplied with the ratio (τBM/Rm) to
calculate the shearing strength (τBM).
The minimum hardness value for nuts with a standard thread (including UNC) is taken from the
strength class in Table 6 in DIN EN ISO 898-2. The minimum hardness value for fine threaded nuts
(including UNF) is taken from the strength class in Table 7 of the same standard.
► Note
If the dimension of the interface area DA is only slightly larger than the bearing area diameter of the
bolt head dw, it must be calculated as a through-bolt connection (note the deformation cone).
(DA to ~1.4*dw)
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44.2.4 Washers
Click on the appropriate checkbox to insert a washer between the nut and the component or the
head and the component.
Select Calculation > Settings to display the Settings tab. In it, if you select Determine specific
thermal expansion of washers, you can also define the thermal expansion coefficients that are
used to calculate the difference in pretension force. You will find a more detailed description in the
"Settings" section.
44.2.5 Extension sleeves without external forces
You can specify the length of an individual extension sleeve in the extension sleeves dialog. In a
single-bolted (tapped thread) connection, a extension sleeve can be used under the bolt head. In a
through-bolt connection, an extension sleeve can be used under the bolt head and under the nut.
No external forces are to act on the extension sleeves defined here. These sleeves are to be used to
create the space between the bolt head or nut and the part.
The extension sleeves are taken into account when sizing the length, calculating the resiliences, and
in the length expansion at operating temperature.
44.2.6 Tightening technique
Uncertainties such as the scatter of coefficients of friction, differently accurate tightening techniques,
and instrument, operating and reading errors, result in the scatter of the assembly pretension force
achieved. For this reason, oversizing the bolt is necessary, and is expressed by the tightening factor
αA = FMmax/FMmin. If the required minimum pretension force FMmin remains constant, an increasing
tightening factor αA means that the bolt must be sized for a larger maximum required assembly
pretension force FMmax (due to the greater scatter). Tightening technique and associated tightening
factors:
Tightening factor αA Tightening technique Adjusting technique
1.1 to 1.2 Tightening with elongation control Sound travel time
1.1 to 1.3 Mechanical elongation due to thrust Specify the bolt elongation and the
bolts in nut or head forcing torque of the thrust bolts
1.2 to 1.5 Mechanical elongation due to Torque
multipartite nut
1.1 to 1.5 Tightening with mechanical Mechanic elongation measurement
elongation measurement
1.2 to 1.6 Hydraulic tightening (VDI Compression or length measurement
2230:1988)
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1.1 to 1.4 Hydraulic non-frictional and torsion- Compression or length measurement
free tightening or additional rotational angle of nut
1.0 (*) Yield point-determined Preset torque-angle of rotation
mechanical or manual tightening coefficient
1.0 (*) Rotation angle-controlled Experimental determination of the
mechanical or manual tightening preload moment and angle of rotation
1.4 to 1.6 Torque-controlled tightening with Pressure measurement
hydraulic tool
1.4 to 1.6 Torque wrench (with experimental Experimental determination of the
load) required tightening torques on the
original bolting part, e.g. by
measuring the length of the bolt.
1.6 to 2.0 Torque wrench (by estimating the Determination of the nominal
coefficient of friction, class B) tightening torque by estimating the
coefficient of friction, value (surface
and lubrication ratios)
1.7 to 2.5 Torque wrench (by estimating the Determination of the nominal
coefficient of friction, class A) tightening torque by estimating the
coefficient of friction, value (surface
and lubrication ratios)
1.6 to 1.8 Torque wrench (by estimating the Determination of the nominal
coefficient of friction) (VDI tightening torque by estimating the
2230:1988) coefficient of friction, value (surface
and lubrication ratios)
2.5 to 4.0 Pulse-controlled tightening with an Torque wrench adjustment with
impact wrench tightening-up moment
(*) FMmax/FMmin is greater than 1. Despite this, αA = 1 is used for the dimensioning formula. See
VDI 2230:1988, section 5.4.3.2.
44.3 Data input for clamped parts
The Clamped parts screen displays data about the materials and geometry of the clamped parts
(connecting solids), the distances involved for eccentric loading/clamping and data about the load
introduction factor.
44.3.1 Geometry of clamped parts (connecting solids)
There are several basic types of clamped parts (connecting solids):
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▪ Plates
▪ Cylinder
▪ Prismatic body
▪ Annulus segment
Figure 44.6: clamped parts (connecting solids).
If you select Plates, it is assumed that the clamping deformation cone will be able to expand freely
sideways. For all the other selection options, click the Geometry button to enter the relevant
dimensions of the clamped parts you want to use in the calculation.
Click the Bore... button to define the through-bore in the clamped component. You can also define
chamfers under the head or nut here. These chamfers are then included when the bearing areas are
calculated. The chamfer reduces the external radius of the bearing area, therefore increasing the
surface pressure.
You simply enter the different material situations in the list. The upper values for the permissible
pressure, Young's modulus and thermal expansion are material values that apply at room
temperature and, unless they are values you have entered, are always shown with a gray
background. If Calculate temperature dependent material data automatically with estimation
formulae is selected in Module specific settings, the values for the operating temperature are
calculated empirically and displayed in the lower half of the particular material. You cannot edit these
values. If this option is not selected, you must enter your own values here. Click the buttons to
call the different empirical formulae so they can be applied in the calculation. Click the button to
add a material, click the button to delete the selected element and click the button to delete all
the positions. The calculated clamp length is displayed in the l k field.
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44.3.2 Distances for eccentric load/clamping
Figure 44.7: Possible load cases in the case of eccentric clamping.
As you can see in the figure (see Figure 44.7), the axis of the center of gravity of the clamping solid 0
- 0 determines the zero-point (origin) of the distances. The distance between load line of action A - A
and the centroid axis 0 - 0 is always positive. The distance ssym between the bolt axis S - S and the
axis of the center of gravity 0 - 0 is set as positive if the bolt axis S - S and the load line of action A -
A lie on the same side of the axis of the center of gravity 0 - 0. If not, this value is negative.
The dimension u defines the distance from the centroid axis 0 - 0 to the point at which gaping first
occurs. This is the distance to the right-hand side in cases I and III, but the distance to the left-hand
side in case II. In cases I and III, u must be positive, and in case II it must be negative. The
guidelines governing the use of signs specified in VDI 2230 Sheet 1 are applied here.
44.3.3 Load application
The VDI guideline defines equations for calculating the load application factor. Select a configuration
as shown in the figure (see Figure 44.8). The interface must lie within the range shown in gray. The
length of the clamped parts h, the distance to the connection piece akand the length of the connected
solid lA (see Figure 44.9) define the position of the application of load point and therefore also the
load application factor.
In single-bolted (tapped thread) connections, only configurations SV1, SV2 and SV4 are available.
Figure 44.8: Configurations for defining the load application factor as shown in VDI 2230 (2015 edition).
V Bolts 783
Figure 44.9: Inputs for defining the load introduction factor as shown in VDI 2230 (2015 edition).
44.4 Constraints data
In this calculation, you can define the yield point utilization, the maximum assembly pretension force
or both tightening torques as constraints. If you define the maximum and minimum tightening torque
as constraints, the tightening factor is then calculated from this torque variation and the friction
coefficient variation. You can also enter values for the number of load cycles, amount of embedding,
preload loss and temperatures for the bolted joint in this window.
Use of the yield point
Usually, when sizing bolts, the bolt is tightened to 90% of its yield point to calculate the pretension
force. However, if you use yield point or angle of rotation-controlled tightening, you can increase this
utilization value up to 100%.
Number of load cycles
If this number of load cycles is ND >= 2*106, the fatigue life for final heat treated and final rolled bolts
are calculated according to the formulae specified in VDI 2230, 5.5/20 and 5.5/21. If smaller values
are involved (ND < 2*106), limited life sizing is performed for the connection (5.5/22 and 5.5/23).
Amount of embedding
The amount of embedding is calculated according to which calculation method you use. You can also
input an extra amount of embedding value for flat seals. In addition, you can overwrite the calculated
amount of embedding with your own value or input the preload loss directly. If you input your own
preload loss, the amount of embedding is no longer taken into account.
Assembly and operating temperature
Now KISSsoft's bolt calculation function has been extended, it can be used for the calculation
guideline specified in VDI 2230, which also calculates bolted joints for operating temperatures
V Bolts 784
between -200 and +1000 degrees Celsius. You can specify different temperatures for the bolt and
the clamped parts (connecting solids). You can also take into account the temperature-dependent
changes to the Young's modulus, the thermal expansion coefficients, the yield point and the
pressures permitted for the materials. You can either use empirical formulae to calculate these
temperature-dependent values, or specify your own values. Since the empirical formulae for steel
have already been determined, you should check the values for high-temperature changes or, even
better, enter your own values here.
All the criteria for the bolted joint are checked in the assembled state, and also in a stationary or non-
stationary state at operating temperature (according to VDI 2230: pretension force, bolt load, fatigue
life, and surface pressure).
KISSsoft automatically performs the calculation for assembly and the operating temperature at the
same time. This calculation should also be performed for a higher temperature difference between
the bolt and the parts. The minimum temperature difference between the parts or the bolt and the
assembly temperature must be at least 30° C, so that results are displayed in the report.
44.4.1 Technical Explanations
The critical influences of temperature on the operating properties of bolts are:
▪ Change in pretension force due to thermal expansion
▪ Change in pretension force due to relaxation (at high temperatures)
▪ Brittleness (at high and low temperatures)
The lack of sufficient general data for the materials for bolts and clamped parts means the number of
calculation options is also limited. The change in pretension force due to thermal expansion can be
calculated very accurately because, as a first approximation, changes to the thermal expansion value
can be viewed as linear, in line with the temperature, at least for the temperature range -100 to
+500°C. The other effects (relaxation and brittleness) can be minimized by selecting appropriate
materials and taking precautionary measures (see the relevant literature).
The calculation of the change in pretension force due to thermal expansion is performed with
temperature-dependent thermal expansion value and Young's modulus, as specified by H. Wiegand
in Schraubenverbindungen, 4th Edition 1988, section 7.1.3.1. All other calculations are based on the
equations in VDI 2230 with the appropriate values at operating temperature.
KISSsoft suggests sensible values for much of the data you can input (Young's modulus, thermal
expansion value, yield point at operating temperature), which are based on current technical
literature. This consists of DIN standards or technical documentation from the company Bosshard, in
Zug, Switzerland. These suggestions are based on the Young's modulus for ambient temperature
and, of course, also on the operating temperature. When calculating the suggestion for the
permissible pressure at operating temperature, the proportional change to the yield point was
assumed. The suggestions are average values for "commonly used steels". They do not refer to one
specific material and must therefore be checked carefully in critical situations because the influence
V Bolts 785
of temperature also varies according to the type of material involved. If you want to calculate material
data automatically, using empirical formulae, simply click on the Calculation > Settings.
44.4.2 Coefficients of friction
In KISSsoft, you can specify an interval for coefficients of friction. The minimum value is used for
calculation with FM and FMmax and the maximum value is used for calculation with FMmin and FM/αA.
The scattering of the coefficient of friction value therefore affects the scatter of the tightening torques.
Figure 44.10: Coefficients of friction in the thread.
V Bolts 786
Figure 44.11: Coefficients of friction in the head bearing area and nut bearing area.
You can also use the sizing according to friction classes A to E as specified in VDI 2230 Sheet 1,
Annex to Table A5 to define the values for the coefficients of friction. The minimum and maximum
coefficients of friction for the thread, the head bearing area and the nut support are then imported
into KISSsoft.
44.4.3 Rotation-angle controlled tightening
For angle of rotation-controlled tightening, the report displays a preload torque and an angle of
rotation split into a number of steps. Here you can enter the value for this preload torque and the
number of steps. The angle of rotation is then calculated with the medium assembly pretension force
(FM + FM/αA)/2. If the yield point utilization is 100%, this force is applied up to the yield point. To
calculate the tightening angle of rotation you can also enter the required plastic strain of the weakest
cross section.
V Bolts 787
44.5 Stripping strength
Select Length of engagement to calculate the length of engagement and check the stripping
strength of the thread according to VDI 2230, section 5.5.5.
Click the Define… button to define the length of engagement data. Use the Sizing buttons to set the
individual defaults which were calculated from the entries in the main screen.
The length of engagement meffmin is calculated from the (theoretical) tensile strength Rm of the bolt
material, the length of engagement meffmax is calculated for the bolt and internal thread (with
Rmmax, dmin or d2min and D2max or D1max according to VDI 2230 Sheet 1, Equation 210/213).
The more critical case is then displayed in the results.
The default value for the Rmmax/Rm coefficient is 1.2. This is also given as a value based on
practical experience in VDI 2230.
To change the Rmmax/Rm coefficient, select Calculation > Settings to display the Settings tab.
To calculate the worst case (VDI 2230, formula 210), you must also take the thread tolerance into
account. To define this influence, the minimum external diameter of the bolt dmin, the maximum flank
diameter of the internal thread D2max, the minimum flank diameter of the bolt thread d2min and the
maximum core diameter of the internal thread D1max can be entered in this window.
The main report lists the stresses, the minimum length of engagement, and the safety against
shearing under load, with the maximum pretension force for the connection.
44.6 Settings
Select Calculations > Settings to enter additional values:
▪ Don't abort calculation when error messages (permissible pressure, permissible pretension
force) occur.
If error messages about exceeding the yield point or the permitted pressure are displayed, the
program continues the calculation if this option is selected.
▪ Calculate minimum preload force FM/αA achieved
If this option is selected, the load case FM/αA is also calculated. The pretension force FM/αA is the
minimum pretension force that must be achieved. αA is the tightening factor. It describes the
pretension force scatter. If this option is selected, the results for this pretension force are
displayed in the report.
▪ Do not increase required clamp load for eccentric clamping
KISSsoft increases the required clamp load to prevent gaping for eccentric clamping. You can
V Bolts 788
switch off this function here. You can then specify your own required clamp load. Take care
when using this option. The calculation assumes that gaping does not occur!
▪ Use the resiliences of a through-bolt joint for a tapped thread joint
If the interface area of the clamped part is relatively small compared to the bolt head bearing
area, the tapped thread joint can be treated like a through-bolt joint when calculating the
resiliences.
▪ Operating force only at operating temperature
Normally, KISSsoft calculates the minimum pretension force based on the required clamp load
and loading at ambient and operating temperatures. This option can be selected if the operating
force only occurs at operating temperature. In this case, the minimum pretension force is then
only calculated at operating temperature.
▪ Calculate temperature dependent material data automatically with estimation formulae
KISSsoft can automatically calculate material data at operating temperature by using empirical
formulae. These empirical formulae do not take into account the material data you entered: they
use an average dependency for "commonly used steels"! If this option is not selected, you can
enter the material data at operating temperature manually.
▪ Determine specific thermal expansion of washers
This displays the input field for thermal expansion values in the sub-window for washers. If this
option is not selected, the difference in pretension force is calculated using the average thermal
expansion of the plates. In other words, the washer has the same thermal expansion as the
plates. This is why you have the option of inputting this value. If you do so, the difference in
pretension force is calculated using the value you specified, but the resilience of the plates is still
used in this calculation. VDI 2230 does not specify that a special thermal expansion calculation
is to be used for washers.
▪ Calculate mounting and operating stress without torsion
You can select this option if the connection is tightened using a process in which torsional
stresses do not occur in the bolt. As a result, only the tensile stress in the bolt is taken into
account for calculating the required safety against yield.
▪ Reduction coefficient
The reduction coefficient is used to calculate equivalent stress when the machinery is in its
working state. In many cases, the torsional stresses in elastically preloaded connections reduce
by 50%. For this reason, VDI 2230 recommends the value 0.5 is used here.
▪ Exceeding the yield point
Three selection options are available here: yield point cannot be exceeded, yield point can only
be exceeded during operation, or yield point can be exceeded during operation and mounting.
This enables you to select your preferred calculation variant.
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▪ Hardening coefficient
An additional hardening factor, kv, is used when calculating whether the yield point has been
exceeded during mounting and during operation. The default value for the hardening coefficient
is 1.15. VDI specifies that it should between 1.1 and 1.2.
▪ Additional torsional moment during operation
An additional torsional moment can be defined when calculating working stress. This torsional
moment is then used in the shearing load calculation. This applies both if the yield point cannot
be exceeded and in cases in which the yield point can be exceeded.
▪ Additional torsional moment during operation
An additional torsional moment can be defined when calculating working stress. This torsional
moment is then used in the shearing force calculation. This applies in cases where the yield
point is exceeded.
▪ Infinite life strength
Selection list used select the type of bolt for which the infinite life strength calculation is to be
performed. In the case of high-strength friction-grip fasteners, the sustainable fatigue life is
reduced by 10% because of special geometrical features. In the case of hot-galvanized high-
strength friction-grip fasteners, the sustainable fatigue life is reduced by 30%. (Comment in VDI
2230, chapter on alternating stress)
▪ Tensile strength of bolt coefficient
This coefficient is used to calculate the minimum length of engagement required to achieve a
practical value for Rm, as in VDI 2230 (see chapter 44.5, Stripping strength).
V Welded Joints 790
45 Welded Joints
Underlying principles of calculation: DIN 18800, Part 1, Edition November 1990, in particular section
8.4 "Connections with arc welding"
45.1 Welded joints
You can apply the calculation method defined in DIN 18800 to these welded seam types:
Butt seam through welded
Double HV welded seam counter welded
HV welded seam, root through welded
HV welded seam, cap position counter welded
HY-seam with fillet weld, not through welded
HY-seam, not through welded
Double-HY-seam with fillet weld, not through Double-HY-seam, not through welded
welded
V Welded Joints 791
Double I-seam, not through welded
Fillet weld, not through welded
Double-fillet weld, not through welded
45.2 Seam length
Table 20 in DIN 18800 shows various configurations that use welded seam length l.
45.3 Welded seam equivalent stress
Use the following formula to calculate the equivalent stress for butt and filled welded seams:
(43.1)
σW,V: equivalent stress [N/mm2]
σr: normal stress (vertical to the welded seam) [N/mm2]
τr: shear stress (vertical to the welded seam) [N/mm2]
τp: shear stress (parallel to the welded seam) [N/mm2]
45.4 Weld seam boundary stress
The weld seam boundary stress σW,R,d is calculated with:
V Welded Joints 792
(43.2)
σW,R,d: weld seam boundary stress [N/mm2]
αW: boundary safety coefficient [-]
Rp: yield point [N/mm2]
γM: Part safety coefficient [-]
45.5 Part safety coefficient
The part safety coefficient yM is usually 1.1, in accordance with section 7.3 in DIN 18800. However,
you can also use the value 1.0 to prove the suitability for use or reduced stiffness.
45.6 Boundary safety coefficient
The boundary safety coefficient αWis defined according to table 21 in the standard:
Weld Seam quality Stress type St37-2 and St52-3 and
seam similar similar
type
1-4 All seam qualities Compression 1.0 1.0
Proven seam quality Tension 1.0 1.0
Unproven seam quality Tension 0.95 0.85
5 - 15 All seam qualities Compression, 0.95 0.85
tension
1 - 15 All seam qualities Shear 0.95 0.85
45.7 Materials
The selection list contains materials from standard DIN 18800.
If you have selected Own Input, a new dialog is displayed here. This shows the material data that
will be used in the calculation: you can specify it to suit your own purposes. You can also define your
own materials directly in the database (see chapter 9, Database Tool and External Tables), so that
these can also be used in subsequent calculations.
V Glued and Soldered Joints 793
46 Glued and Soldered Joints
Calculation basis: [6]. The calculation is performed for glued and soldered joints that are subject to
shear or torque.
Two different load cases are treated:
▪ Shearing force: Transmission of shearing force between two surfaces.
▪ Torque: Shaft-hub connection subjected to torque.
The joint can be either subject to static or dynamic (usually pulsating) load.
The guideline values for the static strength of soldered joints are taken from [6], Table 8/8 (average
values of resistance to fracture due to shearing). The guideline values for glued joints are taken from
Table 8/9. For pulsating load on soldered joints, 50% of the static strength is assumed as the
permitted limit (data not available: you must check these connections to ascertain the endurance limit
of the base material. This may reduce the element safety of the soldered joint by approximately
80%). For glued joints, 30% of the static strength is permitted (as defined in Table 8/9).
At present, the following materials can be used for glued joints:
▪ cured at ambient temperature.
▪ cured at increased temperature.
To calculate the shearing strength value, the program uses the mean value of the minimum and
maximum value from the database. The value achieved by optimum implementation as defined in
Niemann is not used.
At present, the following materials can be used for soldered joints:
▪ soft solder LSn40, LSn60 for short-term loads
▪ soft solder LSn40 at continuous load
▪ Brass solder: Steel NE heavy metals
▪ New silver solder-copper: Steel
▪ Silver solder: Steel NE heavy metals
There is no point in calculating and sizing soldered joints with light Al-based metals, because the
strength of the underlying material is usually less than that of the connection. To calculate the
shearing strength value, the program uses the mean value of the minimum and maximum value from
the database.
V Glued and Soldered Joints 794
46.1 Basic materials
These materials are only used to size the width, on the basis of the strength of the base material.
At present, you can select these materials:
Ck 45 N, Ck 60, CrNiMo, CrNi 4, CrNiMo, CrMo, St 37.3, St 52.3, St 60.2, Ganevasit, PA 12, PA 66,
POM, laminated wood.
You must then still decide which material will be the best for your connection. For example, you
should not select PA 12 if you are using a soldered joint.
46.2 Module specific settings
In this window, you can view the required safety value and the shearing strength to be used in the
sizing. You can adjust this value as required.
46.3 Sizings
▪ Sizing the width on the basis of the base material
Sizing the adhesion width (for shaft-hubs), or the adhesion length (for brackets), on the basis of
the strength of the base material. The connection tear resistance is sized so that it equals the
tear resistance of the underlying material or the fatigue strength of the shaft under pulsating
stress.
▪ Sizing the width on the basis of load
Sizing the adhesion width on the basis of stress. The connection tear resistance is sized so that
it can withstand the forces it is subjected to without compromising the required safety.
V Snap Rings 795
47 Snap Rings
This module is used to perform calculations for shaft or hub snap rings. The calculations are
performed according to the manual published by the company Seeger.
47.1 Basic data
Input the following data in the Basic data tab:
▪ "Geometry" group
▪ Shaft/bore ring: specifies whether the calculation is to be performed for a shaft or for a bore
ring
▪ Retaining ring/circlip: specifies whether the calculation is to be performed for a retaining
ring or a circlip
▪ d1: nominal length, the shaft diameter for a shaft ring, or the bore diameter for a bore ring
▪ d2: groove diameter
▪ d3: inside diameter of the snap ring for shafts or external diameter of the snap ring for bores
in the unstressed state
▪ b: the maximum radial width of the snap ring
▪ Dimension l: (see Figure 47.1)
▪ s: the thickness of the ring
▪ ψ: permissible dishing angle of the snap ring (see Figure 47.2)
▪ g: angled or corner distance/radius
Figure 47.1: Geometry of shaft ring (a) and bore ring (b)
V Snap Rings 796
Figure 47.2: Definition of geometry terms s, ψ, g.
▪ "Operating data" group
▪ q: the load factor, taking into consideration the effect of the shoulder length ratio
▪ μ: the coefficient of friction between the ring surface and the shaft/bore surface
▪ "Materials" group
▪ In this group you can define the material of the ring and shaft/bore. The functionality is
similar to the rest of the KISSsoft modules in the "Connections" module group.
47.2 Automatic calculation of load factor q
Click on the button next to q to display a window in which you can calculate q, based on the ratio
of the shoulder length n to the groove depth t. The groove depth is defined as:
▪ t = (d1 - d2)/2 for shaft rings
▪ t = (d2 - d1)/2 for bore rings
V Snap Rings 797
Figure 47.3: (a) Definition of load factor q, shoulder length n and groove depth t.
47.3 Automatic calculation of the dishing angle ψ
The figure below (see Figure 47.4) is used to automatically calculate ψ.
Figure 47.4: Calculation of ψ, based on d1.
47.4 Module specific settings
Click on Module specific settings to enter the minimum required safety value S directly.
V Hirth coupling 798
48 Hirth coupling
This module performs calculations for Hirth couplings. The calculations are derived and extended
from the manual issued by Voith. To start the calculation module, double-click on the "Hirth" module
in "Shaft-hub connections" in the module tree.
48.1 Basic data
Enter these values in the "Basic data" tab:
▪ In Geometry
Voith profile selection: Specify a Voith profile or select Own Input to enter your own profile.
▪ The Own input section only appears if you selected Own input for entering the profile
z: number of teeth
β: tooth profile
D: external ring diameter
d: internal ring diameter
r: root radius
s: tip clearance
n: number of fixing holes in serration surface
dL: average bore diameter
▪ "Materials"
Work piece 1: Hirth Material 1
ηz,1:load-bearing percentage, Hirth 1. Voith recommends 0.65 if milled and 0.75 if ground.
Work piece 2: Hirth Material 2
ηz,2:load-bearing percentage, Hirth 2. Voith recommends 0.65 if milled and 0.75 if ground.
▪ "Operating data"
T: torque
v: pretension force safety factor. Factor for adjusting the required pretension force. Voith
recommends 1.8 to 3.0.
48.2 Module specific settings
The required safety factor SFmin is defined here.
V Answers to Frequently Asked Questions 799
49 Answers to Frequently Asked Questions
49.1 Adding new bolt types to the database
The KISSsoft database includes the following bolt types:
▪ hexagon socket head cap screw EN ISO 4762
▪ hexagon headed screw with shank (AB) EN ISO 4014
▪ hexagon headed screw without shank (AB) EN ISO 4017
▪ slotted cheese head bolts EN ISO 1207
▪ hexagon headed screw with shank, metric fine thread (AB) EN ISO 8765
▪ hexagon headed screw without shank, metric fine thread (AB) EN ISO 8676
▪ hexagon headed screws with flange, light series, shape F EN 1662
▪ hexagon headed screws with flange, light series, shape U EN 1662
▪ hexagon headed screws with flange, heavy series, shape F EN 1665
▪ hexagon headed screws with flange, heavy series, shape U EN 1665
▪ Own definition of bolt geometry
For each of these bolt types, a number of tables list the various bolts sizes (= bolts series). You will
find the name of the file that contains the bolts series data in the database (see chapter 9, Database
Tool and External Tables).
You enter a new size within an existing bolt type i.e. extend the bolt series (see chapter 49.1.1,
Extending an existing bolt series) or input a new bolt type (see chapter 49.1.2, Creating a new bolt
type).
49.1.1 Extending an existing bolt series
Example: Enter the data for an M8 bolt with a length of 100 mm in the "hexagon socket head cap
bolts EN ISO 4762" series.
Then start the database tool. Display the Screw Type M000 M040Typ table. Select the Hexagon
cap screw EN ISO 4762 dataset in that table. In the File name field, you will see the name of the
file which includes the bolt series data table. Click the Edit button at the end of the input line to open
the file in the editor:
To enter a new bolt:
▪ Look for a similar bolt (M8, length 80mm).
V Answers to Frequently Asked Questions 800
▪ Copy this line. Keep the lines in the same sequence.
▪ Change the data according to Table 1 in EN ISO 4762 (length 100 instead of 80, length l1 72
instead of 52).
▪ Save the file in the "KISSsoft 20xx/ext/dat" installation directory.
▪ Document any changes for other users.
49.1.2 Creating a new bolt type
You must already be familiar with the table structure before you can add a new bolt type. You must
know which value goes in which column (use the variable names from the descriptions in the table
header).
Then, proceed as follows:
▪ In the database, open the dataset that is most similar to the new bolt type.
▪ Copy this dataset by clicking on the (+) button under the name of the new bolt type.
▪ Then, click the Edit button to open the new dataset.
▪ Click the Edit button at the end of the file name input line. This opens a file which still contains
the "old" values.
▪ Overwrite these values with the new values. Note the variables structure (i.e. a specific variable
is assigned to a number, depending on where the number appears) and the sequence of the
lines.
▪ Save the updated file in the "KISSsoft 20xx/ext/dat" directory, with a new name, and close the
Editor.
▪ Add the new file name to the new dataset in the database.
▪ Then, save the new dataset.
VI
Springs
Chapter 50 - 54
VI Compression Springs 802
50 Compression Springs
Compression springs include cylindrical compression springs and conical compression springs. In
both cases, wire is wound or coiled to create a spring. The calculation of compression springs is
based on DIN EN 13906-1 (2013) [77]. Conical compression springs are calculated as described in
the "Metallfedern" literature [78]. Calculations for individual forces, travel and number of coils are
described there. Relaxation is calculated according to DIN EN 13906-1, as are the values for
tolerances and materials. The conical compression springs that can be calculated with KISSsoft have
a constant wire diameter.
Operating data
When you specify a load, you can use your own value as the spring force or travel. You can also
specify whether the spring is to be subject to static, quasi-static or dynamic force.
Geometry
Special features for conical compression springs:
You can select the geometry data according to DIN 2098 Part 1 directly from this table.
If you select Own Input, you can either take selected values from the list or enter your own values.
You can also input the spring length and the spring diameter directly in the main screen.
Instead of the spring length in its non-stressed state, L0, you can also specify a spring length in its
stressed state L1 or L2.
The selection you make for End of spring and Manufacturing affects the calculation of block length
Lc.
Click the Update button to calculate the block lengths and the resulting values for the current
situation, for individual springs, and display them in a table.
Special points to note for conical compression springs:
Both the smaller and larger cone diameter can be defined. The spring lengths can be entered in
either their stressed or non-stressed state.
If the spring ends have been ground even, the block length is calculated as specified in the literature.
Otherwise, it is assumed that the block length is Lc=nt·dmax.
50.1 Strength values
The material strengths are stored in different files, depending on diameter. The transverse strength is
either saved in the tables, as in DIN EN 13906-1 for thermo-formed springs, or calculated from the
predefined tensile strength as tczul = 0.56·Rm .
VI Compression Springs 803
To calculate the endurance limit, use either the Goodman diagram as defined in DIN EN 13906-1 or
an approximation. The approximation assumes a dynamic strength of 0.25·Rm and a pitch of 0.75 for
the graph of the upper stress in the Goodman diagram. For shot peened materials, the dynamic
strength is increased by 20%. These values roughly correspond to the diagrams in the DIN EN
13906-1 standard, but you should regard the safeties more conservatively.
50.2 Shear stress values
The calculation of the highest shear stress also calculates the axial and shear spring travel.
In the case of conical compression springs, this calculation does not include shear spring travel. Only
the proportion of the axial spring travel with the particular diameter is determined.
(47.1)
τmax: highest shear stress [N/mm2]
d: wire diameter [mm]
F: spring force [N]
D: coil diameter [mm]
sQ: shear spring travel [mm]
FQ: shear spring force [N]
L: spring length [mm]
The highest corrected shear stress is calculated by:
(47.2)
τkmax: highest corrected shear stress [N/mm2]
τmax: highest shear stress [N/mm2]
k: stress correction factor
50.3 Bearings coefficient
This coefficient is used for cylindrical compression springs.
The value of the support coefficient ν varies according to the support you select, as shown in Figure
(see Figure 50.1).
VI Compression Springs 804
Figure 50.1: Supports with associated support coefficients for axially stressed compression springs
The support coefficient v is used for calculating the buckling spring travel s k. If the buckling safety
factor is not reached then the spring must be guided, otherwise it will buckle.
50.4 Materials
The selection list includes materials from the DIN EN 10089, DIN 17223-1 (withdrawn), DIN EN
10270-1, DIN EN 10270-1 and DIN 10270-3 standards.
Click on the button next to the selection list to display the material values in greater detail in a
table. If you selected Own Input, the system displays a new dialog here. In it, you can define the
material data used in the calculation to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
50.5 Tolerances
When you select a spring from the table (according to DIN 2098 Part 1), the diameter's tolerance
specified in DIN 2076 C is used. To change the diameter tolerance, click on Own Input to display the
input fields, which you can then use. Click the button next to the wire diameter field to open
another window.
In the Tolerances window, you can select wire diameters according to DIN 2076 (1984, withdrawn),
DIN 2077 (1979, withdrawn), DIN EN 10270-1 (2012), DIN EN 10270-2 (2012), DIN EN 10270-3
(2012), DIN EN 10218 (2012) or select Own Input to enter your own value.
If you select a wire diameter tolerance according to the standard, the tolerance will be inserted
directly. If you select Own Input, you can set the value yourself.
VI Compression Springs 805
Other tolerances are listed in accordance with the quality standard. In the Geometry Tolerances
and Force Tolerances list in the basic data, you can choose one of the quality standards according
to DIN EN 15800 (2009) [79] or DIN 2096 Part 1 (1981) [80]. In the case of conical compression
springs, the average diameter is used to define the coil ratio (w=Dm/d).
50.6 Relaxation
The existing spring force can be located after a specific period of time by calculating the relaxation.
The compression spring settles to a particular value. Relaxation is also known as creep. The
relaxation values are listed in the DIN EN 13906-1 standard, and shown in diagrams. The diagrams
show curves at specific diameters and temperatures, which are then recorded in a relaxation-stress
diagram. By entering the data from 2 different wire diameters temperatures, you can then infer or
extrapolate the relaxation value for a specified level of stress at operating temperature and for a
specific wire diameter.
In KISSsoft, the relaxation diagram for 48h can be displayed in relation to diameter, temperature and
stress. Other graphics that show the progress of relaxation over time and the spring force are also
available. The results for the specified conditions are then displayed in the relaxation report for 48 h.
The value of the spring force after 48 h is also calculated.
To extend the data for the materials relaxation curves, or add new data, add this new information to
the .dat file for the appropriate spring material.
The relaxation curves in this file can be defined with 2 or 3 predefined measurement points. The
curves are then calculated from these points.
50.7 Drawing data
To access the spring data required to create a drawing, click Drawing data. Use the
F10SPRING?.RPT file (for compression springs), or F20SPRING?.RPT file (for tension springs), etc.
(? = d/e/a/f/i/s/r/p/c for the required language) to modify the template to your own requirements.
50.8 Sizing
If you are working with cylindrical compression springs, and select Own Input in the list under
standard, you now see input fields here instead of a table showing the values defined in the
standard.
In addition to calculating the wire diameter and the effective coils for cylindrical and conical
compression springs, you can click the button to perform another sizing calculation.
VI Compression Springs 806
Using the predefined spring rate R = ΔF/Δs, the number of turns n can also be calculated if the wire
diameter has been predefined. The number of turns is defined by this value, but the strength and the
geometric boundary conditions are not checked. The program also suggests a value for the minimum
wire diameter and the associated number of turns. The minimum wire diameter here is defined by the
material's strength.
VI Tension springs 807
51 Tension springs
The tension spring calculation is described in the DIN EN 13906-2 (2013) [81] standard.
Operating data
When you specify a load, you can use your own value as the spring force or travel.
The Initial tension F0 is the force required to open the coils which lie one on top of the other. This
force is only present if the spring is pretensioned.
If Inner preload is not selected, you can influence the number of effective coils.
You can also specify whether the spring is to be subject to static, quasi-static or dynamic stress.
Geometry
You can also input the spring length and the spring diameter directly in the main screen.
Instead of the spring length in its non-stressed state, L0, you can also specify a spring length in its
stressed state L1 or L2.
For the wire diameter, you can either select the diameter values as defined in DIN 2098 Supplement
1 from the list or enter your own value directly in the list.
Figure 51.1: Definitions used for tension springs
51.1 Strength values
The Admissible shear stress is calculated from the tensile strength of cold formed tension springs.
The tensile strength values depend on the diameter and are stored in files. The shear stress is
calculated using the formula τzul = 0.45·Rm. Thermo-formed tension springs should not exceed the
VI Tension springs 808
permissible shear stress of τzul = 600N/mm2. These values apply to static or quasistatic cases.
Tension springs as defined in DIN 2097 should not be subjected to dynamic stress if at all possible.
Shear stress is distributed very unevenly over the cross section of the wire or pin of a tension spring.
You can use a stress coefficient k to approximate the highest arithmetical stress. Additional stresses
are present at the transitions to the eyes when they are placed under load. They can be well above
the permissible shear stresses. As they may be well above the permissible shear stress, no generally
applicable fatigue strength values can be given.
51.2 Shear stress values
The shear stress τ is calculated for the sizing of springs that are subject to static and quasistatic
stress:
(48.1)
τ: Shear stress [N/mm2]
D: medium coil diameter [mm]
F: spring force [N]
d: wire diameter [mm]
Calculating shear stress for springs subjected to dynamic stress:
(48.2)
τk: corrected shear stress [N/mm2]
τ: shear stress [N/mm2]
k: Stress correction factor
51.3 Manufacturing type
Thermo-formed tension springs cannot be produced with "initial tension" because the heat treatment
creates an air gap between the coils. Cold-shaped tension springs can be manufactured in two ways,
either by winding on a coiling bench or by winding on a spring winding machine. As defined in DIN
EN 13906-2, a formula is specified for each manufacturing method which gives the permissible inner
shear stress τ0.
VI Tension springs 809
51.4 Eyes screen
Using the definitions for the Length of eye LH in this screen, you can determine the total length of the
spring. In contrast, the Hook opening m is a reported value that is not used in this calculation.
DIN 2097 defines 13 different eye shapes for tension springs. The program suggests different eye
lengths depending on the shape of the eye. The position of the two eye openings is also handled
separately in this DIN standard.
1/2 German loop 1/1 German loop
2/1 German loop 1/1 German loop at side
2/1 German loop at side Hook
Extended side hook English loop
VI Tension springs 810
Coiled-in hook Screwed plug
Screwed-in screw cap
Screwed-in shackle
1/1 German loop inclined
51.5 Materials
The selection list includes materials from the DIN EN 10089, DIN 17223-1 (withdrawn), DIN EN
10270-1, DIN EN 10270-1 and DIN 10270-3 standards.
Click on the button next to the selection list to display the material values in greater detail in a
table. If you selected Own Input, the system displays a new dialog here. In it, you can define the
material data used in the calculation to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
VI Tension springs 811
51.6 Settings
Figure 51.2: Settings: tension springs
If Calculate spring length based on the coils is selected, and the spring is prestressed (Initial
tension is selected), the length of the spring is calculated from the number of coils. You can no
longer input the lengths in the dialog.
51.7 Tolerances
In the Tolerances window, you can select wire diameters according to DIN 2076 (1984, withdrawn),
DIN 2077 (1979, withdrawn), DIN EN 10270-1 (2012), DIN EN 10270-2 (2012), DIN EN 10270-3
(2012), DIN EN 10218 (2012) or select Own Input to enter your own value.
If you select a wire diameter tolerance according to the standard, the tolerance will be inserted
directly. If you select Own Input, you can define the value yourself.
Other tolerances are listed in accordance with the quality standard. In the Tolerances list in the basic
data, you can choose one of the quality standards according to DIN 2097 [82] or DIN 2096 Part 1
(1981) [80].
51.8 Relaxation
The existing spring force can be located after a specific period of time by calculating the relaxation.
The compression spring settles to a particular value. Relaxation is also known as creep. The
relaxation values are listed in the DIN EN 13906-1 standard (Compression Springs), and shown in
diagrams. It is assumed that the same relaxation values can be used for both tension springs and
compression springs. The diagrams show curves at specific diameters and temperatures, which are
then recorded in a relaxation-stress diagram. By entering the data from 2 different wire diameters
temperatures, you can then infer or extrapolate the relaxation value for a specified level of stress at
operating temperature and for a specific wire diameter.
In KISSsoft, the relaxation diagram for 48h can be displayed in relation to diameter, temperature and
stress. Other graphics that show the progress of relaxation over time and the spring force are also
available. The results for the specified conditions are then displayed in the relaxation report for 48 h.
The value of the spring force after 48 h is also calculated.
VI Tension springs 812
To extend the data for the materials relaxation curves, or add new data, add this new information to
the .dat file for the appropriate spring material.
The relaxation curves in this file can be defined with 2 or 3 predefined measurement points. The
curves are then calculated from these points.
51.9 Drawing data
To access the spring data required to create a drawing, click Drawing data. Use the
F10SPRING?.RPT file (for compression springs), or the F20SPRING?.RPT file (for tension springs),
etc. (? = d/e/a/f/i/s/r/p/c for the required language) to modify the template to your own requirements.
51.10 Sizing
Click the button to calculate the number of turns n, the Wire diameter and the Effective coils for
a predefined wire diameter, using the spring rate r = ΔF/Δs. The program also suggests a value for
the minimum wire diameter and the associated number of turns. The minimum wire diameter here is
defined by the material's strength.
VI Leg Springs 813
52 Leg Springs
The calculation used for leg springs is defined in DIN EN 13906-3 (2014) [83].
Operating data
When you define a load you can either enter a value for the spring force, spring angle, or spring
torque. To do this, you must first specify the torsion arm (R1,R2) on which the force is applied to the
spring.
The value α0 is used to identify the starting angle. This is used together with the direction of load
(sense of winding) to calculate the maximum angle of the spring. Depending on which value you
select in the Guiding of spring list, the report will also include a reference value for the diameter of
the working mandrel or working sleeve. You can also specify whether the spring is to be subject to
static, quasi-static or dynamic force.
Geometry
You can select the geometry data according to DIN 2098 Part 1 directly from this table. If you select
Own Input, you can either take selected values from the list or enter your own values. You can
select and enter the spring diameter directly. The winding clearance is the distance between the
coils.
Figure 52.1: Definitions used for leg springs
VI Leg Springs 814
52.1 Strength values
The admissible bending stress for cold formed leg springs is calculated from the tensile strength. The
tensile strength values depend on the diameter and are stored in files. The bending stress is
calculated using the formula σzul = 0.7·Rm. These values apply to static or quasistatic cases. The
bending of the wire or pin axle due to the load causes the bending stresses to be distributed
asymmetrically. To approximate the arithmetical stress (dynamic case), you can use the stress
coefficient q in the calculation.
52.2 Bending stress values
The bending stress σ is calculated for the sizing of springs that are subject to static and quasistatic
stress:
(49.1)
σ: shear stress [N/mm2]
T: spring torque [Nm]
d: wire diameter [mm]
Calculating the bending shear stress for springs subject to dynamic stress:
(49.2)
σq: corrected bending shear stress [N/mm2]
σ: bending shear stress [N/mm2]
q: stress correction factor
(dependent on the ratio D/d)
52.3 Spring design
To prevent friction, the coils should either not touch each other or be under only slight stress. The
following applies, for the greatest achievable winding clearance:
VI Leg Springs 815
Generally, leg springs are wound. There are two options for the leg design: they can be either bent
with offset (the radius must be specified) or tangential.
with tangential legs with offset legs
52.4 Assumptions made for the calculation
The calculations apply only to leg springs with fixed or circular guided spring ends. If the leg is not
fixed, the spring must be guided by means of a pin or sleeve.
52.5 Materials
The selection list includes materials from the DIN EN 10089, DIN 17223-1 (withdrawn), DIN EN
10270-1, DIN EN 10270-1 and DIN 10270-3 standards.
Click on the button next to the selection list to display the material values in greater detail in a
table. If you selected Own Input, the system displays a new dialog here. In it, you can define the
material data used in the calculation to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
52.6 Tolerances
In the Tolerances window, you can select wire diameters according to DIN 2076 (1984, withdrawn),
DIN 2077 (1979, withdrawn), DIN EN 10270-1 (2012), DIN EN 10270-2 (2012), DIN EN 10270-3
VI Leg Springs 816
(2012), DIN EN 10218 (2012) or select Own Input to enter your own value.
If you select a wire diameter tolerance according to the standard, the tolerance will be inserted
directly. If you select Own Input, you can define the value yourself.
In the Tolerances list in the basic data, you can choose one of the quality standards according to
DIN 2194 (2002) [84].
52.7 Drawing data
To access the spring data required to create a drawing, click Drawing data. Use the
F10SPRING?.RPT file (for compression springs), or F20SPRING?.RPT file (for tension springs), etc.
(? = d/e/a/f/i/s/r/p/c for the required language) to modify the template to your own requirements.
52.8 Sizing
Click the button to calculate the number of turns n, the Wire diameter and the Effective coils for
a predefined wire diameter, using the spring momentum rate RMR = ΔM/Δα. The program also
suggests a value for the minimum wire diameter and the associated number of turns. The minimum
wire diameter here is defined by the material's strength.
VI Disc Springs 817
53 Disc Springs
The calculation for disc springs is described in DIN EN 16984 (2017) [85]. The mass and quality
requirements are handled according to DIN EN 16983 (2017) [86].
Operating data
When you specify a load, you can use your own value as the spring force or travel. You can also
specify whether the spring is to be subject to static, quasi-static or dynamic stress.
The calculations specified in DIN EN 16984 are for disc springs with or without bearing areas for the
ratios 16 < De/t < 40 and 1.8 < De/di <2.5 and materials specified in DIN EN 16983.
Geometry
As specified in DIN EN 16983, disc springs are divided into 3 groups and 3 sequences. Groups 1 and
2 contain the springs without a bearing area, whereas group 3 has the springs with a bearing area.
The disc thickness for group 1 is less than 1.25 mm, in group 2 it is between 1.25 and 6 mm, and in
group 3 it lies between 6 and 14 mm. These groups differ in the hardness of the springs in them.
Series A includes hard springs, i.e. they can withstand greater forces in a shorter spring travel. This
is followed by series B and series C which can withstand the least force in a larger travel of spring. If
you select Own Input, the input fields for geometry data become active, and you can enter your own
values in them. This type of calculation only applies for springs without a support area, because the
ratio of the thicknesses t'/t is not known, but it is still required for the calculation.
Figure 53.1: Dimensions of the disc springs
53.1 Strength values
In the case of springs that are subject to static or quasi-static load (N <= 104), the maximum force on
the spring is calculated. The formula is predefined in DIN EN 16984. This force then is compared to
the spring's effective force Fn (at s = 0.75·h0) and the spring force utilization is calculated. If the
required force is greater than the spring's effective force, Fn, the deviation in the calculation is too
large. The DIN formula for calculating force only applies where the spring's travel is s = 0.8·h0. The
springs can be used in packages or columns to handle larger forces. The total calculated system
VI Disc Springs 818
force is then displayed in a force travel diagram. The calculation for disc springs is performed without
taking friction into account.
The stresses are also calculated at edge points I through IV. Points I and IV are subjected to
compression, and points II and III are put under tension. Under dynamic load, the stress range is
calculated using the maximum stress (either at point II or III) with the associated lower stress level.
The permissible permanent stress range is defined using a Goodman diagram. These values are
then compared. The result is the number of load cycles that the springs should be able to withstand
under load. DIN EN 16983 includes Goodman diagrams which are only valid for materials specified
in DIN 17221 and 17222. If any other materials are involved, you must contact the spring
manufacturer.
53.2 Stress values
Stresses are calculated for edge points I to IV.
Point I:
(50.1)
Point II:
(50.2)
Point III:
(50.3)
Point IV:
(50.4)
σI - σIV: stress at points I-IV [N/mm2]
E: Young's modulus [N/mm2]
μ: Poisson's ratio [-]
De: External diameter [mm]
s: Spring travel of an individual disc [mm]
t: Thickness of an individual disc [mm]
h0: Travel of spring until flat [mm]
VI Disc Springs 819
δ: Diameter ratio (De/Di)
K1 - K4: Variables calculated from formulae (DIN EN 16984)
53.3 Materials
In the selection list, you can select materials according to the standard.
Click on the button next to the selection list to display the material values in greater detail in a
table. If you selected Own Input, the system displays a new dialog here. In it, you can define the
material data used in the calculation to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
53.4 Layout number
To estimate the number of discs or columns required, click the button next to the fields for
number of springs per package or number of packages per column. You can define the maximum
force and the maximum displacement in this screen. These values are then used to calculate and
display the number of springs per package or the number of packages per column.
53.5 Limit dimensions
For all disc springs, the external diameter De must lie in the h12 tolerance field and the inner
diameter Di must lie in the H12 tolerance field.
VI Torsion-Bar Springs 820
54 Torsion-Bar Springs
The calculation for torsion bar springs is defined in DIN 2091 (1981) [87].
Operating data
When you specify the load, you can enter a value for either an angle of rotation or a torsional
moment.
If a default is set for the torsion bar (Torsional bar preplaced is selected), the permitted shear
stress on the torsion bar, τzul, increases.
Geometry
Enter specific parameters to define the geometry of the spring.
For the toothed head form, you must also specify the number of teeth, although this is purely for
documentation and is not used in the calculation. The standard assumes shearing modulus G as a
constant. However, the calculation is still permitted even if this value is slightly different.
Figure 54.1: Defining a torsion-bar
54.1 Tip forms
Torsion-bar springs as defined in DIN 2091 can have one of three different tip forms: rectangular,
hexagonal and toothed. Toothed torsion-bar tips are usually manufactured according to DIN 5481
Part 1 or SAE J 498 b. However, they can also be manufactured with special toothings. The body
forms of the tips apply only to bars that are loaded in one shaft rotation direction. Alternating loads
require special design measures.
VI Torsion-Bar Springs 821
Figure 54.2: Shapes of torsion-bar tips (rectangular, hexagonal, toothed)
54.2 Strength values
Definitions in DIN 2091:
DIN 2091 only applies for the materials defined in DIN 17221.
The permitted shear stresses:
For non-preloaded bars: τzul = 700 N/mm2
For preloaded bars: τzul = 1020 N/mm2
The heat treatment strength for these values is: Rm = 1600 - 1800 N/mm2
For the shearing modulus, G = 78500 N/mm2 is used as the default. Due to preloading (above the
yield point, deformed in the direction of operation) after the torsion bar springs have been heat
treated, there will be a more favorable distribution of the working stress, and a relief in the boundary
zone will be achieved.
54.3 Shear stress
Calculating shear stress τ:
VI Torsion-Bar Springs 822
(51.1)
τ: shear stress [N/mm2]
T: torsional moment [Nm]
d: wire diameter [mm]
54.4 Limiting values
The following limit ratios for torsion bar tips apply to torsion bar springs: rectangular, toothed: df/d >
1.3; hexagonal df/d > 1.25
The strength values from the DIN standard for bar diameters of 10-60mm apply.
The guide value is a head length between 0.5·and 1.5 d.
The ratio Rh/d should lie between 1 and 50.
54.5 Sizing
Enter the torsional moment and angle of rotation and then click the button to calculate the Wire
diameter, the Shank length and the torsional spring rate, from which you can size the bar diameter
d or the shank length ls. In this case, the permitted shear stress value is firstly used to calculate d
and then the bar diameter is used to calculate the shank length ls. Various values are assumed so
that you can size the dimensions. (rectangular, toothed: df = 1.35·d; hexagonal: df = 1.3·d; da = df +
df/7; Rh = (da-d)·1.2). These values are not transferred to the main screen.
VII
Belts and chain drives
Chapter 55 - 57
VII V-belts 824
55 V-belts
Preamble:
Follow the manufacturer’s instructions when sizing and verifying V-belt drives. Most catalogs detail
the entire calculation method. As the amount of power V-belts can transmit improves because of
better materials and flank shapes, manufacturers' data provides the only really reliable values.
Fully automated calculation of V-belts including standard V-belt lengths and standard effective
diameters. The module determines the transmittable power per belt while taking into account the
speed, effective diameter, transmission ratio and belt length. All the belt data is taken from the tables
in manufacturers' catalogs (for example, ContiTech). The belt initial tension is calculated according to
the information provided in the catalogs and the belt friction equation. The calculation outputs values
for end of rope force in no load/load and the axle load at standstill and in operation. The calculation
also outputs the critical speed and tension distance values. The values calculated for the belt-
bending test are essential results for belt inspections.
As a variant, the calculation can also be performed with a third pulley (tensioning pulley). You define
the X and Y coordinates of the tensioning pulley in the V-belt tab. If you open the Configuration tab,
you can use the mouse to move the tensioning pulley. In this case, the particular x and y value is
displayed in the status row. This pulley can be positioned outside or inside as required.
Figure 55.1: Basic data: V-belt calculation
VII V-belts 825
55.1 V-belts data
KISSsoft stores the tabular values (catalog data) in files which you can then edit. You will find these
file names in the KISSsoft database tool for the relevant belt types (for example, Z090-015.dat for
XPA narrow V-belts).
55.2 V-belt standards
The following belt types are available:
▪ XPA-High-performance V-belts-DIN7753/ISO4184-(CONTI-FO-Z)
▪ XPB High-performance V-belts DIN7753/ISO4184 (CONTI-FO-Z)
▪ XPC-High-performance V-belts-DIN7753/ISO4184-(CONTI-FO-Z)
▪ XPZ-High-performance V-belts-DIN7753/ISO4184-(CONTI-FO-Z)
▪ 5/- -High-performance v-belts-DIN7753/ISO4184-(CONTI-FO-Z)
▪ 6/Y-High-performance V-belts DIN7753/ISO4184 (CONTI-FO-Z)
▪ 8/- -High-performance v-belts-DIN7753/ISO4184-(CONTI-FO-Z)
▪ SPZ-Narrow V-belts-DIN7753/ISO4184-(CONTI-V)
▪ SPA-Narrow V-belts-DIN7753/ISO4184-(CONTI-V)
▪ SPB-Narrow V-belts-DIN7753/ISO4184-(CONTI-V)
▪ SPC-Narrow V-belts-DIN7753/ISO4184-(CONTI-V)
▪ 8/- -Multiflex-V-belts-DIN7753/ISO4184-(CONTI-V STANDARD)
▪ 10/Z-Multiflex V-belts-DIN7753/ISO4184-(CONTI-V STANDARD)
▪ 13/A-Multiflex V-belts-DIN7753/ISO4184-(CONTI-V STANDARD)
▪ 17/B-Multiflex V-belts-DIN7753/ISO4184-(CONTI-V STANDARD)
▪ 20/- -Multiflex-V-belts-DIN7753/ISO4184-(CONTI-V STANDARD)
▪ 22/C-Multiflex V-belts-DIN7753/ISO4184-(CONTI-V STANDARD)
▪ 25/- -Multiflex-V-belts-DIN7753/ISO4184-(CONTI-V STANDARD)
▪ 32/D-Multiflex V-belts-DIN7753/ISO4184-(CONTI-V STANDARD)
▪ 40/E Multiflex V-belts DIN7753/ISO4184 (CONTI-V STANDARD)
▪ 3V-9J-Force-belts
▪ 5V-15J-Force-belts
▪ 8V-25J-Force-belts
▪ 3V-9N-Narrow-V-Belts-USA-Standard
▪ 5V-15N-Narrow-V-Belts-USA-Standard
▪ 8V-25N-Narrow-V-Belts-USA-Standard
VII V-belts 826
55.3 Configuring tensioning pulleys
Here, you can select either:
▪ Without tensioning pulley
▪ Tensioning pulley inside
▪ Tensioning pulley outside
If you selected an inside/outside tensioning pulley, you can input the conical spring washer diameter
and the position (x/y) of the tensioning pulley. In the Configuration tab, you can position the
tensioning pulley interactively using the mouse (the x and y values are displayed in the status bar).
55.4 Application factor F1
You can enter this application factor in the basic data screen. If you selected a configuration with a
tensioning pulley, you should increase application factor f1 by 0.1. The table shown below is used to
define the f1 application factor (refer to the catalogs for more information):
Figure 55.2: V-belt application factor
55.5 Center distance
The minimum center distance is calculated from the two belt sheave diameters. You cannot enter a
smaller value here. The sheaves must not touch each other during operation.
The conversion process uses a suggestion for new designs according to the ContiTech catalog.
Here:
0.7*(d1+d2) <= a <= 2.0*(d1+d2)
In KISSsoft, the average coefficient for the suggested value is used in the conversion.
VII V-belts 827
a = 1.35*(d1+d2)
55.6 Belt length
You need to know the belt length before you can calculate a V-belt. If you have not specified a
length, or if you change to a configuration that involves a tensioning pulley, you must recalculate the
belt length.
55.7 Effective number of V-belts
The effective number of V-belts is calculated from the theoretical number by rounding this value up to
the next highest whole number.
55.8 Tensioning pulley diameter
The tensioning pulley diameter should be at least as big as the smallest belt sheave. If at all possible,
you should not use tensioning pulleys, in particular outside tensioning pulleys. However, if you have
to use a tensioning pulley, its diameter should be at least 1.33·d if it is an outside pulley or 1.0·d if it
is an inside pulley (d: diameter of the smaller sheave).
Every manufacturer provides slightly different information about tensioning pulleys.
55.9 Position of tensioning pulley (x/y)
When you configure the tensioning pulley, you can enter the position of the pulley (in X/Y-
coordinates). Here, the axis of the small sheave is the origin of the coordinates system. If you use the
mouse to change the position in the Configuration tab, you can only move the tensioning pulley
within the valid area.
55.10 Inspecting V-belts
(belt bending test)
The actual axial stress of V-belt drives is calculated from data provided by the belt bending test.
Enthusiastic mechanics have a tendency to over-tighten belt drives, and therefore subject them to
loads that are too high for their capabilities.
VII Toothed Belt 828
56 Toothed Belt
Use this method to calculate and size all aspects of toothed belt drives, including the tooth number
and belt length, while taking into account standard numbers of teeth. When you enter the required
nominal ratio and/or the nominal axis distance, the program calculates the best possible positions.
You can also calculate the required belt width, taking into account the correction factors, the
minimum number of teeth, and the number of meshing teeth. You can also print out assembly details
(belt bending test). The data for each type of belt is saved to text files, whose names indicate their
purpose, which can be edited as required.
You can also perform calculations for special stress-resistant toothed belts with integrated steel
ropes (e.g. AT5mm).
As a variant, the calculation can also be performed with a third pulley (tensioning pulley). You define
the X and Y coordinates of the tensioning pulley in the Toothed belt tab. If you open the
Configuration tab, you can use the mouse to move the tensioning pulley. In this case, the particular x
and y value is displayed in the status bar. This pulley can be positioned outside or inside as required.
Figure 56.1: Basic data: Toothed belt calculation
56.1 Technical notes (toothed belts)
Preamble:
Follow the manufacturer’s instructions to achieve the best results when sizing and verifying toothed
belt drives. Most catalogs detail the entire calculation method. As the amount of power V-belts can
VII Toothed Belt 829
transmit improves because of better materials and flank shapes, manufacturers' data provides the
only really reliable values.
Elasticity:
As the manufacturers' catalogs provide very little data on this subject, you must treat the belt
elasticity constraint values with caution. The elasticity (in N) is the force required to lengthen the belt
by 100%.
Weight:
As the details provided in manufacturers catalogs about this subject are not complete, you must treat
these values with caution.
Pretensioning the belt:
As the manufacturers' catalogs provide very little data on this subject, you must treat the constraint
values with caution. The calculation method and the factors it uses are stored in the Z091-0??.dat
files where they can be changed if required.
You can use one of the following procedures to calculate the required pretensioning values for
various types of belts. The data here is taken from the catalogs):
Belt type: Pretension:
Breco AT5, AT10, AT20 0.5 * Circumferential force
Synchroflex AT3, AT3 GIII, AT5 GIII, AT10 GIII 0.5 * Circumferential force
Isoran XL, L, H, 8, 14 0.625 * Circumferential force
HTD 3, 5, 8, 14 0.25 * max. permitted circumferential force
8MGT, 14MGT Poly Chain GT2 0.5 * Circumferential force
RPP-HPR 8, 14 0.5 * Circumferential force
56.1 table: Pretension
Forces in no load/load are calculated in accordance with [10], equation 27/23.
(53.1)
(53.2)
(53.3)
VII Toothed Belt 830
56.2 Toothed belt standard
You can select one of these standards:
▪ XL-ISORAN RPP (FENNER)
▪ L-ISORAN RPP (FENNER)
▪ H-ISORAN RPP (FENNER)
▪ 8mm ISORAN RPP (FENNER)
▪ 14mm ISORAN RPP (FENNER)
▪ 8mm-ISORAN-RPP-GOLD (Megadyne)
▪ 14mm-ISORAN-RPP-GOLD (Megadyne)
▪ 8mm-ISORAN-RPP-SILVER (Megadyne)
▪ 14mm-ISORAN-RPP-SILVER (Megadyne)
▪ RP8mm-Pirelli RPP-HPR
▪ RP14mm-Pirelli RPP-HPR
▪ PG3mm-Power Grip-HTD
▪ PG5mm-Power Grip-HTD
▪ PG8mm-Power Grip-HTD
▪ PG14mm-Power Grip-HTD
▪ 8mm-DAYCO-RPP-(Panther)
▪ 8MGT-Poly-Chain-GT-Carbon (Gates)
▪ 14MGT-Poly-Chain-GT-Carbon (Gates)
▪ 8mm MGT-Poly Chain-GT2
▪ 14mm MGT-Poly Chain-GT2
▪ AT3mm SYNCHROFLEX
▪ AT3mm GEN III-SYNCHROFLEX
▪ AT5mm GEN III-SYNCHROFLEX
▪ AT10mm GEN III-SYNCHROFLEX
▪ AT5mm-BRECOflex
▪ AT10mm-BRECOflex
▪ AT20mm-BRECOflex
Additional standards are available on request.
VII Toothed Belt 831
56.3 Possible sizings/suggestions
The following sizings are possible if you select the different buttons:
Variable Influencing/necessary variables
Belt profile Power
Speed (small pulley)
Operating factor
Number of teeth on belt Center distance
Number of teeth on sheave
Center distance Number of teeth on belt
Number of teeth on sheave (all)
Ratio Center distance
Nominal ratio
Speed (small pulley)
Number of teeth on tensioning Number of teeth (small pulley)
pulley
56.2 table: Possible Sizings
56.4 Configuring tensioning pulleys
Here, you can select either:
▪ Without tensioning pulley
▪ Tensioning pulley inside
▪ Tensioning pulley outside
If you selected an inside/outside tensioning pulley, you can input the conical spring washer diameter
and the position (x/y) of the tensioning pulley. In the Configuration tab, you can position the
tensioning pulley interactively using the mouse (the x and y values are displayed in the status bar).
VII Toothed Belt 832
56.5 Application factor and summand for operational
behavior
You can either enter the application factor manually in the load factor interface, or have the program
define it from the operating parameters. If you selected a configuration with a tensioning pulley, you
must increase the operating factor by 0.1. Use the data in this table to define the factor (refer to the
catalogs for more information):
Driven machine Operating hours per day
0-10 10-16 16-24
Light drive 1.2 1.3 1.4
Medium-light drive 1.4 1.5 1.6
Medium-heavy drive 1.5 1.6 1.7
Heavy drive 1.7 1.8 1.9
Heavyweight drive 1.8 1.9 2.0
56.3 table: Application factors
Summand for operational behavior
(This summand is added to the operating factor in the calculation)
Operational behavior: Summand
continuous, 0-10 hr/day 0
continuous, 10-16 hr/day +0.1
continuous, 16-24 hr/day +0.2
intermittent or with alternating load -0.1
56.4 table: Summand
56.6 Center distance
The minimum center distance is calculated from the two belt sheave diameters. You cannot enter a
smaller value here. The sheaves must not touch each other during operation.
56.7 Belt length and number of teeth on belt
In toothed belt drives, the number of teeth on the belt is used to define the belt length. You need this
value when you perform the calculation for the belt. If you did not specify the number of teeth on the
VII Toothed Belt 833
belt or, if you switched to configuration with a tensioning pulley, you must ensure that the program
recalculates the value for the number of teeth on the belt.
56.8 Effective belt width
The theoretical belt width (minimum width required to transmit the torque) can be calculated from the
data in the manufacturer catalogs. The effective belt width is then taken as the next largest standard
belt width.
As a general rule, the belt width should not be larger than 5*pitch. A warning message is displayed if
you select a belt that is either too wide or too narrow. Although the calculation continues, you use the
data it provides at your own risk.
Defining the effective belt width/factor for the belt width:
To define the belt width, you will need the belt width factor (f_b). Use this formula to calculate this
factor:
(53.4)
The nominal power as specified in the catalog is a tabular value taken from the manufacturers'
catalogs and is dependent on the speed and number of teeth on the smaller belt sheave.
With the calculated coefficient f_b you can then define the effective belt width from a (catalog) table.
However, if f_b does not match a standard belt width, the next biggest width will be used.
Remarks:
The theoretical belt width in the KISSsoft calculation reports corresponds to an interpolated value,
according to calculated factor f_b.
KISSsoft stores the tabular values (catalog data) in files which you can then edit. Use the KISSsoft
database tool to find the exact file name for a specific belt type (e.g. Z091-001.dat for XL-Isoran).
56.9 Tensioning pulley tooth number
The value you use for the number of teeth on a tensioning pulley should be at least as large as the
value given for the diameter of the smallest belt sheave.
Where possible, tensioning pulleys should be used as inside tooth sheaves. However, if necessary,
they can also be used as smooth sheaves from outside. The diameter of the tensioning pulley should
VII Toothed Belt 834
be at least 1.2 *d if positioned outside, or 1.0 *d if positioned inside (d: diameter of the smaller
sheave). Every belt manufacturer provides very different data about tensioning pulleys.
For Poly Chain GT:
An outside tensioning pulley reduces service life and should be avoided if possible.
For AT-belts:
AT5mm with tensioning pulley inside: 25 mm (z > 5)
with tensioning pulley outside: 50 mm (z > 10)
AT10mm with tensioning pulley inside: 50 mm (z > 5)
with tensioning pulley outside: 120 mm (z > 12)
AT20mm with tensioning pulley inside: 120 mm (z > 6)
with tensioning pulley outside: 180 mm (z > 9)
56.10 Position of the tensioning pulley x/y
You must enter this value when you configure a tensioning pulley. Here, the axis of the small sheave
is the origin of the coordinates system. If you use the mouse to change the position in the
Configuration tab, you can only move the tensioning pulley within the valid area.
VII Chain Drives 835
57 Chain Drives
Use this module to calculate chain drives with roller chains as defined in DIN ISO 606 (with
standardized roller chain values taken from a database). The chain geometry (center distance,
number of chain elements) for simple and multiple chains and the transmittable power, radial forces,
and variation in speed, are calculated by the polygon effect, etc. Basis: DIN ISO 10823, [23] and [6].
During this calculation, the program checks the highest permitted speed and shows a suggested
value for the required lubrication.
As a variant, the calculation can also be performed with a third pulley (tensioning pulley). The X and
Y coordinates of the tensioning pulley can be defined in the Chain drives tab. If you open the
Configuration tab, you can use the mouse to move the tensioning pulley. In this case, the particular x
and y value is displayed in the status row. This pulley can be positioned outside or inside as required.
Figure 57.1: Basic data: Chain calculation
57.1 Sizings
▪ Using the drive data as a starting point, the program displays a list of suggested values for
suitable chain drives.
▪ Calculating the center distance from the chain length.
▪ Calculating the chain length from the center distance.
VII Chain Drives 836
57.2 Tensioning pulleys
You require tensioning pulleys if you need to limit the chain deflection or keep to a minimum wrap
angle. You must arrange the tensioning pulleys under no load. They must have at least three teeth.
57.3 Standard
Chain profile standard:
▪ Roller chain DIN ISO 606
The roller chain standard, DIN ISO 606, includes chains as defined in the DIN 8154, 8187 and DIN
8188 standards. Roller chains are the most frequently used type of chain because lubricated rollers
reduce noise and wear. The chains defined in DIN 8187 correspond to the European type, those
defined in DIN 8188 correspond to the American type. You should only install bush chains as defined
in DIN 8154 in a closed housing with sufficient lubrication.
57.4 Chain type
The data shown below depends on the type of chain:
▪ Chain pitch.
▪ Maximum permitted speed of the small gear.
▪ Nominal power at maximum permitted speed.
Tables in DIN ISO 606 pages 8 to 10.
57.5 Number of strands
You can achieve high levels of power by using multiple chains. Chains are often arranged in two or
three strands (Duplex, Triplex). The values for duplex and triplex chains are also given in the same
standard.
57.6 Application factor
Guide values according to DIN ISO 10823, Table 2:
VII Chain Drives 837
Figure 57.2: Application factor for chain calculation
57.7 Speed/number of teeth/ratio
Range of ratio:
favorable i = 1. . . 5,
good i = 1. . . 7,
unfavorable i > 10.
Number of teeth:
Due to the polygon effect, we recommend a minimum number of teeth of 17 . . . 25. A "Number of
teeth" that is fewer than 17 should only be used to produce low levels of power. The preferred
numbers of teeth for use in chain gears, as stated in DIN ISO 606, are: 17, 19, 21, 23, 25, 38, 57, 76,
95, 114.
You should use at least three teeth for tensioning pulleys.
57.8 Configuration
You can select one of these configurations:
▪ without tensioning pulley
▪ with tensioning pulley inside
▪ with tensioning pulley outside
In a configuration involving tensioning pulleys, you must specify the number of teeth and the position
of the tensioning pulley (x/y). In the Configuration tab, you can position the tensioning pulley
interactively using the mouse (the x and y values are displayed in the status bar).
VII Chain Drives 838
57.9 Center distance
Recommended center distance: a = 30·p. . . 50·p (p: pitch)
You should avoid: a < 20·p and a > 80·p
Click the button to calculate the center distance from the number of chain links.
57.10 Polygon effect
When calculating chains, you must take the polygon effect into account both for the reference circle
and the center distance.
▪ Formula for the reference circle:
(54.1)
▪ (see also [10], equations 26/46)
▪ Formula for the center distance:
The length of the loop on the sprocket differs as follows from the formula used for V-
belts/toothed belts:
(54.2)
▪ lUK: Length of loop for chains
lUR: Length of loop for V-belts
VII Chain Drives 839
57.11 Number of links
The number of links should usually be an even number.
Click the button to calculate the number of links from the center distance.
57.12 Sprocket geometry
In KISSsoft, you can display and print out the sprocket geometry as a graphic as defined in DIN ISO
606. The graphics are created with the mean allowances.
Figure 57.3: Geometry of chain sprocket
You can also output other values for a sprocket in a report. The figures in this section show how
specific information is represented in this report.
VII Chain Drives 840
Figure 57.4: Chain sprocket widths
VIII
Automotive
Chapter 58 - 59
VIII Synchronization 842
58 Synchronization
Use this module to calculate the gear synchronization time and total time, based on the specified
geometry, forces and application data. Some additional calculations for heat development, frictional
power, and wear resistance, are also performed. Calculations can be performed for common types of
synchronizations for a given number of cones (single, double or triple cone).
Figure 58.1: The synchronizer module tab
58.1 Geometry
Geometry data is needed for the synchronization ring, also called the cone. Additional data is needed
for the spline tip definition (the indexing) and ball block angle. This is the external ball angle which
holds the synchronizer in its position (engaged or disengaged). Specific limiting values have been
defined for the angle input to ensure synchronization can be guaranteed.
VIII Synchronization 843
58.1 table: Figure: (a) Description of main geometry: S = Sleeve, C = Ring/Conus, H = Hub, G = Gear, (b) Spline tip
geometry
58.2 Operating data
The mechanical force is the force applied to the shifting handle. This force is multiplied by the
mechanical ratio and applied to the sleeve. The coefficient of friction at the beginning of the
synchronization can be defined, for the conus and the sleeve.
The gear inertia and the speed difference are required entries. Torque losses due to mechanical
friction, oil splashing, and other sources, can be defined. The defined losses during shifting will either
help or hinder the process depending on the shifting direction. If there is a small amount of clearance
on the synchronizer sleeve before and after the actual synchronization, the distances can be entered
here to enable the total time (from another gear to the final end position of the sleeve) to be
calculated correctly.
VIII Friction couplings 844
59 Friction couplings
This module is used to calculate friction clutches and brakes in accordance with VDI 2241 [88]. The
results of this calculation can then be used to select a suitable clutch or brake. The couplings are
operated either mechanically, electromagnetically, or by pressure (e.g. hydraulically), thereby either
generating or removing pressing force. The couplings can be designed to run either dry or with
lubrication. This has a significant effect on the coefficient of sliding friction and the coefficient of static
friction.
Figure 59.1: Basic data: Friction couplings
Figure 59.2: View of a closing system
VIII Friction couplings 845
Force is stored in a spring. When the spring is released, the force returns the coupling to its open
state, or vice versa. Compression or disc springs are usually used here. Both types of spring are
pretensioned in their open state. In this example of a closing system, the compression is created
hydraulically, and therefore affects the piston. This additional definition of force storage is not
included in the VDI guideline. The guideline assumes that frictional surface pressure is applied
directly to the plate. As the dynamic characteristics of the springs can also be non-linear, the force
generated by the contact with the first plate is used in the calculation.
In KISSsoft, you can either define the spring forces, or input the reference torque MK and the load
torque ML directly. As specified in VDI 2241, the engagement work of friction and the switching
capacity are defined using an average sliding velocity and an average coefficient of sliding friction.
You can also specify the coefficient of sliding friction as a dependency of 5 sliding velocities, because
this coefficient can vary greatly depending on which sliding velocity is present. However, this does
not take into account the aging of the oil, which would reduce the coefficient of sliding friction.
Figure 59.3: Schematic display of a coupling
The dynamic moment of inertia JL can also be made up of a number of different parameters. If a
mass m is present at the distance r from the rotational axis, its moment of inertia can be calculated
with the formula JL2 = m*r2.
This can then be added to the existing moment of inertia JL.
JL =JL1 + JL2.
Ratios can then reduce the moment of inertia on the clutch shaft J 2red = J2*(n2/n1)2. This reduced
moment of inertia can then be added to the clutch shaft's moment of inertia.
JL = JL1 + J2red
59.1 Calculation
Inputting the spring forces/defining the reference torque
If you decide to input the spring forces (Reference torque check is selected), the reference torque is
calculated as follows:
VIII Friction couplings 846
Fk (N): Piston force (FK = pK/AK)
pK (N/mm2): Compression on the piston
AK (mm2): Piston surface area
Fl (N): Spring force to plates contact
Fv (N): Pretension for spring force
F (N): Resulting force on the first plate (N)
The accelerating torque or the holding torque is then determined from this. Using the different
coefficients of sliding friction, if these have been defined, otherwise using the average coefficient of
sliding friction:
MA (Nm): Accelerating torque
Fstat, Fdyn (N): Resulting force on the first plate
μ (-): Coefficient of sliding friction
rm (mm): average friction radius
zR (-): Number of friction surfaces (plates)
ML (Nm): Load torque
μ0 (-): Coefficient of static friction
The reference torque is then calculated from MΑ+ML. You can also define a torque loss, which has a
negative sign for a coupling and a positive sign for a brake.
However, if you define the reference torque directly, you cannot also define a torque loss. This must
then be taken into account with the reference torque.
The formulae specified in VDI 2241 [88] are used to define the sliding time t3.
VIII Friction couplings 847
For a coupling:
MK=MA, where MK is specified, with the influence of t (in this sequence):
For a brake:
where MK is specified, with the influence of t12 (in this sequence):
The engagement work of friction Q is then calculated with, or without, taking the "torque-rise space-
of-time" t12 into account, depending on whether this value has been defined. The switching capacity
on the total friction surface and the maximum switching capacity are also calculated.
If you input curve points for the coefficient of sliding friction, the area below the calculated curve in
the torque diagram is calculated as the engagement work of friction. The switching capacity is then
derived from the time-based conclusion of this calculation.
Each of these values must be input as specific values for the friction surfaces because these are
provided by the manufacturers in the relevant catalogs.
Furthermore, when you input the switching frequencies and the permitted engagement work of
friction (one-time switching) the program calculates a utilization to show whether the selected
coupling will be adequate.
Qzul (kJ): permissible engagement work of friction
QE (kJ): permissible engagement work of friction (one-time switching)
Shü (1/h): Intersection-point switching frequency
Sh (1/h): Switching frequency per time unit
VIII Friction couplings 848
The utilization AQ is then determined from this permitted value and the calculated engagement work
of friction:
When you select a coupling, you must take into account the reference torque, and most importantly,
the permissible engagement work of friction QE (one-time switching) and the calculated permissible
engagement work of friction (for a higher switching frequency).
59.2 Definition of spring forces
Figure 59.4: Definition of spring forces
These additional inputs, Pretension for spring force Fv and Piston force Fk, are used to
determine the characteristic values required to calculate the resulting spring force. The coefficient of
sliding friction and the average radius rm and the number of plates are then applied to determine the
accelerating torque.
The coefficient of static friction from the Spring force to plates contact Fl is then used to define the
holding torque.
The spring force pretension is taken into account as a positive or negative value, depending on what
kind of system has been selected (closing or opening).
VIII Friction couplings 849
59.3 Definition of the coefficients of sliding friction
and velocities
Figure 59.5: Definition of the coefficients of sliding friction and velocities
The coefficients of sliding friction are specified by the manufacturers in accordance with the sliding
velocities. The VDI 2241 standard assumes that a constant value is used. However, this may result
in a large deviation in results. By inputting a maximum of 5 points you can create a poly line that
connects these points. From this line the program can then derive 10 values for the coefficients of
friction in the sliding velocity areas at the start and at the end. The 10 different accelerating torques
derived from this can then be used later on in the calculation.
59.4 Graphics
The graphics show the speed curve over sliding time t3, the torque diagram over sliding time t3 , and
the coefficient of sliding friction curve for the sliding velocity, of which a maximum of 5 points have
been entered (if defined by the user).
59.5 Settings
If the Use radius to plates gravity center for the calculation check is selected, the radius at the
plate center of gravity is used in the calculations instead of the plate mean radius rm. This radius is
calculated with:
VIII Friction couplings 850
rs (mm): radius at the center of gravity of the plate
ra (mm): external radius of the plate
ri (mm): internal radius of the plate
IX
Various
Chapter 60 - 66
IX Tolerance Calculation 852
60 Tolerance Calculation
In this module, you enter the nominal lengths and their corresponding allowances for various
elements. These values are then used to calculate an overall tolerance. This calculation uses a
constant distribution (arithmetical sum) and the square root of the tolerance squares (normal
distribution) to define the maximum and minimum size of the measurement chains. You can also use
the appropriate allowances to calculate the nominal length/expected value of the measurement
chain. The Tolerance field according ISO is defined according to ISO 286 in which the tolerances
are defined up to a size of <= 3,150 mm. In KISSsoft, for fit (tolerance) classes H, h. JS and js, the
values used in the standard are extrapolated up to a value of 10,000 mm.
Figure 60.1: Basic data
IX Proof of strength with local stresses 853
61 Proof of strength with local stresses
61.1 General
You can start this calculation in the Various section of the modules tree.
61.1.1 Software functionality
The calculation program supplies a complete, written proof of integrity for static and fatigue strength
at the proof point W.
The strength verification is supplied according to the local stress concept as described in the FKM
"Rechnerischer Festigkeitsnachweis für Maschinenbauteile" Guideline. The idea behind the local
stress concept is to estimate the service life on the basis of the elastic-plastic local stress at the
critical point on the part compared to the S-N curve (Woehler lines) elongation derived from an
unnotched test bar. The local concept is implemented as a stress-based variant within the framework
of the FKM Guideline. Therefore, before it can be used, the material must be in a linear elastic state.
In this context, the concept used is not really a local concept like the elastic-plastic notch root strain
concept, but a concept close to the nominal stress concept, except that only the theoretical stress
concentration factor stands on the other side of the equations. It is a useful tool for calculating a
static proof and proof of fatigue strength in the high cycle range (NN > 104).
Input: You can enter the stresses at a proof point W and at a neighboring point B. Alternatively, the
stresses at the proof point and the stiffening are estimated mathematically. You must also specify
parameters such as surface roughness, part size, etc., before you can calculate the design
coefficients. Additional load data, such as number of cycles, spectrum, temperature etc. are also
predefined.
Output: The calculation calculates the utilization factors for static cases and fatigue. It creates a
complete set of documentation for this.
61.1.2 Areas of application for the FKM Guideline
The software is based on the FKM "Rechnerischer Festigkeitsnachweis für Maschinenbauteile"
Guideline, Chapters 3 and 4. The guideline applies to mechanical engineering and its associated
industrial sectors. In real life scenarios, contractual partners must agree how this guideline is to be
implemented. For parts that are subject to mechanical stress, this guideline can be used to calculate
the static and fatigue strength either for a finite or infinite working life. However, this guideline does
not cover other mathematical proofs such as brittle fracture stability, stability or deformation under
load, or experimental strength verifications. Before the guideline can be applied, it is assumed that
the parts have been manufactured so that all aspects of their design, material and operation are
technically free of error and fit for purpose. The guideline is applicable for parts made of iron and
IX Proof of strength with local stresses 854
aluminum alloys that are manufactured either by machining or welding, even at elevated
temperatures, and in particular for
▪ parts with geometric notches
▪ parts with welded joints
▪ static stress
▪ fatigue loads ranging from approximately (N > 104) cycles as an individual or collective load
▪ rolled and forged steel, including stainless mix cast iron alloys and also forged and cast
aluminum alloys
▪ different temperatures
▪ a non-corrosive ambient medium.
Supplementary agreements must be drawn up if this guideline is to be used outside the specified
area of application. The guideline does not apply if a strength verification is required using other
standards, codes or guidelines, or if specific calculation data, such as VDI 2230 for bolted joints, is
applicable.
For simple rod-shaped and planiform parts, we recommend you use a calculation method that
involves nominal stresses. The calculation using local stresses is to be used for volumetric parts or,
in general, where stress is to be calculated using the finite elements method or the boundary element
method, if no specifically defined cross sections or simple cross section forms are present or if the
theoretical stress concentration factors or notch effect values are unknown.
61.2 Background
61.2.1 The FKM Guideline: Rechnerischer Festigkeitsnachweis für
Maschinenbauteile
The idea for this guideline was proposed at a meeting of the DVM in Berlin, Germany, in May 1990,
when experts from the then Federal Republic of Germany met together with experts from the then
German Democratic Republic. The objective was to combine the standards from what were then two
separate guidelines (VDI in the West and TGL in the East) to create one new strength assessment
guideline. The new guideline was to be based, in particular, on the former TGL standards for strength
calculation, VDI guideline 2226, DIN 18800, Eurocode 3 and the recommendations of the IIW. The
FKM Guideline was also updated to take into account the latest discoveries from research into the
fatigue strength of metallic parts. The FKM Guideline is designed for use in mechanical engineering
and associated industrial sectors. The first edition of the FKM Guideline, "Rechnerischer
Festigkeitsnachweis für Maschinenbauteile" appeared in 1994, followed in 1998 by a third,
completely reworked and extended edition (characterized by its much more practical updates and a
more user-friendly structure). A fourth edition, which was even more comprehensive, was published
in 2002. The main innovation of this edition was the inclusion of aluminum materials. An English
translation of this guideline appeared as the fifth edition. The sixth edition of the guideline (2012) has,
IX Proof of strength with local stresses 855
once again, been completely revised, and now includes the results of new research, such as the data
for the proposed "Statischer Festigkeitsnachweis" and "Verbessertes Berechnungskonzept FKM-
Richtlinie" tests. In the meantime, the FKM Guideline has become widely accepted and is regarded
as the best reflection of the current state of technology.
61.2.2 Usefulness of the service life calculation
It is a well-known and proven fact that the service life calculation is not sufficiently accurate. In other
words, coefficients in the range from 0.1 to 10, and in some cases even greater, may occur between
the calculation and the test. However, a basic, if somewhat simplified, statement about the difficulties
in achieving a reliable service life calculation has been made: In this case, the strength verification is
based on a comparison of the stress values and the stress itself. In a static strength verification, the
occurring force can be compared with the sustainable force. The characteristic functions, i.e. the
stress spectrum and the S-N curve (Woehler lines) are compared for a proof of service strength. If
the total damage, which is of core significance to the service life calculation, is then understood as a
quotient of the characteristic functions for stress and sustainable stress, it is clear that this quotient is
very sensitive to changes in these critical values. This means errors in determining the characteristic
functions will have a significant effect on the result. In addition, by influencing the critical values, for
example, by implementing specific measures when selecting materials and at the production stage,
the long-term sustainable service life can be increased.
Three different concepts can be used to calculate the service life of parts that are subjected to
cyclical stress. These are: the nominal stress concept, the local concept and the fracture mechanics
concept. These concepts have specific application areas. For many decades, the technical set of
rules was based solely on the nominal stress concept. However, nowadays the local concept and the
fracture mechanics concept are being used more and more frequently in this set of rules. In the
nominal stress concept, the complex transfer function between load and service life contained in the
total stress-strain event in critical material volumes (notch bottom area) is given directly with the
component S-N curve (Woehler lines) for nominal stresses. By contrast, in the local concept, this
must be represented mathematically by a number of relatively complex modules. This may be the
reason for results according to previous experience not being any more accurate than those
achieved with the nominal stress concept.
Possible sources of errors in calculating the local concept:
Load assumptions
It must be emphasized that the load assumption must be as precise as possible to ensure an
accurate calculation of component service life. Any errors in load assumption can have significant
effects on the service life calculation results. The effect may even be greater than those due to
insufficient accuracy of the different methods used for service life estimations. We recommend you
check the load assumptions carefully and test them if necessary. In this way, any uncertainties in the
load assumptions can be resolved by actual measurements performed at a later date. That is
particularly because this type of measurement can be performed non-destructively, and can usually
provide important information for subsequent designs.
IX Proof of strength with local stresses 856
Local stress
Local stresses can be determined either mathematically or by measurement. It is essential that the
part's geometry is entered accurately, especially the splines and wall thicknesses. A convergence
check must also be performed to ensure the effective stresses are not underestimated. However, a
problem still to be resolved in productive operation is how to calculate the effective level of internal
stresses in a part cross-section, or in a surface layer, so that this can be evaluated when subjected to
load stresses in a service life calculation.
Combined stress
In the case of combined stress, a strength calculation should fulfill the instance of the invariant
(results independent of the selected coordinates system). However, as different S-N curves (Woehler
lines) are used for normal and shear stresses, the resulting calculated service life/damage is no
longer separate from, and independent of, the selected coordinates system.
Material characteristics
Material characteristics cannot usually be determined by simply measuring the finished part. We
recommend you refer to standardized or, at least, well-documented values. It is acknowledged that
these values may be not be easy to obtain and not always relevant. It is also not possible to
determine reliable endurance limit values from tensile strength Rm alone. The fatigue limit can be
estimated using the proof stress Rp0.2. The FKM Guideline defines the values from Rm and also for
the material type.
Cyclical deformation characteristic
A check to see whether cyclical compaction or loss of cohesion is present must be performed to see
whether or not the sequence of load cycles plays a significant role. This effect is not considered in
the calculation program.
Stiffening
A number of different models can be used to ascertain the stiffening. As many comparisons between
calculated results and test results have shown, a mathematical estimate of stiffening is fraught with
uncertainties.
Production processes
When a local concept is applied, it is assumed that the volume element displays cyclical material
behavior. Influences encountered during the production process, in particular surface layer
characteristics, surface roughness, material state and internal stresses must be taken into
consideration. Currently used calculation methods also have their limitations here.
Damage parameters
IX Proof of strength with local stresses 857
A number of damage parameters have been proposed to help determine the influence of mean
stress and the influence of multiple shafts. PSWT, the most well-known damage parameter,
corresponds to a mean stress sensitivity of M=0.41, which is present in this order of magnitude for
through-hardening steel, but assumes entirely different values for low-strength steels or wrought
aluminum alloys. The use of PSWT should be seen as a major source of errors. The extent to which
the influence of internal stresses can be determined is also in question. In the latter case, this is only
known for exceptional cases in practice. Damage parameters are still widely used by researchers to
determine multi-shaft behavior, excluding proportional stress. The influence of multi-shaft stress
states on service life depends greatly on which material is being used. This is because the material's
resilience determines which different damage mechanisms are present.
Damage accumulation
In practice, damage accumulation occurs almost exclusively in accordance with the Palmgren-Miner
linear hypothesis. Although the shortcomings of this hypothesis were recognized early on, no
significant advances that would lead to tolerable errors in the service life calculation have been made
in this area despite decades of intensive international research. The only progress is that, by
summarizing the amplitudes below the endurance limit, various modifications have been proposed
which achieve much better results than the original Palmgren-Miner rule, and in which no damage is
caused to amplitudes below the endurance limit.
Even if the service life calculation methods for evaluating variants and analyzing weak points are
implemented correctly, it is not certain that the current level of knowledge can achieve a reliable
service life calculation for new parts. This requires the use of strategies where calculations are
validated and calibrated by specific experimental analyses. At the current level of knowledge, it is
only possible to make relative forecasts about service life on a purely mathematical basis.
61.3 Implementation in KISSsoft
61.3.1 Main screen
61.3.1.1 Selection of the part form
Selection of the part form: you can choose parts that are rod-shaped, shell-shaped or block-shaped.
They each have different stress components or stress types, and different indexing. If the local
concept is applied, block-shaped parts are usually present. The selected part form influences the
data input for the stress components.
IX Proof of strength with local stresses 858
Figure 61.1: Main screen for the proof with local stresses
Rod-shaped parts: the following part-related coordinates system applies, for rod-shaped parts, i.e.
rods, beams and shafts: The x-axis lies in the rod axis, and the y- and z-axes are the main axes of
the cross section, and need to be specified in such a way that Iy > Iz applies for the moment of
inertia.
For planiform (flat) parts, i.e. discs, plates and shells, the following part-related coordinates system
should apply in the proof point: the X- and Y-axes lie in the plane, and the Z-axis is vertical to it in the
direction of thickness. The normal stress and the shear stresses in the direction of Z should be
negligible.
Block-shaped parts: volume-related coordinates systems apply. The primary stresses σ1, σ2 and σ3
need to be calculated. In the proof point W on the free surface of a 3D part, the primary stresses σ1
and σ2 should act in the direction of the surface and the primary stress σ3 points into the interior of
the part, vertically to them. Generally, there is one stress gradient that runs vertically to the surface,
and two stress gradients that run in the direction of the surface, for all stresses. However, only the
stress gradients for σ1 and σ2, running vertically to the surface, can be taken into account in the
calculation, and not the stress gradients for σ1 and σ2 in both directions on the interface and none of
the stress gradients for σ3.
61.3.1.2 Inputting the stress values on the proof point and on the neighboring
point
If the support factor is determined according to the stress state on the neighboring point, then the
stresses on the proof point W and on the neighboring point B, and also the distance from point B to
point W, will be entered. (Enter compressive stresses as negative values.):
IX Proof of strength with local stresses 859
Figure 61.2: Inputting the stress values on the proof point and on the neighboring point. Inputting the neighboring point
distance.
61.3.2 Stress cases
In the endurance limit diagram, different assumptions are used to determine different levels for the
maximum stress amplitude SAK. Assumptions where sm=const. result in a larger SAK value than for
R=const. This is because the limit lines in the Smith diagram rise by an angle < 45° (mean stress
sensitivity). The most suitable assumption depends on the expected change in stresses in the part
when it is subjected to permitted operational fatigue load. The overload case can therefore be a
decisive factor in whether or not a part is overloaded [66].
Stress case
▪ Type of overloading F1 (constant mean stress): at a constant mean stress, the stress amplitude
increases as the decisive operating force increases.
▪ Type of overloading F2 (constant stress ratio): when the operating force increases, the ratio
between the maximum stress and minimum stress remains the same. This overload case
usually returns conservative results (compared to other overload cases) and should therefore be
used in case of doubt.
▪ Type of overloading F3 (constant minimum stress): when the operating force increases, the
minimum load remains the same.
▪ Type of overloading F4 (constant maximum stress): when the operating force increases, the
maximum load remains the same.
IX Proof of strength with local stresses 860
61.3.3 S-N curve (Woehler lines)
Miner elementary, section 4.4.3.5.2 of the FKM Guideline
If a stress collective is present instead of individual stress, the calculation should usually be
performed using the Miner elementary process.
Miner consistent, section 4.4.3.5.2 of the FKM Guideline
The Miner consistent process (derived from Haibach, see [16]) takes into consideration the fact that
the part infinite life strength will reduce as damage increases. The reduction applies from K D,σ
=1*10.6.
61.3.4 Number of load cycles
Number of load cycles. If calculation according to Miner elementary is selected, then inputs greater
than ND result in constant use.
61.3.5 Temperature
Inputting the temperature in degrees Celsius. The area of application of the FKM Guideline is limited
according to material, see section 1.2.1.7. The temperature factor KT,D is then defined, depending on
the temperature and material type.
61.3.6 Temperature duration
Time period during which the part is subjected to the temperature.
61.3.7 Protective layer thickness, Aluminum, section 4.3.4, Figure
4.3.4
The protective layer factor KS (which is defined via the protective layer thickness) takes into account
the influence of a protective layer on the fatigue strength of a part made of aluminum.
61.3.8 Stress ratios
The mean stress is recorded in the R-value. In comparison to the mean stress-free case (cyclic
loading, R=-1), the S-N curve (Woehler lines) is moved to higher sustainable stress amplitudes in
trials with mean compression stresses. In trials with mean tensile stresses, the S-N curve (Woehler
lines) is moved to lower sustainable stress amplitudes. The sustainable stress amplitude's
IX Proof of strength with local stresses 861
dependency on the mean stress is material-specific, and is called the influence of the mean stress.
This usually increases along with the material's tensile strength.
Here R is defined from -1 up to +1
Figure 61.3: Inputting the specific R-value
Figure 61.4: Inputting your own R-value.
As the surface roughness increases, the S-N curve (Woehler lines) moves to lower stress
amplitudes, but the surface roughness alone is not the cause for this. The strength is much more
affected by the detailed properties of the surface. In addition, despite similar surface characteristics
and the same surface roughness, different processing procedures can cause different material
internal stress states, resulting in S-N curves (Woehler lines) that differ from each other greatly.
61.3.9 Spectra
You can select existing load spectra directly.
Figure 61.5: Selecting load spectra
IX Proof of strength with local stresses 862
You can create a new load spectrum in the database tool (see chapter 17.2.8, Define load spectrum).
61.3.10 Surface factor KV, section 4.3.3, Table 4.3.7
Case factor KV takes into account the influence of surface treatment on the fatigue strength.
61.4 Materials
Figure 61.6: Materials screen: Proof of strength with local stresses
The selection list contains materials from the FKM Guideline.
If you have set the Own Input flag, a new dialog is displayed here. This displays the material data
used in the calculation, which you can specify to suit your own purposes. You can also define your
own materials directly in the database (see chapter 9, Database Tool and External Tables), so that
these can also be used in subsequent calculations.
61.4.1 Surface roughness
The roughness factor takes into account the influence of the surface roughness on the part's fatigue
strength. Experiments are performed to derive it from the infinite life strengths of unnotched test rods
with and without surface roughness, and shown in dependency on the material's total height Rz and
tensile strength Rm. For polished surfaces, it has the value 1.0. The average roughness Rz=200μm
applies for rolled, forged and gray cast scale. The average roughness can also be defined as your
Own Input.
IX Proof of strength with local stresses 863
61.5 Settings
Figure 61.7: Settings
61.5.1 General settings
The references are to sections in the FKM guideline.
▪ Coefficient KF according to equation 4.3.2 and 4.3.3, described in section 4.3.1.2.
Notch effect coefficient as an estimated value to enable the effect of the roughness coefficient to be
determined, according to the nominal stress concept, when the local stress concept is in use.
Flag set: Kf is defined according to formulae 4.3.2 and 4.3.3, described in section 4.3.1.2.
Flag not set: The KF coefficient is set as shown in Table 4.3.1.
▪ Calculating G without 2/deff, section 4.3.1.3.3
If the "Input of neighboring point data" flag is not selected in the "General data" tab, then an
approximation of the related stress gradient is calculated, using the calculation based on the
equations in section 4.3.18. This contains terms for tension/compression, torsion, and bending. If no
IX Proof of strength with local stresses 864
bending is present, it is questionable whether the second term (2/d) in the formulae makes any
sense. The option programmed here is not provided in the FKM Guideline!
Flag set: the stress gradient is defined without applying the second term in formula 4.3.18.
Flag not set: the stress gradient is defined while also applying the second term in formula 4.3.18.
▪ Input of mean stresses and amplitudes
If the flag is set, then the stresses are input in the main screen via the medium and amplitude stress.
▪ Input of mean stresses and amplitudes
▪ Material values at reference diameter:
values are taken from database (at reference diameter) and multiplied by K1.
▪ Rm, Rp depending on value from database, sigW at reference diameter:
Rm, Rp are imported from the database according to size (excluding K1). The fatigue
strength is determined for the reference diameter entered in the database, and then
multiplied by K1.
▪ Rm, Rp depending on value from database, sigW constant:
Fatigue strength not multiplied by K1, correct value must be in database
▪ Rm, Rp depending on value from database, sigW calculated from Rm:
Fatigue strength is calculated from Rm. Rm is stored in the database according to size,
conversion according to FKM.
▪ Input of neighboring point data, section 4.3.1.3.3, Formula 4.3.17
Flag set: Notch sensitivity factor-related stress slope is defined in the neighboring point via the stress
state. To do this, the stress values and the distance between the proof point and neighboring point
must be entered in the main screen.
Flag not set: Notch sensitivity factor-related stress gradient is not determined from the values at a
neighboring point. The related stress gradient at the point of maximum stress is estimated using
formula 4.3.18. To do this, two radii (Radius 1 and Radius 2) must be defined (for the two directions
on the surface), and also a typical part dimension d. See also: module specific setting, Calculation of
G without 2/deff, above.
▪ Direction of load as specified in sections 4.1.0 and 4.6.2.
Flag set: the calculation is carried out for synchronous stresses.
Flag not set: the calculation is performed for asynchronous stresses (4.6.2.2). It can safely be
assumed that this method of approach is a cautious one.
IX Proof of strength with local stresses 865
▪ Use the mechanical material support, see sections 4.3.1 and 4.3.1.3.2
If this flag is selected, the mechanical material support coefficient is used for the calculation,
otherwise the Stieler support coefficient is used. If sharp notches are present, the mechanical
material support coefficient takes into account the strength reserves and contains the static size
coefficient. The mechanical material support number (nwm) is made up of three parts: the static
support number (nst), the mechanical deformation support number (nvm) and fracture mechanical
support number (nbm). Assumption: nst = 1 is applied to the "Smooth shaft" and "Own Input" notch
types.
▪ Selecting materials data, section 3.2.1
The part standard values Rm and Rp must be calculated from the semi-finished product or test piece
standard values Rm,N and Rp,N or from the part drawing value Rm,Z. In exceptional situations, the part
actual values Rm,I and Rp,I can be applied.
See section 3.2.1.2. for more information.
▪ Calculating the endurance limit for surface-treated parts (section 5.5)
If this checkbox is enabled, and you have selected a rolled steel and a surface treatment method, the
calculation method specified in the FKM Guideline, 6th Edition, section 5.5, is performed.
▪ Surface factor
This selection is only used for calculating the endurance limit of surface-treated parts.
▪ Hardening depth
You can use this entry to define the location of the transition point between the hard surface layer
and the core.
▪ Determine core hardness from tensile strength Rm
If this checkbox is selected, the core hardness is estimated from the tensile strength instead of using
the core hardness entered when the material was specified.
61.5.2 Required safeties
The FKM Guideline is one of the few calculation guidelines that lists the required safeties according
to the consequences of failure etc. When used together with safe load assumptions and an average
reliability of the strength variables Pü=97.5%, they apply for both welded and non welded parts.
Safety factors are defined as the results of inspections and tests, on the basis of the selected
material, the defined consequences of failure, the probability that the specific load will occur. This
IX Proof of strength with local stresses 866
guideline differentiates between steel, cast iron (ductile or non ductile), and also aluminum (ductile or
non ductile), i.e. five different classes. You can also specify the safety factors manually.
Figure 61.8: Selecting safeties according to material and load properties
jmt Safety margin against creep strength depending on time
jp Safety margin against yield point
jpt Safety margin against creep limit
jF*jG Safety against endurance limit
61.6 Estimation of the endurance limit for surface-
treated parts (section 5.5)
This calculation should only be used for surface-treated rolled steel. The surface treatments include
the following treatment methods applied to the materials:
▪ case-hardened
▪ nitrided, gas-nitrided, nitro-carburated
▪ induction hardened
IX Proof of strength with local stresses 867
▪ rolling
▪ shot peening
You can define these treatment types either when you specify the material or when you input the
surface factor (Settings).
This process is based on the concept of a local endurance limit. Two points on the part are observed.
The first point is on the part's surface, and the second point is at the transition point between the
hard surface layer and the core. This is calculated with the greatest principal stress σ1. If no principal
stresses have been entered, they are calculated first.
You can also input a hardening depth for this calculation in the Settings. The hardening depth is then
used to calculate the distance from the component's surface to the transition point between the hard
surface layer and the core.
The constant Kf can either be calculated in accordance with formulae 4.3.2 and 4.3.3 or taken from
Table 4.3.1. You also have the option of inputting the core hardness in the Settings when you specify
the material. Alternatively, this can also be estimated from the tensile strength.
This approach is used to calculate the internal stress, which is included in the calculation of mean
stress sensitivity. In this case, the degree of utilization for the point on the component's surface is
calculated first, followed by the degree of utilization at the transition point between the hard surface
layer and the core. The greater of the two degrees of utilization is then used for the proof. Both
degrees of utilization should be < 1.
The results are only displayed in the report if this calculation method has been selected for rolled
steel with the predefined treatment types.
IX Hertzian Pressure 868
62 Hertzian Pressure
Use this module to calculate the Hertzian pressure between two bodies. In the case of a load on a
rolling pair that is applied vertically to the contact surface, elliptical flattening occurs for point contact,
and rectangular flattening occurs in the case of linear contact.
For the case of general contact, the theory presented in reference [89] is used. Based on this
reference, a grid of triangular pressure distribution elements is used to calculate the line contact
between bodies with an arbitrary profile, while applying a given vertical line load. The bodies are
assumed to extend infinitely, vertical to their profile. The profiles of the two bodies are taken from two
data files. The files have three columns that contain the index, the position and the profile value.
Figure 62.1: Format of the body profile data file
All values in this file must be entered in millimeters.
The profile file for each body can have different discretization and position values. However, we
recommend you use the same discretization and position for both bodies. The accuracy of the results
will depend on the density of the profile points (discretization length). Edge contact effects are also
considered. The contacting surfaces are assumed to be frictionless. This general contact option
enables the user to generate a 2D plot of the subsurface stresses and a plot of the contact pressure
along the profiles. You will find more detailed information about the calculations and equations used
in the reference document mentioned above.
The Hertzian equations are used to help calculate the maximum pressure (Hertzian pressure) and
also the proximity of the two bodies (ball, cylinder, ellipsoid, plane; convex or concave). The
calculation formulae have been taken from "Advanced Mechanics of Materials, 6th Edition [90]. The
IX Hertzian Pressure 869
underlying principle for calculating point contact is that the diameter of the bodies is defined on two
main planes, from which an equivalent diameter is then defined. The calculation is performed in one
main plane for linear contact, so there is only one equivalent diameter. The location and value of the
maximum principal shear stress in the interior of the body are also determined.
An approximation of the cylinder/cylinder configuration has been calculated using the dissertation
from Weber/Banaschek [19]. The formula (55) from Norden's book [13] is used to calculate the
approximation of the cylinder area.
Figure 62.2: Main window for Hertzian pressure
In the main screen for Hertzian pressure (see Figure 62.2) you can define the normal force, the
configuration, and also the diameter (and, in the case of linear contact, the supporting length leff) and
the materials of the bodies:
You can select one of these configurations:
▪ Ball - ball
▪ Ball - cylinder
▪ Ball - ellipsoid
▪ Ball - plane
▪ Ellipsoid - ellipsoid
▪ Ellipsoid - cylinder
▪ Ellipsoid - plane
▪ Cylinder - cylinder
▪ Cylinder - plane
▪ Any contact
On the right, in the main screen, an image of the current configuration is displayed to help you to
understand the input values better.
For normal force there is also a sizing option. If you click the sizing buttons next to the normal force,
you can enter the required Hertzian pressure, and the system will then calculate the normal force
from it.
IX Hertzian Pressure 870
If the support area has a concave bend then you must enter the diameter as a negative value.
Negative diameters are only possible in the case of Body 2.
62.1 Settings
Use the Depth display factor to define the depth display in the graphic. The depth of the point τmax
is multiplied by this coefficient. The resulting depth is then displayed in the graphic. The default
setting of this coefficient is 6.
IX Hardness Conversion 871
63 Hardness Conversion
You access the hardness conversion module in the Extras > Hardness conversion menu.
Hardness conversion is also present in the materials screens as a sizing function. You can therefore
use a hardness value to define the tensile strength in these screens.
This module includes the hardness conversion calculation as specified in DIN EN ISO 18265, Edition
2-2014. During the conversion, select Extras > Hardness conversion to display a selection list in
which you can select the required material. The other conversions (for the materials) use the table for
unalloyed and low-alloy steels and steel casting. The stored tables can be used to convert the value
of the tensile strength into Vickers, Brinell or Rockwell hardness, as required. Due to possible
variations, the received values should only be used if the default testing process cannot be applied.
The interim values of the value conversion table are interpolated from the neighboring values.
Figure 63.1: Hardness conversion input screen
Integrated conversions of the steels and steel groups according to DIN EN ISO 18625:
▪ Unalloyed and low-alloy steels and steel casting (Table A.1)
IX Hardness Conversion 872
▪ Through hardening steel in heat treated state (Table B.2)
▪ Through hardening steel in untreated, soft-annealed or normally annealed state (Table B.3)
▪ Through hardening steel in hardened state (Table B.4)
▪ Cold-working steels (Table C.2)
▪ High-speed steels (X80WMo6.5, X82WMo6.5, X90WMo6.5, X97WMo3.3, X100WMo6.5,
X85WMoCo6.5.5, X105WMoCo6.5.5 and X79WCo18.5) (Table D.2)
The range of validity for unalloyed and low-alloy steels and cast steel (with the conversion in the
material screens applied) is limited as follows:
▪ Tensile strength Rm: 255 to 2180 N/mm2
▪ Vickers hardness HV: 80 to 940 HV
▪ Brinell hardness HB: 76 to 618 HB
▪ Rockwell hardness HRB: 41 to 105 HRB
▪ Rockwell hardness HRF: 82.6 to 115.1 HRF
▪ Rockwell hardness HRC: 20.3 to 68 HRC
▪ Rockwell hardness HRA: 60.7 to 85.6 HRA
▪ Rockwell hardness HRD: 40.3 to 76.9 HRD
▪ Rockwell hardness HR 15N: 69.6 to 93.2 HR 15N
▪ Rockwell hardness HR 30N: 41.7 to 84.4 HR 30N
Rockwell hardness HR 45N: 19.9 to 75.4 HR 45N
IX Linear Drive Train 873
64 Linear Drive Train
Use this calculation module to calculate drive screws. Drive screws are used to convert rotational
movement into longitudinal movement or to generate great forces.
Although trapezoidal screws are almost exclusively used as drive screws, some rough operations
also use buttress threads.
Figure 64.1: Linear drive train basic data
Figure 64.2: Dimensions of trapezoidal screws
Two different linear drive train configurations can be calculated:
IX Linear Drive Train 874
▪ Load case 1
Stress on the spindle in a spindle press
▪ Load case 2
Stress on the spindle in a gate valve
Figure 64.3: Linear drive train stress cases
The information provided in Roloff Matek [66] is used to calculate linear drives (drive screws).
64.1 Calculation
Short and long linear drive trains subjected to pressure are handled separately in the calculation
process.
Short pressure stressed drive screws
Short pressure stressed drive screws are not at risk of buckling and therefore are not tested for this.
The required cross section of the thread can therefore be defined using the formula:
IX Linear Drive Train 875
σd(z)zul: under static load: Rp/1.5; under pulsating load σzdSch/2.0; under alternating load:
σzdW/2.0;
Long pressure stressed drive screws
The formula for calculating the necessary core diameter of the thread is taken from the Euler
equation:
S: Safety (S≈6 to 8)
lk: mathematical buckling length, lk≈0.7*l (Euler buckling case 3 is used for general guided spindles)
Calculation of the strength:
Stress case 1:
The upper part of this configuration is subject to torsion and the lower part is subject to compression
and therefore buckling.
Torsional stress:
Wp: polar moment of resistance Wp»0.2*d3^3
τtzul: permissible torsional stress; Static load τtF/1.5; Pulsating load τtsch/2.0; Alternating load
τtW/2.0;
Compressive (tensile) stress:
A3: Minor diameter cross section thread
σd(z)zul: permissible compressive (tensile) stress
Stress case 2:
IX Linear Drive Train 876
The upper part of this configuration is subject to torsion and the lower part is subject to compression,
infrequent tension and torque.
Formula for the part to be checked:
The required torque corresponds to the thread torque, if not subject to any moments of friction.
d2: Flank diameter of the thread
φ: Lead angle of the thread (for single thread trapezoidal screws φ≈3°...5.5°)
ϱ': Thread friction angle
Figure 64.4: Values for the friction angle
The + in the formula stands for "tightening the spindle", and - stands for "loosening the spindle". The
KISSsoft calculation calculates both situations and outputs the results in a report.
Calculation for buckling (only for long spindles):
First of all, calculate the slenderness ratio.
IX Linear Drive Train 877
λ: Slenderness ratio of the spindle
lk: mathematical buckling length
i: Gyration radius
Only 3 different materials can be used for the spindle so that the slenderness ratio can be defined
correctly.
Elastic buckling is present if λ>=λ0 = 105 for S235, or λ>=89 for E295 and E335.
The non-elastic area as defined by Tetmajer and λ <105 for S235.
For λ<89 and for E295 and E335:
The Johnson parabola equation can also be used for the calculation for a non-elastic case. (also for
other materials)
The safety can then be calculated as follows:
The required safety for elastic buckling is Serf≈3 to 6. For non-elastic buckling, it is Serf≈4 to 2.
Buckling no longer needs to be calculated for a slenderness ratio < 20.
Calculation of the nut:
The surface pressure of the nut is calculated from the nut length:
IX Linear Drive Train 878
P: Pitch of thread
l1: Length of the nut thread
d2: Flank diameter of the thread
H1: Flank engagement of the thread
pzul: permissible surface pressure
Due to the uneven distribution of surface pressure, the nut length should be no greater than 2.5*d.
During sizing, the length is limited to 2.5*d even if a longer one is input.
Efficiency and self-locking:
The efficiency of the conversion from rotational movement into longitudinal movement:
The conversion of movement is only possible for non-self-locking threads, because the limiting value
in this case is that, φ=ϱ', the efficiency is 0.5.
If φ>ϱ ' the thread is no longer self-locking.
Each permissible value is taken from the Roloff Matek tables.
64.2 Sizings
When you select Own Input, this calculation module can calculate the core diameter d3 of a long
spindle that is subject to pressure.
It can also define the nut length on the basis of permissible surface pressure and the required safety.
IX Linear Drive Train 879
64.3 Settings
Figure 64.5: Settings input window
▪ Coefficient permissible surface pressure: this factor is used to define the ratio to Rm, in other
words pzul = fpzul*Rm
▪ Required safeties for diameter, shearing, stress, surface pressure and buckling: for the
calculation and the sizings
64.4 Materials
Figure 64.6: Nut materials input window.
IX Linear Drive Train 880
The selection list contains materials from the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the material data used
in the calculation which you can specify to suit your own purposes. You can also define your own
materials directly in the database (see chapter 9, Database Tool and External Tables), so that these
can also be used in subsequent calculations.
You can only select these different materials for nuts. For the spindle material you can choose E295
(St 50.2), E335 (St 60.2) and S235 (37.3) materials, because the calculation of buckling is only
designed for use with these materials.
The strength values for the 3 materials have been fixed:
▪ E295 (St 50.2): Rp02 = 295 N/mm2; σzdSch = 295 N/mm2; σzdW = 195 N/mm2; λ0 = 89; τtSch
= 205 N/mm2; τtW = 145 N/mm2
▪ E335 (St 60.2): Rp02 = 335 N/mm2; σzdSch = 335 N/mm2; σzdW = 235 N/mm2; λ0 = 89; τtSch
= 230 N/mm2; τtW = 180 N/mm2
▪ S235 (St 37.3): Rp02 = 235 N/mm2; σzdSch = 225 N/mm2; σzdW = 140 N/mm2; λ0 = 105;
τtSch = 160 N/mm2; τtW = 105 N/mm2
IX Deformation of the Gear Body 881
65 Deformation of the Gear Body
This model is designed to calculate the deformation of a gear body using the finite elements method
(FEM).
65.1 Calculation procedure
The first step of the calculation involves importing the required data, which is listed in the following
figure:
The most important values are:
facewidth (b1)
hub width (b2)
operating pitch diameter (dw)
shaft diameter (dsh)
normal module (mn)
hub width coefficient (SR1)
hub width coefficient (SR2)
hub width coefficient (h1)
hub width coefficient (h2)
web thickness coefficient (bs)
cavity coefficient (k1)
cavity coefficient (k2)
You can enter this value either as a coefficient or as a dimension. Internal gears can also be
calculated.
IX Deformation of the Gear Body 882
Some of this data can also be taken directly from a specified gear pair calculation file.
You can also input the FE mesh density.
Once you have set the geometry data, you can select the hub material from the database. Then, you
must define the applied load. To do this, apply line load to the gear body (in a specified load
direction). Another option is to calculate the stiffness matrix of the gear body, and then save this data
in a file. This file can then be imported directly into the shaft calculation file, to define the stiffness
matrix of the gear body and take this into account in the shaft calculations.
The FEM Solver KISSsoft calls in the background is the Code_Aster open source solver, which you
can find by clicking on http://www.code-aster.org/ . The preprocessor used to build the FE model is
also an open source program, called Salome, located at http://www.salome-platform.org/. To ensure
you have the correct versions, install both programs from the KISSsoft DVD, or download them from
the KISSsoft website. The only precondition for using this method is that Java is installed (it can be
downloaded from https://www.java.com https://www.java.com) and you have its bin path set correctly
in KISSsoft in Extras > Settings > Directories JAVADIR, where the java.exe can be found.
Remember that the folders for these FEM programs (FEPreProcessor and FESolver) can be copied
to any location. In KISSsoft, they should be copied to Extras > Settings > Directories > FEMDIR
(this is usually the KISSsoft installation directory). Do not use path names that contain accented
characters such as German umlauts or other special characters.
Both the solver and the pre-processor are available with a GPL license, as are the versions on the
websites mentioned above. (You will find more details about this license in the installation directories
for these programs in KISSsoft, and on the relevant web sites.)
Note that you will be prompted to give the pre-processor network access through the Windows
firewall the first time you run it. However, you can simply click on "Cancel" and ignore this message.
65.2 Results
Once you have defined a single line load, the maximum deformation of the gear body and the
coordinates of the point of maximum deformation are displayed. Select the Graphics -> Gear body
deformation menu option to also display the deformation of the line to which the line load was
applied. If necessary, you can then start the FE program yourself. To do this, select the Calculation
> Open Salome menu option once the calculation has finished running. You can then either open
the "GearBody.unv" file to view the FEM meshing model, or open the "Aster.0.med" file to display the
results. To view the mesh in Salome, select the Mesh module from the drop-down list in the Salome
tool bar and then select File > Import > UNV file. To view the results, select the ParaViS module in
Salome and then open the "med" file mentioned above. You will find more detailed information about
working with meshes and the results files in Salome in a special set of KISSsoft instructions. You can
request this documentation from the Hotline. You can also use the KISSsoft graphic to display the FE
mesh and results by selecting the Graphic > Display FEM results menu option.
IX Plastics Manager 883
66 Plastics Manager
This module can be used to add new plastic materials to the KISSsoft material database, if the
material characteristics are available. When a material is added to the database, KISSsoft generates
its associated .dat material file.
Currently, KISSsoft has over 67 plastic materials in its database. However, although a large number
of different plastics are available for gear calculations, you may often need to enter your own
materials in the KISSsoft database. Before you can add a new material to the KISSsoft database,
you need to know at least the material properties displayed below:
▪ Poisson's ratio
▪ Coefficient of friction for oil, grease and dry run
▪ Temperature-dependent Young's modulus
If other material properties (tensile strength and yield point, temperature-dependent wear
coefficients, thermal expansion coefficient, permissible root/flank stresses, etc.) are also known, they
can also be added to the KISSsoft database. The Young's modulus, tensile strength and yield point
can also be entered for dry material properties. The more material characteristics this database
contains, the more accurately plastic gear calculations can be performed.
If gear test results are available, the permissible root or flank stresses can also be calculated, and
the results entered in a .dat file for the material. This data can then be used to calculate safety
factors over the entire rating life of the gears.
In the Basic data tab, you can input general material characteristics (density, material type,
absorption of water etc.) and also tribological characteristics (coefficient of friction and wear
coefficient). Specific heat capacity and conductivity are used purely for information purposes in the
material database.
Tribological properties can be entered individually for oil, grease and dry runs. If the data is available,
you can enter temperature-dependent wear coefficients for all lubrication conditions in the
appropriate temperature-dependent wear factor table. Click the button next to the Material name
input field to import material data from the M-Base database (if available). If a material dataset is not
available, please contact M-Base for more information.
If the wear coefficient's temperature dependence is not known, KISSsoft assumes the same
temperature range for the wear coefficient as was used for the Young's modulus data. Additional
comments are also displayed in an appropriate .dat file.
You can also input temperature-dependent material data (Young's modulus, tensile strength and
yield point) in the Test data tab.
If results from gear testing are available, it is possible to calculate the permissible fatigue strength for
root and/or flank. Enter the test data in the "Test gear measurements" table in the Test data tab.
IX Plastics Manager 884
66.1 Gear test results
There are two different methods for using test results to calculate the permitted root and/or flank
stress. In the first result type (Case I), all measurements on the test rig are performed with an
unchanged cylindrical gear pair configuration (calculation file with file extension "*.Z12"). The
geometry of the test gears does not change between the measurement results. In the second result
type (Case II), you can use different cylindrical gear geometries for each measurement (calculation
file with extension for 2 gears ("*.Z12"), 3 gears ("*.Z15"), 4 gears ("*.Z16") and planetary gear units
("*.Z14") with different lubrication conditions. This means you can assign different geometries for
each measurement result. However, you cannot enter and calculate both datasets at the same time.
To switch between the two cases, go to Module specific settings > Test gear geometry based on
one file.
66.1.1 Case I, test results for unchanged test gears
Such test results are usually measured on test rigs. Geometry of the test gears must be defined in a
separate KISSsoft .Z12 file, which can be selected on the user interface (Test data tab). In this case,
only 1 lubrication regime is possible and must be defined in test file.
Before test result data is entered in the table, a file must be created and selected for the test gear.
The table in the user interface is adjusted to suit the test, using the settings in the gear file. The
material characteristics of the failed gear in the test file are not important, as they are overwritten with
user-defined values set in the Basic data and Test data tabs. The selected material of the failed
gear must be a plastic (for example, PA66 (VDI 2736)). The correct material characteristics must be
set for the material from which the counter gear that is to be mated is made.
A failed gear must be specified for the selected test file. If both materials from the selected test file
are a type of plastic, the user can select either gear 1 or gear 2. In other cases, the failed gear is set
automatically. It is only possible to have failure on either gear 1 or gear 2, not on both gears
simultaniously.
The following limitations apply for the test files:
▪ Calculation method for plastic gears must be selected
▪ The Calculate temperatures root/flank option must be deselected (for grease and dry runs)
▪ Calculation without load spectrum
▪ At least 1 gear must be made of plastic material
▪ The Rating tab must be visible.
To calculate the permissible root and/or flank strength, the following test results must be available:
IX Plastics Manager 885
▪ Torque, speed and cycles to failure of the failed gear. According to VDI 2736, all the tests
should run until failure
▪ Environmental, root and flank temperature (dependent on the "failure cause") or oil temperature
(for oil lubrication) of the failed gear.
▪ If the mating gear is plastic, and the failure cause is set to flank, the mating gear's flank
temperature must also be set.
▪ The type of "failure cause" can be set to no failure, root, flank or wear.
The test gear allowances table can also be imported from a file. However, you must use a suitable
file structure (see example file K17_testResults.dat).
Additional settings that control the calculation of permissible root and/or flank strength are available
in the Test data tab in Module specific settings. Sections 1.2 and 1.3 have more detailed
explanations of the individual parameters.
66.1.2 Case II. Test results with different gear geometry
To enable this option, deactivatet the "Test gear geometry based on one file" option in Module
specific settings. The required input fields in the "Test gear measurements" table in the Test data
tab are modified to suit the selection you make.
In the "Test gear measurements" table, select the failed gear, "failure cause" and mating gear for
every test file. The gear numbers for the .Z12 file are [1, 2], for "*.Z15" they are [1, 2, 3], for "*.Z16"
they are [1, 2, 3, 4] and for "*.Z14" they are [1=sun, 2=planets, 3=internal gear]. Enter values for
torque, speed, cycles to failure and temperatures in the individual gear files in the test.
Additional settings that control the calculation of permissible root and/or flank strength are available
in the Test data tab and in Module specific settings. Sections 1.2 and 1.3 have more detailed
explanations of the individual parameters.
66.2 Additional settings in the "Test data" tab
Damage probability: Calculated average cycles to failure (50% damage probability) are recalculated
to a selected damage probability according to the selected statistical method.
Merge temperature differences Δθmerge: As specified in VDI 2736-4 [12], at least 3 tests should be
performed for every test condition (torque and speed). In theory, gears running under the same test
conditions should have identical root and flank temperatures. However, this is often not the case in
reality. These temperature deviations can be taken into account with Δθmerge.
Torque Speed Root temperature NL
IX Plastics Manager 886
1 1.00 Nm 750 rpm 100 °C 1.01·106
2 1.05 Nm 750 min 105 °C 1.13·106
3 1.00 Nm 750 rpm 120° C 0.82·106
4 1.00 Nm 750 rpm 98 °C 1.05·106
Table 66.1: Merging test results
If Δθmerge= 8°C, then tests 1, 2 and 4 from Table 1 will be merged together and used for further
evaluation. Test 3 will be ignored.
Torque merge deviation: If the torque (or stress) deviation is lower than the set torque merge
deviation (in %), then these measurements are used for further evaluation. Example from Table 1:
Tests 1, 2 and 4 are combined if the merge deviation is 5%. If the Merge deviation is smaller, then
just tests 1 and 4 are merged together (test 3 is not taken into consideration because of the Δθ merge
condition).
Temperature difference for grouping Δθgroup: After merging, the results must also be grouped
according to the root or flank temperature so they can be written to a material .dat file. With Δθ group, it
is possible to group results even though the measured temperatures are not identical. If Δθgroup =
5°C, then tests 1, 2 and 3 from Table 2 will be grouped together and written at the same temperature
of 20°C (the minimum temperature is used always as a reference temperature).
Stress Root temperature NL
1 100 MPa 20°C 1.01·106
2 80 MPa 22°C 2.13·106
3 60 MPa 25°C 3.82·106
4 40 MPa 98°C 5.14·105
5 30 MPa 102°C 9.02·105
Table 66.2: Grouping results in a .dat file
The following statistical methods are available for calculating the cycles to failure (the calculation is
based on the user-defined damage probability):
▪ Statistical method acc. to VDI 2736-4
▪ Normal distribution
▪ Weibull distribution (2 parameter)
Statistical method acc. to VDI 2736-4
The procedure specified in VDI 2736-4 [12] (load cycle) to failure is used for the statistical calculation
of the cycles. The only difference is that a default damage probability of 10% is used in the VDI
IX Plastics Manager 887
standard. In contrast, in KISSsoft, the cycles to failure can be calculated with a user-defined damage
probability.
Normal distribution
A normal (Gaussian) distribution can be used to calculate the number of cycles to failure. You will
find more detailed information about this method in the technical literature [91].
Weibull distribution (2 parameters)
A 2-parameter Weibull distribution can be used to calculate the number of cycles to failure. You will
find more detailed information about the method applied here in [92]. The relative least squares
method is used to calculate the Weibull parameter.
Gear data measured for dry materials
Click on the checkbox to specify whether test gears are to be measured in their dry state. The
calculation will then take into account the relevant material properties for calculating tooth flank
stress.
66.3 Module specific settings
Minimum number of data points for merging:
The user can limit the minimum number of tests needed for merging. The minimum possible number
is 2, however VDI 2736 requires at least 3 measurements.
Minimum number of data points for grouping
Use this setting to specify the minimum number of merged points needed to group results in a .dat
material file. The minimum possible number is 2.
Permitted deviation of cycles to failure:
For each testing condition (torque and temperature), at least 3 tests should be performed to get a
statistical distribution of cycles to failure. A warning message is displayed if the standard deviation of
cycles to failure, divided by the mean value of cycles to failure, exceeds the set value.
Permitted speed deviation:
A warning message is displayed if the standard deviation for speed divided by the mean value for
speed exceeds the set value.
Stress correction coefficient of reference test gear (YST):
Calculated tooth root stresses are normalized by the stress correction factor and then recorded in a
.dat material file.
IX Plastics Manager 888
Root safety (SFMIN):
Calculated tooth root stresses are divided by the root safety factor and then written to a .dat file.
Flank safety (SHMIN):
Calculated tooth flank stresses are divided by the flank safety factor and then written to a .dat file.
Power-on time, Housing heat-transfer resistance, Housing heat-dissipating surface:
The set values are used to calculate gear heat transfer coefficients based on the measured root and
flank temperatures. For more information see VDI 2736-2 [12].
Pulsator test results
Select this option to evaluate tooth root endurance data measured by the pulsator machine.
Test gear geometry based on one file
Here, you can select either one of two different test result types (see chapter 66.1, Gear test results).
Calculate wear factors from measured gear wear
If you select this option, the wear coefficients are calculated on the basis of the average wear as
defined in the Test data tab.
Display permissible root/flank stresses in LOG scale
The tooth root/flank stress can be displayed either in a LOG-LOG scaling or in a LOG-LIN scaling.
66.4 Extrapolation of the calculated permissible root
and/or flank stresses
The calculated results can be extrapolated if root and/or flank fatigue results are available. Do this in
the Data extrapolation tab. In the first step, you can extrapolate data up to the user-defined number
of cycles (Extrapolate to cycles). This extrapolation can be performed with an average pitch or
0.5∙average pitch. In steps 2 and 3, you can define which step is to be performed according to the
user-defined load cycles. These options are available in the first step:
▪ Set permissible stress to 0
▪ Set the number of cycles to infinite (for a specific permitted stress)
▪ Extrapolate load cycles with varying pitch.
Individual extrapolation options are available for root, flank oil, flank grease and flank dry results. The
effect of data extrapolation can be seen in Graphics under S-N curve (Woehler line).
IX Plastics Manager 889
Select the Extend temperature range option to extend the calculated results to lower temperatures.
Set the parameters for the minimum temperature (must be lower than the lowest calculated
temperature in the "Test gear measurements" table) and the factor for increasing permissible stress
(the factor must be ≥ 1). The results are displayed in the S-N curve (Woehler line) graphics or in the
generated .dat file.
66.5 Other calculation options
If test results are available, the wear factor kw can be calculated from the worn tooth geometry as
defined in VDI 2736-2. This option must be enabled in Module specific settings (select Calculate
wear factors from measured gear wear). An additional field, the "Average wear" field, is then
displayed in the measurement table. To calculate the coefficient k w, select "wear" as the cause of
failure. The calculated wear coefficients are displayed in the report. The wear coefficients are not
written to the .dat file.
If lubrication is either grease or dry running, the heat transfer coefficients k θ for the root and flank of
the failed gear are automatically calculated according to VDI 2736-2. The calculated coefficients are
also shown in the report.
66.6 Writing material data to the KISSsoft database
In the Material DAT file tab, you can generate and open a .dat data file, and automatically save
material data to a KISSsoft database. The permissible root or flank stresses are calculated
automatically according to VDI 2545 (YF, methods B and C) and according to VDI 2736 (YF,
methods B and C). All permissible stresses are automatically written to the .DAT file.
66.7 Graphics
The following graphics are available, based on the material inputs and calculated results.
▪ Young's modulus versus temperature
▪ Tensile strength and/or yield point versus temperature
▪ Wear coefficient versus temperature
▪ S-N curves (Woehler lines) for root and flank (all lubrication types)
IX Plastics Manager 890
66.8 Importing material files from M-Base
Material datasets from the M-Base Material Data Center can also be processed. If a dataset is
available, click on Calculation > Import material data to import it into KISSsoft and process and
convert it. Material datasets from the M-Base Material Data Center contain general information about
the relevant plastics (Young's modulus, tensile stresses etc.). However, these datasets do not
include information about infinite life strengths.
X
KISSsys
Chapter 67 - 67
X KISSsys: Calculation Systems 892
67 KISSsys: Calculation Systems
67.1 General
KISSsys is an extension to the KISSsoft calculation program. With KISSsoft, you can size, optimize
and recalculate individual shafts, gears or shaft-hub connections. In contrast, KISSsys is suitable for
administering machine element systems.
Some special links between different calculations are already present in KISSsoft. For example,
bearing forces can be transferred from the shaft calculation and gears can be placed onto a shaft.
However, in the case of larger systems, such as a multi-level gear unit with several shafts and gears,
separate performance data and speeds must be entered for each individual stage. If several loads
are to be calculated, the load must be updated in each calculation.
In contrast to KISSsoft, where the individual calculations take center stage, KISSsys provides a way
of observing a system as a whole. However, KISSsys has not been designed to replace KISSsoft.
Instead, it is an extension that uses the tried and tested calculation modules that are already present.
You could say that KISSsys administers the relationships between individual elements but leaves the
calculation of the individual elements to KISSsoft.
67.1.1 Structure of KISSsys
KISSsys is based on an object management system called Classcad. Classcad manages the
administration of KISSsys elements, evaluates the expressions for variables and provides an
interpreter with which the user can also generate functions for special purposes.
This forms the basis for a user interface and a link to KISSsoft. The user interface functionality is
different for administrators, who generate new systems or change system structures, and for normal
users who, while using the same structure, merely want to change data, recalculate, and view
results. It takes more effort, and a better understanding of the program structure, to generate new
systems than to use an existing system, which is easy to do.
67.1.2 Ways in which KISSsys can be used
At the most basic level, you can use KISSsys to group calculations. All the calculations in a system
can be called up from one interface. You can also display an overview of the most important results
of all calculations. This makes it immediately obvious which particular gear pair or shaft is critical.
Even just this view of all the calculations that are of interest makes work considerably easier.
Using KISSsys, you can then to specify relationships between variables. For example, you can
calculate the speeds in a gear unit from the initial speeds and the transmission ratios. KISSsys can
X KISSsys: Calculation Systems 893
also describe the power flow. In KISSsys, you therefore only need to enter the load for the
calculations in a few places. This enables you to quickly recalculate a complex system for varying
load cases.
KISSsys enables you to store tables for loading cases or even variants. This means you do not have
to constantly reenter the load data. KISSsys can also store the data for variants of a construction.
You can then perform all the calculations for a selected load or variant with one click of a button.
For example, imagine a shaft with a radial force of unknown direction (e.g. via a belt drive/ belt force,
whose direction is only determined when the equipment is installed). If it is necessary to define the
worst case scenario, you could use KISSsys to rotate this force in steps of up to 360°.
KISSsys is not only extremely useful in the design stage, but is also useful in the sales environment.
With KISSsys, you can, for example, store a standard gear unit in your computer. If the client later
requests different loads on a gear unit of this kind, instead of the ones originally used for its
construction, KISSsys lets you quickly check whether the gear unit will meet the new load
requirements.
Different example applications are detailed on the KISSsoft CD or website.
67.1.3 The user interface
The user interface provides several views of the administered data. There are table views, which are
primarily designed to provide you with a good overview of the calculations. Another view, which has a
tree structure, represents the hierarchy of an assembly structure, while the two-dimensional power
flow diagram is primarily designed to display the kinematic coupling of the system. You can also
create a three-dimensional display of the entire system or of particular subsystems.
This section details the options for using the KISSsys system without administrator rights.
X KISSsys: Calculation Systems 894
Figure 67.1: The KISSsys user interface with tree view, diagram view, 3D view, tables and 2D diagram
67.1.3.1 Tree view
The tree view (on the left in→ (see Figure 67.1)) lists all elements present in the system,
hierarchically. Use this option to display an assembly structure. A bitmap image is displayed next to
the element's name. This image identifies the type of the element. Bitmaps with a blue background
are KISSsoft calculations, and bitmaps with a gray background are variables such as figures,
functions or character strings. Right-click to open a separate context menu which has functions for an
element.
Each element has a Properties dialog which you can display here. The Properties dialog has an
overview of the available data elements or variables. However, these can only be changed by the
administrator.
In the KISSsoft calculations you can select kSoftInterface in the context menu to start the
appropriate KISSsoft module. The calculation data can then be changed or evaluated in KISSsoft.
Select kSoftReport to display the calculation report and select Calculate to perform the calculation
in the background without a user interface. Data is only exchanged with KISSsoft via the KISSsys
calculation elements.
X KISSsys: Calculation Systems 895
67.1.3.2 Diagram view
Diagram view (on the right in→ (see Figure 67.1)) shows the kinematic coupling of the elements. To
start with, the element structure has nothing to do with the calculations. The calculations only use the
data that relates to the shafts, gears and connections. These can be added or deleted as required.
The structure consists of shafts and their sub-elements: gears, forces, couplings and bearings. The
kinematic coupling and the power flow between the shafts is achieved via connections. The
connection has the calculation standard for transferring the speed to the next element (usually simply
the ratio). It also transfers a torque and a loss of efficiency.
The externally supplied torque and a speed are defined with speed/torque elements. In each case,
you can specify whether the speed or the torque are known, or whether they should be calculated by
KISSsys. The number of predefined values must correspond to the number of degrees of freedom.
Use the left-hand mouse button to move elements within the diagram view. Right-click to display a
context menu, like the one in the tree view. You can change the zoom factor by clicking on the '+' or
'-' buttons, or in the context menu which you access with a right-click.
67.1.3.3 Table view
To display the tables, select Show in the context menu in tree or diagram view. The contents of the
tables are defined when the system is set up. Although the values displayed in black cannot be
changed, you can edit numbers or strings shown in red. A special table for user interfaces has fields
with a gray background. Start these functions by double-clicking on them.
You can print the contents of the table, or press Ctrl-C to copy it and then, for example, paste it into
a spreadsheet.
67.1.3.4 3D view
To display the windows for the 3D view, select Show in the context menu in tree view. Use the left-
hand mouse button to rotate the view, use the right-hand mouse button to enlarge or reduce the view
and move it with the center mouse button. One of the main views can be selected from the menu or
from the tool bars.
In 3D view you can export the 3D geometry to the CAD system (via the context menu). If you want to
display graphical elements (see System.kSys3DElements), you can export the elements from that
file if you have the appropriate license. If a 3D kernel is present and you want to generate solid
elements, a CAD file will be generated directly.
X KISSsys: Calculation Systems 896
67.1.3.5 Message output
In the lower part of the program window (see → (see Figure 67.1)) there is an output window for
messages. Error messages and warnings from KISSsoft calculations are displayed under Messages.
Calls by KISSsoft are reported under KISSsoft, so this view is usually not required.
In the lower program window, as in KISSsoft, you will see an information tab. If information about a
particular function is present, it is displayed in this tab.
67.1.3.6 Menus, context menus and the tool bar
In the File main menu, you can open, store and save models, open and close projects, and close
KISSsys. You can also open or close KISSsys templates.
Each individual docking window in the user interface can be hidden or displayed in the View main
menu. You can also refresh all views.
The System main menu is where you generate the KISSsoft report and run kinematics and KISSsoft
calculations. You can also select a load spectrum for the model from the KISSsoft database or define
your own in KISSsys. Use these functions to call the characteristics of the elements and variables
overviews.
In the Insert menu, the Assistant will guide you through the steps required to create a simple gear
unit or a single stage planetary gear unit. The Elements Box works like the Assistant in that it lets you
add elements, but without any structural limitations. Default templates are used to add predefined
models or templates to an existing model.
In the Extras menu, you will find the administrator settings, the license tool, the configuration tool and
the language setting. Select Extras > Settings to change general program settings such as the
names of individual elements or table settings.
In accordance with Windows conventions, at the end of the menu bar you will find the Help icon
which you can use to navigate in the KISSsoft manual and in the KISSsys program. In Help > Info,
you will find information about the program version and about the support provided by KISSsoft.
In the Window main menu, you will find actions for organizing the opened sub-windows, such as
tables and 3D views. The print option is only enabled if a table is open.
In addition to the main menu, KISSsoft uses context menus in many locations. Use context menus to
access actions for a particular area or model element. Normally, you click the right-hand mouse
button to display context menus.
The tool bar gives you faster access to actions from the menus that are used particularly frequently.
You should also read the tool tips: they display information about the actions in the tool bar and also
the more detailed explanations in the status bar.
X KISSsys: Calculation Systems 897
67.2 Creating Models in KISSsys
This chapter is intended for KISSsys users.
You can create new models in KISSsys in four different ways. These are described in the next four
sections.
67.2.1 Classic method
If you enable the Administrator in KISSsys Extras > Administrator, the system displays, in the
Template tab, all elements that are required for creating a model. To create a model, copy the
elements you want from the template and insert them in the navigation tree. You can also create
elements by moving them from the template to the navigation tree. All possible models can be
created using this traditional method.
67.2.2 Element Assistant
The Element Assistant, which you call by selecting Insert > Elements, is based on the classic
method. If you use this assistant, you no longer have to drag and drop or cut and paste data. To
insert an element, simply click on it, and the system automatically inserts it in the current structure in
the navigation tree. You can use the Element Assistant to create all possible kinds of variants.
67.2.3 System Assistant
Under Insert > System of Shafts KISSsys provides an Assistant with which you can create
cylindrical gear stages. This Assistant guides you through the model step by step when you are
creating it. You use it in the same way as the standard Assistant. Use this function to create a
cylindrical gear unit.
Use the existing KISSsys Assistant to create parallel shafts with the following combinations of gears:
▪ Cylindrical gear
▪ Bevel gear
▪ Worm wheel
▪ Face gear
Use the Planetary Gear Stage Assistant to create a single stage planetary gear unit.
This Assistant leads you through the model step by step when you are creating it. You use it in the
same way as the standard Assistant.
X KISSsys: Calculation Systems 898
67.2.4 Setup with icon
The default setting is that all the elements are listed on the left-hand side of the screen as icons, so
you can construct a model from the very beginning.
67.2.5 Creating and modifying tables
You can use a predefined table, called "UserInterface", to create your own tables in KISSsys Model.
This table is stored in the template in "Tables". Using this "UserInterface" table, you can add all
parameters from the elements and your own texts. You can change the table's name to suit your
needs.
For each cell, no matter what it contains, you can right-click with the mouse to select Format in the
context menu. There you can set the font, color, background color, and position, of the text for that
cell.
67.2.6 Adding variables to tables
One way of inserting variables in the "UserInterface" table is to select a variable from the "Properties"
dialog and then click on the appropriate icon in the "Tool bar" menu. You can then insert the
variables either as text (Name), as a reference, or as an expression.
Text
You can also input texts directly in the cell. Alternatively, you can click on the Text icon to transfer the
required value to the cell. To do so, select the parameter you want to insert from an element's
property and preselect a cell in the table. Then click on the Text icon. This transfers the required
value to the cell. You can also hold down the left-hand mouse button and drag and drop the required
parameter, to insert it directly. The default setting is for text to be inserted. Click on Extras >
Settings > Tables tab to define the default setting as a text, reference or expression.
X KISSsys: Calculation Systems 899
Reference
Referenced data is displayed in red. These values are referenced with a parameter in the element
property. You can modify the value both in the table and in the property.
You can add referenced values to cells in the same way as you add texts. Select the parameter you
want to insert from an element's property and preselect a cell in the table. Then click on the
Reference icon. This transfers the required value to the cell. Alternatively, you can hold down the
right-hand mouse button and insert the parameter in the appropriate cell. A selection window is
displayed, in which you can select a text, reference or expression, as required.
Expression
The expression is merely shown as a value and cannot be modified in the table. You can insert an
expression into a cell in the same way as a reference.
67.2.7 Individual names for elements
Individual names can be used for all KISSsys elements. The individual name is assigned to the
element automatically when it is assigned to the model. This behavior can set individually for each
element (Extras > Settings > Elements).
Use the <autoInc> and <localInc> tags to add an index to the individual name at the insertion
position. The first of these tags increments the index globally. This means that no other element in
the model can have the same name. The second of these tags increments the index locally (in the
same folder). Use the <parentName> tag to add the name of the hierarchically superior element.
X KISSsys: Calculation Systems 900
The "Automatically/Ask" option is set to suppress or display the dialog that prompts the user to define
the name for the new element for the model. Click on "Reset" to select the KISSsys default name.
You can use the "Ask all", "Automatic all" and "Reset all" functions to modify all the elements at the
click of a button.
67.3 Extended functionality for developers
In addition to the functionality already described, more functions are available for developers.
▪ To open a template file, click on File > Open Templates. Alternatively, click on Insert > Default
templates to load the template file. It is displayed as a tree under Templates.
▪ To add new elements in tree view, you can "Copy" and "Paste" them. The new elements are
added as copies from a template file.
▪ You can rename and delete elements via context menu functions.
▪ The data in the Properties dialog can be edited. New variables can be added and deleted
▪ Hidden variables will be displayed and all functions can be performed.
▪ Hide messages by selecting Extras > Suppress messages.
67.3.1 Properties dialog
In tree view, or in the diagram for an element, you can open the KISSsys Properties dialog via the
context menu. In it, you can add new variables or change existing ones. Only one Properties dialog
is available. A second one is not displayed.
X KISSsys: Calculation Systems 901
Figure 67.2: The KISSsys Properties dialog
Figure 64.2 shows the Properties dialog. On the left, you see a tree view in which you can select
data elements or variables, and on the right, you see a dialog for the selected variable. The following
fields are available for the variables:
▪ Type: Display the variable type (see chapter 67.4.1, Variables).
▪ Name: The name of the variable. You can change the name here. However, if a variable has to
be used in formulae or references, you must also change the name there, as otherwise the
variable cannot be found.
▪ Reference: Enter the reference target here for reference elements. A name must be entered in
quotation marks. An alternative would be the name of a string variable (see chapter 67.4.1.1,
References). For variants (see chapter 67.4.1.2, Variants), enter the index in an array. Here, an
invalid reference is marked in red.
▪ Value: The current value of the variable.
▪ Expression: An expression used for calculating the variable. If an expression is present, the
value is calculated on the basis of that expression.
▪ "KISSsoft→ KISSsys" flag. The variable can be transferred from KISSsoft to KISSsys.
X KISSsys: Calculation Systems 902
▪ "KISSsys→ KISSsoft" flag. The variable can be transferred from KISSsys to KISSsoft.
You can convert the variable into a reference or variant variable and vice versa by clicking on the
Reference or Variant button.
67.3.2 Table view
The format of the tables is defined in the hidden definition variables. There are different types of
tables:
▪ Table for calculations: This table is best suited for displaying the data for several elements of
the same type. The definition format is:
[[type,rows,columns],['variable1','variable2',..]
[element1,element2,..]]
In the case of type 1, you can edit each displayed value, in the case of type 2 you can edit all
values that have no expression, and in the case of type 3 you can edit all values for which the
KISSsys→ KISSsoft flag has been set. The Number of Rows or Columns is not used.
▪ Table for arrays or variants: In this table, the arrays or variant variables are each displayed in a
separate column. The definition format is:
[[type,rows,columns],['variable1','variable2',..]]
In the case of type 21, you can edit each displayed value, in the case of type 22 you can edit all
values that have no expression, and in the case of type 23 you can edit all values for which the
KISSsys → KISSsoft flag has been set. The Number of Columns is not used.
▪ Table for user interface: You can configure this table to suit your needs. The definition is
[[type,rows,columns],[[A1,B1],[A2,B2]]]. The contents can be inserted via a context menu in
the table, and should not be changed in the definition. Since the definition is changed
interactively, you must not set an expression here. The number of rows or columns should also
only be changed in a dialog. Otherwise information about reference elements will be lost.
X KISSsys: Calculation Systems 903
67.4 The following elements are available
67.4.1 Variables
The following variables can be used:
▪ Real: A numerical value.
▪ String: A character string. Input in quotation marks e.g. "Text".
▪ Point: A coordinate or vector with 3 components. Input in {1,2,3} format.
▪ Array: A one-dimensional or multidimensional field. Input e.g. as ["Text",1.23,{1,2,3},[1,2]].
▪ Function: An executable function. Input best entered via the special input screen.
▪ ElementID: The ID of a Classcad object. Output as $31, input as name of the object with no
quotation marks.
▪ List: Displayed as selection list and acts as a number in the Interpreter (index of the list
beginning with 0). The selection list is defined as an array via the Edit list menu option, e.g.
["one","two","three"].
▪ Database List: The name from the KISSsoft database is displayed in a selection list. In the
Interpreter, this type also acts as a number according to the database ID. To define the
database assignment as an array, select the Edit the list menu option: ["database","table"]
Each of the variables has a name, a value, an expression and different flags. If an expression is
present, the value of the variables is defined via this expression. The expression is therefore
particularly well suited for inputting formulae. If, in contrast, a formula is entered in place of the value,
this formula will be evaluated and the result will be assigned. The actual formula will be lost. The
KISSsoft > KISSsys and KISSsys > KISSsoft flags determine how data is exchanged between the
two programs. Only variables with the appropriate flag activated are exchanged.
In the case of functions, the function is placed in the expression, and the value has no meaning.
For the Real, String, Point, List and Database List data types there are additional reference
elements and variant elements.
67.4.1.1 References
A reference element behaves like any other variable, with the difference that another variable fetches
the data. A valid variable name must be entered as the target for the reference element. The
reference target must be entered as a character string. This will be either an actual name in quotation
marks or an expression resulting in a character string, e.g. a concatenation of character strings (e.g.
gear1+'.z' with the string variables gear1 or 'gearwheel1.z'). The system marks an invalid reference
in red.
X KISSsys: Calculation Systems 904
67.4.1.2 Variants
Internally, the variant elements administer a field of variables, whereas externally they behave like a
normal variable. The variant is assigned an index variable as additional data. This index variable is
used to index the field. The index variable must be entered as an array of variables
(e.g.[system.index]). You can use these data types to store load spectra or system variants. The
results can then be displayed in tables.
67.4.2 Calculation elements
All the elements for KISSsoft calculations are derived from classes which begin with the name kSoft.
They have a blue background in the tree view.
The calculation elements have a range of functions:
▪ Calculate: performs a KISSsoft calculation in the background.
▪ kSoftInterface: starts KISSsoft interactively
▪ kSoftReport: runs the calculation and displays the report.
▪ SetFlags: sets the flags for data exchange between KISSsoft and KISSsys to suit the required
storage location.
▪ Save in KISSsys: the data is transferred in both directions.
▪ Save in KISSsoft: data with a stored expression is transferred from KISSsys to KISSsoft. All
other data is only transferred in the other direction.
This function sets the flags only once, when it is selected. It therefore has no effect on later changes.
▪ kSoftModul: this hidden function displays the KISSsoft module descriptor.
▪ getTranslationTable: this hidden function shows the translation table for variable names from
KISSsys to KISSsoft. In the calculation element, the translation table can be extended via the
TranslationTable array: For example, an entry of
[['eps_a_min','ZP[0].Eps.aEffI'],['eps_a_max','ZP[0].Eps.aEffE'] adds a link between the
variables eps_a_min and eps_a_max and the relevant KISSsoft variables. Up to now, the
names of the KISSsoft variables could only be taken from the report templates, which are .rpt
files.
▪ getUtilization: this function returns the utilization, and the required safety/safety ratio.
In the fileName variable, you can specify a KISSsoft calculation file which will automatically be
loaded at the start of the calculation, before any other variables are transferred. You can use the
savingMode variables to specify whether this KISSsoft calculation file should be saved
automatically:
X KISSsys: Calculation Systems 905
▪ Don't ask and don't save When KISSsoft is shut down, you will not be prompted to save the file
if changes have been made to it.
▪ Ask for saving When KISSsoft is shut down, you will be prompted to save the file. (KISSsoft
default response)
▪ Save automatically When KISSsoft is shut down, the calculation file is saved automatically
without a user confirmation prompt.
▪ Save file in KISSsys No file name will be entered in the fileName variable. Instead, the entire
calculation file will be saved in the KISSsys element.
The shaft calculation includes the special UpdateShaftElements method. Use this method if an
element of force is to be added/deleted on a shaft. It evaluates the type and number of elements of
forces on the shaft and transfers them into the 'forces' array in the shaft calculation. This array is a
defining factor for the forces in the shaft calculation.
67.4.2.1 Relationship of calculations with elements
Templates which automatically link the calculation with the shafts and gears are provided. The
Dialog function is designed for this purpose. If you want to make a fundamental change, i.e. if more
elements of forces are added to the shaft, you must call this dialog again to update the relationships.
67.4.2.2 Storage strategies for calculations
There are different options for saving the calculation data:
1. Save all the data in the KISSsys file. Calculations can only be accessed via KISSsys: Select
Save file in KISSsys, in savingMode. It is best to set the flags bidirectionally.
2. Save all the data in a KISSsoft file, and the file can also be changed outside of KISSsys: Select
Ask for saving, or Save automatically in savingMode. The flags must be set to Save in
KISSsoft with SetFlags. Note here that the calculation data will only be loaded from the
KISSsoft file when the calculation is called for the first time. After the KISSsys file is opened, you
should therefore call kSoftCalculate once again.
67.4.2.3 Importing existing KISSsoft calculations
If KISSsoft calculations are already present for elements of a new KISSsys system, you can simply
load the files in the KISSsoft window. However, you should note a few points:
▪ The file name stored in the fileName variable, in the KISSsys calculation element, will be
changed. The name must either be deleted or modified.
X KISSsys: Calculation Systems 906
▪ The elements of forces and the bearings are overwritten during the shaft calculation. For this
reason, you need to call the Dialog or UpdateShaftElements function after importing the
calculation. The elements of forces and bearings cannot be imported, and neither can the
positions. This data must be entered in KISSsys.
▪ In the case of gears, you must ensure that the sequence of the gears matches up.
67.4.3 Elements for shafts
Different elements can be placed onto shafts. They will also be transferred to the KISSsoft shaft
calculation. The position on the shaft is defined with the position variable.
▪ kSysHelicalGear: A cylindrical gear.
▪ kSysBevelGear: A bevel gear. The position of the peak is defined by the direction variable.
▪ kSysWorm: A worm.
▪ kSysWormGear: A worm wheel.
▪ kSysCoupling: A coupling. Diameter d and Width b can be entered for the 3D display.
▪ kSysBearing: A normal type of bearing. Losses can be recorded in Tloss. The direction of the
loss torque should be defined with a -sign(speed) in the expression.
▪ kSysRollerBearing: A rolling bearing. The bearing geometry is imported from the KISSsoft
bearings database every time you refresh the calculation. Losses can be recorded in Tloss. The
direction of the loss torque should be defined with a -sign(speed) in the expression.
▪ kSysCentricalLoad: A centrical load. KISSsys will always give default values for torque (Ty) but
not power. This torque will also be included in the kinematics calculation.
▪ kSysMass: An additional mass on the shaft.
▪ kSysRopeSheave: A pulley (rope sheave). Unlike the torque, the belt force is not calculated via
the connection. It is up to you to ensure that the belt force in two belt sheaves matches up.
▪ kSysFaceGear: A face gear.
67.4.4 Connection elements
▪ kSysGearPairConstraint: a connection between two cylindrical or bevel gears.
▪ kSysPlanetaryGearPairConstraint: a connection between a gear and a planet. You can select
the type of pairing: sun-planet, planet-internal gear or planet-planet. Both gears must also be
entered in this sequence. A planet carrier must also be selected. The number of planets must be
defined in the NofPlanets variables in the planet carrier coupling.
X KISSsys: Calculation Systems 907
▪ kSysPlanetaryBevelGearConstraint: a connection between a bevel gear and a rotating bevel
gear for bevel gear differentials. As in the case of the planetary connection, the sequence of the
bevel gears and the number of planets must be defined. An efficiency cannot be specified here.
▪ kSysWormGearConstraint: a connection between a worm and worm wheel. You can also define
two efficiencies (eta1 and eta2) for the driving worm or driving gear.
▪ kSysCouplingConstraint: A connection with ratio 1 between two couplings. The coupling's
kinematic force can be selected or deselected. You can also specify a value for slip, e.g. for
flake graphite couplings or synchronizations. The torque in the connection is usually calculated,
but can also be specified.
▪ kSysBeltConstraint: A connection between belt sheaves. The transmission ratio is calculated
from the diameter ratio. A slip and an efficiency can be specified. The ratio and the prefix
operator into account when entering a value for slip. This calculation is performed according to:
n1 - d2/d1 . n2 = slip
▪ kSysConnectionBearing: A connection between two shafts
▪ kSysConnectionRollerBearing: A connection between two shafts
▪ kSysSynchronizer: A shaft synchronizer
Use the setConfig(slipConstraint_r/[slipConstraint_r, slip_r],
torqueConstraint_r/[torqueConstraint_r, torque_r]) function to activate or deactivate the
connection:
▪ 1.: closed, without slip: setConfig([TRUE, 0], FALSE),
▪ 2.: open, without torque: setConfig(FALSE, FALSE),
▪ 3.: open, with torque: setConfig(FALSE, [TRUE, 20])
▪ kSysSpeedOrForce: An element for specifying speed or torque. Both values can either be
specified or else calculated by the system. You can also preset the power as an alternative to
the torque.
Use the setConfig(speedConstraint_r, torqueConstraint_r/[torqueConstraint_r, type_r,
torque_r]) function to change the presets. If you specify a load type, the values shown below have
these meanings: 0..torque with prefix operator, 1..torque driving, 2..torque driven, 3..power driving,
4..power driven. Examples:
▪ 1. Speed and torque specified: setConfig(TRUE, TRUE),
▪ 2. Speed and torque with value specified: setConfig(TRUE, [TRUE, 0, 20]),
▪ 3. only driving power specified: setConfig(FALSE, [TRUE, 3, 20])
X KISSsys: Calculation Systems 908
67.4.5 Displaying elements in a 3D graphic
Each element has an OnRefresh3DView function which generates the 3D display. If necessary, this
function can be overwritten. You can set the color of an element in the range from 0 to 255, with the
kSys_3DColor variable, and set the transparency with the kSys_3DTransparency variable. These
two variables must be created if necessary.
67.4.6 System settings
You can use any of the setting options in the System element:
▪ kSoftAcceptChanges: default setting yes, the changes will be transferred from KISSsoft. If the
setting is no, nothing will be transferred. If it is asked, you will be prompted to confirm whether
the changes should be accepted when KISSsoft is shut down.
▪ kSysKinematicFunc: you can call up the OnCalcTorque function while the kinematics are being
calculated. The standard implementation of this function calls up the calculation of the bearing
actions for all shafts.
▪ kSysKinematicMode: kinematics can either be calculated iteratively or non iteratively. Iterations
for the torque must be selected if you want to include the efficiencies. Iterations for speeds are
only necessary if formulae for speeds have been entered.
▪ kSys3DElements: you can display either graphical elements or solid elements (3D kernel
required). Graphical elements are generated more quickly, although solid elements are more
detailed. If is also possible, for example, to display an imported housing.
▪ project_name: the project name is displayed in the KISSsoft calculation reports.
▪ project_contract: the commission number is displayed in the KISSsoft calculation reports.
67.5 Programming in the Interpreter
The expressions used in variables and in functions have programming options.
67.5.1 Expressions in variables
The programming options in expressions are restricted. No local variables can be used.
Between the data types, the operators are defined in accordance with Table 64.1. A range of
mathematical functions is also available. These are listed in Table 64.2.
Data type Operations Description
X KISSsys: Calculation Systems 909
Real +,- Addition and subtraction
*,/ Multiplication and division
<,>=,=,!=,>=,> Relational operators
!,AND,OR Logical operators
String +,LEN Concatenation and length operators
<,>=,=,!=,>=,>,! Relational operators
Point +,- Addition and subtraction
*,** Scalar and vector multiplication
:x,:y,:z Access to components
LEN Vector length
Array [],+,LEN Indexing, concatenation and length operator
67.1 table: Permitted operators for data types
abs(x) Supplies the value of x
sign(x) Supplies the prefix operator of x (+1, -1 or 0 if x=0)
min(a,b,...) Supplies the smallest value of the arguments
max(a,b,...) System supplies the largest value of the arguments
a_r(x) System converts from degrees to radian measure
r_a(x) System converts from curve to degrees
sin(x) System calculates sin of x in the radian measure
sinh(x) System calculates sinh of x in the radian measure
asin(x) System calculates arcsin of x in the radian measure
cos(x) System calculates cos of x in the radian measure
cosh(x) System calculates cosh of x in the radian measure
acos(x) System calculates arccos of x in the radian measure
tan(x) System calculates tan of x in the radian measure
tanh(x) System calculates tanh of x in the radian measure
atan(x) System calculates arctan of x in the radian measure
atan(y,x) System calculates arctan of x in the radian measure
exp(x) System calculates e to the power of x
ln(x) System calculates the natural logarithm of x
log(x) System calculates the decadic logarithm of x calculates
X KISSsys: Calculation Systems 910
sqrt(x) System calculates square root of x
pow(x,y) System calculates x to the power of y
fmod(x,y) System calculates x modulo y
67.2 table: Predefined mathematical functions
A variable's expression can include the specified operations and any function calls. If limited
expressions are to be used, the expression must begin with # and the result must be returned with
RETURN:
#
IFa>bTHEN
RETURNa;
ELSE
RETURNb;
ENDIF
67.5.2 Functions
The different options for programming in functions are best described with the help of examples. A
function's header looks like this:
//ÜbergebeneVariablenvomaufrufendenProgramm
PARParameter1,Parameter2;
//DeklarationvonKonstanten
CONSTPI=3.1415926,E=2.71828;
//DeklarationvonlokalenVariablen
VARa,b,c,d;
Here, the lines that begin with // are comments. Each of these three lines may only occur once, and
the declared variables must be separated with a comma. A non-initialized parameter or variable is
VOID. This can be checked with ISVOID(variable).
Limited statements have two variants: IF or SWITCH statements:
//IF-AnweisungmitoptionalemELSIFundELSEBlock IFParameter1>5THEN
a=sin(PI*Parameter1);
ELSIFParameter1<0THEN
a=Parameter1; ELSE
X KISSsys: Calculation Systems 911
a=0;
ENDIF
//SWITCHAnweisungmitAuswahlüberZahlenoderTexte
SWITCHParameter2
CASE'Null':b=0;
CASE'Eins':b=1;
DEFAULT:b=5;
ENDSWITCH
There are four program variants for loops:
//FORSchleifemitoptionalerSchrittweite
FORa=1TO8STEP2DO
b=b+a;
IFb>100THEN
BREAK;//beendetdieSchleife
ENDIF
NEXT
//WHILESchleife
WHILEb<100DO
b=b*10;
WHEND
//DOSchleife
DO
b=b*10;
UNTILb>100;
//FORALLSchleifewirdfüralleElementeeinesArraysausgeführt
X KISSsys: Calculation Systems 912
c=[1,2,3,4,5,6,7,8,9];
a=0;
FORALLcdDO//dbekommtjeweilsdenWerteinesElementesvonc
a=a+d;
NEXT
There is a special syntax for calling up functions that belong to objects. The standard method is to
specify the object name followed by a point and the name of the function. However, the name of an
object can also be contained in a local variable. This enables you to change the object for the
function call at runtime.
//DieFunktionOBJ_GetMemberwirdfürObjekt1aufgerufen.
Objekt1.OBJ_GetMember('variablenname');
//aistlokaleVariablevomTypStringmitdemNameneinesObjektes
a='Objekt1';
//EswirdeineServicefunktionfürdasObjektmitNamenaaufgerufen
b=a.OBJ_GetMember('variablenname');
//ruftvomBenutzerangelegteFunktionfürObjekt1auf.
a.Benutzerfunktion();
//dievomBenutzerangelegteFunktionwirdfürdas
//aktuelleObjektaufgerufen.
Benutzerfunktion();
//dievomBenutzerangelegteFunktionwirdfürdas
//übergeordneteObjektaufgerufen.
^.Benutzerfunktion();
The system searches for variable names relative to the current object. If object.z is used in an
expression, the system will first attempt to find this variable below the current object. If it is not
present, the search will continue in the hierarchically superior object (in accordance with ^.object.z)
and so on.
X KISSsys: Calculation Systems 913
67.5.3 Important service functions
OBJ_GetChildren() Supplies an array with all child objects.
OBJ_GetName() Supplies the name of the object.
OBJ_GetId() Supplies the ID of the object.
OBJ_GetId() Supplies the ID of the object.
OBJ_HasMember() Tests whether a variable is present
OBJ_GetMember() Supplies the variable of the current object.
OBJ_FindMember() Supplies the variable of the current or hierarchically superior
object.
67.3 table: Important service functions
67.5.4 Variable dialogs
In interpreter functions, variable dialogs can be generated for the input of variables. The call is:
res = CADH_VarDialog(["Title", Width, Height, Pitch], [dialog element 1], [dialog element 2],
etc.);
The title is displayed in the dialog title line, and the width and height values show the dialog's
dimensions in pixels. The pitch (between 0 and 1) describes the relationship between the width of the
field description and the dialog width (default value 0.4). This definition of the dialog size can be
followed by any number of arrays that each define the individual dialog elements.
The return value is an array. Its first value is res[0] =1 if the dialog has been closed by the user
clicking OK. Otherwise, it is zero. The other elements of the returned array supply the results of the
input fields.
Below, the following convention is used to define the type of a variable: _str=String, _n=Int, _r=Real,
_b=Bool. For example, in the case of Caption_str, this means that the Beschr variable is of the type
String.
67.5.4.1 Dialog elements for the variable dialog
The following dialog elements are available for the variable dialogs:
Horizontal grouping:
The horizontal grouping provides a framework in which the individual dialog elements are lined up
beside each other. Their position must always be defined by a vertical group, which means that all
dialog elements in a horizontal grouping must be defined in a vertical group. A horizontal group is
defined as follows:
X KISSsys: Calculation Systems 914
[C:VDGL_HORZ,Caption_str,DistAbove_n,DistAfter_n,[Dialogelem]]
▪ C:VDGL_HORZ: type definition for horizontal grouping.
▪ Caption: the horizontal grouping's caption. If "Caption" is not an empty string, a frame will be
drawn around the horizontal group.
▪ DistAbove: space above the horizontal group to the next dialog element.
▪ DistAfter: space after the horizontal group to the next dialog element. "DistAfter" and
"DistAbove" are specified in pixels.
▪ [Dialogelem]: element array used to define the dialog elements located in the horizontal
grouping. This array must only contain elements of the type VDGL_Vert.
Vertical grouping:
The vertical grouping provides a framework in which the individual dialog elements are lined up
below each other. The width of the dialog elements is defined by the vertical group. A vertical group
is defined as follows:
[C:VDGL_Vert,Caption_str,[XStart_r,XEnd_r],XPart_r,[Diag],Marg_n]
▪ C:VDGL_Vert: type definition for vertical grouping
▪ Caption: the vertical grouping's caption. The vertical grouping always has a frame drawn around
it.
▪ [XStart,XEnd]: XStart and XEnd define a factor (between 0 and 1) for the width of the vertical
group relative to the width of the hierarchically superior dialog. They also define the X-position of
the vertical group.
▪ XPart: a factor between 0 and 1 that defines the ratio between the prompted value and the input
value for the dialog fields (the text assigned to an input field is called the "prompt"). If XPart=-1,
the prompt is positioned above the dialog element.
▪ [Diag]: element array used to define the dialog elements in the vertical grouping.
▪ Marg (margin): An optional parameter that defines the displacement of the dialog elements
relative to the edge of the vertical group. This means that the dialog elements contain the "Marg"
(margin) distance from both the left-hand and right-hand edge of the vertical group.
RealEditFeld:
Provides an edit box in which you can enter a floating comma number.
[C:VDGL_Real,Prompt_str,Preset_r,res,res,Places_n]
▪ C:VDGL_Real: type definition of RealEditFeld.
X KISSsys: Calculation Systems 915
▪ Prompt: text assigned to the input field.
▪ Preset: preset value.
▪ res: a space (place) has been reserved here for two optional parameters which are not currently
in use. However, these places must not be left empty in the definition (e.g.
[C:VDGL_Real,Prompt,Preset,0,0,Places] would be a correct solution but not
[C:VDGL_Real,Prompt,Preset,,,Places]).
▪ Places: an optional parameter defining the number of decimal places in the input field.
▪ ReturnVal: (return value). The return value is the input string.
IntEditFeld:
Provides an edit box in which you can enter a whole number.
[C:VDGL_Int,Promt_str,Preset_n]
▪ C:VDGL_Int: type definition of IntEdit field.
▪ Prompt: text assigned to the input field.
▪ Preset: preset value.
▪ ReturnVal: (return value). The return value is the input string.
StringEditFeld:
Provides an edit box in which you can enter text.
[C:VDGL_Str,Promt_str,Preset_str]
▪ C:VDGL_Str: type definition of the StringEdit field.
▪ Prompt: text assigned to the input field.
▪ Preset: preset value.
▪ ReturnVal (return value): the return value is the input string.
Text display:
The system generates a text display. If an empty string is entered instead of text, the text field can
also be used to define a space.
[C:VDGL_Prompt,Prompt_str,Fieldheight_n]
▪ C:VDGL_Prompt: type definition of text display.
▪ Prompt: field text.
▪ Fieldheight: height at which the text is displayed.
X KISSsys: Calculation Systems 916
IntComboBox:
Provides a combo box in which you can enter a whole number.
[C:VDGL_IntCom,Prompt_str,[Entr_n],Sign_n/[Ind_n],0,0,AsVal_b]
▪ C:VDGL_IntCom: type definition of IntComboBox.
▪ Prompt: text assigned to the combo box.
▪ [Entr]: element array with the available list items (in the case of an IntComboBox, the
components must be whole numbers).
▪ Sign/[Ind]: Here, you have the option of using "Sign" to either set a constraint value, which is
contained in the list, directly, or using "Ind" to select a value in a particular list position as a
constraint value (the first element in the list is located at position 0)."Sign" or "[Ind]" are optional
parameters.
▪ AsVal: If the optional "AsVal" parameter has been set, and does not equal 0, the return value
becomes the input. Otherwise, the return value is the index of the selected entry.
IntEditComboBox:
Provides a editable combo box in which you can enter a whole number. Please ensure that the
values entered here are whole numbers.
[C:VDGL_IntComE,Prompt_str,[Entr_n],Sign_n/[Ind_n]]
▪ see IntComboBox
▪ ReturnVal: (return value). the return value is the input string.
RealComboBox:
Provides a combo box in which you can enter a floating comma number.
[C:VDGL_RealCom,Prompt_str,[Entr_r],Sign_r/[Ind_n],0,0,AsVal_b]
▪ see IntComboBox
RealEditComboBox:
Provides a editable combo box in which you can enter a floating comma number.
[C:VDGL_RealComE,Prompt_str,[Entr_r],Sign_r/[Ind_n]]
▪ see IntComboBox
X KISSsys: Calculation Systems 917
▪ ReturnVal: (return value). The return value is the input string.
StringComboBox:
Provides a combo box in which you can input a string.
[C:VDGL_StrCom,Prompt_str,[Entr_str],Sign_str/[Ind_n],AsPos_n]
▪ see IntComboBox
▪ AsPos: In contrast to the IntComboBox, the return value here represents the index of the
selected field, if the optional parameter "AsPos" has been set and does not equal 0. Otherwise,
the return value is the input.
StringEditComboBox:
Provides a editable combo box in which you can enter a string.
[C:VDGL_StrCom,Prompt_str,[Entr_str],Sign_str/[Ind_n]]
▪ see IntComboBox
▪ ReturnVal (return value): the return value is the input string.
X KISSsys: Calculation Systems 918
67.5.4.2 Example application of a variable dialog
Figure 67.3: Example of a variable dialog
The program code for the variable dialog in Figure 64.3 is shown in the following example. As many
elements as possible have been used in it:
// VARIABLES DECLARATION
VAR res,result1,result2,result3,result4,result5,fullResult;
// DIALOG AND INPUT DATA
res = CADH_VarDialog(["Example of Variable Dialog",500,400,0.4],
[C:VDLG_StrCom,"StrCOMBOBOX1:",["Gear1","Gear2","Gear3"],[2],0],
[C:VDLG_Prompt,"TEXT1:",30],
[C:VDLG_IntCom,"IntCOMBOBOX1:",[12,17,19],17,0,0,1],
// HORIZONTAL GROUP WITH ONE VERTICALGROUP
[C:VDLG_HORZ,"HORIZONTAL UNIT1",20,10,
X KISSsys: Calculation Systems 919
[ // Warning: remember brackets!
[C:VDLG_VERT,"VERTICAL UNIT1",[0.3,0.9],-1,
[C:VDLG_Str,"StringFld:","Test Program"],
[C:VDLG_RealComE,"RealCOMBOBOX1",[5.3,7.1,9.1],[2]]
],
20
] // Warning: remember brackets!
],
// HORIZONTAL GROUP WITH TWO VERTICAL UNITS GROUPS
[C:VDLG_HORZ,"HORIZONTAL UNIT2",10,10,
[C:VDLG_VERT,"VERTICAL UNIT2",[0.01,0.35],-1,
[C:VDLG_Int,"IntFld:",6],
[C:VDLG_StrComE,"StrCOMBOBOX2:",["Gear1","Gear2"],[0]]
],
10
],
[C:VDLG_VERT,"VERTICAL UNIT3",[0.4,1],-1,
[C:VDLG_Real,"RealFld:",5.6,0,0,3,3],
[C:VDLG_IntComE,"IntCOMBOBOX2:",[5,7,9],7]
]
X KISSsys: Calculation Systems 920
);
// res [0] contains 1 if OK was pressed , or else
IF res[0] THEN
// READ RESULTS FROM DIALOG:
result1 = res[1]; //res [1]= Gear3
result2 = res[2]; //res[2]= TEXT1:
result3 = res[3]; //res[3]= 17
result4 = res[4]; //res [4]= [["Test Program",9.1]]
result5 = res[5]; //res[5]= [[6,"Gear1"],[5.6,7]]
fullResult=res; //res=["Gear3","TEXT1:",17,[[''Test
Program",9.1]],[[6,"Gear1"],[5.6,7]]]
CADH_Message(fullResult);
ENDIF
67.5.4.3 Interactions with variable dialogs
You can interact with variable dialogs. Selections in lists, changes in input fields, and selections in
lists, can trigger callbacks to a user-defined function. Then, you can also change dialog elements
from this callback routine.
To do this, set a local function as a callback via the title input in the variable dialog:
res = CADH_VarDialog([[“Title“,PROC(Callback)], Width, Height, Pitch], [dialog element 1],
[dialog element 2], etc.);
The local callback function will now be called if you make changes to the dialog. The function is
declared as follows:
PARres;
PROCCallback
X KISSsys: Calculation Systems 921
PARhandle,elemNo,event,eventPar;
IFTYP(elemNo)=STRINGTHEN
IFelemNo='@combo'ANDevent=C:CBN_SELCHANGETHEN
IFeventPar=0THEN//owninput,enableinput
CADH_VarDialogAccess(handle,[['@input1',C:VDLG_ENABLE,TRUE]]);
ELSE//disableinput,setvaluetozero
CADH_VarDialogAccess(handle,[['@input1',C:VDLG_ENABLE,FALSE],
['@input1',c:VDLG_ASSIGN,0]]);
ENDIF
ENDIF
ENDIF
ENDPROC
res=CADH_VarDialog([['Titel',PROC(Callback)],400,4000.4],
[[C:VDLG_Real,'@input1'],'Input1:',2],
[[C:VDLG_StrCom,'@combo'],'Selection:',
['owninput','calculate'],[0],TRUE]);
A handle is transferred to the dialog as a code parameter, along with an element identifier, the event,
and additional parameters. The possible events are:
Element type Event Parameter
Dialog Initialization none
WM_INITDIALOG
Combobox Selection Current value
CBN_SELCHANGE
Input field Leave field Current value
WM_KILLFOCUS
Button selected none
BN_CLICKED
X KISSsys: Calculation Systems 922
Either the number of the element according to the index in the results array is transferred as the
element number, or the name of the element is transferred. As in the example, a name can be
defined by transferring an array, with a type and name in its first element, for the dialog element.
Use this function to access the dialog from the callback routine:
CADH_VarDialogAccess(handle, [[elemNo, action, param],[elemNo, action, param],...]
The following actions are permitted here:
Action Description Parameter
VDLG_ASSIGN Assignment to input field New value
VDLG_SELECT Selection in combo box [position]/value
VDLG_ENABLE Select or deselect TRUE/FALSE
VDLG_SETFOCUS Focus on new element Element's ID
If no action is specified, the value in the input field is returned. The data is returned as an array, with
as many elements as code parameters.
67.5.5 Defining 2D graphics
In KISSsys, you can generate two-dimensional graphics for displaying results which are present in
arrays. You can store the definition of the graphic in the data variable expression of the kSys2DPlot
graphical element. Bar and line graphics can be displayed in at the same time. The definition of the
graphic consists of three parts:
▪ Axis system (1- or 2-axis systems can be defined)
▪ XY-line graphic
▪ Bar graphic
Each of these parts is described in more detail below.
67.5.5.1 The definition of the axis system (af)
At least one axis system must be defined. The second one is optional. The definition for the axis
system is as follows:
[ | Xaxisname_str , | min_x_r , | max_x_r ] , [ | Yaxisname_str , |
min_y_r , | max_y_r ] , [ axiscolour_str/array , | axiscross_x_r ,
axiscross_y_r ] , [ | scaleinterval_x_r , | scaleinterval_y_r , [ |
exponential_x_n , | exponential_y_n ]
X KISSsys: Calculation Systems 923
where:
▪ XAxisname: name of the X-axis.
▪ YAxisname: name of the Y-axis.
▪ min: minimum value of the axis (optional).
▪ max: maximum value of the axis (optional).
▪ axiscolor: the axis color is defined in a string (red, green, blue, yellow, white, gray, cyan, brown,
magenta, purple, black) or as an array [r_n, g_n, b_n] (where "r", "g" and "b" represent the red,
green and blue color values from 0 to 255 (optional).
▪ axiscross: the intersection point of the axes (optional).
▪ scaleinterval: increment of the axis scaling.
▪ exponential: if 1 is input, the axis will be logarithmically subdivided.
67.5.5.2 The definition of an XY-line graphic (dg_l)
The following information is required for an XY-line graphic:
grouptype_n , [ dataarray_x_r ] , [ dataarray_y_r ] , [ | linename_str , |
|linecolour_str/array , | linestyle_n ] , | assignaxis_n
where:
▪ grouptype: =1 (for lines graphic).
▪ dataarray: contains the data's X- or Y-coordinates.
▪ linename: name of the element.
▪ linecolour: line color.
▪ linestyle: line type (0: continuous, 1: interrupted, 2: dashed, 3: semicolon, 4: dash dot dot)
▪ assignaxis: number 1 or 2 of the coordinates system
67.5.5.3 The definition of a bar chart (dg_b)
A group of data is defined as follows for a bar chart:
grouptype_n , [ dataarray_1_r , ... , |dataarray_n_r ] , [
barcolour_str/array ] , | bargroupname_1_str , [ | barelementlabel_1_str ,
... , barelementlabel_1_str ] , | barclass_n
where:
▪ grouptype: = 2 (for bar chart).
▪ dataarray: contains the data for the group.
X KISSsys: Calculation Systems 924
▪ barcolour: color of the group's bars.
▪ bargroupname: name of the group.
▪ barelementlabel: names for individual elements.
▪ barclass: display as group (=0) or sorted by elements (=1).
67.5.5.4 The entire definition
The entire definition must begin with the definition of the axis system. After this, you can list any
number of definitions for line and bar charts. Each part definition must be enclosed in square
brackets, just like the entire definition:
[ [af_1] , | [ af_2] , | [dg_l_1] , ..., | [ dg_l_ n1 ] , | [ dg_b_ 1 ] ,
..., [ dg_b_ n2 ]]
If lines and bars are used simultaneously, a second coordinates system will automatically be applied.
This can, however, be changed by the definition of a second coordinates system. An example of the
available options is listed as follows:
[['x-ACHSE'],['y-Achse',0],[[40,250,150],[-1000,-10]],[30,20,0,0]],
[['x-ACHSE2'],['y-Achse2',0],['blue',[0,0]],[30,20,0,0]],
[1,[-1000,-500,0,500,1000],[5,20,40,55,71],['LINE1','red',0]],
[1,[-1000,-500,0,500,1000],[2,20,46,60,83],['LINE2',[200,5,150],3]],
[2,[5,25,16,10,4],['red',3],'group1'],
[2,[40,35,25,20,12],['red',3],'group2']
The example shows two lines and two groups of bars in two separate coordinates systems.
67.5.5.5 Displaying the graphic
After you have defined the graphic in the data variables, you can use the graphical element's Show
function to display the graphic. You can update it later by selecting the Refresh function in the menu
or the graphics window.
X KISSsys: Calculation Systems 925
67.6 Specific functions
Some specific calculations are integrated in KISSsys.
67.6.1 Load spectrum calculation
With KISSsys the user can generate an entire gearbox or drive train in a single file. Calculations can
be then performed for the whole system using KISSsoft modules. If several stress cases are present
(load spectrum or load cycle), you can use this load spectrum in KISSsys to analyze an entire
system.
The user is then able to define load cases for the whole system and perform the calculation for all the
components. Service life calculations with a load spectrum can be used with the same components
as in KISSsoft.
Safety factors and rating lives of different gears and bearings can be calculated. This load spectrum
can also be used to calculate shaft fatigue and static safeties. The remaining components (which
cannot be used to perform a calculation with a load spectrum) are regarded merely as a test for the
"weakest" part.
The load spectrum functionality can be used for the following types of calculation:
▪ Calculation of a gear unit with a user-defined load
▪ Calculation of a gear unit with a single load stage taken from the load spectrum.
▪ Calculation of a gear unit with a predefined load spectrum (similar to the ones defined in
KISSsoft)
It is also possible to extend the spectrum by adding extra additional values or settings, for example to
consider different shift speeds for each bin, which is itself defined by a frequency, torque or power,
and a speed.
The following KISSsoft modules are also required to perform at least one strength calculation for the
elements that need to be calculated:
▪ Gear service life and safety factors with load spectrum
ZZ1 (load spectra) including modules Z16, Z16a, Z18 and Z18a
▪ Shaft calculation with load spectrum
WA8 (load spectra) including modules W01s and W06s
▪ Full version of KISSsys for template implementation and setup
K11c SYS module
X KISSsys: Calculation Systems 926
67.6.2 Efficiency Calculation
You can use the efficiency calculation in KISSsys to calculate the heat level in a particular gear unit.
Several different methods are implemented to enable you to select how the calculation is to be
performed, according to the ISO/TR 14179 standard, Part 1 and Part 2.
Thermal analysis can be defined in two sections: power loss and heat dissipation. An external cooler
can also be taken into account. Power loss and heat dissipation can be split up into several sections
to enable the effect of all the individual gear unit components to be taken into consideration.
There are two main types of power loss: load-dependent and non-load-dependent. Both types of loss
are usually present when a gear unit is running. Power loss can also be subdivided into gear unit
elements, such as gears, bearings and seals. Meshing and churning losses are taken into account
for gears, whereas rolling, sliding, seal and drag friction are taken into account for bearings, and seal
friction is taken into account for seals. In some cases, the results must be treated with caution
because the calculation methods used may not fully support the type of geometry.
Heat dissipation can be divided into heat dissipation through the housing, base, and turning parts
(input/output shafts and couplings) and cooling oil flow.
You can then simply calculate the total efficiency and the total heat dissipation capacity of a gear unit
for a given lubricant temperature, cooler power and input power. You can also specify two of these
three entries and calculate the optimum value for the third parameter, which is the value with which
you achieve the best heat level for the gear unit. In other words, the value where the heat dissipated
equals the heat generated through the power loss.
The difference between Part 1 and Part 2 of the standard is the way in which the different values are
entered for the calculations. The main benefit of Part 1 is that it enables you to enter your own heat
transfer coefficient for heat dissipation through the housing (if it has a very specific shape), whereas,
in Part 2, this coefficient is calculated using an approximation of the shape of the housing. The main
benefit of this part is that it also takes fins, bases and turning parts into consideration when
calculating heat dissipation.
67.6.3 Taking into account housing deformation in static KISSsys
calculations
67.6.3.1 Introduction
The inclusion of housing deformation in KISSsys static calculations is based on the use of a reduced
stiffness matrix for the housing, as calculated by the Finite Element Method (FEM). This reduced
stiffness matrix should include the nodes that refer to the center position of the bearings that connect
the shafts of the gear unit to the housing.
X KISSsys: Calculation Systems 927
67.6.3.2 Main calculation steps
The calculation steps for performing this kind of analysis are summarized below. The actual process
used to generate the reduced stiffness matrix is not described, because it is different for each FEM
computer program. Please refer to your FEM program manuals for more information.
▪ Step 1: Import the stiffness matrix and the FEM nodes coordinates
The first step is to read the stiffness matrix and the FEM node coordinates. To do this, calling the
relevant function in the housing element, in the KISSsys model (right-click, select
ImportStiffnessMatrix). Both the stiffness matrix and the nodes coordinates should be positioned in
the same file, together with information about the system of units used. An example this type of file
(that can now be handled by KISSsys) is shown below:
*******
▪ You will find more detailed information about the FE programs supported by the software, and
the file format requirements, in the relevant instructions (available on request).
▪ Step 2: Position the housing correctly in the KISSsys model
Since the FEM model and the KISSsys model may not have a matching coordinates system,
you should then position the housing correctly in the KISSsys model. To do this, right-click on
the housing element again, and select the ResetPosition function. In the next dialog, you can
either input the origin and alignment of the housing CS directly, or use the ThreePointPositioning
function. To use this function, select three points (e.g. bearing) in the KISSsys model from a
drop-down list, and then enter the coordinates of the same three points in the housing
coordinates system. Make sure that these three points are not collinear. This procedure returns
the housing CS with respect to the KISSsys CS. You can also perform a visual check to see that
X KISSsys: Calculation Systems 928
the positioning is correct by importing a simplified step file of the housing (e.g. only wireframe)
and displaying it in the KISSsys 3D viewer. To import a step file into the housing, right mouse-
click on it and select Dialog. We recommend you use a simplified version to avoid overloading
the KISSsys model. Finally, you can also decide how the FEM nodes are displayed on the
KISSsys model, by right-clicking on the housing element and selecting ShowNodes in the
context menu. Every time the orientation of the housing is changed, you must select
ShowNodes again, to update the nodes view in KISSsys. If you click on ShowNodes, you also
see the IDs of the displayed FEM node, which makes it easier to validate the positioning. At this
point, we must mention that you do not need to add a step model to the housing element,
although you can use this model as an additional aid for validating the correct positioning.
▪ Step 3: Perform the analysis
Click the housing calculation button to start the analysis. The first step in the calculation is to
map the FEM nodes on KISSsys bearings. The program reports all the nodes that can be
mapped and displays their distance to the closest bearing. At this point, you need to know if the
rejected nodes actually correspond to bearings. You can then decide whether to continue with
the calculation or cancel it. One possible reason for specific bearings not corresponding to
nodes is that the housing is positioned incorrectly in the KISSsys CS. If this is the case, then the
previous step must be repeated. If this is not the case, and the difference between FEM nodes
and bearings (as reported in the mapping message) is not too great, you can change the
tolerance used in the mapping process. This may happen, for example, if the FEM node is
positioned at the edges of a bearing instead of in the middle. The tolerance used in the mapping
can be changed in the housing properties in KISSsys (right-click on the housing and select
Properties window). There, the tolerance is given in millimeters.
If you continue the calculation, the program reduces the stiffness matrix for the part that
corresponds to the mapped nodes, and therefore ignores all nodes that were not mapped to
bearings. The calculation also ignores any predefined offsets and tilting values previously
specified in the bearings and sets them to zero. The algorithm runs all the KISSsoft calculations
and derives the forces on the bearings from their results. The program then uses these forces to
calculate the offsets and tilting on the bearings (using the FEM stiffness matrix). The KISSsoft
calculations are then run again with the resulting offsets, which may result in new bearing forces
and offset values. This procedure is continued iteratively until there is convergence between
successive forces and offset calculations. There may be cases where the maximum permitted
number of iterations is reached due to housings with low stiffness. If you cancel the calculation,
the system will display the percentage difference between the last two iterations and apply the
results from the last iteration. You can set the "Maximum no. of iterations" in the housing
X KISSsys: Calculation Systems 929
element's properties (right-click on the housing element, and then select Properties). The
relevant property is called "maxNumberOfIterations". You should input a number greater than
4 to ensure the algorithm finds a useful solution. After the calculation is finished, you can
perform further studies, as for example contact analysis on gears, in order to see the effect of
housing stiffness on the design parameters of the gear unit.
You can also use several housings, each with a different stiffness matrix, in the KISSsys model.
In this case, the program prompts you to select the housing it should use, before starting the
calculation. This can be very useful if you want to compare the effect of different housing
designs on the gear unit design. The results for each housing calculated using this method are
then stored in the housing element. These results can then be viewed again by clicking on the
housing element's RestoreOffsetResults function (right-click on the housing). The following
functions for handling displacement are also available (the tolerances remain the same).
▪ ResetBearingOffsets: reset all bearing offset values to zero
▪ SaveBearingOffsets: save the current displacement values.
▪ RestoreBearingOffsets: recover the saved displacement values.
67.6.4 Modal analysis of shaft systems
67.6.4.1 Introduction
The modal analysis of shaft systems function in KISSsys is used to calculate the eigenfrequencies
and eigenmodes of an entire shaft system, including the effect of the gear connection between
shafts. Performing a modal analysis for individual shafts is not realistic. This analysis must be
performed for the entire topology of the shaft system. The necessary calculation steps, together with
important restrictions, are detailed below.
67.6.4.2 Calculation procedure
To calculate the system dynamics, first import a KISSsys ShaftSystem calculation into the model.
Right-click and then select "Modal analysis" in the context menu, to display a dialog in which you can
set various parameters for the calculation. You must define the number of eigenfrequencies to be
calculated, and specify whether only torsional or all vibration types are to be included, whether
gyroscopic effects are to be taken into account (does not apply to torsional vibrations), and which
calculation method is to be used to calculate tooth contact stiffness. The following selections are
available for this last option:
▪ According to ISO 6336, where the tooth contact stiffness as described in this standard is used.
X KISSsys: Calculation Systems 930
▪ Using the KISSsoft Contact Analysis (CA) algorithm, where a full contact analysis is performed
in the gear connections. If KISSsoft does not have a contact analysis calculation for a particular
gear pair type, or if the gear pair does not transfer power, the ISO 6336 process is used for that
specific pair.
▪ Infinite: the tooth contact stiffness is assumed to be infinite. Select this option if you want to
check limiting conditions.
▪ Ignore: the tooth contact stiffness is assumed to be zero, and there is therefore no connection
between the vibrating shafts (each shaft is vibrating independently).
All the dynamic calculation properties mentioned above are also available in the calculation's
Properties window (right-click on Calculation and select the Properties window).
67.6.4.3 Results
After the calculation is finished, a new tab opens, in which a 3D animation of the vibrating system can
be displayed. There, you can select the eigenfrequency you want to view and also define the
animation speed and the scaling of the deformations. The eigenfrequency values and tooth contact
stiffnesses used for each gear pair are also displayed in the system dynamics report, together with
other useful analysis results and a 2D plot diagram. To display this report, right-click on
ShaftSystem calculation and then select ShowReport. If necessary, click on the SavePlot button
to save the 3D plot, if it is to be used (unchanged) in subsequent calculations, (so that a new plot is
generated each time). After the calculation is finished, the program also generates a table that shows
the mode shape data of all the shafts in the system.
Please note that the only gears displayed in the animation window are those that belong to a shaft
calculation file. Nevertheless, all the gears are taken into account in the modal analysis.
Finally, also note that, if a modal analysis is performed for a planetary system, this does not take into
account the effect of the turning planets' position on the system bending stiffness. This is similar to
the quasi-static calculation procedure usually followed in eigenfrequencies analysis.
67.6.5 Campbell diagram for shaft systems
67.6.5.1 Introduction
A Campbell diagram can be used to investigate the effects of shaft speed on the eigenfrequencies. It
determines the critical eigenfrequencies for each speed or multiple of that speed.
67.6.5.2 Calculation procedure
To run a calculation for shaft systems with a Campbell diagram, click on the ShaftSystem calculation
element in KISSsys. Right-click on the element, and then select the CampbellDiagram option. The
X KISSsys: Calculation Systems 931
Campbell diagram dialog has all the necessary entries. You can select the reference shaft for the
calculation from a list of shafts in the system that include a coupling with a defined boundary
condition. In this dialog, you can also select the calculation method for calculating the gears and the
speed range of the reference shaft. You can define the various different speeds, together with the
number of eigenfrequencies, that are to be taken into account in the Campbell diagram. Finally, you
can select the number of resonance curves that are to be drawn in the Campbell diagram. The
calculation starts with a kinematic analysis of the system for each speed of the reference shaft. The
speeds of all of the shafts are updated and then a modal analysis is performed for each of these
speeds.
67.6.5.3 Results
Once the calculation is finished, you can view the 2D plot of the Campbell diagram directly in
KISSsys. A more detailed 2D display, and a number of other useful analysis results, appear in the
report which is generated when you right-click on ShaftSystem Calculation and then select
ShowReport. All the calculation data is also available in the results table that is generated in
KISSsys. You can also click on the "SavePlot" button to save the 2D plot, if it is to be used
(unchanged) in subsequent calculations, (so that a new curve is generated each time).
67.6.6 Analysis of unbalance response of shaft systems
67.6.6.1 Introduction
The unbalance response analysis functions can be used to calculate the real dynamic behavior of a
shaft system that is subjected to dynamic loads (unbalance masses). The calculated behavior
includes deformations, rotation, forces and moments. The necessary inputs and the results achieved
by the calculation are described below.
67.6.6.2 Calculation procedure
To call the unbalance response analysis, click on a ShaftSystem calculation element in KISSsys.
Right-click on the element, and then select the Unbalance response option. The next dialog
contains all the inputs required to perform the calculation. You can select the reference shaft for the
calculation from a list of shafts in the system that include a coupling with a defined boundary
condition. You can then select the X-axis of the unbalance response diagram for the calculation (and
therefore also define the type of calculation to run). Two options are available here:
▪ Reference shaft speed. The reference shaft speed is modified within the range you specified
(min/max speed) with the predefined number of steps. A kinematic calculation is performed for
each speed in the entire shaft system and the speed of all the shafts is calculated. These
speeds are then used to calculate the dynamic loads, which are then applied to the model. The
result is the unbalance response in the specified reference position on the shaft.
X KISSsys: Calculation Systems 932
▪ Y-coordinate of the reference shaft. In this case, the length of the reference shaft is subdivided
into the predefined number of sections, and the unbalance response calculation is performed for
the specified speed. This results in the exact shape of the reference shaft at this speed.
You can then also select the calculation method you want to use to calculate contact stiffness, which
is similar to the modal analysis calculation.
The effect of speed on the stiffness of rolling bearings (only for bearings with internal geometry) can
also be taken into account. If this option is selected, a static calculation is performed for each speed,
and the bearing stiffness used in the dynamic analysis is modified accordingly.
You can also define the material damping for torsion, axial and bending vibration in this dialog. Note
that the viscous damping of bearings must be defined separately for each bearing in the shaft
calculation (freely definable units) or in its properties in KISSsys (SI units).
67.6.6.3 Results
Once the calculation is complete, a 2D plot is generated from the data you have entered. More
detailed analysis results and other plot data are displayed in the report which is generated when you
right-click on the ShaftSystem KISSsys element and then select ShowReport. You can also click on
the SavePlot button to save the 2D Plot, if it is to be used (unchanged) in subsequent calculations,
(so that a new curve is generated each time). A table with all the data used in the plot is also
generated. Note that this calculation method not only calculates results at the reference position of
the reference shaft (as defined in the input data for the unbalance response analysis), but also
calculates analysis results for all the documentation points that are defined in the system's shaft
calculations. These documentation points can therefore be used as measuring points for dynamic
behavior. The results of the documentation points are displayed both in the report and in the results
table.
XI
Bibliography and Index
Chapter 68 - 68
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[78] Meissner, M.; Schorcht, H.J.; Metallfedern - Grundlagen, Werkstoffe, Berechnung, Gestaltung
und Rechnereinsatz, 2. Auflage; Berlin; Springer-Verlag; 2007
[79] DIN EN 15800; Zylindrische Schraubenfedern aus runden Drähten: Gütevorschrift für
kaltgeformte Druckfedern, DIN Taschenbuch 29; Berlin; Beuth Verlag; 2011
[80] DIN 2096; Zylindrische Schraubenfedern aus runden Drähten und Stäben: Gütevorschrift für
warmgeformte Druckfedern, DIN Taschenbuch 29; Berlin; Beuth Verlag; 2011
[81] DIN EN 13906-2; Zugfedern: Berechnung und Konstruktion, DIN Taschenbuch 29, 12.
Auflage; Berlin; Beuth Verlag; 2015
[82] DIN 2097; Zylindrische Schraubenfedern aus runden Drähten: Gütevorschriften für
kaltgeformte Zugfedern, DIN Taschenbuch 29; Berlin; Beuth Verlag; 2011
XI Bibliography 939
[83] DIN EN 13906-3; Drehfedern: Berechnung und Konstruktion, DIN Taschenbuch 29, 12.
Auflage; Berlin; Beuth Verlag; 2015
[84] DIN 2194; Zylindrische Schraubenfedern aus runden Drähten und Stäben: Kaltgeformte
Drehfedern (Schenkelfedern), Gütenorm, DIN Taschenbuch 29; Berlin; Beuth Verlag; 2011
[85] DIN 2092; Tellerfedern: Berechnung, DIN Taschenbuch 29; Berlin; Beuth Verlag; 2011
[86] DIN 2093; Tellerfedern: Masse, Qualitätsanforderungen, DIN Taschenbuch 29; Berlin; Beuth
Verlag; 2011
[87] DIN 2091; Drehstabfedern mit rundem Querschnitt: Berechnung und Konstruktion, DIN
Taschenbuch 29; Berlin; Beuth Verlag; 2011
[88] VDI 2241; Schaltbare fremdbetätigte Reibkupplungen und -bremsen, Blatt 1 (1982), Blatt 2
(1984); 1984
[89] Johnson, K.L.; Contact Mechanics; Cambridge University Press; 1987
[90] Boresi, A.P., Schmidt R.J.; Advanced mechanic of material, 6th Edition; John Wiley and Sons
Inc.; 2002
[91] Ribeiro, M.; Gaussian Probability Density Functions: Properties and Error Characterization;
2014
[92] Zaka, A.; Akhter, A.; Methods for Estimating the Parameters of the Power Function
Distribution; 2013
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