Cylindrical + Planetary gears + Manufacturing

CPM1 (Basic)

ZPK Cylindrical gears
Calculation of cylindrical gear pairs and single gears
Calculation of geometry, control measurements (DIN 3960, DIN 3962, DIN 3963, DIN 58400)
Tolerances as specified in updated ISO 1328-1,2:2020
Reference profiles according to DIN 867, JIS 1701-1, deep tooth forms and short cut toothing, machining addition, grinding of tooth root
Strength calculation for a cylindrical gear, either as specified in ISO 6336 (module ZA10), DIN 3990 (module ZA11), AGMA 2001 (module ZA12), VDI 2545 (module ZA17), VDI 2736 (module ZA21) or GOST 21354-87 (module ZA22)
Input of speed for epicyclic gears configuration
Calculation of tooth friction and power loss according to Niemann
Flash temperature progression
Calculation and 2D and 3D display of the tooth form for external and internal toothing
Scuffing according to DIN 3990 and ISO/TS 6336-20/21
Micropitting according to ISO/TS 6336-22 (Method B)
Calculation of case hardening depth according to FVA 271
Calculation of gear mesh frequencies, assembly phase frequencies and hunting tooth frequencies
Input of individual flank line modifications per tooth
Generation of variants for modifications
Arc of circle and spline approximation for 2D Export (requires module CA1)
Extended 2D and 3D display of the tooth form (module ZY1)
Tip shortening for involute or imported tooth forms
Animation of meshing gears, simultaneous display of more than one machining step, measuring function in the graphic, function for saving data for A – B comparison,
collision check, marking of contact point, marking of collision
Manual input of active tip and active root circles in the single gear calculation
Output of manufacturing drawings
Extensive material database
Save tools to the database and compare with existing tools
Contains this module: ZY1
Rights: Z01, Z01z, Z04b, Z04c, Z05i, Z05t, Z05v, Z19e, Z19m

ZA10 Strength according to ISO 6336:2019 and ISO 6336:2006 (replaced)
Rights: Z02a

ZA1 Planetary gears, three gears, four gears
Rights: Z01a, Z19g

ZY1 Extended tooth form display
For 2D and 3D graphics, animation of meshing gears, simultaneous display of more than one machining step, measuring function in the graphic, function for saving data for A – B comparison, tooth form and tool in normal section, collision check, marking of contact point, marking of collision
Rights: Z05x, Z05j, Z05k

ZA5 Sizing functions and special calculations
Sizing of profile shift using different criteria
Calculation of profile shift and tooth thickness allowance taken from measured tooth geometry, pre-machining tools with grinding stock, topping tools
Sizing of the reference profile for a required transverse contact ratio
Rough sizing of modifications (microgeometry), tip and root relief (linear, progressive and logarithmical), crowning and helix angle modification sizing, taking into account axis inclinations as specified in ISO 6336-1, Annex B or in ISO 6336-1, Annex E (requires module ZA35)
Report for tolerances according to ISO 1328, DIN 3961, DIN 58405, BS 436, AGMA 2001 or AGMA 2015
Calculation with manufacturing profile shift
Sizing of center distance to take into account balanced specific sliding
Profile and flank line diagrams (K diagrams)
Rights: Z01x, Z15, Z19a, Z19d, Z19h, Z19l, Z19n

ZA3 Rough sizing macrogeometry
for gear pairs and planetary gear stages
Sizing according to required safeties, determination of the center distance and facewidth for solutions with the same torque capacity, display of multiple variants, specification of total weight
Rights: Z03
ZA4 Fine sizing macro geometry
for gear pairs and planetary gear stages, three gears, and four gears
Variation of the module, number of teeth, profile shifts, pressure angle, etc.
Calculation of all executable variants, taking into account the installation constraints of planet gears
Automatic sizing of deep tooth forms (requires module ZA5)
Calculation of transmission error for all variants (requires module ZA30)
Specification of cutter and pinion-type cutter lists per gear
All solutions are classified on the basis of different criteria
Display of results in tables and graphics
Rights: Z04, Z04a

ZZ1 Load spectra and transmittable torque
Calculation of transmittable power with and without load spectrum
Calculation of service life with and without load spectrum
Calculation of safeties with load spectrum (for cylindrical, bevel, and cross helical gears)
Taking into account the direction of rotation of the individual stages, and their load direction (for cylindrical gears)
Graphical display of speed and torque classes
Rights: Z16, Z16a, Z18, Z18a, K23

ZA24
Tooth root stresses with 2D FEM
Calculation of tooth root stresses for cylindrical gear pairs (with straight or helical teeth)
Calculation with integrated FEM Solver CM2®
FEM results displayed in KISSsoft
Rights: Z38a

ZA30 Contact analysis for cylindrical gears
taking into account flank modifications and shaft deformation
Tooth flank fracture according to ISO/TS 6336-4:2019 (requires module ZZ4)
Calculation of the excitation force according to FVA-No. 487
Calculation of path of contact under load
Graphical display of the results in the excitation force, efficiency, forces and stresses groups
Calculation and display of Hertzian pressure, contact pattern and tooth root stresses along the actual tooth flank
Load-free contact pattern and display of the assembly contact pattern
Calculation with conical profile shift
Calculation of contact stiffness and transmission error under load, based on the actual tooth form
Display of specific sliding, sliding velocity and sliding factors for gears under load from actual tooth form
Display of friction power and local heat generation along the meshing
Wear calculation for plastic (dry run) and steel (cold wear)
Calculation and display of the progression of wear
Calculation of safety against micropitting according to ISO/TS 6336-22
Calculation of lubrication gap according to ISO/TS 6336-22 and AGMA 925 with actual normal force
Calculation of power loss and speed across the meshing
Rights: Z24, Z25, Z27, Z30, Z31, Z31a, Z32, Z32b, Z32c, Z36, Z39a, Z39b, Z39c, Z39d and K05w

ZA35
Face load factor KHbeta according to ISO 6336-1, Appendix E
Calculation of gaping and load distribution while taking into account flank modifications and shaft deformation
Tolerance variations with (+/-)fma and (+/-)fhb
Results are displayed in graphics and reports
Results for individual planets can be output
Rights: Z02c

ZZ4
Tooth flank fracture for cylindrical and bevel gears
For cylindrical gears according to ISO/TS 6336-4
For bevel and hypoid gears according to ISO/DTS 10300-4:2019 (draft) (requires modules ZC2 or ZC9)
Rights: Z07k

ZA34
Planetary stage contact analysis
taking into account flank modifications and shaft deformation
Floating sun wheel
All other functionalities as described in ZA30
Rights: Z24, Z25, Z27, Z30, Z31, Z31a, Z32c, Z34, Z36, Z39a, Z39b, Z39c, Z39d, K05w
ZM4
Manufacturing allowances
Twist due to manufacturing for generation grinding, simulation of waviness for flank and profile slope deviation
Rights: Z05f, Z05u
ZM5 Rollout
Analysis of the root form circle taking into account various tolerance fields of the final machining stock and hobbing cutter
Rights: Z05z
ZM10 Hobbing
Process analysis for hobbing with specification of the hobbing cutter geometry, cutting process (infeed strategy, cutting speed) and interference check.
Option to input specifications for multiple cuts
Calculation of processing time, tool costs per part, feed mark depth, maximum chip thickness
Rights: Z20h

CPM2 (Designer)

CPM3 (Expert)

General Description

Cylindrical gear basis modules

Configurations

Spur and helical gear, double helical, herringbone, with or without face width offset
Grease or oil lubricated or dry running gears
Metallic and plastic gears
Involute and non-involute gears
Any number of teeth, any type of tooth height, internal or external gears
Symmetrical and asymmetrical profile

Gear geometry calculation

Gear geometry along ISO 21771, DIN 3960
Reference profile along ISO 53, DIN 867, JIS B 1701, GOST 13755, DIN 3972, DIN 58400, BS 5482
Tooth thickness tolerances along DIN 3967, ISO 1328, DIN 58405, GOTS 1643
Centre distance along ISO 286, DIN ISO 2768, DIN 7168, DIN 58405, GOST 1643
Gear quality along ISO 1328, AGMA 2015, DIN 3961-3963, AGMA 2000, GOST 1643, JIS B 1702
Own input

Gear rating

DIN 3990 method B, DIN 3990 method B with YF along method C, DIN 3990 Part 41 (vehicles)
ISO 6336:2006 and ISO 6336:2019
Static rating against yield
AGMA 2001-C95, AGMA 2101-D04, AGMA 2001-D04
AGMA 6004-F88, AGMA 6011-J14, API 613 :2021, AGMA 6014-B15, AGMA 6015-A13, GOST 21354-87
Plastic gears along Niemann, VDI 2545, VDI 2545 modified, VDI2736
BV / Rina FREMM3.1, Rina 2010, DNV41.2, Loyds Register 2013
ISO 13691:2001 (high speed gears)
For nominal load or load spectrum

Reports

Default report or user specific template
Geometry and strength reports
Tooth scuffing, micropitting and wear
Tooth thickness dimensions, tooth tolerances
Modifications, manufacturing
X-Y coordinates of tooth profile

Cylindrical gear general modules

Gear geometry calculation

Based on gear or tool reference profile with protuberance, buckling root, reference thickness, semi- non- full topping
Or based on *.dxf import of tool geometry
Calculation based on mating gear geometry
Import and export of gear or tool geometry from CAD system
Calculation of theoretical, acceptance and operating backlash for metallic and plastic gears and housings

Load spectrum calculation

Direct input of load spectrum or import from text or Excel file or time series
Calculation of lifetime based on required safety factor, safety factors based on required lifetime and permissible torque based on required safety factor and lifetime
Calculation of partial damages
Calculation of equivalent torque
For DIN 3990, ISO 6336 and AGMA 2001 rating

AGMA925 calculations

Calculation of scuffing safety
Calculation of contact stress, lubricant film thickness

Micropitting and scuffing calculation

Micropitting rating along ISO/TS 6336-22
Specific lubricant film thickness calculation along AGMA 925
Lubricant film thickness calculation along ISO/TS 6336-22 based on true contact stress
Scuffing rating along ISO 6336-20, ISO 6336-21, DIN 3990-4

Flank fracture calculation

Along ISO/TS 6336-4 method
Along method A (based on LTCA) or method B (based on formulas)
Case crushing calculation along DNV 41.2

Master gear calculation

Calculation of master gear geometry
Meshing of master gear with workpiece
Sizing function for form diameters

Cylindrical gear sizing modules

Configurations

Sizing functions to find optimized gears (in terms of mass, power density, stiffness, space, … requirements)
Functions to reverse engineer gears
Functions to optimize gear properties

Rough sizing

Proposal of several gear solutions for required power rating, required ratio, given material
Considers gear quality, permissible ratio error
For single load level or load spectrum

Fine sizing

Define permissible ranges for module, pressure angle, helix angle, center distance, face width, gear quality, profile shift, …
Define target ratio and permissible deviation
Define maximum number of solutions
Set maximum permissible tip diameter and minimum permissible root diameter
For pre-defined number of teeth or varying number of teeth
Different filter and sorting functions
Report with assessment of solutions for different criteria

Profile shift sizing

Sizing from gear pair data
Sizing for target profile shift sum
For balanced specific sliding / speed increaser
To avoid pointed tooth or undercut
For maximized strength on flank or root or maximized scuffing strength

Sizing of tooth height / reference profile

Sizing of reference profile for target transverse contact ratio
Sizing of maximum possible root radius

Sizing of profile and lead modifications

Sizing of tip and root relief Sizing of end relief and crowning
Automatic search for optimum modifications

Cylindrical gear modifications

Configurations

Combine modifications in profile and lead direction, combined and topological modifications
Create K chart and lead diagram
Define tolerances range based on AGMA 2000, using constant band width or import tolerance bands from GAMA ®
Display each modification separately in 2D diagram, display resulting combination
Show flank modifications in 3D, combining all modifications
Gear 3D geometry includes modifications

Tip chamfer, tip rounding in different sections
Face chamfer, tip face chamfer
Modifications manager using variants of sets of modifications

Root modifications

Root with pre-machining and or final machining, independent root diameter tolerances
Grinding notch, partial final machining of root
Root geometry optimization for minimized root stresses

Manufacturing errors as modifications

Flank waviness with wavelength, amplitude and angle
Natural twist from generating grinding
Profile and helix form and slope deviation

Lead and profile modifications

End relief (left and right end), flank line crowning (centrical, eccentrical)
Helix angle modification
Linear and progressive tip / root modification
Profile crowning (barreling), also in combination with tip relief, roll length or diameter centered
Pressure angle modification
Tip chamfer or rounding
Flank twist

Triangular end relief (left and right end)
Topological modification
…

Gear body influence

Modelling and FEM

Hub / web / rim arrangement
Parametrized geometry
Automatic meshing, parabolic tet elements
Automatic meshing, parabolic prism elements
Modeling of local radii
Automatic defeaturing capabilities
Geometry preview, mesh preview
Import of *.stp files
Multibody modelling (separate materials for
rim and body)
Result review per body

Calcualtions and integration

Calculation of deformation and reduced
stiffness matrix
Stiffness matrix connected to shaft calculation
In combination with LTCA
2D and 3D-gear body deformation

Tooth geometry export

Options

With or without profile / lead modifications
Modifications may be different per tooth
Modifications may be different per flank
Output in transverse, normal and axial section
Output of tooth or gap, single or half tooth
Output as x,y format to use e.g., in spreadsheet calculations
Output as x, y, z format in line with Gleason or Klingelnberg format for measuring machines

Rating with time series

Import and conversion

Import time series of speed and torque from text file
Convert to load duration distribution load spectrum (LDD), save LDD for gear rating
Considers changes in torque direction
Considers changes in speed direction
Graphical display of resulting load and speed distribution

Configurations

Rain flow count method according to Amzallag or ASME
Simple count method

Loaded tooth contact analysis

Configurations

Considers all modifications in profile and lead direction and topological modifications
Calculation over one or several pitches
Pitch errors may be considered in part or fully
Calculation for nominal or operating center distance
Calculation for nominal or partial load level
Meshing friction considered in calculation
Considers true gear geometry from manufacturing simulation
For internal and external gears
User defined resolution in calculation
Line load calculation along ISO 6336-1, Annex E with consideration of manufacturing errors

Mesh stiffness calculation

Calculation of transmission error TE for spur and helical gears, showing peak to peak transmission error PPTE, average and standard deviation
Calculation of normal force, torque variation, contact stiffness, bearing forces, kinematics, specific sliding, and local heat generated over meshing cycle
Results displayed vs. roll angle, pinion diameter, length on path of action, pinion angle of rotation
Calculation has been verified in benchmarks against reference software, practical experience in full load tests and FEM calculations
Different methods for slice linking spring stiffness

Output

Graphics, exportable as graphic format or *.dxf
Report including calculation settings and results summary
Report including all graphics

True contact ratio calculation

Calculation of true transverse contact ratio under load
Calculation of true total contact ratio under load

Detailed backlash calculation

Backlash from true tooth form

Backlash is calculated as an angular backlash.
Theoretical backlash is calculated based on true tooth form. Tooth form may be involute, involute with modifications or non-involute. For non-involute tooth form or involute tooth form with modifications, backlash is not constant over the meshing cycle.
Backlash is calculated for highest, lowest and mean tooth thickness / diameter / center distance combination, resulting in three curves.
Collisions and tip to root interferences are indicated by zero backlash condition
Gear modifications in lead direction are considered, backlash is calculated for a number of slices along the face width
Tooth deformation and temperature influence are not considered
Works also for tooth form from imported *.dxf files

Backlash, acceptance backlash, operating backlash

Theoretical backlash in transverse and normal section, chordal and arc value, considering tooth thickness and center distance tolerances.
Acceptance backlash considering runout, manufacturing errors and axis misalignment.
Operating backlash considering housing and gear temperatures and moisture absorption.
Contact and collision check in 2D graphic in transverse section for any tooth thickness, diameter and center distance tolerance combination.
Recommendation of tooth thickness tolerances in case of gear jamming.
Backlash definition through manufacturing profile shift or tooth thickness tolerances.
Calculation of tooth thickness / backlash from span measurement or from diameter over pins.
Strength calculation on theoretical gear or on gear with backlash.

2D FEM of virtual spur gear

FEM models

2D plane stress model using parabolic triangular elements with variable mesh density
Mesh density is maximized for critical area in the root
Resulting stress levels are calculated for contact point of 30° (60°) tangent to theoretical tooth form, for contact point of 30° (60°) tangent to actual tooth form and for point with highest stress
Stress levels are reported and compared to nominal stress calculated along ISO 6336
FEM pre-processor (Salome) and solver (Code Aster) are remote controlled requiring no interaction.
Pre- and post-processor may be opened after calculation to check mesh, boundary condition and results
Different stress values like von Mises, max and min principal and others may be shown. Different color bars may be used.

Root stress calculation

For standard gear geometry with trochoidal fillet based on circular tip of tool
For non-standard gear root geometry including machining notches / grinding notches
For non-trochoidal, e.g., circular, or elliptic root shape
Also, for cycloidal and circle shaped (non-involute) gears
For asymmetrical involute gears

3D FEM

FEM model

For spur and helical gears
Using parabolic tetraeder elements

Planetary gears

Overview

Based on helical gear calculation modules
Calculation of planet pin location for non-evenly spaced planets
Influence of rim thickness of ring gear and planet gears considered
Assembly check
Sizing function for load distribution factor along AGMA 6123
Rough and fine sizing function

Strength rating, planets

DIN 3990 method B, DIN 3990 method B with YF along method C, DIN 3990 Part 41 (vehicles)
ISO 6336:2006 and ISO 6336:2019
Static rating against yield
AGMA 2001-C95, AGMA 2101-D04, AGMA 2001-D04
AGMA 6004-F88, AGMA 6011-J14, API 613 :2021, AGMA 6014-B15, AGMA 6015-A13, GOST 21354-87
Plastic gears along Niemann, VDI 2545, VDI 2545 modified, VDI2736
BV / Rina FREMM3.1, Rina 2010, DNV41.2, Loyds Register 2013
ISO 13691:2001 (high speed gears)
For nominal load or load spectrum
Planet system reliability
Micropitting rating along ISO/TS 6336-22, scuffing rating along ISO 6336-20, ISO 6336-21, DIN 3990, AGMA 925
Flank fracture rating along ISO/TS 6336-4 and case crushing rating along DNV 41.2

Kg calculation

For systems with perfect pin position or for pins with positioning error
Quasi-static load distribution neglecting dynamic effects
Sun may be floating or stationary
Kg is calculated for momentary force equilibrium for different meshing positions
Considering system equilibrium for in-phase and out-of-phase systems
Phasing check

Planetary tooth contact analysis

FEM calculation of planetary carrier

Planetary carrier torsion is calculated inside KISSsoft with FEM
Salome / Code Aster is used as pre-processor and solver, using Python scripts
Based on parameterized model of the carrier (import of carrier geometry is not directly possible)
Mesh generation is automatic
Includes sizing function for planetary carrier geometry
Results may also be directly imported from FEM results file

Ring gear deformation

In case of ring gears supported only on one side, the conical deformation may be considered for the planet – ring gear mesh

Sun gear arrangement

Floating or fixed sun gear
In case of floating sun gear, quasistatic momentary equilibrium is calculated

Link to shaft calculations

Planetary carrier tilting in carrier bearings or due to manufacturing errors may be considered from shaft calculation
Sun shaft twist, sun shaft tilting may be considered in LTCA with planets
Planet pin deformation and planet bearing deformations is automatically imported from shaft calculation
Planetary tooth contact analysis may be integrated into System Module models

Hobbing process

Process analysis for hobbing with specification of the hobbing cutter geometry, cutting process (infeed strategy, cutting speed) and interference check.
Calculated results are processing time, tool costs per part, feed mark depth and maximum chip thickness.
Sizing of the hob is available with consideration of shaft interference, shortest processing time and others.
Additional sizing functionalities are implemented such as calculation of smallest hob width, maximum chip thickness and feed mark depth.

Roll out Analysis

The roll out functionality allows the analysis of the root form circle taking into account various tolerance fields of the final machining stock and hobbing cutter.
Especially for tools using semi-topping and protuberance, it is important to verify the tolerances, to detect if grinding notches may occur or if the tip chamfer will be sufficient after hard finishing.

Database for hobs and shaping cutters

Existing tool designs can be imported into the KISSsoft database to determine whether they can be re-used. This functionality is available for hobs and shaper cutters.
The tools in the database can be checked to see whether the dimensions are within permissible deviations and are therefore suitable for reuse.
The permissible deviations can be specified individually for the parameters of engagement angle, head height, head radius and many more.
If a new tool is required, the reference profile data can be exported and added to the database. With the click of a button, a request for a new tool can be sent to Gleason.

Dressing disc & modifications

KISSsoft checks whether an existing dressing disc can be used, reducing tool cost and lead time.
The resulting gear modifications such as tip relief or pressure angle modifications, including tolerances, are displayed in a profile diagram.
These can be compared with the initial designed modifications and assessed for deviations in noise excitation.

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