1 / 14 5. August 2009 tut-101-02-GPK.

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KISSsys tutorial:
GPK

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1 Using this tutorial
This tutorial is meant to be as starting instructions for correct working procedure through gearbox
design with GPK ready made models.
In this tutorial ThreeStageHelicalGearbox will be used as a basis. Similar procedure is to be used
when working with any other GPK model.
Using GPK models doesnt require any programming skills or model building. Every component and
functionality needed for working with these models is already programmed in the library models. In
case if user wants to add something (calculations, new components) in the model to meet own
requirements, this can be added. In this case, please contact KISSsoft AG for more help.
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Table of Contents
1 Using this tutorial ............................................................................................................................. 1
2 Sizing task......................................................................................................................................... 3
2.1 Input data .................................................................................................................................. 3
2.2 Meaning of this tutorial ............................................................................................................ 3
3 Preparations ...................................................................................................................................... 3
4 Sizing a gearbox ............................................................................................................................... 4
4.1 General notes ............................................................................................................................ 4
4.2 Settings ..................................................................................................................................... 4
4.3 Pre sizing .................................................................................................................................. 4
4.3.1 Iteration for sizing............................................................................................................. 4
4.3.2 Final sizing........................................................................................................................ 4
4.3.3 Gears ................................................................................................................................. 4
4.3.4 Shafts ................................................................................................................................ 4
4.3.5 Final notes of sizing.......................................................................................................... 4
5 Final calculations.............................................................................................................................. 4
5.1 UserInterface............................................................................................................................. 4
5.2 Strength calculation .................................................................................................................. 4
5.3 Torque capacity ........................................................................................................................ 4
5.4 Reports...................................................................................................................................... 4

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2 Sizing task
2.1 Input data
Design 3-stage helical gearbox with input speed of 3000rpm clockwise and required output moment
20000Nm. Total ratio 100 3 %. Gearbox will be used in upright position so that input and outputs are
on the same side of the gearbox and vertically on the same plane. Space between input and output is to
be ~500mm.

Table 2.1-1 Input data for gearbox sizing
Input speed 3000 rpm
Required minimum output torque 20000 Nm
Ratio 100 3 %
Required lifetime 10000 h
Oil General type industrial oil
Operating temperature 70 C
Required safeties Shafts 1.25, Gears SH = 1, SF = 1.4
2.2 Meaning of this tutorial
After completing this tutorial, user is able to use GPK library models on his/her own. These ready
made models can be used as a template models to start to create own gearbox layouts and
calculations. This tutorial will show correct working procedure through the design procedure. In every
case all described steps are not necessary to go through and in other cases some more iterations or
tuning is needed to get the best possible solution.
3 Preparations
According to given data GPK model ThreeStageHelicalGearbox will be selected as a starting point.
If you dont have that model, please go to http://www.kisssoft.ch/english/products/gpk.php and
download correct file from there (ThreeStageHelicalGearBox.ks).
Create a project folder and place this GPK file in the folder. Open KISSsys and select working
directory to be this newly created project folder. Go to Menu - File - Open and select file
ThreeStageHelicalGearBox.ks. The correct GPK file is opened and ready for use.

At the end of this tutorial, please save the file before you will close it to keep your own modifications.
Use Save As to keep original model for later use.

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4 Sizing a gearbox
4.1 General notes
All the operations described in here are made using the tables. The tables are created to ease the
operation of the models. It is also possible to use the tree structure of the model to run the same
functionalities and procedures. In general all the information, variables and functions are saved in the
properties of the different elements. Using the right mouse on the tree, it is possible to view the menu
for every element and have a look at the list of the possible variables and functions and also to run the
functions.
4.2 Settings
Start with giving correct global setting values in the Settings-table.

Figure 4.2-1 Settings via table

1. Select lubricant and lubrication method, as well as the lubrication temperature. Note! Ambient
temperature has an effect only when using plastic gearing.
2. Define the mounting position and required lifetime for the gearbox
3. Define the efficiency for gears manually or let the program calculate the efficiency while running
the kinematic calculation. Adjust KA to 1.25.
4. Select calculation methods for components. Use ISO 281 for bearings to consider also the
lubrication.
5. Define materials for components. Pinion type gears will be gear1, gear3 and gear 5 in shafts 1, 2
and 3, so materials for those shall be equal.
6. Press Refresh to accept all changes. Use functions Model ID to give correct information to
model and Price settings to define pinion shafts and price estimations. (Note! Approximate price
for gearbox is calculated according to given base costs/kg. User needs to define these prices
according to own knowledge)
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Figure 4.2-2 Model information dialog


Figure 4.2-3 Price setting dialogs for price calculation settings

7. Use the function setup I/O to define speed for the shaft1 (Boundary1) and torque for the shaft4
(Boundary2). Torque can be always defined as input or output torque, meaning the gearbox can
easily be driven in both directions.

Figure 4.2-4 Power definition dialog

8. In this point it is also possible to change the bearings to the supports only or visa versa. This can be
done using the function Bearing Setup.
4.3 Pre sizing
Because no initial information about the gearbox size is given, the sizing of the gearbox can be start by
giving total required ratio for gearbox. Type in value of 100 for total ratio and give deviation from that
3%. Then press Divide_i to divide this total ratio over the three reductions. The ratios reached
automatically are good starting values and can afterwards be changed if needed. When helix angle
range is to be modified it can be done using the function Gear sizing param. Range can be selected
here freely, e.g.
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Figure 4.3-1 Definition for the helix angle


Figure 4.3-2 Sizing of gears and sizing of shafts and bearings

After the settings it is possible to try the gear sizing. Select initial sizing strategy for gears to be i
fixed from the drop down list and execute sizing functions Sizing gear pair 1, Sizing gear pair 1
and Sizing gear pair 1 in this order. With this sizing method only the ratio is fixed for gears and all
other values (helix angle, width, centre distance) are selected in order to have a good overall
solution. After the pre sizing, the gears are proposed and new layout can be seen in 3DView. After
gears pre sizing, the same can be done for the bearings and the shafts. Select desired bearings from the
list Type of bearing and select how shaft ends are positioned from the list of Coupling side and
Gear side in the first shaft. Initially we will use Deep groove ball bearings because they are
cheapest and most common type of bearings. Also type in the required shaft safeties (fatigue = 1.25
and Static = 1.25). Then double click on function Shaft and bearing sizing to make initial sizing for
bearings and shafts.

Message for some geometrical errors appears. So we need to do some adjustment for gearbox.


Figure 4.3-3 Information of geometrical error during first pre sizing

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Figure 4.3-4 Geometrical error and possible collision in 3DView
4.3.1 Iteration for sizing
The first and last gear pair is colliding. This can be prevented by increasing the centre distance of the
second gear pair. At the same time we can also adjust the centre distances of the other stages to be
more reasonable rounded numbers. This can be done by typing in the new values for Pair1 = 200, Pair2
= 270 and Pair3 = 300 and select sizing strategy to be i,a fixed and execute gear pair sizing again.
Finally the same should be done for the shafts and bearings to get a new layout.
Before Sizing of shaft and bearings you can also turn the gearbox in the correct working position by
changing shaft angles to consider all forces correctly for every bearing. There may be several
internal layouts for the gearbox to achieve the required output shaft position.


Figure 4.3-5 Gearbox positioning in space and new pre sizing



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Figure 4.3-6 Gearbox layout after pre sizing
4.3.2 Final sizing
After pre sizing the final sizing for gears, shafts and bearing selections must be done. Also the correct
geometry for shafts should be entered, because after pre sizing shaft geometry is only presented as one
diameter and one length of cylinder.


Figure 4.3-7 Definition of shaft1 after pre sizing

After you have completed the final sizing of the components, please remember to use function
Refresh in right hand side upper corner from UserInterface to actualize all the changes.
4.3.3 Gears
Make the final sizing for all gear individually through each gear pair mask. E.g. you may adjust
profile, corrections, profile modification coefficients, width or any other variable that is necessary. In
this example we will change gear widths to be reasonable values. Type of profile modification is set
for high load capacity under Special inputs and then automatic Profile correction for tip is
preformed to get better load distribution for the gears. This will be done for every gear.
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Figure 4.3-8 Gear pair final sizing via KISSsoft mask

After setting values for all the gears, the gear geometry should look like follows.
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Figure 4.3-9 Geometry after the final sizing of all the gears
4.3.4 Shafts
Define correct shaft data for every shaft. That can be started by deleting initial shaft geometry and then
input new geometry via shaft graphical input window. Bearings and force elements can be also
repositioned and correct bearings can be selected to support the shafts.

Figure 4.3-10 Detailed geometry for shaft1 after input in graphical shaft editor

Define new shaft geometry and insert notch factors. You may have to make couple of iterations for
shaft diameters, if bearing lifetime will get too high or too low with selected shaft diameter. It is also
possible to change bearing type to be more loads carrying type of bearing if shaft diameter gets too
big.
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Define also new cross section to calculate. This can be done e.g. automatically using the sizing from
the shaft tree. First remove the current cross sections and after this create the cross section where the
shaft strength is to be calculated.

Do the similar procedure for the other shafts also. For shafts 2,3 and 4 it is also possible to add notch
effect of keyway or pressure fit, depending on how loose gear is fixed on shaft. These notch effects
can be found as Subelements in graphical shaft editor.


Figure 4.3-11 Shaft2 after defining final shaft geometry


Figure 4.3-12 Shaft2 after defining final shaft geometry

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Figure 4.3-13 Shaft4 after defining final shaft geometry

The bearings are selected using the graphical shaft interfaces. The list of the selected bearings is seen
here.

Figure 4.3-14 Selected bearings for the gearbox
4.3.5 Final notes of sizing
In this example Deep groove ball bearings and Cylindrical roller bearings are used. This selection
is made because when loads gets quite big due to high torque, bearing size will get bigger, if depp
groove ball bearings are used in each shaft. That may also lead to an over sizing of shafts. In this case
bearing types are changed to Cylindrical roller bearings on last two shafts. This type of bearings has
more load carrying capacity and therefore shaft size doesnt get too big and safety factors for shafts are
in reasonable level. Deep groove ball bearings are anyway one of the cheapest bearings and detailed
analysis of total price may be needed to make correct selection for bearings.
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5 Final calculations
5.1 UserInterface
Use function Refresh in UserInterface before final strength calculation to make sure that all
changes in components are actualised before calculation.


Figure 5.1-1 Use Refresh function before final calculations to actualize every component after changes
5.2 Strength calculation
After every component has been selected and adjusted do final strength calculation. That can be done
via UserInterface with function Calculate Strength. After calculation is performed you should see
massage that strength is calculated.

Figure 5.2-1 Message after strength calculation, indicating that everything is ok
5.3 Torque capacity
Are you also interested to know what the torque capacity of your gearbox with defined components is?
That can be easily checked with function Calc. MaxTorque from the UserInterface. The function
will iterate input torque until some of the required criteria will fail. The result will be given as
maximum torque for the gearbox.

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Figure 5.3-1 Information about torque capacity calculation


Figure 5.3-2 Requirements to be fulfilled


Figure 5.3-3 Limiting calculation and max torque is displayed after torque capacity calculation

Limiting calculation is the bearing2 on the last shaft. The maximum applied torque for shaft4 as output
is 20387 Nm with given efficiencies. Initially 20000Nm as output torque requirement was given for
the gearbox. This means after the gearbox dimensioning the required lifetime and torque can be
achieved.
5.4 Reports
After all calculations last step is to create necessary documentation of gearbox. That can be done with
function Reports from UserInterface


Figure 5.4-1 Report selection dialog

Select desired report from the list and select Ok. All available reports are saved automatically to the
project folder and can be also accessed later. General report is short summary of most important results
e.g. to be given for customer. KISSsoft reports is a full report of all results in one file according to
KISSsoft protocols. Bearing forces will create a file consisting of global coordinates of every
bearing with bearing force components, e.g. to be used in housing FEM analysis.