Beruflich Dokumente
Kultur Dokumente
GPK
07/11/2014
KISSsoft AG
Rosengartenstrasse 4
8608 Bubikon
Switzerland
Tel: +41 55 254 20 50
Fax: +41 55 254 20 51
info@KISSsoft.AG
www.KISSsoft.AG
Foreword
This tutorial is meant to be used as a starting instruction for correct working procedure through gearbox
design with GPK pre-made models.
In this tutorial we will use a ThreeStageHelicalGearbox with Bearings as a basis. Similar procedure is to be
used when working with any other GPK model.
Using the GPK models doesnt require any programming skills or model building. Every component and
functionality needed for working with the models is already programmed in the models. In case the user
wants to add something (calculations, new components...) to meet own requirements, it can be added. In
this case contact KISSsoft AG for more help.
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Contents
1.
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1. Sizing task
1.1 Input data
Design a three-stage helical gearbox with input speed of 3000rpm clockwise and a required output moment
of 20000Nm. Total ratio 100 3 %. The Gearbox will be used in upright position so that input and outputs
are on the same side of the gearbox and vertically on the same plane. Space between input and output is to
be ~500mm.
Input speed
Required minimum output torque
Ratio
Required lifetime
Oil
Operating temperature
Required safeties
3000 rpm
20000 Nm
100 3 %
10000 h
General type industrial oil
70 C
Shafts 1.25, Gears SH = 1, SF = 1.4
2. 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/downloads/gpkdownload.php and
download the correct file from there (ThreeStageHelicalGearBox.ks).
Create a project folder and place that GPK library file into the folder. Open up KISSsys and select working
directory to be that newly created project folder. Go to Menu File Open and select the file
ThreeStageHelicalGearBox.ks. The GPK file is opened and ready for use.
3. Sizing a gearbox
3.1 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 infomation, variables and functions are saved in the properties of the different
elements. By use of the right-mouse click on the tree it is possible to view the menu for every element and
have a look at the list of possible variables and functions and also to run the functions.
3.2 Settings
Start with giving correct global setting values for Settings table.
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1.
6.
7.
8.
2.
5.
4.
3.
5.
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 classical method (according to ISO 281) for bearings to
consider also the lubrication.
5. Define materials for components. Pinion type gears will be gear1, gear3 and gear5 on shafts 1, 2 and 3,
so materials for those shall be equal.
6. Double-click Update model to accept all changes. Use functions Model ID to give correct information
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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7. Use the function Setup I/O to define speed for the Shaft1 (Boundary1) and torque for the Shaft4
(Boundary2). Torque can always be defined as input or output, meaning the gearbox can be easily
calculated for both directions.
8. At this point it is also possible to change the bearings to support only. This can be done using the
function Model Setup.
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3.3 PreSizing
Because no initial information about the gearbox size is given, the sizing of the gearbox can be started by
giving a total required ratio for the gearbox. Type in the value of 100 for total ratio and give it a deviation of
3%. Then click on Divide ratio to divide this total ratio over the three reductions. The ratios reached are
good starting values and can afterwards be changed if needed. When the 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.
After the settings have been made it is possible to try the gear sizing function. Select initial sizing strategy i
fixed from the drop-down list and execute sizing functions: Sizing gear pair 1, Sizing gear pair 2 and
Sizing gear pair 3 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 presizing, gear geometries are proposed and an updated layout can be seen in 3DView. Then the same can be
done for the bearings and the shafts. For Shaft and bearing sizing choose Use types defined below and
select desired bearings from the list Types of bearing. Select how shaft ends are positioned from the list of
Coupling side and Gear side in the first shaft. Initially we will use the Deep groove ball bearing (single
row) because they are the 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.
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If a Message for geometrical errors appears, we need to do some adjustments for the gearbox.
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After the pre-sizing the 3DView can be also adjusted. By clicking on the
icon in the top menu bar and
changing the settings in the dialog. To turn the housing invisible in the 3DView right-click on Housing in
the structure tree, choose SetColor and set transparency to 1.
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While final sizing please remember to use the function Update model in the right hand side upper corner
of the tab UserInterface to update all the changes made.
3.3.3 Gears
Make the final sizing for all gears individually using the according gear pair mask found in the structure tree
on the left hand side. You may adjust e.g. the reference profile, modifications, tooth form, the profile shift
coefficient, facewidth or any other variable that may become necessary. In this example we will change
gear widths to be reasonable values.
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The type of profile modification is set for high load capacity under Rating - Details and Optimal tip relief
(micropitting, scuffing) will be checked to get better load distribution for the gears. This will be done for
every gear.
For specific modifications, the modifications tab can be activated from the Calculation menu on top of the
screen
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After setting values for all the gears. The GearPairResults should like this:
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3.3.4 Shafts
Define correct shaft data for every shaft. Start 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. If you right-click a bearing you can also choose
sizing which opens a dialog with a choice of pre-specified bearings and the corresponding service life.
Figure 3.18 Detailed geometry for shaft1 after input in graphical shaft editor
Define new shaft geometry and insert notch factors. If bearing lifetime will get too high or too low with
selected shaft diameters you may have to execute some iterations before you find fitting shaft
measurements. It is also possible to change bearing type into a more loads carrying type of bearing if shaft
diameter gets too big.
You can also define a new cross section to calculate. This can be done e.g. automatically using the sizing
function from the shaft tree. First remove the current cross sections then create cross sections where the
shaft strength is to be calculated.
Proceed the same way with the other shafts. For shafts 2, 3 and 4 it is also possible to add a notch effect of
key way or pressure fit, depending on how loose the gear is fixed on the shaft. These notch effects can be
added by right-clicking on the shaft and choosing the appropriate option from the add-menu while in
graphical shaft editor.
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Figure 3.1918 Final geometry for shaft2 with key way notch effect
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The bearings are selected using graphical shaft interfaces. The list of selected bearings is shown as
follows:
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4. Final Calculations
4.1 UserInterface
Use function Update Model and Calculate Kinematics in UserInterface-tab before final strength
calculation to make sure that all changes in components are updated before calculation.
1.
2.
3.
Figure 4.1 Use "Update model" and "Calculate Kinematics" before final calculations to actualize every
component after changes
Figure 4.2 Message after strength calculation, indicating the calculation was a "success"
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Figure 4.4 Limiting calculation and max. torque is displayed after torque capacity calculation
Limiting calculation is the second gearpair. The maximum applied torque output for that gearpair is
20226.577Nm 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.
4.4 Reports
After all calculations are done the last step is to create the necessary documentation for the gearbox. That
can be done with the function Reports from UserInterface
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Select the desired report from the list and select Ok. All available reports are saved automatically to the
project folder and can be accessed later. The General report is a short summary of most important results
e.g. to be given for customer. KISSsoft reports are a full documentation of all results in one file according
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.
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