· 2019-09-02 · gearbox system model gear design analysis and optimization software tools...

GEARBOX SYSTEM MODELGEAR DESIGN ANALYSIS AND OPTIMIZATIONSOFTWARE TOOLSTRAINING AND SUPPORT

RELEASE 5.5 2018

DONTYNE SYSTEMS LIMITED IS A COMPANY REGISTERED IN ENGLAND AND WALES WITH COM-PANY NUMBER 05973058REGISTERED OFFICE: ROTTERDAM HOUSE, 116 QUAYSIDE, NEWCASTLE UPON TYNE NE1 3DYVAT REGISTRATION NUMBER: 902 9027 45

UKEMAIL : [email protected] : +44 191 206 4021

www.dontynesystems.com

www.dontynesystems.com

GEAR DESIGN SOLUTIONS

New for Release 5.5Asymmetric design and FE of spur & helicalBeveloid designSkiving manufacturing simulationHoning manufacturing simulationVirtual Multi-Axis machineFace Mill generation of bevels in 5-axisCMM simulation of measuring gears without rotary table

DONTYNE GEAR DESIGN SOLUTIONS / 2DONTYNE GEAR DESIGN SOLUTIONS / 1

“Dontyne’s software brought us a huge improvement in productivity: reducing hours of work to seconds. The visual representations make the software very intuitive to use and understand, and the results are quite accurate. The endeavour was so successful that more collaboration is inevitable.”

Eaton Corporation

Dr. Michael Fish,Director & Co-Founder,Dontyne Systems Ltd

“The gear metrology expertise from Dontyne and the applications experience of Renishaw was an ideal combination to produce software that offers a high level of functionality and exploits the benefits of Renishaw’s co-ordinate measuring machine (CMM) scanning systems.”

Renishaw plc

“The lead times and accuracy made possible by the introduction of the Optimal calculation would simply not have been possible without the software.”

Gaudlitz GmbH

For a list of references and technical papers associated with Dontyne Systems products and personnel refer to our website www.dontynesystems.com

GEARBOX SYSTEM MODELGEAR DESIGN ANALYSIS AND OPTIMIZATIONSOFTWARE TOOLSTRAINING AND SUPPORT

Dontyne Systems business model is based on an ability to be flexible and responsive to our customer’s requirements. The further integration of our design software with machine tools and inspection systems continues to bring benefits for the customers and is in keeping with Industry 4.0, which promotes greater production efficiency through such integration.

Recent development has had an emphasis on improving existing machine simulations such as hob and continuous grind, as well as adding new items such as Profile/Form Grinding and 5-Axis for gear production. Skiving and honing are being introduced for Release 5.5. This has led to the sale of several site and world licences for machine centre tools for companies with production sites across the world to keep consistency and accuracy across multiple facilities. We have also added asymmetric gear form design and analysis on demand from a growing number of companies.

Dontyne Gears has been formed as a separate entity in order to research and develop the design and manufacturing techniques enabled by the GPS software. It will also ensure seamless integration of the software to the tooling manufacture and machines used in the project work. The company will undertake design and analysis using the GPS. It is also possible to define tooling and verify accuracy by producing prototypes. By the end of this year, it will also be possible to run the gears in test rigs on site to validate various performance characteristics. There is already significant interest in the facility and this has enabled us to attract in-kind support from various companies in the use of their equipment.

We will continue to promote the developments at significant exhibitions and conferences worldwide. Adding to the usual locations in UK, Germany, USA and Japan we are adding regular shows in India (IPTEX) and South Korea (SIMTOS). Because these are large centres of gear production the companies in these regions will benefit greatly from our software package. We look forward to all opportunities to meet and expand our customer base.

AFRC

Dontyne Systems is proud to become a Tier 2 member of the Advanced Forming Research Centre (AFRC) based at the University of Strathclyde, UK. This institution has a great deal of government support and some top names in the engineering world looking at using modern materials and machine tools to improve production efficiency in forming techniques such as forging and rolling. Dontyne Systems has offered a site licence of Gear Production Suite, which will provide a suitable platform for the work in years to come. We look forward to contributing as consultants to some projects as and when required to further improve production accuracy and efficiency in those sectors.

Gear Expo 2017

What a show Gear Expo was for us. We were able to show our software in connection with spiral bevel machining on a VC500 Mazak centre and inspection both on board with the Renishaw SprintTM system and in-process control with the Renishaw EquatorTM. We were pleased to welcome many existing clients, and potential new clients to our booth.

Thank to Mazak and Renishaw for helping with the organisation and installation. Great job everyone.

As Dontyne Systems launches it’s latest update to it’s acclaimed Gear Production Suite, Director and Co-Founder, Dr. Michael Fish talks about what customer’s can expect from this update and what lies ahead for Dontyne Systems Ltd.

Dontyne Offices HQ,

Newcastle, England

DONTYNE GEAR DESIGN SOLUTIONS / 3

RELEASE 5.5 2018

PLANETARY

Single Stage Layout

DESIGN AND RATING TO ISO AND AGMA

GEAR DESIGN PRO

FEATURES INCLUDE :-

Involute spur and helical gear geometryAssembly check for equal spacingSingle or double planet arrangementInterference checks for outer diametersSpeed and torque of all componentsISO 6336 rating (inc. 2008 updates)Tolerances to ISO 1328Cumulative damage and safety factor Standardized tooth proportions or calculate for maximum contact ratioPlots of gears in 2D and 3DDXF output of transverse tooth profileCo-ordinates output of tooth profileMeasurement over balls and chordal pan including contact heightMetric or Imperial(English) unitsMaterial database (user defined)Phasing calculation

SPLINES

FEATURES INCLUDE :-

ISO 4156 SplinesDIN 5480 SplinesANSI B92.1 1970 SplinesAdd remove teeth Override dimensions for custom splineNon-Standard NPA Helix angle and tapered tooth

FEATURES INCLUDE :-

Involute internal and external spur and helical gear geometryISO 6336 and AGMA 2001 – D 04 ratingTolerances to ISO 1328 and AGMA 2015 Standardized tooth proportions or calculate for maximum contact ratioPlots and export of gears in 2D and 3D including micro-geometryMeasurement over balls and chordal span including contact heightGear sizing Flash temperature calculationsGraphical plot of specific slidingPlot of theoretical path of contactMaterial database (including user defined)SN fatigue curve plotsMetric or Imperial (English) units

Produce spline designs to ISO 4156, DIN 5480 and ANSI B92.1 1970 with an ANSI rating system. The side, inner and outer fits are considered. The root rounding can be arbitrarily adjusted to user preference. All profiles can be exported as DXF to wire erosion machines.

Variable tooth forms including helical thread

InspectionMaterial database including user definition


Asymmetric design and analysis option

Beveloid form with tapered tooth face as well as Tilted, Crossed, or Crossed and Tilted for Spur & Helical.

BEVELOID AND CROSSED AXIS GEARS


ISO/AGMA 23509-A08 BEVEL

GENERIC BEVEL

GEAR DESIGN PRO

Straight Bevel Zerol BevelSpiral Bevel

The “Generic” bevel gear

DXF 3D line gridIGES Bspline surfaceASCII X,Y,Z Co-ordinatesG-Code

Generic bevel refers to the fact that the geometry is not specific to a machine process but is the true theoretical form of the gear with full line conjugation between components without any virtual back plane approximations. The spiral types can be defined as straight, logarithmic (equal angle), circular, or involute.

In addition, typical modifications such as profile crowning, face crowning, and slope can be applied to modify the load bearing pattern shape and position. If there is a requirement for small batch then these forms can be produced on modern 5-Axis CNC milling machines. Face milling or face hobbing gear generating machines are not required.

Surface mismatch

flank 1 flank 2

Contact lines shown

Create a small interference

Define Conjugate Surface Apply Micro-Geometry

FEATURES INCLUDE :-

Straight bevel3 spiral typesMicro modificationsConjugation check90 or non-90 degree designVariable root radius from toe to heelExtend / Crop Tooth Form

GENERIC BEVEL ANALYSIS



The load analysis program calculates the deformation of gear tooth components and their consequences on properties such as stress and transmission error (accuracy of ratio) under load. Versatile graphics and reporting features offer a quick interpretation of the resulting analysis and formatting for customer reports.

Links to metrology and manufacturing equipment enable evaluation of existing gear components as well as newly designed components. The Advanced level of this module incorporates the FE calculation GATES originally developed and experimentally validated at The Design Unit, Newcastle-Upon-Tyne,

England. Already implemented by some of the most trusted gear design and manufacturing institutions in the UK, the program has been used in the development of an extensive range of marine, industrial and automotive applications.

Surface modification can be applied to

minimise transmissions error (and hence noise

and vibration effects) at a specific load.

Up to 4 different modification options can be

stored with each component.

Calculation of micro

geometry due to flank

twist effect

FEATURES INCLUDE :-

Surface definition, (profile and flank line modification)Contact stressRoot bending stress3D FE model of tooth stiffnessPower loss and efficiencySurface topological modification definitionMultiple load casesDouble helical gearsEffect of gear misalignmentVarious graphical interfacesImport of measured gear surface

Gear contact stress Bearing load pattern

Specific film thickness calculation and ISO TR-

15144 micro-pitting method A

Power loss and efficiency

SURFACE MODIFICATIONS DEFINED BY :-

Normal pressure angle change Linear / parabolic profile modification4th degree polynomialCalculated bias (flank twist)A user model exported to GPS formatMeasured data compatible to common manufacturing systems

Nominal 3D surface modification / 3D surface

with simulated or measured bias

Micro-geometry definition


LOAD ANALYSIS MODEL

GATES , Gear Analysis for Transmission Error and Stress

The asymmteric designer

is linked to 2D FE and tool

design for improved analysis

and ease of production.


ADVANCED LOAD ANALYSIS MODELMICRO GEOMETRY OPTIMISATION

NON INVOLUTE LTCA

Up to 10 increments for each parameter

Available surface Modifications

Pinion and wheel can be linked so that steps change together

Involute User Defined

Up to 9 load cases for each modification

Tooth surface stress

Transmission Error (TE)

User selects results for optimum modification parameters

Up to 20,000 micro geometry variations can be defined for each batch run

Loaded Tooth Contact Analysis for user defined tooth profiles for Spur and Helical gears. Profiles can be imported from user data files or embedded geometry routine under licence (e.g. Convoloid below). Other modules can define tooling for machining and inspection to create a control system for production.

EXAMPLE OF CUSTOMER DEFINED PROFILE®

Dontyne Systems has completed several projects to develop customer specific applications or integrate functionality into the Gear Production Suite under licence.One example is an exclusive agreement on Convoloid gearing from Genesis Partners (US). Convoloid technology has the potential to dramatically improve performance in helical systems, while gear components can be produced using common machine tools and production methods.

Reduced stress enables more power

Low tooth numbers and optimized root forms (no undercut)

Increase life potential

Reduced weight

Reduced centre distance

Improvement over involute for same ratio and face width

Analysis used to establish envelope of operation where advantage is maintained.Centre distance tolerance

-0.075 mm

+0.075 mm

Links to 2D FE model any root or flank form

Phasing 1Shows offset along base tangent for each mesh

ADVANCED LOAD ANALYSIS MODEL PLANETARY GEAR LTCA

Phasing 2Phasing offset plotted in transverse section with line of action scale for comparison

Planetary Load shareThe torque split due to variation in tooth stiffness as the planetary system rotates

BEVEL GEAR LTCA The Planetary LTCA model can be used to investigate phase of engagement, critical to optimising design parameters for a given arrangement

The contact model can include deflections entered directly or passed from Gearbox Model tool

Transmission Error under load Contact Stress

Contact region under load

2D FE can be performed at toe, mid, and heel to find optimum root form.



MACHINE CENTREAUTOMATIC TOOL DESIGN FOR GEAR FORM

FEATURES INCLUDE :-

Tool designTool databaseSimulation of profile generation and micro geometryAnalysis of max/min tolerances on generated profileProtuberance and short lead hobbing techniques on profileUse tool generated profile in bending stress calculation for accurate rating

Gear hobbing generated profile to check tool design

GENERATE GEAR FROM TOOL DATABASE

HOB & CONTINUOUS GRIND (WITH DRESSING)

ADVANCED FUNCTIONSForce BalancingAccurate modelling of the manufacturing processes allows automatic tool design, including assessment of the effects of tolerancing, prior to cutting metal.

Modelling the effects of small grinding worm diameter and multiple threads for higher accuracy model.

FE analysis function enable engineers to assess potential problems such as stress concentration due to a grinding notch in gear fillet.

Hob roll out diagram including stock allowance and tolerancing

Define micro-goemetry on dressing tool

Grinding simulation shows profile modification on gear with break out and chamfer

Asymmetric and non-involute tool design and roll-out check

Tool database with filter systemDefine new tool

Force Balancing

Profile error calculated from existing tooling


MULTI AXIS – END MILL AND FACE MILL

FORMING – FORGING,ROLLING, INJECTION MOLDING

PROFILE/THREAD GRINDING

Define 5-Axis movement and cutting strategy for Spur, Helical and Bevel

Invert errors on mould

Tool corrected by mapping error to previous tool surface for higher accuracy tool in a 2D plain

Invert errors on mould

New profile form grinding simulation introduced, which includes the application of micro-geometry.

Shaving cutter sharpening Diagram

As the tooth thickness is reduced with sharpening along the x axis, the blue line depicts the outer diameter reduction required to maintain force balance. User can click on diagram to create optimum design.

SHAVING

Options added to Machine Centre module with full tool definition.

SHAPING, SKIVING, AND HONING

Tool calculation and G-code export for 5-axis production.


Protuberance for Shaper Cutters


Features include :-

Interfacing to gear measuring machines and co-ordinate measuring machines Evaluation of linear errors Profile/flank/pitch to common standards (ISO, DIN, AGMA)2D scan for full form inspection in root 3D Surface inspection Simulation of physical inspection(measurement over balls, tooth span)Simulation of contact testingStatistical analysis of productionDefinition of master surfaceDiagnostics and optimization of tool and machining process by compensation of errorsSimulation of inspection

The Gear Production Suite can interface to a variety of measuring devices for a range of geared tooth components. The adjacent picture shows an Equator® using 3D model. The adjacent picture shows an Equator® using 3D models from Dontyne Systems Gear Production Suite to inspect helical teeth flanks in as little as 25 seconds. Other tooth forms such as bevel gears, spline, and Convoloid® are also possible.

Virtual testing – tooth span, measurement over balls, transmission error

Advanced Analysis Functions

Statistical evaluation of multiple measurements and creating a master surface

Simulation of measurement on CMM or EquatorTM on the machine or at the design stage can avoid problems in inspection.

GPS interface to EquatorTM to avoid error in data transfer and utilise measurement data.

INSPECTION CENTRECO-ORDINATE EVALUATION DIRECT FROM GEAR INSPECTION AND CMM EQUIPMENT

Standard parameter evaluation

Projection Heat Map



GEAR PRODUCTION SUITE (Key)

Gear Design ProDesign and rate gear components using common standardsLoad Analysis ModelSimulate operating characteristics of gear pairsInspection CentreDefine component quality and simulate testing procedureMachine CentreCalculation of component form based on machine and tool settingsOptimalCalculate optimum machine and tool settings

Optimal - Tooth measurements before and after correction

Each module is a powerful tool in it’s own right and can be individually licensed, but there is additional benefit to utilising all modules together. Data gathered at the machining and inspection stage can be compared to the design specification and the contact models by networking in-house or even via Internet using the Gear Production Suite as a process control platform. The data can be used for many purposes other than direct design such as correct tooling or machining errors (see opposite). The software can be used to optimise both product quality and performance giving direct return on investment.

Tool corrected by mapping error to previous tool surface for higher accuracy tool in a 2D plain

Before CalculationThe theoretical surface (black) and tool surface (blue) can be designed in Gear Production Suite or imported from CAD, measured data imported from measuring equipment

After CalculationThe error between theoretical and measured surface is mapped by a vector (green) and used to create modified tool surface

Error vectors mapping theoretical and measured surface

New toolsurface

Old tool

Before After

The calculation can be applied to multiple layers or a complete surface model for corrections to a 3D volume

Distorted gear due to shrinkage Invert errors on mould Improved quality gear

OPTIMAL



3D graphical interface

Gearbox view of motor sport transmissionGearbox contains spur and spiral bevel gears

GEARBOX DESIGNER

Gearbox Concept tool

Drag and drop concept level layout of gearbox system for rapid development of transmissions to determine speed, torque, clutching, and power to analyse efficiency with live test for valid connections.

This is a specialist module to help in the very earliest stages of gear box design. It allows a transmission layout to be constructed in several minutes, with no need to create a spreadsheet specific arrangement. A system model can then be constructed from the concept layout.

Static Deflection Model

This tool can create a gear box layout and uses a fully coupled matrix to determine the deformation through the gear, shaft, bearing and housing. It is possible to import a stiffness matrix from 3rd party software. Controls exist to indicate power through the system and emphasise The Advanced level of the tool links directly to detailed design and analysis tools within the Suite.

8 Speed Lepelletier Automatic

Standard Features include :-

Spur, Helical and Bevel gears

Shaft Deflections

Misalignments in Line of Action

Forces

Shaft Stresses

Fully Coupled Housing Stiffness Matrix

3D Gearbox Graphics

Deflected Plots

Concept or Detailed Gears

Import Nastran data from CAD

Shaft Assembly DesignerThe shaft sections, gear positions and supports are input

Shaft calculations for gear misalignmentPower flow plot


· 2019-09-02 · gearbox system model gear design analysis and optimization software tools...

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Transcript of · 2019-09-02 · gearbox system model gear design analysis and optimization software tools...