Manual

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KISSSOFT RELEASE 03/2012 USER MANUAL

Edition 1.4

Copyright Notice:

2012 KISSsoft AG

Uetzikon 4

CH-8634 Hombrechtikon Switzerland

All rights retained

This documentation may not be copied without the express written approval of KISSsoft AG.

Table of Contents

I General I-38

1 I nsta ll ing KI S S sof t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -3 9

1.1 Basic installation .......................................................................................... I-40

1.2 Downloading a license file .......................................................................... I-41

1.3 Licensing ..................................................................................................... I-42

1.3.1 Test version .................................................................................. I-42

1.3.2 Student version ............................................................................. I-42

1.3.3 Single user version with dongle ................................................... I-42

1.3.4 Single user version with license code ........................................... I-43

1.3.5 Network version with dongle ....................................................... I-43

1.3.6 Network version with the license code ......................................... I-44

2 S etting Up KI S S sof t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -45

2.1 Directory structure ....................................................................................... I-46

2.2 Language settings ........................................................................................ I-47

2.3 System of units ............................................................................................ I-48

2.4 Defining your own default files ................................................................... I-49

2.5 Rights ........................................................................................................... I-50

2.6 Global settings - KISS.ini ............................................................................ I-51

2.6.1 Definitions in [PATH] .................................................................. I-51

2.6.2 Definitions in [SETUP] ................................................................ I-52

2.6.3 Definitions in [REPORT] ............................................................. I-53

2.6.4 Definitions in [GRAPHICS] ........................................................ I-54

2.6.5 Definitions in [LICENSE] ............................................................ I-54

2.6.6 Definitions in [CADEXPORT] .................................................... I-54

2.6.7 Definitions in [INTERFACES] .................................................... I-55

2.6.8 Definitions in [SOLIDEDGE] ...................................................... I-55

2.6.9 Definitions in [SOLIDWORKS] .................................................. I-56

2.6.10 Definitions in [INVENTOR] ........................................................ I-56

2.6.11 Definitions in [CATIA] ................................................................ I-56

2.6.12 Definitions in [PROENGINEER] ................................................ I-57

2.6.13 Definition in [COCREATE] ......................................................... I-57

2.6.14 Definitions in [THINK3] .............................................................. I-58

2.6.15 Definitions in [HICAD]................................................................ I-58

2.7 User-defined settings ................................................................................... I-59

2.7.1 Configuration tool ........................................................................ I-59

3 S tarti ng KI S S sof t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -6 2

3.1 Initial parameters ......................................................................................... I-63

3.2 Disconnect license from the network ........................................................... I-64

4 Eleme nts of the KI S S s of t U ser I nterf a c e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -6 5

4.1 Menus, context menus and the Tool Bar ..................................................... I-66

4.2 Docking window .......................................................................................... I-68

4.2.1 The module tree ............................................................................ I-68

4.2.2 The project tree ............................................................................. I-69

4.2.3 The Results window ..................................................................... I-69

4.2.4 The Messages window ................................................................. I-69

4.2.5 The info window .......................................................................... I-69

4.2.6 Manual and Search ....................................................................... I-70

4.3 Graphics window ......................................................................................... I-71

4.3.1 Tool bar and context menu ........................................................... I-72

4.3.2 Comment field .............................................................................. I-74

4.3.3 Context menu ............................................................................... I-74

4.3.4 Properties ...................................................................................... I-74

4.3.5 Toothing ....................................................................................... I-76

4.4 Main input area ............................................................................................ I-78

4.4.1 Report Viewer .............................................................................. I-78

4.4.2 Helptext viewer ............................................................................ I-79

4.5 Tooltips and status bar ................................................................................. I-80

5 KI S S sof t C alc ul at ion Module s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -81

5.1 Standard and special tabs ............................................................................. I-82

5.2 Input elements .............................................................................................. I-83

5.2.1 Value input fields ......................................................................... I-83

5.2.2 Formula entry and angle input ...................................................... I-83

5.2.3 Switching between systems of units ............................................. I-84

5.2.4 Tables ........................................................................................... I-84

5.3 Calculating and generating a report ............................................................. I-85

5.4 Messages ...................................................................................................... I-86

6 Pro jec t M an ag emen t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -87

6.1 Creating, opening and closing projects ........................................................ I-88

6.2 Adding and deleting files ............................................................................. I-89

6.3 The active working project .......................................................................... I-90

6.4 Storage locations .......................................................................................... I-91

6.5 Project properties ......................................................................................... I-92

7 R esult s and R ep orts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -9 3

7.1 Results of a calculation ................................................................................ I-94

7.1.1 Add your own texts in the results window ................................... I-94

7.2 Calculation reports ....................................................................................... I-95

7.3 Drawing data ................................................................................................ I-96

7.4 Report settings ............................................................................................. I-97

7.4.1 General ......................................................................................... I-97

7.4.2 Page layout ................................................................................... I-97

7.4.3 Header and footer ......................................................................... I-97

7.4.4 Start and end block ....................................................................... I-98

7.5 Report templates .......................................................................................... I-99

7.5.1 Storage locations and descriptions ............................................... I-99

7.5.2 Scope of a report ........................................................................ I-100

7.5.3 Formatting .................................................................................. I-100

8 Datab as e Tool a nd Ext erna l Tab les . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -109

8.1 Viewing database entries ........................................................................... I-111

8.2 Managing database entries ......................................................................... I-114

8.2.1 Generating a database entry ....................................................... I-114

8.2.2 Deleting a database entry ........................................................... I-115

8.2.3 Restoring a database entry .......................................................... I-115

8.3 Import and export data with the database tool ........................................... I-116

8.4 External tables ........................................................................................... I-117

8.4.1 Functions tables .......................................................................... I-118

8.4.2 Range tables ............................................................................... I-120

8.4.3 List tables ................................................................................... I-121

8.4.4 List of key words used................................................................ I-123

8.5 Description of database tables ................................................................... I-125

8.5.1 Center distance tolerances ......................................................... I-125

8.5.2 Machining allowance cylindrical gear........................................ I-125

8.5.3 Reference profiles....................................................................... I-125

8.5.4 Compression springs standard .................................................... I-125

8.5.5 Selection of hobbing cutters ....................................................... I-126

8.5.6 Base material glued and soldered joints ..................................... I-126

8.5.7 Manufacturing process Bevel and Hypoid Gears ....................... I-126

8.5.8 V-belt Standard .......................................................................... I-126

8.5.9 Spline Standard .......................................................................... I-127

8.5.10 Chain profiles ISO606 ................................................................ I-127

8.5.11 Adhesives ................................................................................... I-127

8.5.12 Load spectra .............................................................................. I-127

8.5.13 Solders ........................................................................................ I-128

8.5.14 Surface roughness ...................................................................... I-128

8.5.15 Key standard ............................................................................... I-128

8.5.16 Polygon standard ........................................................................ I-129

8.5.17 Woodruff Key standard .............................................................. I-129

8.5.18 Bolts/ pins ................................................................................... I-129

8.5.19 Lubricants .................................................................................. I-129

8.5.20 Screws: Tightening factor ......................................................... I-131

8.5.21 Screws: Bore ............................................................................. I-131

8.5.22 Bolts: strength classes ............................................................... I-131

8.5.23 Screws: Thread type ................................................................... I-131

8.5.24 Screws: Nuts .............................................................................. I-132

8.5.25 Bolts: type ................................................................................. I-132

8.5.26 Screws: Washers ....................................................................... I-132

8.5.27 Selection of pinion type cutters .................................................. I-132

8.5.28 Disk spring standard ................................................................... I-132

8.5.29 Tolerances standard ................................................................... I-132

8.5.30 Beam profiles ............................................................................. I-133

8.5.31 Multi-Spline standard ................................................................. I-133

8.5.32 Materials ..................................................................................... I-133

8.5.33 Roller bearing ............................................................................. I-138

8.5.34 Roller bearing tolerance ............................................................. I-146

8.5.35 Roller bearing Tolerance classes ................................................ I-146

8.5.36 Tooth thickness tolerances ......................................................... I-146

8.5.37 Toothed belt standard ................................................................. I-146

9 Desc rip t ion of t he p ub lic interf ac e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -149

9.1 Interfaces between calculation programs and CAD - Overview................ I-150

9.1.1 Efficient interfaces ..................................................................... I-150

9.1.2 Open interfaces concept in KISSsoft .......................................... I-151

9.2 Defining input and output .......................................................................... I-153

9.2.1 Preamble ..................................................................................... I-153

9.2.2 Requirements placed on the 3rd party program ......................... I-154

9.2.3 Used files .................................................................................... I-154

9.2.4 Service life of files ..................................................................... I-155

9.2.5 Explicitly reading and generating data ....................................... I-155

9.3 Example: Interference fit assembly calculation ......................................... I-156

9.4 Geometry data ............................................................................................ I-158

9.5 COM Interface ........................................................................................... I-159

9.5.1 Registering the server ................................................................. I-159

9.5.2 Server functionality .................................................................... I-159

9.5.3 Example of a call from Excel ..................................................... I-160

10 3 D int erf ac e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -164

10.1 Overview of the available CAD interfaces and their functionality ............ I-165

10.2 Generation of 3D gears .............................................................................. I-166

10.3 Generation of 3D shafts ............................................................................. I-169

10.4 Viewer with neutral format interface ......................................................... I-171

10.4.1 Export of 3D shafts in Parasolid ................................................. I-171

10.4.2 Face gear - 3D geometry ............................................................ I-172

10.4.3 Bevel gear - generating a 3D model ........................................... I-173

10.4.4 Worm wheel - generating a 3D model ....................................... I-174

10.5 3D interface to Solid Works ...................................................................... I-176

10.5.1 Gear teeth in the case of an existing blank ................................. I-176

10.5.2 Integrating the KISSsoft Add-in (menu items in CAD) ............. I-178

10.5.3 Add-in functions (calls) .............................................................. I-181

10.6 3D interface to Solid Edge ......................................................................... I-184

10.6.1 Changes of the parameters for generation .................................. I-184

10.6.2 Gear teeth in the case of an existing blank ................................. I-184

10.6.3 Integrating the KISSsoft Add-in (menu items in CAD) ............. I-186


10.6.5 Opening the calculation file for the created gear ........................ I-191

10.7 3D interface to Autodesk Inventor ............................................................. I-192

10.7.1 Gear teeth in the case of existing shaft data ............................... I-192

10.7.2 Add-in (menu items in CAD) ..................................................... I-193


10.7.4 Opening the calculation file for the created gear ........................ I-197

10.8 3D interface to Unigraphics NX ................................................................ I-198

10.8.1 Add-in (menu items in CAD) ..................................................... I-199


10.8.3 Running KISSsoft via an add-in ................................................. I-201

10.9 3D interface to ProEngineer ...................................................................... I-209

10.9.1 Integrating the KISSsoft Add-in ................................................. I-212

10.9.2 Modifying the selected 3D model .............................................. I-216

10.9.3 Cutting teeth on an existing shaft ............................................... I-217

10.9.4 Modifying the teeth on an existing shaft .................................... I-219

10.9.5 Changing base settings in the interface ...................................... I-220

10.10 3D interface to CATIA ...................................................................... I-222

10.10.1 Registering the interface ............................................................. I-222

10.11 3D Interface to CoCreate ................................................................... I-225

10.12 3D interface to ThinkDesign .............................................................. I-227

10.12.1 Integrating the KISSsoft Add-in ................................................. I-229

10.12.2 Interface to hyperMILL .............................................................. I-229

11 11 . A n sw er s to F req ue n tly A sked Qu est ion s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I -23 0

11.1 Change the output of angles in reports ...................................................... I-231

11.2 Input materials for gear calculations in the database ................................. I-232

11.3 How can I test the software? ...................................................................... I-233

11.4 What licenses are available? ...................................................................... I-234

11.5 Add your own texts in the results window ................................................ I-235

11.6 Restore previous stages of the calculation ................................................. I-236

II Toothing II-237

12 I ntroduc tio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I -23 8

13 Cyli ndric a l g e ar s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I -23 9

13.1 Basic data .................................................................................................. II-241

13.1.1 Normal module .......................................................................... II-241

13.1.2 Pressure angle at the normal section ......................................... II-241

13.1.3 Helix angle direction for gear teeth ........................................... II-242

13.1.4 Helix angle at reference diameter .............................................. II-242

13.1.5 Center distance .......................................................................... II-242

13.1.6 Number of teeth ......................................................................... II-243

13.1.7 Face width ................................................................................. II-243

13.1.8 Profile shift coefficient .............................................................. II-244

13.1.9 Quality ....................................................................................... II-246

13.1.10 Geometry details ....................................................................... II-250

13.1.11 Materials and lubrication ........................................................... II-251

13.2 Rating ........................................................................................................ II-257

13.2.1 Calculation method.................................................................... II-257

13.2.2 Service life ................................................................................. II-262

13.2.3 Application factor ...................................................................... II-262

13.2.4 Power, torque and speed ............................................................ II-263

13.2.5 Strength details .......................................................................... II-264

13.2.6 Strength details (AGMA) .......................................................... II-277

13.2.7 Define load spectrum................................................................. II-278

13.2.8 Calculate scuffing ...................................................................... II-281

13.3 Coefficients ............................................................................................... II-282

13.3.1 Transverse coefficient ............................................................... II-282

13.3.2 Dynamic factor .......................................................................... II-282

13.3.3 Load distribution coefficient ..................................................... II-283

13.3.4 Alternating bending factor ......................................................... II-284

13.3.5 Face load factor ......................................................................... II-287

13.3.6 General calculation procedure for KHbeta as specified in ISO 6336-

1, Appendix E. ........................................................................................ II-301

13.4 Reference profile ...................................................................................... II-302

13.4.1 Configuration ............................................................................ II-302

13.4.2 Processing .................................................................................. II-309

13.4.3 Tip alteration ............................................................................. II-310

13.5 Tolerances ................................................................................................. II-312

13.5.1 Tooth thickness tolerance .......................................................... II-312

13.5.2 Tip diameter allowances ............................................................ II-314

13.5.3 Root diameter allowances ......................................................... II-314

13.5.4 Center distance tolerances ......................................................... II-315

13.5.5 Settings ...................................................................................... II-315

13.6 Modifications ............................................................................................ II-316

13.6.1 Dialog window: Define grinding wheel for gears ..................... II-317

13.6.2 Type of modification ................................................................. II-318

13.6.3 Underlying principles of calculation ......................................... II-319

13.6.4 Profile modifications ................................................................. II-321

13.6.5 Tooth trace corrections .............................................................. II-326

13.6.6 Sizing modifications .................................................................. II-332

13.6.7 Notes on profile correction ........................................................ II-334

13.7 Tooth form ................................................................................................ II-336

13.7.1 Context menu ............................................................................ II-337

13.7.2 Operations ................................................................................. II-338

13.8 Flank breaking .......................................................................................... II-358

13.9 Contact analysis ........................................................................................ II-360

13.9.1 Notes about contact analysis ..................................................... II-361

13.9.2 Calculation of contact analysis taking the shafts into account .. II-364

13.9.3 Contact analysis of a planet system ........................................... II-369

13.10 Gear pump ......................................................................................... II-373

13.11 Operating backlash ............................................................................ II-376

13.11.1 Reference temperature ............................................................... II-378

13.11.2 Relative water absorption during swelling ................................ II-378

13.11.3 Coefficient of thermal expansion for housing ........................... II-379

13.12 Master gear ........................................................................................ II-380

13.13 AGMA 925 ....................................................................................... II-382

13.14 Rough sizing ..................................................................................... II-384

13.15 Fine Sizing ........................................................................................ II-389

13.15.1 Required entries in the input window ........................................ II-390

13.15.2 Constraints I .............................................................................. II-390

13.15.3 Conditions II .............................................................................. II-392

13.15.4 Results ....................................................................................... II-397

13.15.5 Graphics .................................................................................... II-399

13.15.6 Geometry-fine sizing for 3 gears ............................................... II-400

13.15.7 Additional strength calculation of all variants ........................... II-400

13.16 Measurement grid ............................................................................. II-401

13.17 Profile modification optimization ..................................................... II-404

13.18 Settings .............................................................................................. II-407

13.18.1 General ...................................................................................... II-407

13.18.2 Plastic ........................................................................................ II-410

13.18.3 Planets ....................................................................................... II-412

13.18.4 Sizings ....................................................................................... II-413

13.18.5 Calculations ............................................................................... II-414

13.18.6 Required safeties ....................................................................... II-419

13.18.7 Contact analysis/Face load factor .............................................. II-420

13.18.8 Rating ........................................................................................ II-421

13.18.9 3D generation ............................................................................ II-421

13.19 Tooth thickness ................................................................................. II-424

14 Bevel a nd H yp oid g ear s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I -425

14.1 Principles of calculation ........................................................................... II-426

14.1.1 General ...................................................................................... II-426

14.1.2 Overview of the bevel gear manufacturing process and the

terminology used in it ............................................................................. II-426

14.1.3 Calculation according to Klingelnberg, Gleason and Oerlikon . II-427

14.2 Basic data .................................................................................................. II-428

14.2.1 Type ........................................................................................... II-428

14.2.2 Normal module (middle) ........................................................... II-433

14.2.3 Reference diameter Gear 2 ........................................................ II-434

14.2.4 Pressure angle at normal section ............................................... II-434

14.2.5 Pressure angle driving/driven flank: Hypoid gears ................... II-434

14.2.6 Helix angle ................................................................................ II-435

14.2.7 Shaft angle ................................................................................. II-437

14.2.8 Offset (Center dist.) ................................................................... II-438


14.2.10 Facewidth .................................................................................. II-439


14.2.12 Tooth thickness modification factor .......................................... II-439

14.2.13 Quality ....................................................................................... II-440

14.2.14 Tip and root angle ..................................................................... II-441

14.2.15 Angle modifications .................................................................. II-442


14.2.17 Manufacturing process .............................................................. II-444

14.3 Manufacturing........................................................................................... II-445

14.3.1 Cutter radius .............................................................................. II-445

14.3.2 Number of blade groups ............................................................ II-445

14.4 Rating ........................................................................................................ II-446

14.4.1 Methods used for strength calculation ....................................... II-446

14.4.2 Required service life .................................................................. II-450




14.5 Coefficients ............................................................................................... II-453

14.5.1 Bearing application factor ......................................................... II-453

14.5.2 Dynamic factor .......................................................................... II-454

14.5.3 Bevel gear factor at flank and root ............................................ II-454

14.6 Reference profile ...................................................................................... II-456

14.6.1 Default values for tip base clearance ......................................... II-456

14.6.2 Default values for addendum coefficients ................................. II-456

14.7 Rough sizing ............................................................................................. II-457

14.7.1 Face width ratio ......................................................................... II-457

14.7.2 Module ratio .............................................................................. II-458

14.8 Notes on calculations according to the Klingelnberg standard ................. II-459

14.8.1 Bevel gears with cyclo-palloid gear teeth ................................. II-459

14.8.2 Hypoid gears with cyclo-palloid gear teeth ............................... II-459

14.8.3 Normal module ranges for Klingelnberg machines (cyclo-palloid) II-

460

14.8.4 Bevel gears with Palloid toothing ............................................. II-461

14.8.5 Definitions and dimensions of standard cutters for palloid toothing

II-462

14.8.6 Minimum safeties ...................................................................... II-462

14.8.7 Surface roughness at tooth root ................................................. II-463

14.8.8 Toothing quality bevel gears ..................................................... II-463

14.8.9 Characteristic number................................................................ II-463

14.9 Settings ..................................................................................................... II-465

14.9.1 Calculations ............................................................................... II-465

15 F ac e g ear s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I -466

15.1 Underlying principles of calculation......................................................... II-467

15.2 Basic data .................................................................................................. II-470

15.2.1 Normal module .......................................................................... II-470


15.2.3 Helix angle at reference diameter .............................................. II-473

15.2.4 Axial offset ................................................................................ II-473


15.2.6 Quality ....................................................................................... II-475



15.3 Rating ........................................................................................................ II-478


15.3.2 Required service life .................................................................. II-480



15.4 Coefficients ............................................................................................... II-482

15.4.1 Face load factor ......................................................................... II-482

15.5 Modifications ............................................................................................ II-483

15.5.1 Addendum reduction ................................................................. II-483

15.5.2 Type of tip modification ........................................................... II-483

15.6 Settings ..................................................................................................... II-484

15.6.1 General ...................................................................................... II-484

15.6.2 Sizings ....................................................................................... II-485

15.7 Notes on face gear calculation .................................................................. II-486

15.7.1 Dimensioning ............................................................................ II-486

15.7.2 Pinion - Face gear with Z1 > Z2 ................................................ II-487

16 Worms w i th g lobo id w orm w hee ls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I -488


16.2 Basic data .................................................................................................. II-491

16.2.1 Axial/transverse module ............................................................ II-491


16.2.3 Lead angle at reference diameter ............................................... II-491



16.2.6 Face width ................................................................................. II-493


16.2.8 Tooth thickness modification factor .......................................... II-494

16.2.9 Quality ....................................................................................... II-494



16.3 Rating ........................................................................................................ II-498


16.3.2 Service life ................................................................................. II-499


16.3.4 Permissible decrease in quality ................................................. II-499



16.4 Tolerances ................................................................................................. II-503

16.5 Settings ..................................................................................................... II-504

16.5.1 General ...................................................................................... II-504

16.5.2 Reference gearing ...................................................................... II-505

16.5.3 Calculations ............................................................................... II-506

16.5.4 Required safeties ....................................................................... II-507

17 Cross ed h el ic al g ear s and p r ec is ion mec ha n ic s w orm s . . . . . . I I -509


17.2 Basic data .................................................................................................. II-511

17.2.1 Normal module .......................................................................... II-511


17.2.3 Helix angle reference diameter gear 1 ....................................... II-511


17.2.5 Face width ................................................................................. II-512


17.2.7 Quality ....................................................................................... II-513

17.2.8 Define details of geometry ........................................................ II-514


17.3 Rating ........................................................................................................ II-516


17.3.2 Service life ................................................................................. II-519




17.4 Settings ..................................................................................................... II-525

17.5 Notes ......................................................................................................... II-526

17.5.1 Checking the contact pattern ..................................................... II-526

18 Nonc irc ul ar g e ars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I -527

18.1 Input data .................................................................................................. II-528

18.1.1 Geometry ................................................................................... II-528

18.1.2 Tolerances ................................................................................. II-531

18.1.3 Reference profile ....................................................................... II-531

18.2 How to use KISSsoft ................................................................................ II-533

18.2.1 Angle error ................................................................................ II-533

18.2.2 Checking the meshing ............................................................... II-533

18.2.3 Improve tooth form ................................................................... II-534

18.2.4 Accuracy of the tooth form ....................................................... II-534

18.2.5 Export individual teeth .............................................................. II-535

18.2.6 Report ........................................................................................ II-536

18.2.7 Temporary files ......................................................................... II-536

19 R ep orts m enu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I -53 8

19.1 Drawing data ............................................................................................. II-539

19.2 Manufacturing tolerances ......................................................................... II-540

19.3 Rating ........................................................................................................ II-541

19.4 Service life ................................................................................................ II-542

19.5 Torque sizing ............................................................................................ II-543

19.6 Proposal for the hardening depth EHT ..................................................... II-544

20 G rap hic s men u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I -545

20.1 AGMA 925 ............................................................................................... II-549

20.1.1 Lubricant film thickness and specific oil film thickness ........... II-549

20.2 2D geometry ............................................................................................. II-550

20.2.1 Gear tooth forms ........................................................................ II-550

20.2.2 Cutter/Tool ................................................................................ II-551

20.2.3 Manufacturing a gear................................................................. II-551

20.2.4 Meshing ..................................................................................... II-551

20.2.5 Profile and tooth trace diagram ................................................. II-552

20.2.6 Flank curvature radii ................................................................. II-556

20.2.7 Angle of flank normal ............................................................... II-556

20.2.8 Drawing ..................................................................................... II-556

20.2.9 Assembly ................................................................................... II-556

20.3 3D geometry ............................................................................................. II-557

20.3.1 Tooth system ............................................................................. II-558

20.3.2 Tooth form ................................................................................. II-558

20.4 Evaluation ................................................................................................. II-559

20.4.1 Specific sliding .......................................................................... II-559

20.4.2 Flash temperature ...................................................................... II-560

20.4.3 Hardening depth ........................................................................ II-561

20.4.4 Whler line for material ............................................................ II-562

20.4.5 Safety factor curves ................................................................... II-563

20.4.6 Oil viscosity, depending on temperature ................................... II-563

20.4.7 Theoretical contact stiffness ...................................................... II-564

20.4.8 Contact line (face gear) ............................................................. II-565

20.4.9 Stress curve (face gear) ............................................................. II-566

20.4.10 Scuffing and sliding speed (face gear) ...................................... II-567

20.5 Contact analysis ........................................................................................ II-569

20.5.1 Axis position ............................................................................. II-569

20.5.2 Transmission error ..................................................................... II-569

20.5.3 Acceleration of transmission error ............................................ II-571

20.5.4 FFT of Transmission Error ........................................................ II-571

20.5.5 Contact lines on the tooth flank ................................................. II-572

20.5.6 Normal force curve .................................................................... II-572

20.5.7 Normal force distribution .......................................................... II-572

20.5.8 Torque curve ............................................................................. II-572

20.5.9 Single tooth contact stiffness ..................................................... II-572

20.5.10 Stiffness curve ........................................................................... II-573

20.5.11 FFT of Contact Stiffness ........................................................... II-574

20.5.12 Bearing force curve and direction of the bearing forces ........... II-574

20.5.13 Kinematics ................................................................................. II-574

20.5.14 Specific sliding .......................................................................... II-575

20.5.15 Power loss ................................................................................. II-575

20.5.16 Heat development ...................................................................... II-575

20.5.17 Stress curve ............................................................................... II-575

20.5.18 Flash temperature ...................................................................... II-576

20.5.19 Safety against micropitting ........................................................ II-576

20.5.20 Wear .......................................................................................... II-578

20.6 Gear pump ................................................................................................ II-581

20.7 3D export .................................................................................................. II-582

20.8 Settings ..................................................................................................... II-583

21 A nsw ers to F req uen tly A sked Qu est ion s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I -584

21.1 Answers concerning geometry calculation ............................................... II-585

21.1.1 Precision mechanics .................................................................. II-585

21.1.2 Deep toothing or cylindrical gears with a high transverse contact

ratio II-585

21.1.3 Pairing an external gear to an inside gear that has a slightly different

number of teeth ....................................................................................... II-586

21.1.4 Undercut or insufficient effective involute ................................ II-586

21.1.5 Tooth thickness at tip ................................................................ II-587

21.1.6 Special toothing ......................................................................... II-587

21.1.7 Calculating cylindrical gears manufactured using tools specified in

DIN 3972 ................................................................................................ II-587

21.1.8 Composite deviations as defined in DIN 58405 ........................ II-588

21.1.9 Automatic change of reference profiles .................................... II-589

21.1.10 Non-identical (mirrored symmetry) tooth flanks ...................... II-589

21.1.11 Internal teeth - differences in the reference profile if you select

different configurations .......................................................................... II-589

21.1.12 Effect of profile modifications .................................................. II-591

21.1.13 Number of teeth with common multiples .................................. II-592

21.1.14 Allowances for racks ................................................................. II-592

21.2 Answers to questions about strength calculation ...................................... II-593

21.2.1 Differences between different gear calculation programs ......... II-593

21.2.2 Difference between cylindrical gear calculation following ISO 6336

or DIN 3990 ............................................................................................ II-593

21.2.3 Calculation using methods B or C (DIN 3990, 3991) ............... II-594

21.2.4 Required safeties for cylindrical gears ...................................... II-594

21.2.5 Insufficient scuffing safety ........................................................ II-595

21.2.6 Material pairing factor (hardening an unhardened gear) ........... II-596

21.2.7 Defining the scoring load level (oil specification) .................... II-596

21.2.8 Influence of tooth trace deviation fma due to a manufacturing error

on the face load factor KH .................................................................... II-596

21.2.9 Load spectrum with changing torque ........................................ II-597

21.2.10 Strength calculation with several meshings on one gear ........... II-598

21.2.11 Bevel gears: Determine permitted overloads ......................... II-600

21.2.12 Take shot-peening data into account in calculating the strength of

gears II-601

21.2.13 Calculation according to AGMA 421.06 (High Speed Gears) .. II-602

21.2.14 Comparison of a FEM calculation with crossed helical gear

calculation ............................................................................................... II-603

21.2.15 Estimate the strength of asymmetrical spur gear toothings ....... II-603

21.2.16 Determine the equivalent torque (for load spectra) ................... II-604

21.2.17 Check changes in safeties if the center distance changes .......... II-604

21.2.18 Warning: "Notch parameter QS . outside RANGE (1.0...8.0) "

II-605

21.3 Abbreviations used in gear calculation ..................................................... II-606

III Shafts and Bearings III-613

22 Def ining S haf ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I I -614

22.1 Input window ........................................................................................... III-617

22.1.1 Shaft editor ............................................................................... III-617

22.1.2 Elements-tree ............................................................................ III-619

22.1.3 Elements-list ............................................................................. III-620

22.1.4 Elements-editor ........................................................................ III-621

22.2 Element overview .................................................................................... III-622

22.2.1 The Shaft element ..................................................................... III-622

22.2.2 Outer contour ............................................................................ III-627

22.2.3 Inner contour ............................................................................ III-634

22.2.4 Forces ....................................................................................... III-634

22.2.5 Bearings .................................................................................... III-639

22.2.6 Connection elements ................................................................ III-642

22.2.7 Cross-sections ........................................................................... III-643

22.3 Basic data ................................................................................................. III-645

22.3.1 Position of shaft axis in space .................................................. III-645

22.3.2 Number of eigenfrequencies .................................................... III-646

22.3.3 Number of buckling modes ...................................................... III-646

22.3.4 Speed ........................................................................................ III-646

22.3.5 Sense of rotation ....................................................................... III-647

22.3.6 Reference temperature .............................................................. III-647

22.3.7 Housing temperature ................................................................ III-648

22.3.8 Lubricant temperature .............................................................. III-648

22.3.9 Load spectra ............................................................................. III-648

22.3.10 Gears......................................................................................... III-648

22.3.11 Roller bearing ........................................................................... III-649

22.3.12 Tolerance field .......................................................................... III-650

22.3.13 Enhanced service life calculation according to ISO 281 .......... III-650

22.3.14 Consider weight ........................................................................ III-650

22.3.15 Consider spinning effect ........................................................... III-650

22.3.16 Housing material ...................................................................... III-651

22.3.17 Lubricant .................................................................................. III-651

22.3.18 Impurity .................................................................................... III-651

22.4 Module-specific settings .......................................................................... III-652

22.4.1 Non-linear shaft ........................................................................ III-652

22.4.2 Consider deformation due to shearing and shear correction

coefficient .............................................................................................. III-653

22.4.3 Standard radius on shoulders .................................................... III-653

22.4.4 Node density ............................................................................. III-654

22.4.5 Iterative calculation of load distribution................................... III-655

22.4.6 Axial clearance ......................................................................... III-655

22.4.7 Failure probability .................................................................... III-655

22.4.8 Required service life ................................................................. III-656

22.4.9 Maximum service life coefficient ............................................. III-656

22.4.10 Surface roughness of housing ................................................... III-656

22.4.11 Calculation method for friction ................................................ III-656

22.4.12 Type of oil lubrication .............................................................. III-656

22.4.13 Bearing manufacturers ............................................................. III-657

22.4.14 Show coordinates system ......................................................... III-657

22.4.15 Show automatic dimensioning ................................................. III-657

22.4.16 Equivalent stress for sizings ..................................................... III-657

22.4.17 Maximum deflection for sizings ............................................... III-657

23 Calc ul at ing S h af t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I I -658

23.1 Bending and Bearing Forces, Distribution and Force of Torque ............. III-660

23.1.1 Calculating force on bearings with a contact angle .................. III-662

23.2 Eingenfrequencies .................................................................................... III-664

23.2.1 Bending critical speed .............................................................. III-665

23.2.2 Torsion-critical revolutions ...................................................... III-665

23.3 Buckling ................................................................................................... III-666

23.4 Strength .................................................................................................... III-667

23.4.1 Calculation method................................................................... III-668

23.4.2 Type of calculation ................................................................... III-672

23.4.3 Service life ................................................................................ III-673

23.4.4 Strength parameters in accordance with Hnchen and Decker III-673

23.4.5 Strength parameters in accordance with FKM ......................... III-674

23.4.6 Strength parameters in accordance with DIN ........................... III-676

23.4.7 Stress ........................................................................................ III-676

23.4.8 Stress ratio ................................................................................ III-676

23.4.9 Maximum load factor ............................................................... III-678

23.4.10 Load factor for endurance calculation ...................................... III-678

23.4.11 Cross-sections ........................................................................... III-678

23.4.12 Sizing ........................................................................................ III-680

23.4.13 Cross-section types ................................................................... III-680

23.4.14 General entries .......................................................................... III-686

23.5 Tooth trace modification .......................................................................... III-687

23.6 Campbell diagram .................................................................................... III-690

24 Beari ng c a lc ula tio n G enera l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I I -6 9 2

24.1 Classification of bearings ........................................................................ III-693

24.1.1 Properties .................................................................................. III-693

25 R oller bear ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I I -6 9 5

25.1 Selecting the type of roller bearing .......................................................... III-696

25.1.1 Characteristics of the most important bearing types ................ III-696

25.1.2 Comparing types ...................................................................... III-698

25.2 Load capacity of roller bearings .............................................................. III-701

25.2.1 Dynamic load capacity ............................................................. III-701

25.2.2 Static load capacity ................................................................... III-701

25.2.3 Bearing calculation with internal geometry ............................. III-702

25.3 Thermally permissible operating speed ................................................... III-703

25.3.1 Thermal nominal speed ............................................................ III-703

25.3.2 Process for calculating thermally permitted operating speed (DIN

732-2) III-705

25.4 Torque of friction ..................................................................................... III-707

25.4.1 Calculation according to SKF Catalog 2004 ............................ III-707

25.4.2 Calculation according to SKF Catalog 1994 ............................ III-709

25.5 Maximum Speeds .................................................................................... III-711

25.6 Service life ............................................................................................... III-712

25.6.1 Extended service life calculation according to Supplement to DIN

ISO 281 (2007) ...................................................................................... III-712

25.6.2 Service life calculation with load spectra ................................. III-713

25.7 Failure probability ................................................................................... III-715

25.8 Bearings with radial and/or axial force ................................................... III-715

25.9 Calculating axial forces on bearings in face-to-face or back-to-back

arrangements .................................................................................................... III-716

25.10 Oil level and Lubrication type ......................................................... III-718

26 R oller Bear ing s (I nt er nal g eomet ry) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I I -719

26.1 Bearing data tab ....................................................................................... III-720

26.1.1 File linkage ............................................................................... III-720

26.1.2 Bearing data .............................................................................. III-722

26.2 Load tab ................................................................................................... III-725

26.2.1 Load .......................................................................................... III-725

26.2.2 Enhanced service life calculation according to ISO 281 .......... III-725

26.3 Graphics ................................................................................................... III-727

26.3.1 Load distribution ...................................................................... III-727

26.3.2 Pressure curve .......................................................................... III-727

26.3.3 Stiffness curve .......................................................................... III-729

26.3.4 Pressure curve for each rolling body ........................................ III-730

27 Hydrody nam ic p l ain r a dial be aring s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I I -73 1

27.1 Calculation methods ................................................................................ III-732

27.2 Module-specific inputs ............................................................................ III-733

27.3 Thermal expansion coefficients ............................................................... III-734

27.4 Mean surface pressure ............................................................................. III-735

27.5 Lubrication arrangement .......................................................................... III-736

27.6 Heat transfer surface ................................................................................ III-740

27.7 Heat transfer coefficient .......................................................................... III-741

27.8 Oil temperatures ....................................................................................... III-742

27.9 Sizing the bearing clearance .................................................................... III-743

27.10 Sommerfeld Number ........................................................................ III-744

27.11 bearing width ................................................................................... III-745

27.12 Permissible lubricant film thickness ................................................ III-746

28 Hydrody nam ic ax ia l sl iding b ear ing s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I I -747

28.1 Calculation ............................................................................................... III-750

28.2 Sizings ..................................................................................................... III-751

28.3 Calculation of volume specific heat......................................................... III-752

28.4 Threshold values in the calculation ......................................................... III-753

29 A nsw ers to F req uen tly A sked Qu est ion s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I I I -754

29.1 Intersecting notch effects ......................................................................... III-755

29.2 Notch effects on hollow shafts................................................................. III-756

29.2.1 Notches on the outer contour .................................................... III-756

29.2.2 Notches on the inner contour .................................................... III-756

29.3 Fatigue Limits for New Materials ............................................................ III-757

29.4 Taking double helical gearing into account in the shaft calculation ........ III-758

IV Connections IV-759

3 0 Cyli ndric a l int erf eren c e f i t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 760

30.1 Inputting Tolerances ................................................................................ IV-763

30.2 Coefficient of friction .............................................................................. IV-764

30.3 Variable outside diameter of the hub ....................................................... IV-766

30.4 Convert external pressure with multiple interference fit ......................... IV-767

30.5 Materials .................................................................................................. IV-768

30.6 Settings .................................................................................................... IV-769

30.7 Sizings ..................................................................................................... IV-771

3 1 Conic a l in terf erenc e f it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 772

31.1 Calculation ............................................................................................... IV-774

31.2 Application factor .................................................................................... IV-775

31.3 Axial tensioning with nut ......................................................................... IV-776

31.4 Variable outside diameter of the hub ....................................................... IV-778

31.5 Conicity ................................................................................................... IV-779

31.6 Materials .................................................................................................. IV-780

31.7 Settings .................................................................................................... IV-781

31.8 Sizings ..................................................................................................... IV-782

3 2 Clamp ed c onnec t ion s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 783

32.1 Calculations ............................................................................................ IV-784

32.2 Sizings .................................................................................................... IV-785

32.3 Settings ................................................................................................... IV-785

32.4 Materials ................................................................................................. IV-786

3 3 Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 787

33.1 Main window ........................................................................................... IV-789

33.1.1 Additional inputs for DIN 6892 method B ............................... IV-790


33.3 Load factor ............................................................................................... IV-794

33.4 Own inputs ............................................................................................... IV-795

33.5 Permissible pressure ................................................................................ IV-796

33.6 Materials .................................................................................................. IV-797

33.7 Settings .................................................................................................... IV-798

33.8 Sizings ..................................................................................................... IV-799

3 4 S traig h t -s ided sp l ine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 80 0

34.1 Standard profiles ...................................................................................... IV-801


34.3 Torque curve/ Frequency of change of load direction ............................. IV-803

34.4 Occurring flank pressure .......................................................................... IV-804

34.5 Length factor ............................................................................................ IV-805

34.6 Share factor .............................................................................................. IV-806


34.8 Materials .................................................................................................. IV-808

34.9 Settings .................................................................................................... IV-809

34.10 Sizings .............................................................................................. IV-810

3 5 S p line s ( streng t h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 811





35.5 Length factor ............................................................................................ IV-817

35.6 Share factor .............................................................................................. IV-818


35.8 Materials .................................................................................................. IV-820

35.9 Settings .................................................................................................... IV-821

35.10 Sizings .............................................................................................. IV-822

3 6 S p line (g eometr y and streng th) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 823

36.1 Underlying principles of calculation........................................................ IV-824

36.1.1 General ..................................................................................... IV-824

36.1.2 Calculation of spline connections as described in DIN 5480 with

diameter centering ................................................................................. IV-824

36.2 Basic data ................................................................................................. IV-826

36.2.1 Geometry standards .................................................................. IV-826

36.2.2 Normal module ......................................................................... IV-827

36.2.3 Pressure angle at normal section an ......................................... IV-827

36.2.4 Number of teeth ........................................................................ IV-828

36.2.5 Profile shift coefficient ............................................................. IV-828

36.2.6 Quality ...................................................................................... IV-829

36.2.7 Geometry details ...................................................................... IV-830

36.2.8 Methods used for strength calculation ...................................... IV-831

36.2.9 Application factor ..................................................................... IV-831

36.2.10 Resulting shearing force ........................................................... IV-832

36.2.11 Define details of strength ......................................................... IV-833

36.2.12 Materials ................................................................................... IV-836

36.3 Tolerances ................................................................................................ IV-837

36.3.1 Tooth thickness tolerance ......................................................... IV-837

36.3.2 Effective/Actual ....................................................................... IV-838

36.3.3 Ball/pin diameter shaft/hub ...................................................... IV-839

36.4 Gauges ..................................................................................................... IV-840

3 7 Polyg o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 841






37.6 Materials .................................................................................................. IV-848

37.7 Settings .................................................................................................... IV-849

37.8 Sizings ..................................................................................................... IV-850

37.9 Graphics ................................................................................................... IV-851

3 8 Woodruf f K ey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 85 2





38.5 Length factor ............................................................................................ IV-858

38.6 Share factor .............................................................................................. IV-859


38.8 Materials .................................................................................................. IV-861

38.9 Settings .................................................................................................... IV-862

38.10 Sizings .............................................................................................. IV-863

3 9 Bolts a nd P in s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 864

39.1 Influencing factors ................................................................................... IV-866

39.2 Materials .................................................................................................. IV-867

39.3 Settings .................................................................................................... IV-868

39.4 Permitted values....................................................................................... IV-869

39.5 Sizings ..................................................................................................... IV-870

40 Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I V- 871

40.1 Special features in KISSsoft .................................................................... IV-873

40.2 Inputs for Basic data ................................................................................ IV-874

40.2.1 Operating data .......................................................................... IV-874

40.2.2 Bolt data ................................................................................... IV-884

40.2.3 Type of bolt connection ............................................................ IV-888

Manual

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