Document Changes in Release 03-2016

KISSsoft Release 03/2016

Changes from Release 03/2015 to Release 03/2016

Issue date: 14 April 2016

KISSsoft AG

Rosengartenstrasse 4

8608 Bubikon

Switzerland

Tel: +41 55 254 20 50

Fax: +41 55 254 20 51

[email protected]

www.KISSsoft.AG

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Contents

General ........................................................................................................................................................... 3 Base packages ................................................................................................................................................ 4

Base packages ............................................................................................................................................ 4 System modules .............................................................................................................................................. 6

KISSsys ....................................................................................................................................................... 6 Expert Modules KISSsys ................................................................................................................................. 7 Expert Modules Gears .................................................................................................................................... 8

Cylindrical gears .......................................................................................................................................... 8 Configuration / Dimensioning ................................................................................................................... 8 Methods for strength calculation .............................................................................................................. 8 Contact analysis ....................................................................................................................................... 9

Bevel gears ................................................................................................................................................ 10 Worm gears (Globoid) ............................................................................................................................... 11 Crossed helical gears or Worm gears (Cylindrical-Worm gear) ................................................................ 11 Noncircular gears....................................................................................................................................... 11 Further gear specific modules ................................................................................................................... 11

Expert modules shafts and bearings ............................................................................................................. 12 Shafts......................................................................................................................................................... 12 Bearings..................................................................................................................................................... 12

CAD Interfaces .............................................................................................................................................. 13 3D Export ................................................................................................................................................... 13

COM Interfaces ............................................................................................................................................. 13

This changes are relevant in the results, if opening an existing KISSsoft calculation from older

release.

NEW These new features are highlights of the release 03/2016, regarding new modules, calculations

or handling comfort.

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General

Modules Changes / Enhancements

General NEW The dynamic user interface allows to adapt the user interface to individual needs very

easily. A list of supported elements is available on request. Also the user can add own

parameters for documentation purposes now.

Settings: the path to the FE software (FEMDIR) can be defined now under ‘Extras – Settings’.

This allows a server installation of the FE software Code_Aster and hence the utilisation in

network mode.

Handling: by default, windows scrolls a drop down list (as i.e. material or bearing list) when a

mouse pointer hovers over it and the user rotates the mouse wheel. This may cause

unintentional changes of the input. Therefore this feature is deactivated now.

Database

Tool

Materials: a new database class for the material of the housing is added, which is used for

the calculation of the operating backlash and in the shaft calculation.

Material of gears: the sinter material Astaloy 85Mo from Höganäs is added. Also two plastic

materials from SABIC and Stanyl TW341 from DSM are added.

Some plastic material data are updated to either VDI guideline or suppliers notice.

Lubricants: for gear scuffing calculation, the values for the FZG Scuffing Test procedure

A10/16.6R/90 and S-A10/16.6R/90 are added. From Fuchs Lubritech, 2 greases are

actualized and 4 new oils are added.

Rolling bearings: data for SKF bearings are updated according to the current

specifications from the manufacturer. NEW Also many more rolling bearings are added, so the

database now includes roughly 11’500 SKF rolling bearings.

Rolling bearings: data for TIMKEN bearings are updated according to the current

specifications from the manufacturer.

Rolling bearings: data for KOYO bearings are updated according to the current

specifications from the manufacturer. The dynamic load numbers are changed according to

the technical report ‘dynamic load rating revision’ from JTEKT (July 2014).

Rolling bearings: data for NSK bearings are removed from the KISSsoft database and not

accessible by the user anymore. This is due to the age of the data (2004) and that the lifetime

calculation is different in the NSK catalogue from the lifetime calculation of ISO. Still, if older

KISSsoft files with NSK bearings are opened, the existing bearing data will be available and

used.

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Base packages

Base packages


ZPK

Cylindrical gear basic package

ISO/TR 15144 (Micropitting): as decided by the ISO committee, for helical gears an

error in the formula for the calculation of nominal Hertzian contact stress will be corrected in

the standard. Also the load sharing factor XY for helical gears will be interpolated in the range

of εβ = 0.8...1.2. Both changes are already implemented in KISSsoft Release 2016.

Tab ‘Tooth form’: when using the operations ‘gear generating process’ and ‘pinion type

cutter’, the conversion for manufacturing profile shift from the base tangent length for pre-

machining and final machining is added, if the option ‘own input’ is applied.

New tab ‘Final machining’: a new tab is added which contains the input data for gear final

machining. In older versions, the input was located on the tab ‘modification’.

NEW Grinding of gear root is available now. There are several options added as ‘flank and

root with equal grinding allowance’ and ‘own input (grinding flank and root)’. Also ‘grinding

flank, until root diameter df,e’ is available. Note, that grinding of the gear root affects the

reference profile for the strength calculation too.

Tab ‘Modification’: for the modification type ‘tip / root relief, linear with transition radius’ the

radius can be defined now in ‘Factor 2’. For the modification types ‘eccentric crowning’ and

‘eccentric profile crowning’ an asymmetric shape is possible now, where different crowning

radii for side I and II can be defined with ‘Factor 2’. A new modification type ‘tip relief, linear

with crowning’ is introduced, where the amount of crowning is identical at root and tip form

diameter.

Tab ‘Factors’: the rim thickness factor YB can be entered by the user under ‘Z-Y factors…’.

For the face load factor calculation, the axis misalignment values can be split into a constant

and a proportional (load-dependent) part.

Graphic: in the graphic ‘Wöhler lines (S-N curves)’, now the ‘Root - damage accumulation’

and ‘Flank - damage accumulation’ are shown, if a load spectra is applied. The displays of

measuring ball in transverse section and measuring circle in transverse section are removed.

Tolerances: for ISO 1328, AGMA 2000 and AGMA 2015, it is possible to extrapolate the

tolerance values in cases where the diameter or number of teeth are outside of range (under

‚Module specific settings – General‘).

Root form circle: for the calculation of the root form circle dFf, the user can now define a

threshold below which the undercut is not taken into account (under ‘Module specific settings

– Calculations’).

WPK Shaft and bearing basic package

Shaft editor: the representation of bearings in the shaft editor is more detailed now for many

bearing types.

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NEW The shaft can be mirrored using the new button . All relevant calculation inputs are

adjusted (position of shaft axis in space, oil level, etc.).

Graphics: in the graphics ‘3D display - Deformation (bending)’ and ‘3D display - Deformation

(eigenfrequencies)’, the model can be cut at an arbitrary section. The offset of the plane can

be defined by the user. Also, the bevel gears are represented now with the hand of spiral.

Rolling bearings calculation: the calculation of rolling bearings friction according to

the main catalogue SKF is updated from edition 2004 to 2013. Additionally, the calculation

method according to the Schaeffler catalogue 2014 (FAG, INA) is added (under ‘Module

specific settings – Rolling bearings’).

The calculation of the ‘thermally permissible service speed’ and ‘reference speed’ is now

also integrated in the module ‘shaft calculation’. Up to now, it was only available in the module

‘bearing calculation ISO 281, ISO 76’.

The clearances for SKF CARB® toroidal rolling bearings are provided according to the

SKF 2013 catalogue.

If rolling bearings data is added by the user to the KISSsoft database, it can be saved now

within the calculation file (to be activated in ‘Module specific settings – Rolling bearings’). This

makes it easier to send KISSsys or KISSsoft files with complete data.

The seal friction calculation can be deactivated now (under ‘Module specific settings – Rolling

bearings’).

The user can now input his own force/displacement curve with a dat file. This is available for

both radial and tilting stiffness.

Bearing lifetime calculation, classical: the factors e, X1/X2 and Y1/Y2 are updated

for the deep groove and angular contact bearings according to ‘Wälzlagerpraxis’ (Schaeffler,

2015).

MPK Shaft-hub connections

Splines: NEW the strength calculation for involute splines according to AGMA 6123-B06 is

implemented now.

Interference fit: in case of high operating temperatures, the interference fit may become

loose. In this case, so far the calculation was aborted. Now the user can activate the option to

continue the calculation. The report shows only the results for the allowances (under module

specific settings – ‘in case of negative interference during operation continue calculation and

report allowances’).

SPK Bolt calculation

VDI 2230, sheet 1 (2015): the edition 2015 is implemented. It mainly includes

corrections of the edition 2014 which were already implemented in KISSsoft due to feedback

from Prof. Lori.

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FPK Springs: the picture in the ‘drawing data’ report is now identical to the graph in the DIN

standard.

System modules

KISSsys


SYS KISSsys

NEW static equilibrium in System: a function is available now to automatically determine

the static equilibrium within the complete transmission. Herewith, the effect of for instance

misalignments of rolling bearings to the contact of meshing gears and hence the transmission

error can be checked. The functionality is provided in the settings table.

NEW 3D modelling process: creating a new KISSsys model is simplified significantly. While

adding elements to the model in KISSsys, default geometries are applied automatically and

the machine elements become visible immediately. Also, the positioning of the shafts is

automated, as the positioning is done during the connection of gears.

NEW Fast group based modelling: creating a new KISSsys model is now possible by adding

complete gear stages as one group, as i.e. cylindrical gear stages, planetary stages or even

user defined stages. If the group is added to an existing stage, merging of the shafts is possible

now too.

NEW Damages tables: the damages results are shown now in individual tables for gears,

shafts and bearings. An overview of the most critical elements is given in the additional table

‘highestDamage’. The results are calculated by using the function ‘GetDamage’ by right

mouse click on the damage table.

NEW Auxiliary results template: with the template ‘auxiliary results’, the inertia, kinetic

energy, etc. are calculated and shown. The template can be added to any KISSsys model.

The calculations are provided by a right mouse click on the template.

Load spectra template: different lubricant temperature can be defined now for each load bin.

Also the efficiency for each load bin can be determined.

New icons: for chain drive and belts, new icons are implemented, to be more consistent with

the KISSsoft icon shapes. Also for load spectra calculation, the icons are now divided into ‘load

spectra calculation with database’ and ‘load spectra calculation with template’.

New functions: the load distribution factor Kγ and application factor KA from the gear

calculation can be applied now to the shaft calculations. The corresponding instructions are

available on request.

Changes in KISSsys models required by the user: several improvements of

templates and programming may require adaption of user generated code from previous

KISSsys releases. A list of changes is available on request.

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GPK Gearbox calculation package

GPK Model: an additional GPK model with herringbone gears and journal bearings is available

in the folder ‘SpecialGearBox’. Also, all GPK models and sample files are updated.

Graphics: a new 3D graphic viewer is available with better representation possibilities (same

as in the shaft and gear calculation), in addition to the previous 3D viewer.

Progress bar: if the calculation is started, a progress bar is shown now, with the option to

cancel the calculation. It represents the status of the KISSsoft calculations.

Expert Modules KISSsys


KS2

Efficiency: gear meshing losses can now be determined by the gear contact analysis. It is

also possible now to determine the operating temperature based on a given operating drive

cycle.

KS3

NEW Vibration calculation: the calculation of unbalanced response is implemented now. It

calculates the amplitude of the excited vibrations over the speed. As exciting forces, the

unbalanced masses of shafts are considered. Both viscous and structural damping can be

defined by the user and are taken into account.

The damping values for rolling bearings can be entered in the KISSsoft bearing calculation, in

the tab ‘damping’. The tab is only visible if the bearing calculation is started from KISSsys.

NEW The Campbell diagram for shaft systems is calculated. A big number of reports and

plots are provided which show the results for several eigenmodes and directions.

KS4

NEW Housing deformation: the stiffness matrix in the native format of ABAQUS (symmetric)

and NASTRAN (symmetric and asymmetric) can be imported now. Also the initial bearing

offsets from i.e. housing calculation with FE can be imported and considered in the iteration.

The bearing forces are provided now in the global coordinate system.

There are some more functionalities added as i.e. the maximum number of iterations during

the calculation can be modified now by the user. In the 3D view, the ID number of each master

node is shown now, when using the ‘ShowNodes’ functionality.

The housing deformation can be included now also in load spectra calculations, which returns

the bearing deviation values for each load bin.

KS10

NEW

Export to MBS Software: the export from KISSsys data to multibody simulation (MBS)

software is available now. Typical possible exported data are the geometry of shafts, gears

and bearings, the stiffness matrix for bearings and gear meshing stiffness. Some software may

also use the dynamic forces as gear transmission error and shaft unbalanced masses. All data

are provided in text files with the required format of the respective software.

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The module KS10 exports the KISSsys data for the software MSC Adams Gear AT. The data

contain information for the system, bearing with inner geometry, shafts and gears geometry.

The data are exported into several subfolders and can be imported into Gear AT directly.

Expert Modules Gears

Cylindrical gears

Configuration / Dimensioning


ZA4 NEW Fine sizing: the variation of the reference profile (addendum gear 1, 2 and tip clearance)

is possible now. Also, the strength calculation can optionally be done using the largest possible

theoretical root radius.

The contact analysis can be activated directly from the result list. This allows to reduce the

number of solutions prior to start the contact analysis. Also the original solution is calculated

by the contact analysis for the sake of comparison.

ZA5 Sizing and conversions: for sizing of tooth trace modifications (in the tab ‘modifications’), the

option ‘Exact sizing in acc. with ISO 6336-1 Appendix E (without manufacturing allowance)’ is

split into the two variants ‘Exact sizing in acc. with ISO 6336-1 Appendix E: centric crowning +

helix angle modification’ and the new option ‘Exact sizing according to ISO 6336-1 Appendix

E: eccentric crowning’.

Methods for strength calculation


ZA10 ISO 6336: the ‘tooth root stress correction factor YS’ and ‘tooth root form factor YF’

change slightly if a pre-cutter without protuberance is applied. The calculation is now

performed using the theoretical profile shift x (when As < 0.05*mn) instead of the pre-

manufacturing profile shift xE.e.This was discussed in the ISO committee.

ISO 6336 and AGMA 2001, 2101: the rim thickness sr is now deduced from sr = (df.i – di)/2

(worst case, before the theoretical root diameter was used). In case that the factor sr* is given,

now the rim thickness used in calcualtion is exactly mn*sr* (before it was sligthly different).

This affects the resulting rim thickness factor.

ZA11 DIN 3990-4: scoring according DIN 3990-4, analogue STplus, can be selected. This new

option covers differences between the interpretation of the standard as implemented in

KISSsoft and STplus.

ZA13 NEW VDI 2737: the proposition for a new edition for 2016 is integrated. There is now the

choice between case I (constant stress gradient σa/σm) and case II (constant mean stress σm),

under ‘module specific settings – calculations’.

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According to an exchange with authors of the standard, the factor for loading KFK now also

considers the face load factor for tooth root stress KFβ.

ZA17

ZA21

NEW for VDI 2736 (and VDI 2545): if wear for plastic gears is calculated, additionally the

shearing safety according to Fürstenberger is shown in the report in section 4a.

Contact analysis


ZA30

ZA34

Contact analysis cylindrical gears and planetary gear

NEW Now, also load spectra can be considered in the contact analysis. The result table

shows the results for each load bin as PPTE, line load and Hertzian pressure values. The

report shows all details for each load bin.

The sizing button for partial load, which considered the overload factors (K-factors) is replaced

by a checkbox. The detailed settings regarding the overload factors can be done in the ‘Module

specific settings – Face load factor/Contact analysis’.

Pressure peaks based on the change of the curvatures at the tip rounding can be interpolated

now. Also, the plastic deformation can be considered now by the maximum endurable elastic

stress in the meshing contact (under ‘Module specific settings – Face load factor/Contact

analysis’).

The analysis area regarding tooth depth and face width can be modified by the user now

(under ‘Module specific settings – Face load factor/Contact analysis’). The results based on

the reduced area will be reported in the additional variables σHreduced, etc.

It is possible now to smoothen the results for σH, σF1,2, SB and Slam by using low pass filters

(under ‘Module specific settings – Face load factor/Contact analysis’). By default, they are

switched off.

For the display of the transmission error, optionally the backlash can be taken into account

(under ‘Module specific settings – Face load factor/Contact analysis’).

If gears with different face width are in contact, now the correct normal force Fn instead

of normal force Fnb is applied.

Several optimisations in the algorithms may lead to slight changes in the results.

ZA33 NEW Modification sizing: a new graph shows the solutions in the same manner as in fine

sizing.

In the result table, now the mean power losses are shown instead of the maximum power

losses.

ZA35 Face load factor calculation KH: if the face load factor is calculated considering the shaft

deformations, the equivalent linear misalignment of the shafts is calculated and the values

fΣβ and fΣδ are shown in the report ‚face load factor‘. Occasionally, these values are used in the

industry and for comparison reasons, KISSsoft now shows these results as well.

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The load factors (K-factors) can now independently be considered for gear meshing load

distribution and / or the axis alignment of the shafts (under ‘Module specific settings – Face

load factor/Contact analysis’). This results in different values for the face load factor KH

In the window ‘axis alignment’, the user can define how the gears are to be considered

in the shaft calculation with respect to the bending line. Now the several options are considered

as per selection by the user.

ZA36

Planet carrier deformation: when the deformation of the planet carrier is calculated by the

FE software Code_Aster, which is delivered along with KISSsoft, the software Salome can be

opened now and the meshing and the deformation results checked visually.

NEW For calculating the planet carrier deformation using the FE software Code_Aster, which

is delivered along with KISSsoft, several parameters for a more detailed geometry are added,

as different wall thickness for side I and II or the definition of cavities. For consideration of an

existing planet carrier, it is possible now to import a STEP file into KISSsoft and to calculate

the deformation with the Code_Aster software.

NEW Result files from a planet carrier deformation calculation with ABAQUS can be imported

now in its native format.

Bevel gears


ZC1 Tab ‘Basic data’: the gear type ZEROL is added to the drop-down list of the hand of spiral

selection.

Graphic: in the evaluation graphics, the new graphics ‘Wöhler lines (S-N curves)’ and

‘Safety factor curve’ are added. In the graphic ‘Wöhler lines (S-N curves)’, also the ‘Root –

damage accumulation’ and ‘Flank – damage accumulation’ are shown, if a load spectra is

applied.

NEW In the Graphic ‘Geometry 2D – tooth form’, the tooth form for inside (toe) and outside

(heel) position can be checked individually. This has to be activated under ‘Module specific

settings – Generation of 3D – displaying 2D geometry for inside and outside’.

the axis misalignment VHJ are changed according to the definition from Klingelnberg,

as the ISO 10064 doesn’t contain an explicit indication of the sign of the V deviation. The

picture is improved accordingly.

ZC2

ZC9

ISO 10300: the sample calculations for bevel and hypoid gears according to ISO/TR 19041

are added to the ‘examples’.

ZC12 Fine sizing: the contact analysis can be activated from the result list. This allows to reduce

the number of solutions prior to start the contact analysis. Also the original solution is

calculated by the contact analysis for the sake of comparison.

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ZC13

Sizing for topological modification: new format for ZEISS available.

ZC30

Contact analysis: several optimisations in the algorithms may lead to slight changes in

the results.

NEW The axis misalignment VHJ of pinion and ring gear is calculated directly by the

deformation of the corresponding shafts. The shaft files are automatically connected to the

bevel gear contact analysis by using KISSsys, also the manual linking of the individual shaft

files without KISSsys is possible. The bending of the shafts is also considered, so that the shaft

angle deviation ΔΣ is considered in the contact analysis. In addition, the axis misalignment

VHJ of the calculation point are calculated and transferred automatically to the calculation, if

no shaft files are applied.

Worm gears (Globoid)


ZD1 Geometry: the input field of ‘tooth thickness modification factor xs*’ is moved from the dialog

‘Basic data – Details’ into the tab ‘Basic data’.

The input field for the characteristic values h*, p*, s* are moved from ‘Basic data – Details’ to

‘Module specific settings – Calculations’.

Crossed helical gears or Worm gears (Cylindrical-Worm gear)


ZE3

ZE5

NEW for VDI 2736 (and VDI 2545): the wear calculation according to Pech is implemented.

It covers the calculation of wear and plastic (non-elastic) deformation. The calculation is valid

for metallic worms in combination with plastic worm wheels.

In the material database the label [WORM] in the material designation is shown now if the

plastic material can be applied for worm gears.

Non circular gears


ZG1 Non circular Gears: it is possible to calculate 3 non circular gears (in the arrangement as 3

gears train), where the last gear is the same gear as the first one. Also, non-circular gear

calculation for rack and pinion is possible. Specific instructions will be provided on request.

Further gear specific modules


ZZ1 Load spectra: the calculation option ‘consider only one load bin in the load spectra’ is added.

It is also possible now to directly link and edit a dat file including the load spectra in the

calculation.

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If the option for face load factor ‘own input, per load bin’ is used, the face load factor for the

calculation with reference power can be entered now in the tab ‘factors’.

ZZ3 NEW Operating backlash: two new options are added for more detailed determination of the

smallest operating backlash, ‘consideration of tooth bending’ and ‘bending of shafts’

(according ISO 6336-1, Annex E).

ZZ4

Tooth Flank Fracture: changes in the draft of the ISO/DTS 19042 are implemented.

Expert modules shafts and bearings

Shafts


WA2 NEW Tooth trace modification with displacement matrix: the displacement matrix file can

be derived now from gear body deformation calculation from the KISSsoft module DPK. This

leads to a more precise calculation of tooth trace modifications including gear body

deformation.

WA5

WA6

WA7

Hänchen&Decker, DIN 743, FKM Richtlinie: the damage accumulation is calculated and

shown in the report, if a load spectra is applied.

WA8 Load spectra: for each load bin, the shaft bending line is available now and can be checked

in the graph ‘displacement’. The data for each bending line, including the forces and moments,

are provided in temporary files for further evaluation (to be activated in ‘Module specific

settings – Calculations’).

Further shaft specific modules


DPK

NEW

Gear body deformation: for asymmetric gear bodies, the resilience of the gear body can be

calculated now by using the integrated FE Software Code_Aster (flexibility of gear rims and

webs in axial plane). This gives a more precise determination of the gear flank misalignment.

The results of the deformation calculation can be shown with the post and pre-processing

software Salome.

Bearings


WB2

WB4

Rolling bearings ISO/TS 16281: temporary files are saved (if activated in ‘Module specific

settings – Calculations’) with data of internal geometry results as force per rolling body,

pressure, etc. These data may be used for i.e. interfacing external MBS software or evaluation

with Excel.

14.04.2016 13 / 13

Report: the documentation of the operating bearing clearance is more detailed now. Also the

reaction moments are documented now for the rolling bearings.

WB3 NEW Hydrodynamic bearings: the standard DIN 31657 is available now. It contains the

calculation for multi-lobed and tilting pad journals.

NEW The standard ISO 12130 for the calculation of tilting-pad thrust bearings is equal to the

standard DIN 31654. So, both names are shown now.

The bearing data are moved into the new tab ‘Bearing specific inputs’.

CAD Interfaces

3D Export


CB2 Solid Edge: the interface to Solid Edge ST8 is implemented. Simplified view is available, which

represents the cylindrical gear in axial section (to be activated in KISS.ini).

CB3 Solid Works: the interface to Solid Works 2016 is implemented.

CB4 Autodesk Inventor: the interface to Autodesk Inventor 2016 is implemented.

CB6 Creo Parametric: now the path of the PLM system can be defined in KISSsoft in order to save

the temporary files of the gear generation.

CB7 Siemens NX: only versions back to NX 7 are further supported.

COM Interfaces


CC2 COM Interface Expert: the function ‘IsLubricantRelevant’ is removed. Instead use

‘IsBearingLifetimeModified’.

Documents

Document Changes in Release 03-2016