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Optimisation of engine torque using variable valve actuation

2012-02-14T23:39:00.001-08:00

The engine studied is a new one : 3.2L, V6, GDI with double
VVT (intake and exhaust).
The engine has been studied in the maximum power
configuration and the performances have been studied at
different engine speed, from 1000 to 7000 [rpm] with step of
500 [rpm].
For the performance predication a commercial 1D fluid-dynamic
solver (Gtpower) has been coupled with the optimisation
algorithm.

The VVA system is not yet present on the engine. For this
reason, the optimisation technique has been used in the project
phase as mean to evaluate engine performance variation.
The aim of the work is the optimisation of engine torque
using Variable Valve Actuation Systems: VVT for intake
and exhaust timing and VVA for the intake valve lift and
opening duration .

The variable valve actuation systems used for the optimisation
work are:
- VVT ( Variable Valve Timing): this system is able to change the
position of valve start opening (see1)
- VVA (Variable Valve Actuation): this system is able to change valve
lift and opening duration

NOTE:The combined use of these two systems allows the users to obtain the required
valve lift characteristics for typical performance objectives.

Before the optimisation phase the model has been tuned
using some experimental data, such as:
1) Pressure waves on the intake and exhaust manifold
2) In cylinder pressure
3) Combustion rate
4) Friction
5) Pressure losses on the intake and exhaust systems
6) Temperature on the catalyst cupel (intake and exhaust)

NOTE: The VVA system is able to create different valve lift and opening
duration. Using modeFrontier, it is possible to consider the valve lift and
opening duration plots as numbers, and so as parameters. Following that way,
calling the files relative to them with numbers (increasing at increasing lift)
the optimisation solver is able to evaluate their influence in a correct
way.

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Application of a Quasi-Dimensional Combustion Model

2012-02-14T23:36:00.001-08:00

The above values were held fixed for the calculation
of any operating condition of the engine. In addition, they
are very similar to the ones identified for the simulation
of a very different research engine [5]. This practically
means that the model description of the kernel duration,
initial flame development, turbulent flame propagation
and combustion termination, is able to reproduce the
underlying physics in a satisfactory way.
Fig. 5-Fig. 7 report the mean performance
parameters of the engine at WOT. Agreement with the
experimental data is satisfactory all over the engine
speed range. An increased volumetric efficiency can be
observed at about 3000 rpm (Fig. 5). The 1D
schematization of the intake and exhaust pipe network
probably determines an overestimation of the gas-
dynamic tuning at this particular engine speed. The latter
inaccuracy also reflects in the IMEP, BMEP, Power and
BSFC profiles in Fig. 6 and Fig. 7.
A more detailed comparison is presented in Fig. 8-
Fig. 13, in terms of instantaneous pressure cycles at
WOT. The figures also report the pressure cycles
computed with the base version of the model (eq. (2)).
The correction proposed (eq. (16)) enhances, as
expected, the burning rate at high speeds, and
considerably improves the prediction of the in-cylinder
pressure peak, especially in the medium-speed range. In
each operating condition, combustion start, maximum
pressure and expansion phase are well reproduced by
the improved fractal model.
In order to check the model accuracy at part-load
too, some analyses were carried out at fixed rotational
speed (2000 rpm) and for different load levels (WOT and
2.3 bars BMEP). Two different VVT positions (0° and 25°
cam angles) were also analyzed. The results obtained
are summarized in Fig. 14-Fig. 16. The prediction of the
pressure cycle is satisfactory also in these more critical
operating conditions on both high pressure cycle (Fig.
14) and mass exchange phase (Fig. 15). Fig. 15
particularly puts into evidence the strong reduction of the

pumping work achieved through a delayed camshaft
position, reflecting in a relevant BSFC improvement. The
coupled effects of the spark advance, residual fraction
level at intake valve closure, and valve timing really
determine a very different development of the
combustion process, as shown in Fig. 16.
In the tested operating conditions, a maximum EGR
level of about 24% was reached (Fig. 16). A further
validation of the combustion model with a percentage of
residual gases greater than 30-40% is however required
to fully asses the model accuracy.

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Robust Optimization of ABS Control Parameters

2012-02-14T23:26:00.001-08:00

ABS for Automobiles
Anti-lock Braking System
-Prevents wheel lock-up to secure steerability and controllability in
emergency braking situations.
-If wheel rotation exceeds the stability limit, brake pressure will be
decreased to adjust the rotation to be within the stable region.
-Then, brake pressure will be increased again until it exceeds the stability
limit to maintain the rotation status of the stability limit region as long as
possible.

Multi Objective Robust Design Optimization
Perform global exploration by considering the issue as
multi-objective optimization problem of
-Output average value: Maximization (minimization)
-Output standard deviation: Minimization
when probability distribution variation is applied to the input.

Optimization Process
Step1
-Scheduler: FMOGA (RSM Evaluation: 0.8/Linear annealing)
-First generation individuals: 25 DOE (Random)
-Number of generations: 15
-Number of robust sampling: 110 (Actual samples: 10, RSM: 100)
Step2, 3
-Scheduler: FMOGA (RSM Evaluation: 0.6/Fixed)
-First generation individuals: 20 Pareto solutions for previous Step
-Number of generations: 15
-Number of robust sampling: 110 (Actual samples: 10, RSM: 100)
CPU: Pentium 3 (1.0GHz) Dual (RAM: 780MB)
Total calculation time: Approximately 25 hours

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Integration of AVL Boost with modeFrontier

2012-02-14T23:21:00.001-08:00

-The optimisation target is given by the squared
difference between experimental and simulation data,
relatively to the 3 conversion curves (CO, HC and H2)
-Once the LO_optim.bwf model is set and the target
functions are built, the integral value Y_MEAN_INT_DX
for all the three target curves is defined as output variable
(SD_CO, SD_HC, SD_H2)
-The global optimisation objective is given by the
minimisation of global_error = (SD_CO+SD_HC+SD_H2)

-A different approach has been considered:
-After 718 designs calculated by NSGAII (global_error=50),
multi-objective scheduler MOGT is run (minimise SD_CO,
SD_HC, SD_H2 as 3 different objectives)
-MOGT starts from a good configuration (#718) and sets 3
constraints on the values of the 3 objectives, that should
be less than the ones of the starting configuration

-A last approach has been considered:
-Simplex mono-objective algorithm is used from random
DOE (particular efficient in problems that are not highly
non-linear)

-An example of integration of AVL Boost with modeFrontier
has been shown
-The test case was relative to the calibration of 6 kinetic
parameters in a catalytic conversion reaction
-Different optimisation algorithms has been used to minimise
the difference between the experimental and the simulated
conversion curves

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Coupling AMESim v4_2 with modeFRONTIER

2012-02-14T23:19:00.001-08:00

Create the simulation model and assign the
Input Parameters which shall be used as
input variables for modeFRONTIER
-Specify Simple Output and/or Compound Output Parameters to
be processed as Output Variables by modeFRONTIER

-Using the selection by Introspection, this facility lets you specify AMESim parameters by
selecting the parameter names directly in the introspection dialog
-You can start the Introspection process by clicking on the small folder near the parameter name.
-A dialog will immediately report you about the introspection progress

Run modeFRONTIER Node Interface–Assign Assign
Variables Variables
-The Introspection dialog lets you specify the desidered parameter,
selecting it on the Parameters Table.
-Alternatively you can type the parameter name on the Selected
Parameter textfield.
- The Parameters Table contains all the parameters available in the
project.

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KISSsoft think design interface-How create a new gear in thinkdesign

2011-12-23T18:23:00.001-08:00

Run thinkdesign

Run KISSsoft (from windows or thinkdesign)

Load gear calculation file or insert data and run calculation

Set thinkdesign as CAD program for 3D export

Run 3D export

In thinkdesign you’ll find the model

Informations about gear are in text near the model and as file properties, so you can add symbolic text in 2D drawing

How configure thinkdesign add-in

If you don’t see kisssoft menu in thinkdesign, copy these two file from kisssoft\think3 subfolder

to in thinkdesign\autoload subfolder

C:\Program Files\think3\2008.1\thinkdesign\autoload

hyperMILL

Because hyperMILL has the same thinkdesign kernel, the think3 KISSsoft interface is running

with hypermill, too.

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KISSsoft Tutorial-Analyzing the Geometry of Worm Gears that have a Globoid Worm Gear

2011-12-23T18:22:00.001-08:00

1 Task

1.1 Task

To calculate a worm gear with center distance 100 mm. The worm has 2 teeth, and the worm

gear has 41 teeth. The axial/transverse module is 4. The pressure angle at the normal section

is 20°. The worm's toothing length is 60 mm. You should select a sensible tooth width for the worm gear. The axis tolerance is js7. The worm's tooth thickness deviation in the normal section is between 0 and -0.04 mm. The tooth thickness deviation for the worm gear is between -0.128 and -0.168. The external diameter of the worm is 44 -0.01 mm. The root diameter is 26.4 -0.110 mm. The effective tip clearance is to be 0.8 mm. The root radius factor is 0.2. The inside radius diameter is 134.4 mm. The tolerance for the external diameter of the worm gear is between 0 and -0.01, for the active root diameter it is between - 0.360 and -0.473. The worm is to be manufactured with accuracy grade 6 as specified in DIN 3974. The worm gear is to be manufactured with quality 7. The lead direction is to the right. The worms flank form is ZI.

1.2 Starting the drive element of a worm gear with a globoid worm wheel.

Once you have installed and activated KISSsoft either as a test or licensed version, follow these steps to call the KISSsoft system. Usually you start the program by clicking "Start?Program Files?KISSsoft 03-2011?KISSsoft".This opens the following KISSsoft user interface:

Figure 1.1 Starting KISSsoft, initial window

In the Modules tree window, click the "Modules" tab to call the "Worms with enveloping worm

wheel" calculation:

Figure 1.2 Calling the worm gear calculation.

1.3 Inputting data in the main screen

After you call the analysis for a worm gear with a globoid gear, this input screen appears. In the

"Strength" group, now select " Only geometry calculation" as the calculation method.

Figure 1.3 Input screen for worms

Input values for the axial/transverse module, number of teeth, quality and worm face width in the "Basic data" tab. You must also input the axis distance (1). The subsequent interim value

is calculated because only the lead angle needs to be calculated. To do this, click the "Convert

button" (2) and then click "Calculate" (3) to determine the lead angle. Finally, click Accept (4) to transfer this data to the main screen (see Figure 1.4).

Figure 1.4 Interim state with the Sizing lead angle input screen

Click the "Details" button to call the "Define details of geometry" sub-screen and then select the appropriate flank form ZI. You must also input the inside diameter of the worm gear as 134.4 mm.

Figure 1.5 Interim status with "Define details of geometry" input screen

1.4 Special features of worm gear teeth flank surfaces

The flank surfaces of a worm gear are defined in a different way from those in cylindrical gears.

Figure 1.6 Calling the information graphic to describe wheel rim width b2R and wheel width b2H en

Then click the "Sizing button" to calculate the gear width .

Figure 1.7 Calculated wheel rim width b2R

1.5 Input data for the gear pair

In the "Reference profile" tab, select "Own Input" as the predefined tool profile. Then click the relevant "Convert button" to calculate the addendum and dedendum coefficients for the worm. Then click Accept to transfer the dedendum and addendum coefficient values to the

main screen.

Figure 1.8 Calculating the worm root or tip diameter

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KISSsoft interface to CATIA V5- user handbook

2011-12-23T18:20:00.001-08:00

1 General description

KISSsoft AG develops calculation programmes in most different areas. The product KISSsoft is

a programme for the calculation, interpretation and optimization of machine elements. For the modul to calculate the gear wheels the company SWMS systems has developed an interface to

CATIA V5. About this interface it is possible to produce in CATIA V5 the gear wheels calculated in KISSsoft.

1.1 Functional description

1.1.1 Product target

Goal of this application is the construction of the gear wheels calculated in KISSsoft in CATIA V5.

1.1.2 Types of gear wheels

The following types of gear wheel are supported by the interface.

? Internal / external Spur Gears

? Internal / external Helical Gears

? Crossed Axes Helical Gears

? Worm Gears

? Bevel Spur Gears

1.2 Prerequisite and integration

1.2.1 User section

The dialog of the interface is aimed at users who are familiar with common windowssoftware as

well as with the software product CATIA V5.

1.2.2 System prequisite

The software is usable on workstations (PC). For the use of the software the following minimal

requirements on the software surroundings are put:

- Windows 2000/XP

- CATIA V5 R14, R15, R16

KISSsoft version which supports the interface and ties (04-2006 =)

The hardware prerequisites suits by the prerequisites for the software CATIA V5.

1.2.3 Extent of supply

- interface

- documentation (in electronic form)

1.2.4 Implementation and connection to other systems

The delivered interface is called upon by KISSsoft for the term and communicates via the Visual

BASIC interface of CATIA with CATIA V5.

1.2.5 Installation

The following section describes the installation of the CATIA interface for KISSsoft

Remark for new KISSsoft version:Use the KISSsoft setup for installing the CATIA-interface.

To the start of the file "Setup.exe" the represented welcoming dialog appears.

You click on to reach the adjusting dialog.

In this dialog the KISSsoft contents directory and the target directory must be selected for the CATIA -- interface.

Click to this on the button next to the title "KISSsoft contents directory" and select the KISS-soft contents directory in the structure tree.

As a target directory for the CATIA -interface the directory "CATIA" will be shown in the KISS-soft contents directory automatically.

Would you like to install the interface in another directory you click next to the title "target directory" for CATIA -interface and select the folder you requested in the directory tree.

Under "further settings" you can set up the option ,so that the interface will be typed in as standard interface in the KISS-soft- configuration file automatic.

Remark: Write authorities are necessary for the installation on the file "Kiss.ini" as well as on the KISSsoft contents directory.

After all settings are done, the installation is started by clicking on the button

figure 3: setup – installation process

After completion of the installation the setting will be finished by clicking on the button .

2 Creating gear wheel

The following section describes the construction of gear wheels in CATIA V5 which are calculated with KISSsoft.

2.1 Preparing KISSsoft

To use the CATIA interface for KISSsoft, at first you start KISSsoft and CATIA V5. Open the needed calculation data in KISSsoft or carry out the desired adjustings in KISSsoft as normal.

You start the module over the menu entry calculations/Tooth form Z5 for the calculation of the tooth form. Gear wheels can be imported in CATIA out of this module.

figure 4: calculation of the tooth form

3 Settings of the tooth form calculation

After the start of the module for the tooth form calculation you run the calculation with the help of

the button calculate. Following you select the settings in the area "representation".

? circular approximation

? tooth form of wheel X

? CATIA

With the help of the button 3D you start the dialog for the import of the gear wheel in CATIA . Make sure before that CATIA is started and ready for entering.

figure 5: tooth form calculation

3.1 Dialog creating of gearing

After the gear wheel import from KISSsoft was started, the following represented dialog opens.

figure 6: dialog creating of gearing

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KISSsoft Tutorial-Bevel Gears

2011-12-23T18:19:00.001-08:00

1 Starting KISSsoft

1.1 Starting the software

Once you have installed and activated KISSsoft either as a test or licensed version, follow these steps to call the KISSsoft system.Start the program by clicking "Start?Program FilesKISSsoft 03-2011?KISSsoft". This opens the following KISSsoft user interface:

Figure 1.1 Starting KISSsoft, initial window

1.2 Starting the calculation module

Start the "Bevel and hypoid gears" calculation module by double-clicking the corresponding

entry in the "Modules" window in the top left-hand corner of the main window.

Figure 1.2 Selecting the "Bevel and hypoid gears" calculation module from the "Modules" window

2 Introduction

There are various different types of bevel gears, and every design has special features that must be taken into consideration.This tutorial describes these various designs and provides information about how they can be analyzed in the KISSsoft system.

2.1 Differential bevel gears

Differential bevel gears are usually straight toothed. For manufacturing reasons, their construction is usually very different from the theoretical design. Therefore, we recommend you use a different approach to analyze an existing set of bevel gears from a drawing.

The drawings for differential bevel gears often contain very little theoretical data. Usually, the drawing does not show a theoretical external tip diameteror an external reference diameter

Instead it shows the finished external diameter so that the external reference diameter must

be estimated. It is also often not clear whether the module is the middle or external module. However, this can be checked quite easily withThe transverse and normal modules are identical because the gear is straight toothed.

2.2 Calculating geometry in KISSsoft

1. In the "Geometry"→"System data" tab, select the "Standard, fig 2 (Tip, Pitch and Root apex NOT in one point)" option.This type allows you to input tip and root angles (see Figure ).

Figure 2.1 Selecting "Standard, fig 2" type

2. Input "Reference diameter gear 2 (outside)" or "Normal module (in middle)" according to the drawing. If the values are not specified on the drawing, use the graphics on the drawing to determine them.

3. Input the "Pressure angle" and "Number of teeth" in accordance with the drawing.

4. Input the "Facewidth". If the facewidth is not predefined, you must measure it on the drawing. Here, use the reference cone length.

5. Input the "Profile shift coefficient" and "Tooth thickness modification factor"= 0.

6. Before you can input the "Tip and root angle gear 2", you must first run the calculation withor press "F5" to calculate the reference cone angle. Right-click on "Convert" to input the tip and root angle. Then click "Calculate" to calculate the tooth angle and

include this in the calculation (see Figure ).

Figure 2.2 Input and convert tip and root angle

7. You do not need to enter anything under "Manufacturing data" because this data will be ignored

8. Either clickor press "F5" to run the calculation. To generate and open the report, clickor press "F6". You can then compare the results in the report with the default data on the drawing, for example the angle (see Figure ).

Figure 2.3 Bevel gear report, section 1 tooth geometry

2.3 Calculation of static strength

Differential bevel gears are usually calculated with static load because they usually operate in static applications. The static calculation only takes root fracture due to bending into account.

1. In the "Strength"→"System data" tab, select the "Differential, static calculation" calculation method (see Figure )

Figure 2.4 "Differential, static calculation" strength calculation

2. Input performance/torque/rotation data using the default values

3. Differential bevel gears are normally used with several strands. Check and input the "Number of strands" under "Pair data"→"Details". The default value is 2, because this

is the most common situation.

4. Either clickor press "F5" to run the calculation. To generate and open the report, clickor press "F6".

2.4 Inputting an existing set of bevel gears from a Gleason data sheet

To analyze an existing set of bevel gears (with spiral toothing) using drawings or Gleason datasheets ("Gleason dimension sheets"), follow this procedure.

Bevel gear drawings and the Gleason dimension sheet usually contain precise, comprehensive

information about intermeshing. In KISSsoft, use the "Conversion from GLEASON data sheets" function to input this data. The required data is

2.4.1 Calculating the geometry

1. In the "Geometry"?"System data" tab, select the "Constant slot width" or "Modified

slot width" type (see Figure).

Figure 2.5 Selecting "constant slot width" type or "non constant slot width" type

2. Click on "Conversion from GLEASON data sheets" to the right of the type and input the

data (see Figure and Figure ).

Figure 2.6 Conversion from GLEASON data sheets

Figure 2.7 Inputting data from Gleason datasheets

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KISSsoft Tutorial-Sizing a Planetary Gear Set for Precision Mechanics

2011-12-22T19:24:00.001-08:00

1 Task

To size a planetary gear set with an input torque of 450 Nmm (0.45 Nm) at 10000 rpm. The nominal transmission ratio is 4.25. The required service life is 20,000 hours, with an application factor of KA=1.25.

The package size (external diameter of the gear rim) is 35 mm, including 3 mm material between the root diameter and the external diameter. The gears are made of sintered powdered metal. The module must be greater than 0.5 mm (due to manufacturing requirements). The tooth form must be optimized to make full use of the fact that the gears are not manufactured using the generation process. The calculation method used here is the one specified in AGMA: 210104-D04.

2 Starting KISSsoft

2.1 Starting the software

You can call KISSsoft as soon as the software has been installed and released. Usually you

start the program by clicking "Start?Program Files?KISSsoft03-2011KISSsoft". This opens

the following KISSsoft user interface:

Figure 2.1 KISSsoft main window

2.2 Starting the "Planetary gear" calculation module

In the "Modules tree"window, double-click the "Modules" tab to call the calculation for a "Planetary gear", see Figure 2.2.

Figure 2.2 Selecting the "Planetary gear" calculation module from the "Modules" window

2.3 Basic settings

If the AGMA 2101101 method is used for a planetary gear set, it is a good idea to activate the

graphical method for factor Y (as this influences the calculation of root stress). To do this, go to

the "Strength" tab, select "Details" and click the "Pair data" group. Activate the graphical method and define where the force is to be applied. As some of the solutions found during the draft design phase will have geometric errors (which cause KISSsoft to cancel the calculation automatically), we recommend you go to the module specific settings and activate "Allow large profile shift" and "Don't abort when geometry errors occur". This allows the KISSsoft software to continue with a calculation even if an error has occurred. See Figure 2.3.

Figure 2.3 "Define details of strength" and "Module specific settings" for this example

2.4 Setting constraints

Go to the "Geometry" tab and input the required number of planets (Figure 2.4). The load distribution coefficient K? increases the load placed on an individual planet. In this case, set it to 1.0.

Figure 2.5 Defining the load distribution coefficient

2.5 Rough sizing

Click [OK] to return to the main dialog. Open Rough sizing and specify the required calculation

method (1) and the material (2). Then input the application factor (3) and the service life (4). Click the radio button next to the Power field to define the load (5), see Figure 2.7.

Figure 2.6 Call the Rough sizing function

Figure 2.7 Setting the materials, calculation method, application factor and required service life

Specifying the load To specify the unit used for torque, click the right-hand mouse button on the appropriate field (Figure 2.8).

Figure 2.8 Specifying the unit for torque

Define the reference gear (1), the calculated value(2) (if the torque and number of rotations have been defined, the performance will be calculated) and input the data for the number of rotations and torque (3) (see Figure 2.9).

Figure 2.9 Specifying the load

Then enter the nominal transmission ratio (6).

Figure 2.10 Rough sizing settings

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KISSsoft Tutorial-Lifetime analysis of cylindrical gears

2011-12-22T19:22:00.001-08:00

1 Task

1.1 Task

To analyze the strength of a cylindrical gear pair as specified in ISO6336,method B.A load spectrum is used in this example. The safety factors, service life and permissible power rating are to be calculated.

The following data is specified for this cylindrical gear pair:

2 Calling the program

2.1 Starting the software

You can call KISSsoft as soon as the software has been installed and released. Usually you start the program by clicking "Start→Program Files→KISSsoft 03-2011→KISSsoft". This opens the following KISSsoft user interface:

Figure 2.1 Starting KISSsoft, initial window

3 Entering the data

3.1 Inputting the load spectrum

KISSsoft provides a range of different options for you to input load spectra. If the load spectrum is stored in the database it is also available to other calculations.In contrast, if you use the"Own input" option to enter the load spectrum, it is only available to the current calculation.

3.1.1 Database: direct entry

After you have opened the database tool as shown in Figure 3.2 with authorization to write data to it (you may have to run KISSsoft as the Administrator), you now have a range of options for defining load spectra in the database. Select "Load spectra" from the list and click on "Edit" to call the appropriate table.

Figure 3.3 Generating a new data record

Click "+" to create a new data record. If a data record is marked, its data is copied and "_NEW" is attached to its label. If no data record is marked, a new one will be created. Now enter a description.

You now see information about the "frequency, power or torque and speeds" for the corresponding load level elements.You can also specify whether the load spectrum refers to the torque or the transmitted power. Once you have finished entering data for this load spectrum, click "OK" and then click "Save" to save this data record. Then click "Close" to close the database tool and return to the KISSsoft system's initial screen. The load spectrum is now available for analysis.

Figure 3.4 Inputting the load spectrum

3.1.2 Database: data input from a file

You can also transfer a load spectrum to the database as a file. To do this, enter the required load

spectrum in a text editor as shown below:

Frequency Torque/Power/ Speed

For example:

0.1 0.2 0.2

0.2 0.3 0.5

0.4 0.9 0.8

0.3 1.0 1.0

This file is saved as a file with the file extension *.dat (in this example "Example-Tut-010.dat", for preference in the ...\KISSsoft 03-2011\ext\DAT folder (for more information,see Figure 3.5) or in any other folder (for more information see Figure 3.6).

In the KISSsoft installation folder you will find a folder called C:\Program Files\KISSsoft 03-2011\ext\DAT. If you store files with the file extension *.dat in this folder, the KISSsoft system will be able to find them automatically. In this case, you only need to enter the following:

Figure 3.5 Inputting the file description in which the load spectrum was saved

If you save the file with the load spectrum to a different folder, you must also store the entire path + file name in the "File name" field. If the path name is too long, follow the steps described above:

3.1.3 Own input

After you have clicked the Figure 3.7 plus button as shown in , you can now define load spectra in the database using the "Own input"function. Click the plus buttonto call the "Input load spectrum" window. Here you can either input a load spectrum directly or load it from a file. Then click "OK" to assign the load spectrum to the calculation.

Figure 3.7 Calling "Own input" load spectrum

3.2 Inputting toothing data

To call the cylindrical gear calculation, go to the modules tree window in the KISSsoft main screen.

There, click the "Modules" tab and then click"Cylindrical gear pair [Z012]".Then input the toothing data specified below:

Figure 3.8 Inputting toothing and load data

(1) Reference gear

(2) Load: here you must input two of the three values (speed, torque, power)

(3) Calculation method

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KISSsoft Tutorial-Tooth Form Optimizations Part A

2011-12-22T19:19:00.001-08:00

KISSsoft Tutorial-Tooth Form Optimizations, Tooth Form Modifications specifically for Plastic, Sintered, Wire-eroded and Form-forged Gears

1 Introduction

1.1 Summary of the design strategy

These instructions describe a strategy for optimizing the design of gears that are manufactured

using moulding methods (injection moulding, sintering, forging etc.). These special methods for

sizing and optimizing gears manufactured using these methods are integrated in the KISSsoft calculation software.

The sizing process involves these steps:

- Define the approximate sizes (module, face width, etc.) using the strength calculation

- Define allowances

- Optimize tooth height (aim: achieve effective transverse contact ratio 2.0 whist taking

into account tip rounding, running-in curve for noise reduction)

- Tip-rounding

- Optimize running-in curves/profile correction (aim: improving the wear safety factor)

- Optimize root fillet (increased the root safety factor)

- Determine a mould for the manufacturing process

1.1 Introduction

Nowadays,gears are increasingly manufactured from plastics because the development of new materials has made them able to achieve increasingly higher load capacities. The special

properties of plastics allow them to be used in many more areas than steel. A designer can therefore select the best possible material for their particular application. In doing so, they define the most important properties of a gear pair, such as load capability, resistance to wear, compression ratio, stiffness and noise emissions.

Metallic gears are usually manufactured in a milling process. In contrast, plastic gears are

usually injection moulded. If the mould is produced by a wire erosion process, the tooth form can be optimized at no additional cost. In a milling process, this is only possible with expensive, specialist tools.However, the injection moulding process does not achieve a particularly good toothing quality and, once again, this is a problem that can only be solved by implementing specific measures. Gears that have been modified in this way are referred to as hybrid tooth forms in the technical literature.

The KISSsoft calculation software includes a large number of special methods for sizing and

optimizing plastic gears. These procedures are fully integrated into a comprehensive, modern

software system that enables you to develop and monitor both standard and hybrid tooth forms.

2 Defining tooth geometry

2.1 Introduction

You can change tooth geometry in many different ways to achieve the optimum ratio of tooth contact. Depending on the importance of the targets to be achieved, such as low noise emission, low vibration, strength, sliding, balance, you must prioritize the measures to be taken. When you start this optimization process, we recommend you set the following defaults:

2.2 Tip-rounding

For tooth forms produced using a moulding process, the tooth tip edges must be rounded,because corners can never be created accurately in injection moulding. It is a good idea to input this data in the main screen for gear 1 and gear 2. As a result, all the most important data (such as contact ratio, etc.) will then be calculated to include tip-rounding.

This is now illustrated in an example: The KISSsoft system has a tutorial file for this calculation.

This is "Tutorial - 011". Open this file in the cylindrical gear calculation module:

Figure 2.1 Opening cylindrical gear calculation and the tutorial file

Figure 2.2 Example file for plastic gears, after calculation ("")

Click in the tool bar or press "F5" to calculate the tooth form data. Without tip-rounding the

contact ratio would be 1.6680. You can see the tooth form as a graphic in the lower part of the

window. You can also view the tooth form here and move it to the required position (see the marking on the lower right of Figure 2.2).

Figure 2.3 Tooth form display

You should now save the tooth form locally. To do this, open the "Property browser" (1). Activate the tooth form of Gear 1 (2) and click the "Save" button (3). This opens an information window. Here you can make any necessary changes (for example, color) and additional entries (4). Then click "OK" (5) to save Gear 1's tooth form. Follow this procedure again to save Gear 2's tooth form. You can now view the changes you have made to the tooth form. Then, close the "Property browser".

Figure 2.4 Saving the tooth form

To define the tip-rounding, go to the "Modifications" tab (see the uppermost marking in Figure

2.5) and input the relevant values for Gear 2 and Gear 5:

Figure 2.5 Defining tip rounding, here 2 mm radius

Then click onto apply the changes. If you look carefully at the graphic, you will see the rounding on the teeth. The original tooth form is also displayed (in black/green or blue).

Figure 2.6 Rounded tooth tip

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KISSsoft Tutorial-Tooth Form Optimizations Part B

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KISSsoft Tutorial-Tooth Root Optimization

2011-12-22T19:17:00.001-08:00

1 Overview

1.1 Task

This tutorial shows how tooth root geometry influences tooth strength and how it can be optimized. It recommends you use the "Graphical method" if you want to study the root strength of non-standard root geometry.

To do this, you use the strength calculation and tooth geometry calculation.

1.2 Results

Three different root geometries are to be examined:

1. resulting root geometry, with a tool root radius factor P=0.38

2. resulting root geometry, with a tool root radius factor =0.45

3. optimized root geometry (elliptical rounding)

The following results for safety factors are found when you use a combination of ISO 6336 and

ISO 6336 and the "Graphical method":

Table 1.1 Comparison of calculated safety factors for tooth root bending strength safety factors

depending on method As you can clearly see, by optimizing the root geometry, the safety factor against bending failure has been increased by 16%. However, this optimized root rounding requires a special tool (modified cutter). For this reason, we recommend you use this method for mass production (e.g. by form grinding) or if the gears are manufactured by wire erosion or sintering.

*Note: if you use the unmodified ISO 6336 method (or other methods like DIN 3990 or AGMA

2001) you cannot estimate a modified root geometry. You can see this because the results from Geometry 2 to Geometry 3 do not change.

1.3 Theory

The value fP is the radius of the root of the reference profile of the gear as shown below:

Figure 1.1 Reference profile of the gear,

The strength rating specified in ISO 6336 uses only a single point in the root where factors YF

and YS are calculated.This point is defined by the contact between a tangent to the root intersecting the symmetry line at a 30° angle and the root itself. YF and YS are then calculated as shown in formulas (2) and (3). The resulting root stress is then calculated in accordance with formula.

Figure 1.2 Calculating the tooth root stress as specified in ISO 6336

The actual construction of the root rounding therefore implies a larger or smaller degree of error.

KISSsoft therefore includes a modification in the calculation methods, allowing for the calculation of YF and YS factors along the whole of the root. In this case, the point at which the

product of YF*YS reaches the maximum is taken as the point where the strength rating is performed.

This is the only method that allows you to evaluate the effect of optimized root roundings.

1.4 Other contents of this tutorial

In section 2, the root safety factor is calculated according to the unmodified ISO 6336 method

(Method B). However, you cannot use this method to take into account the effect of root optimization. The root safety factor is therefore only calculated for Geometry 1 and 2.

In section 3, the root safety is then calculated using the graphical method (an optional modification to ISO 6336 by KISSsoft). Here you can clearly see the effect of optimized root rounding.

The comparison between the calculated results is shown in Table 1.1

Further explanations and comments are given in section 4.

All calculations/changes are performed only for Gear 1.

2 Strength calculation as specified in ISO6336

2.1 For Geometry 1 (=0.38)

To open the example used in this tutorial, click "File/Open" and select "CylGearPair 1 (spur gear)" or click the "Example" tab.

Figure 2.1 Open example calculation "CylGearPair 2 (spur gear)"

The selected calculation method is ISO 6336, Method B. To check which reference profile was

used, click the "Reference profile" tab. In this example a standard reference profile (1.25/0.38/1.00) as specified in ISO 53.2 profile A has been used.

Figure 2.2 Selected calculation method

Figure 2.3 Standard reference profile as used for first calculation

Figure 2.4 Result of calculating the safety factor of the tooth root stress in Gear 1

The resulting tooth form is displayed in a graphics window. Click the button (upper right marking) to make it into a floating window and enlarge it. You can save the tooth forms so they can be compared later on. To do this, follow the steps marked in Figure 2.5

Figure 2.5 Resulting tooth form with =0.38

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KISSsoft Tutorial-Compression Springs as Specified in EN 13906

2011-12-22T19:13:00.001-08:00

1 Starting KISSsoft

1.1 Starting the software

Once you have installed and activated KISSsoft either as a test or licensed version, follow these steps to call the KISSsoft system.Usually you start the program by clicking "Start→Program Files→KISSsoft 03-2011→KISSsoft". This opens the following KISSsoft user interface:

Figure 1.1 Starting KISSsoft, initial window.

1.2 Selecting a calculation

In the Modules tree window, select the "Modules" tab to call the calculation for compression springs:

Figure 1.2 Selecting springs, compression springs.

2 Analyzing Compression Springs

2.1 Task

To analyze a cold formed compression spring 4 x 40 x 235 made of spring steel. Search for this

data:

This tutorial then describes how you input the following data:

Table 2.2 Operating data.

2.2 Inputting operating data

As shown below, you can input operating data directly in the input window. Here you can input

either the forces or the ways.

Figure 2.1 Input window, "Operating data" group.

The types of support are displayed in a help graphic that you open by clickingnext to the

Support field. The support coefficient v is used for calculating the buckling spring travel sk. If the required level of buckling safety is not achieved, the spring must be led, otherwise it will buckle.

If the spring must be led, the KISSsoft system issues a warning message when you perform

the calculation to inform you of this fact.

Figure 2.2 Warning shown if the spring will buckle and must be led.

Figure 2.3 Types of support with the corresponding support coefficients.

2.3 Inputting the geometry and selecting materials

The KISSsoft database includes a wide range of different compression springs, all of which

correspond to the specifications in DIN 2098, supplementary sheet 1. You can select the spring

you require directly from this list. This example uses a spring selected from this list.

However, if the spring you require is not present, simply select "Own Input" and input your own parameters for a spring. You will find more detailed information about this below.

To find a suitable spring, first click "Update". The system now calculates and displays values

that match your input, such as spring travel, spring forces. This helps you make the best possible choice.

Click the right-hand mouse button in the spring selection list to determine which values are to be displayed.

Figure 2.4 Input window, "Geometry" group - spring selection.

You can then either select or input the shape of the spring ends, the manufacturing method and

the tolerances in the area below the table.

Figure 2.5 Clicking the right-hand mouse button to select the values to be displayed.

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KISSsoft Tutorial-Bolt Analysis in Accordance with VDI 2230

2011-12-21T19:47:00.001-08:00

1.1 Starting the software

Once you have installed and activated KISSsoft either as a test or licensed version, follow these steps to call the KISSsoft system. Usually youstart the program by clicking"Start?Program FilesKISSsoft 03-2011?KISSsoft". This opens the following KISSsoft user interface:

Figure 1.1 Starting KISSsoft, initial window

1.2 Selecting a calculation

In the Modules tree window, select the "Modules" tab to call the calculation for bolts:

Figure 1.2 Selecting the "Bolts" calculation module

2 Calculation of a flanged connection

2.1 Task

Size and verify the bolting for a flanged coupling using the following data:

The connection is made using through bolts (notation as specified in VDI 2230:2003 - bolted joint) with nuts, and with washers under the nuts and under the bolt head. Input this data in the "Basic data" tab as follows:

Figure 2.1 Inputting known data, selecting the calculation method

2.2 Proposal for a reasonable bolt diameter

After you have defined the load and input the basic data for the bolt, click the "Sizing button"

in the main window and the program proposes values for a suitable bolt diameter.This proposal is based on a simplified bolt layout as specified in VDI 2230: 2003. This method usually results in over-dimensioned bolts. Experience shows that the minimum permitted bolt diameter is often one or two sizes smaller! Note the message that appears when you click the Sizing button. If you click the Sizing button, the software suggests a bolt diameter that is based on VDI 2230: 2003.

2.3 Defining the nuts and washers

In the "Basic data" tab, you can now input the data for the nuts and washers:

Figure 2.5 Calling the subscreens for defining washers and nuts

Figure 2.6 Defining the nut and washers. (The values for the diameter etc. do not appear until you input the data)

2.4 Defining clamped parts

The "Clamped parts" tab contains all the details about clamped parts. As a flanged connection is being calculated,the software recommends you define the geometry of the clamped parts (flange) as segments of an annulus:

Figure 2.7 Note: define "segments of an annulus" when calculating flange connections

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KISSsoft Tutorial-Shaft Analysis

2011-12-21T19:45:00.001-08:00

1 Starting KISSsoft

1.1 Starting the software

Figure 1.1 Starting KISSsoft, initial window

1.2 Selecting a calculation

In the Modules tree window, select the "Modules" tab to call the calculation for shafts:

Figure 1.2 Selecting the "Shaft" calculation module under Shaft-Hub-Connections

2 Analyzing a Shaft

2.1 Task, opening the example calculation

You are to mathematically investigate a shaft that has already been modeled, see Figure 2.1.

The following criteria are relevant:

- Shaft deformation

- Bending critical speed

- Static and fatigue strength

Figure 2.1 Shaft to be analyzed

The shaft is driven by a motor attached to the coupling. The nominal power is 75W at a speed

of 980 rpm. This power is taken from the system at the helical gear.

This shaft is present in KISSsoft as an example file called Shafts 1. W10. You can either open

this file directly in the help index window by double-clicking the left-hand mouse button on the

"Examples" tab or by selecting "File"-"Open" by clicking on the file in the appropriate KISSsoft subdirectory, ?\example, with "Open".

Figure 2.2 Opening the example calculation

Click the "Shaft editor" tab to view the tab as shown in Figure 2.1.

Figure 2.3 Opened shaft calculation

You will find details of how to generate a shaft model with the help of the graphical shaft data

input interface in KISSsoft Tutorial No. 006.

When you open the shaft file the system performs an initial calculation using the settings you entered. Once you have finished defining the shaft, either click in the menu bar (or press F5) to calculate all the shaft-specific values. The results are shown either as a graphic or as a

table of values.

2.2 Results

All important results are listed in the Results tab. To open this window, click the icon in the upper right-hand corner. You can then resize the window as necessary.

Figure 2.4 Enlarged display of results

2.3 Deformation analysis

In the "Basic data" tab, click the drop-down list to open the "Strength" group. This is where you input how the gears modeled on the shaft are to be taken into account in the calculation:

- Ignore the mass and stiffness of the gears on the shaft

- Consider gears as masses only (the gear is mounted loosely on the shaft and, although it transfers its own weight, along with the external loads to the shaft, it does not stiffen the shaft)

- Consider gears as mass and as stiffness (the gear is attached rigidly to the shaft and forms a single unit with the shaft)

Figure 2.5 How gears are considered

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KISSsoft Tutorial-Roller Bearings

2011-12-21T19:42:00.001-08:00

1 Task

1.1 General

In the KISSsoft system, roller bearings are usually analyzed as part of the shaft analysis process. The calculation of roller bearings that is also available in the KISSsoft software is not discussed here. In this case, roller bearings are not viewed separately from their environment.

Instead, they are treated as part of a system that consists of a shaft, external load and bearing.

The great advantage of this approach is that the calculation of loads placed on the roller bearing is performed automatically and therefore is less prone to user errors. The same applies to statically over-determined systems. You can also analyze individual bearings that are subject to a known load. For more information about this, see section 2.4.

1.2 Task

The multiple bearings shown in the example in Figure 1.1 are to be analyzed. The system is statically over-determined: The first bearing is positioned within the shaft and the third bearing

is an axial bearing supported on its right-hand side. The other bearings are not subject to axial

forces.

Figure 1.1 Example bearings for this tutorial

1.3 Modeling the system

First of all, model the shaft geometry as shown in Figure 1.1 (see also Tutorial 006: Shaft Editor). In a second step, define the two force elements (bevel gear and cylindrical gear) with the data shown in Table 1.2.

Figure 1.2 Defining the force elements

After this, the following system should be available in the graphical Shaft editor:

Figure 1.3 Geometry of the shaft and force elements

1.4 Adding bearings

In the "Elements-tree", right-hand mouse click on "Bearing" and then select the "Roller bearing" option from the context menu:

Figure 1.4 "Elements-tree" with the context menu for the "Bearing" group

As shown in Figure 1.4, the "Elements-editor" lists the most important bearing parameters. To

position the bearing at y=10 mm within the shaft, click the radio buttonto the right of the "External diameter" input field. From the drop-down list with the same name, select the entry 52.00 mm and select "Type Koyo 6205 (d=25 mm, D=52 mm, B=15 mm)" from the drop-down list for the label. Then click the Sizing button to the right of the drop-down lists for the Inner diameter or External diameter to modify the relevant diameter to the shaft's geometry at the specified position.

Figure 1.5 "Elements-editor" with roller bearing parameters

If this bearing is not present in the list, check that bearings produced by Koyo have been included in the list of available bearings. To do this:

1. In the menu bar, click "Calculation".

2. There, select "Settings". This opens the "Module specific settings" window.

3. In the "Bearing manufacturers" group you can now select the companies you want to include in the list of available bearing manufacturers. If necessary, activate "Koyo" by clicking the checkbox of the same name.

4. Click OK to close the window.

The system comprising shaft, loads and bearings should now look like the one shown in Figure 1.1.

1.5 Roller bearing calculation

Start the shaft calculation by clicking onin the tool bar or else press F5 to run the roller bearing calculation. You can see a quick overview of the results in the "Results" window (see Figure 1.6). Please note that you must enter the bearing names manually.

Figure 1.6 "Results" window with a quick overview of the roller bearing analysis

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KISSsoft Tutorial-Shaft Editor

2011-12-21T19:40:00.001-08:00

1 Starting the Shaft editor

1.1 Starting the Shaft editor

For more information, refer to KISSsoft Tutorial 005, Shaft calculation, Section 1.2.

1.2 Calling the Shaft editor, settings

The main shaft calculation screen (Figure 1.1) consists of these tabs: "Shaft editor", "Basic

data" and "Strength". In the Shaft editor you can model various shafts, taking into account their constraints and loads. These shafts can then be used in other calculations (deformation, strength etc., see Tutorial 005). The "Basic data" tab is where you input the basic settings (shaft position, speed, sense i.e. direction of rotation) either directly or by clicking the "Calculation/Settings" menu option (for further information about calculation-specific settings, press "F1" to call the Help/Manual).

Figure 1.1 Shaft editor, module-specific settings, input speed, materials etc.

2 Modeling a shaft

2.1 General remarks

To model a shaft in the KISSsoft system, you must input the main dimensions, notch geometry,

external loads and positioning/constraints and critical cross sections. You define these values

in the"Elements-tree". To do this, select the appropriate element and right-hand mouse click on a list of elements that can be added to the calculation. You can also create sub-elements for axial symmetric contours (cylinder and cone).

Figure 2.1 The five most important elements required to create a shaft

2.2 Coordinate system

Note that the coordinate system is right-handed and Cartesian.

Positive x-axis : out of the screen

Positive y-axis: from left to right, in direction of shaft axis

Positive z-axis: from bottom to top

Position of application: angle between positive x-axis and towards

positive z-axis

You can display or hide the coordinates system by activating/deactivating the "Show coordinate

system" checkbox in "Module specific settings".

2.3 Editing functions, screen view

The following editing functions are available in the graphical Shaft editor:

On the right-hand side of the Editor, you see the following icons which you can use to input elements more easily:

2.4 Entering main dimensions

To define a shaft section, select the element in the "Elements-tree Outer→contour" or select the corresponding icons from the vertical tool bar, for example, for "Cylinder" and the appropriate dialog opens in the Elements-editor (Figure 2.3).

Figure 2.3 Dialog in which you define a shaft section (cylinder)

You then define the diameter, length and surface roughness in the Elements-editor. Every new

shaft section you add can be positioned either before (to the left) or after (to the right)of existing sections. To add a shaft section to an existing section, first select the existing section with a left-hand mouse click and then right-hand mouse click and select "Add an element in front" to insert the new shaft section. To modify an existing element in the Elements-editor, simply select it with a left-hand mouse click. If this is not available in the display window, click "Calculation/Elements-editor" to display it (Figure 2.4).

Bores ("Inner contour→cylindrical bore") are also added to the existing shaft, from left to right. However, if you want the bore to be present only on the right-hand end of the shaft, first define a bore with diameter zero from the left end of the shaft.

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KISSsoft Tutorial-Cylindrical Gear Pairs

2011-12-21T19:37:00.001-08:00

1 Task

This tutorial explains how to input data you already know for cylindrical gear pairs in the KISSsoft system.

You must therefore perform the following steps for an existing cylindrical gear pair:

1) Input the necessary data in KISSsoft

2) Verify it in accordance with ISO 6336

3) Document the results

1.1 Input data

The method you use to input the following data is described at the end of section 2 in this tutorial:

1.1.1 Power data

1.1.2 Geometry

1.1.3 Reference profile

2 Solution

2.1 Starting the software

Figure 2.1 Starting KISSsoft, initial window

2.2 Selecting a calculation

In the Modules tree window, select the "Modules" tab to call the calculation for cylindrical gear

pairs:

Figure 2.2 Calling cylindrical gear calculation

The KISSsoft input window then opens:

Figure 2.3 Input window: KISSsoft Cylindrical gear calculation

The following sections describe how to input parameters for the gear pair.

2.3 Gear Pair Geometry

In the "Basic data" tab, "Geometry" group, input the normal module (1.5 mm), pressure angle

(20°), helix angle (25°), center distance (48.9 mm), number of teeth (16/43), tooth widths (14/14.5 mm), profile shift coefficient (0.3215/. ..) and the quality (8/8). You cannot input a value for the profile shift of gear 2 directly because this value is calculated from the center distance and profile shift of the first gear.

However, you can click the Sizing buttonto size the value to match your requirements.

You can set the quality to suit you, no matter which calculation method is in use.

Figure 2.5: Input window n "Basic data" tab, "Geometry" group

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KISSsoft Tutorial-Fine Sizing of Cylindrical Gears

2011-12-21T19:34:00.001-08:00

1 Task

1.1 Task

A helical gear pair is to be designed such that it has a service life of 5,000 h when transmitting 5 kW at 400 rpm (application factor = 1.25) The ratio shall be 1:4 (reducing speed) and 18CrNiMo7-6 is to be used as the gear material. The helical gear pair is to be optimized to achieve the best possible noise/contact ratio. Strength calculation is to be performed as specified in ISO 6336 Method B.

1.2 Starting gear pair calculation (helical gear pair)

Figure 1.1 Starting KISSsoft, initial window

In the Modules tree window, select the "Modules" tab to call the "cylindrical gear pairs" calculation:

Figure 1.2 Calling cylindrical gear calculation

To open the example used in this tutorial, click "File/Open" and select "Tutorial-009-Step1" (to

"Tutorial-009-Step5") or click the tab in the "Example" window. Each section in this tutorial describes which file you need to open (as shown below).

Figure 1.3 Options for opening the example files used in this tutorial at different stages of progress

2 Rough sizing of a gear pair

2.1 Calling the Rough sizing function

Use the Rough sizing function to create a sensible initial layout for a cylindrical gear stage. To

do this, input the required key data after you call the Rough sizing function by clicking "Calculation"→"Rough sizing" in the Rough sizing screen.

To access this stage of the calculation directly, open the "Tutorial-009-Step1" file

Figure 2.1 Calling Rough sizing

Here it is essential that you define the required ratio (including any permitted variation in % (here 5%)) and input the transmissible power and the material. You can also predefine the required helix angle or center distance. The helix angle depends on the type of bearing used with the shaft. The helix angle may be larger or smaller, depending on how much axial force the bearings can support. The helix angle can be optimized later on during Fine Sizing. Here, in the Rough sizing function, you should only input an approximate value for the helix angle, or "zero" for a spur gear. You can input additional information in the "Rough sizing" input window in the "Geometry" group. For example, the number of teeth on the pinion, the geometry proportions and the center distance.

Figure 2.2 Input window Rough sizing group: "Geometry" ? Conditions Number of teeth, gear 1

Click the "Details" button in the "Rough sizing" input window in the "Strength" group to predefine the safety factors that are to be achieved.

Figure 2.3 Input window Rough sizing group: "Strength" ? Conditions safeties

Click the ìCalculate-button and the KISSsoft system will calculate different solutions for a gear

pair that fulfills the specified conditions. These solutions are then displayed in the list shown below.

Figure 2.4 Cylindrical gear-Rough sizing, results

To select one of these solutions, (here with a center distance of 107 mm), click on it in the list

and then click the "Accept" button. Then click "Close" to close the list.

To access this stage of the calculation directly, open the "Tutorial-009-Step2" file

Figure 2.5 Normal module, number of teeth, width, profile shift and center distance as proposed by the KISSsoft system

2.2 Modifications

You can now modify the proposed values, for example, for the gear width you can input a pinion width of 28 mm, or a gear width of 27 mm (directly in the appropriate fields). You can also change the reference profile in the drop-down list in the "Reference profile" tab.

Figure 2.6 "Reference profile" tab, information about the reference profile

To modify the profile shift of gear 1 (gear 2 will then be calculated to match), click the Sizing buttonto open the "Sizing of profile shift coefficient" dialog window in the lower figure. This window contains proposed values for various different profile shift coefficients (see Figure 2.7):

Figure 2.7 Dialog window; size profile shift coefficients

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PowerINSPECT hanging the Excel Template

2011-12-11T22:51:00.001-08:00

Introduction

When you launch the Excel Report from PowerINSPECT ,

you will produce an Inspection Report in Microsoft Excel.

The Inspection Report follows a template created in another Excel spreadsheet.

The Excel Template spreadsheet determines the content and the layout of the Inspection Report.

This document will show you how to make these changes to Excel Templates.

Where Files are saved

Any templates supplied with PowerINSPECT are in the same directory.

If you create any new templates, you should “Save as” in that same directory.

PowerINSPECT is normally found in C:\dcam\product

Within the PowerINSPECT folder there should be a sub-folder called “Template.” This is where the Excel templates should be saved.

Important

If you open an Excel template file you will see a number of ‘tabs’ at the bottom of the window. Clicking on these tabs will allow you to transfer between different pages or ‘worksheets’ within the document.

The different worksheets have been carefully designed to produce reports on all the different inspection features in PowerINSPECT.

You should make changes to only two worksheets:

The Template (shown above), and

The Header (shown below)

Making changes to an Excel Report

As described in the Introduction there are three types of information in the Excel Report:

Information which is the same every time the report is printed

This includes things like your company logos, address and contact details.

This information is often right at the top of the report and usually gives information about your company- not the contents of the report.

Information which sometimes changes for different parts or different customers

This will usually identify who the report is for, and what part it describes.

It will normally be near the top of the Inspection Report (what we would consider the ‘Header’), or at the bottom.

The layout and contents may need to change according to customer requirements, as the following examples show.

The actual contents of these sections are determined by the user in the PowerINSPECT session:

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Customising PowerINSPECT Excel Report Part B

2011-12-11T22:49:00.001-08:00

SurfacePoint.ChartArea:

This area contains the cells that will be copied at the end of a Surface Point Group. This area can contains statistics, error graphs and gauss graph.

The location of the graph inside the Surface Point Chart Area are named :

SurfacePoint.ChartLocationSurface

Point.GaussLocation

The name of the Error Chart must be SurfacePoint_Graphe.

The name of the Gauss Graph must be GrapheGauss.

You can extract statistical information by using Excel Database build-in functions and the PowerINSPECT database name and criteria.

The Excel name for the PowerInpsect Surface point database is SurfacePoint.Database.

PowerINSPECT provide also two filters used to extract statistic for the whole set of point or for only out of tolerances points, they are:

SurfacePoint.AllCriteria ( no filter )

SurfacePoint.OutOnlyCriteria (out of tolerances points)

For example:

To insert the mean of the error for the current Surface point group into a cell, use this formula.

=DBMEAN(SurfacePoint.Database,"Delta",SurfacePoint.AllCriteria)

To insert the number of out of tolerance point into a cell, use this formula:

=DBNB(SurfacePoint.Database,4,SurfacePoint.OutOnlyCriteria)

Note 1: the SurfacePoint.ChartLocation and SurfacePoint.GaussLocation must lie inside the SurfacePoint.ChartArea.

Note 2: The Gauss graph is shared by Surface Point, Edge Points and Guided point. If you don't want to use the Gauss graph in your customised report, remove the GaussLocation named cells but do not remove the Gauss Graph it-self.

Note 3: The Error graph contains 4 series, one for the abscissa, two for the tolerances ( upper and lower) and the last one for the error. You can customise the graph as you like using the standard Excel tools.

The GROUP Section

this section describes the look of a Group sub-header on the report.

The variables you can add to the Group Area are :

The EDGE POINT Section

this section describes the look of a edge point on the report.

This section acts as the formally described SurfacePoint Section. Please refer to this section for details.

The variable you can used in this section are :

The GUIDED POINT Section

This section describes the look of a guided point on the report

This section acts as the formally described SurfacePoint Section. Please refer to this section for details.

The variables you can use in this area are :

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Customising PowerINSPECT Excel Report Part A

2011-12-11T22:46:00.001-08:00

Introduction

PowerINSPECT Excel reports are based on template files. Template files are, in fact, Excel Workbooks that describe how the information from PowerINSPECT will be arranged on the final report.

A Template File is divided into different Excel sheets. When customising a PowerINSPECT Excel Report, you will have to modify only two of them: The Template sheet and the Header sheet.

The Template sheet describes the look of the final report and is divided by section, each of one describing a specific report part.

The Header sheet is used to transfer variables between PowerINSPECT and the Report Generator, this sheet will reflect the variables that are defined in the PowerINSPECT Variable Property Sheet as shown in figure 1.

Figure 1 the PowerINSPECT Variable Property page

The Database sheet is used internally to record data for the Graphics and should not be modified.

The other sheet (3D Measure, Guided Point, Edge Point, Surface Point) are used to transfer items information between PowerINSPECT and the Report Generator and should not be modified.

The Test Gauss sheet is used internally to record data for the Gauss Graph and should not be modified.

Before you start.

Creating a new template file.

To create a new template file, please have a look to the existing template files. It's easier to modify a template that is almost what you need than to create one from scratch.

Make a copy of this file and copy it to the template directory with a different name.

Note : the template directory should be C:\dcam\product\PowerInspect1350\template.

Figure 2 the PowerINSPECT Zone Edition Dialog box

Avoiding problem with hidden documents:

When PowerINSPECT is creating a report, the PowerINSPECT Report generator load the requested template file and hide it. This template file is loaded as read only.

Before trying to modify a template, please check that the file is not hidden.

Go to the menu Window/unhide and select the document you what to unhide.

Some EXCEL prerequisites :

The PowerINSPECT Excel report mechanism use intensively named cells. Please read the Excel ? documentation to understand how to define named cells before starting. For example, to know which cells will be copied to the report, the PowerINSPECT Report Generator will look after a name 'Header'. Then, the PowerINSPECT Report Generator will copy this area to the clipboard and paste it to the final report.

Figure 3 the Excel Name dialog box

Using the Excel Tools to define Named Cells

To get a list of all used names in the Template Workbook select the command INSERT/NAME/DEFINE into EXCEL. The following dialog box will appear and will show you all the name used by the PowerINSPECT Report Generator.

span style='mso-ignore:vglayout;;z-index:1;left:0px;margin-left: -31px;margin-top:1px;width:215px;height:98px'
span style=';mso-ignore:vglayout; left:0pt;z-index:1'

Figure 4 PowerINSPECT Excel ToolBar

Using the PowerINSPECT Tools to manage Named Cells

The PowerINSPECT Report Generator provide a tool that will help you to define Named Cells in the Template Sheet.

Click on the EditZone Button in the PowerINSPECT Excel Toolbar to open the PowerINSPECT Zone Edition Dialog Box to define or locate named cells.

When you click select a section and a zone the matching cells in the Excel template will be hilighted.

You can redefine the zone by clicking the button , and then select the new cells. Then, press the Define button to save the new value.

Process

Template File
a Excel file that contains formatting ruled used by the PowerINSPECT Report Generator to create the final PowerINSPECT Report. The templates files are located in the c:/dcam/product/PowerInspect1350/template directory.

PowerINSPECT Document
a document created in the PowerINSPECT Main Application that contains the measure sequence and the associated results , the extension of this file is .PWI

PowerINSPECT Report Generator (PRG)
a Excel Add-in Macro that will create a final report file with the unformatted data sent by PowerINSPECT and the Template File.

Report
the report is the final PowerINSPECT report created as an Excel File by the PowerINSPECT Generator. This file is located in the same directory as the matching PowerINSPECT Document.
I.e. if the PowerINSPECT document is c:/dcam/product/powerInspect1350/myfiles/foo1.pwi the report file will be c:/dcam/product/powerInspect1350/myfiles/foo1.xls

How it's working

When you click on the Excel Icon in the PowerINSPECT Application, PowerINSPECT will send unformatted data from the current active measure to Excel. The PowerINSPECT Report Generator (PRG) will then open the final report (foo.xls) and create a sheet that will contains the final formatted report for that measure. The name of this sheet will be the measure name (i.e MasterPart or Measure 1). The report will contains one sheet for each measure you have in the PowerINSPECT Document (foo.pwi), and will be located in the same directory as your PowerINSPECT Document.

Then the PRG will open the Template file requested by PowerINSPECT. The PRG will analyse the unformatted data and, for each measure item, the PRG will transfer the unformatted item data to a transient area. The template file will now reflect new formatted information and PRG will transfer the Formatted Data to the final report.

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Manuale Fanuc Nuovo senza motorizzato

2011-12-09T18:27:00.001-08:00

A) INIZIO E FINE DI UN PROGRAMMA
L'indirizzo " O " serve per numerare i programmi (es. o1234 max. 4 cifre)
B) INDIRIZZO " N "
La lettera " N " serve a numerare i blocchi e anche a facilitare la ricerca automatica di un blocco.
La numerazione è progressiva di 5 in 5.
Fare attenzione a non numerare più blocchi con lo stesso numero, altrimenti eseguendo una ricerca automatica il CNC selezionerà il primo blocco contenente il numero da noi immesso.
C) NOMENCLATURA
Un programma è composto da informazioni ricavate da un disegno tecnico e da istruzioni per governare la macchina utensile.
L' insieme di dati scritti su una riga dopo la lettera " N " (numero) si chiama " blocco". Es.
N10 T101(sgrossatura)
N20 G97S1000M3F.1
N30 G0X200Z3M8
N40 G1Z-3
D) I MOVIMENTI DEGLI ASSI
Il movimento può essere programmato sia con comandi assoluti che incrementali.
L a denominazione degli assi sono: X e Z dove per X si intende l' asse verticale,mentre per Z quello orizzontale.

E) LO ZERO PEZZO
Per prima cosa bisogna identificare sul pezzo da lavorare ,un punto di riferimento,dal quale partiranno tutte le quote.
Tale punto per l' asse X è posto sull' asse mandrino,mentre per l'asse Z è meglio crearlo sulla faccia del pezzo finito.

Nei comandi assoluti, vengono programmate le coordinate del punto finale rispetto allo zero pezzo.
Nella programmazione le coordinate sono seguite da un segno positivo (+) e da un segno negativo (-) che stabilisce il senso di direzione della lavorazione.
Il segno + può essere omesso, in quanto è sempre riconosciuto dal CNC.
F) COMANDI INCREMENTALI
Nei comandi incrementali si programma la distanza da eseguire rispetto l'ultimo punto programmato.

Comando assoluto

Comando incrementale

Descrizione

Comando del movimento asse " X "

Comando del movimento asse " Z "

Capitolo 2

A) IL MOVIMENTO DEGLI ASSI
Il tipo di movimento che gli assi possono assumere,nel campo operativo della macchina utensile,è definito da quattro funzioni " G " permanenti e autoescludenti tra loro.
Inserite nel programma,impongono agli assi un determinato tipo di movimento che potra' essere modificato solo programmando una diversa funzione.

Movimento rapido assi

Movimento rettilineo di lavoro

Movimento circolare orario in lavoro

Movimento circolare antiorario in lavoro

B) MOVIMENTO RAPIDO " G0 "
Serve per posizionare o allontanare l' utensile dal pezzo.
Es. G0X50
G0Z20
G0X50Z20

C) MOVIMENTO DI LAVORO CILINDRICO E CONICO " G1 "
Serve per la lavorazione di torniture cilindriche,coniche o sfacciature.
Es. G0X200
        G1X100 (sfacciatura)
        G0X200Z2
        G1Z-100 (tornitura cilindrica)
G0X200Z2
        G1Z0
        X60Z-30 (tornitura conica)

D) MOVIMENTO CIRCOLARE " G2/G3 "
Serve per la programmazione di archi.

per archi in senso orario

per archi in senso antiorario

Formato del blocco : N-----G2----X----Z----R----F

numero di sequenza

G2/G3

funzioni per la direzione dell' arco

punto finale dell' arco

raggio dell' arco

avanzamento

N10 G0X14Z2
N20 G1Z0F.2
N30 X18Z-2
N40 Z-10
N50 G2X22Z-12R2F.2
N60 G1X30
N70 X38Z-25
N80 Z-31
N90 G2X42Z-33R2F.15
N100 G1X48
N110 G3X54Z-36R3F.25
N120 G1Z-40F.3
N130 G0X300Z300
N140 M30

Capitolo 3

A) ROTAZIONE DELLA TORRETTA E UTILIZZO CORRETTORI
II CNC è predisposto per l' utilizzo di una torretta automatica per un totale di 12 posizioni.
La funzione per chiamare una posizione viene definita con la funzione " T " e viene seguita da tre o cifre che indicano quale delle 12 posizioni viene chiamata e il numero di correttore utilizzato.
Es. T505 posizione torretta n°5 e correttore utensile n°5.

B) ROTAZIONE MANDRINO
Per far ruotare il mandrino bisogna programmare nel blocco tre funzioni :

G96
G97

velocità di taglio costante m/min
giri fissi giri/min

S....

metri al minuto
giri al minuto

M3
M4

rotazione oraria
rotazione antioraria

La lettera " S " indica sia la velocità di taglio che il numero dei giri fissi del mandrino in funzione all' indirizzo " G " che la precede :
1) se preceduta da " G96 " la " S " indica la velocità di taglio costante in m/min
   es. G96S150 equivale a una velocità di taglio (vt) di 150 metri/min. quindi
         ad ogni variazione di diametro corrisponderà una variazione di giri.
2) se preceduta da " G97 " la " S " indica il numero di giri fissi.
   es. G97S1000 il mandrino girerà sempre a 1000 giri al minuto.
C) LIMITAZIONE DEL NUMERO DI GIRI DEL MANDRINO " G92 "
La funzione " G 92 " serve a limitare il numero di giri del mandrino durante la lavorazione.
Posizionare tale funzione sempre sul primo blocco del programma.
La funzione " G92 " rimane memorizzata e attiva fino a quando non verrà modificata in un altro blocco.
Non è attiva quando si utilizzano i giri fissi " G97 ".
D) ARRESTO ROTAZIONE MANDRINO
Per fermare la rotazione del mandrino si programma "M5" in un blocco a se'
o dove ci sia uno spostamento in rapido.
E) AVANZAMENTO
Il valore viene espresso con la funzione " F " .
Programmando in G95 si impone un avanzamento in mm. per giro
Programmando in G94 si impone un avanzamento in mm. per minuto.
                G95

F0.2

0.2 mm. per giro

1 mm. per giro

F1.5

1.5 mm. per giro

G94

F10

10 mm. per minuto

F350

350 mm.per minuto

F4000

4000 mm.per minuto

La funzione " F " è modale quindi rimane attiva fino a quando avremo bisogno di modificare nuovamente l' avanzamento.
F) REFRIGERANTE
Le funzioni si scrivono : " M8-M9-M7 "

comando di erogazione refrigerante,è attivo all'inizio blocco

comando di arresto refrigerante,è attivo a fine blocco

comando di erogazione refrigerante ad alta pressione (opzione)

Per passare da " M8 " a " M7 " è consigliabile disattivare il refrigerante con " M9 ".

Capitolo 4

A) SOSTA " G4 "
In un programma può capitare di eseguire delle soste programmate,per un fondo gola,oppure dopo una funzione M ,o dopo la chiusura del mandrino,o dopo l' avanzamento della contropunta,ecc.
Cio' è reso possibile con l'inserimento in un blocco a se' della funzione "G4 " seguito dalla lettera U per indicare il tempo della sosta.
Es. G4U5 (sosta di 5 secondi)
G4X5 (sosta di 5 secondi)
G4P5000 (sosta di 5 secondi)

B) ARRESTO CICLO DA PROGRAMMA
La funzione " M00 " viene definita come arresto programmato.
Con questa funzione si blocca la rotazione de mandrino,si arrestano i movimenti degli assi,il refrigerante e si disabilita il blocco del portellone.
Per fare ripartire il ciclo è necessario premere una volta il pulsante stop e due volte il pulsante start.
C ) IL SALTO DEL BLOCCO
Si programma all’inizio del blocco (/N10G0X...) tutti i blocchi barrati vengono ignorati dal CNC.

Es. T606

N5 G97 S1000M3
N10      G0X49.9Z1
N20      G1Z-50F0.2
N30      X49
N40      GOZ200
N50/     M00 (stop programma)
N60      G0X50Z1M3
N70      G1Z-50
N80      X49
N90      G0X200Z200M5
N100    M68
N110    M30
D) MESSAGGI O APPUNTI
Si possono inserire dei messaggi o degli appunti in qualsiasi blocco programmato per facilitarne la lettura da parte dell' operatore inserendo il commento tra parentesi tonde.

E) LA PROGRAMMAZIONE DIRETTA
Con questo tipo di programmazione si inseriscono traiettorie rettilinee,smussi,raccordi, angoli,raggi,non definendoli per punti,ma utilizzando i dati del disegno meccanico.
A=ANGOLO
,C=SMUSSO
R=RACCORDI
F) FUNZIONE A
E' possibile programmare direttamente l'inclinazione di traiettorie rettilinee.
Per determinare il valore dell'angolo " A " occorre posizionare gli assi di figura A oppure B senza ruotarli,sul punto di inizio conicità con riferimento alla direzione di lavorazione dell'utensile programmato al lavoro.

Capitolo 5

A) FUNZIONE " ,C "

B) FUNZIONE " R "

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Manejo De Puertos ConLabview

2011-12-09T18:24:00.001-08:00

Objetivo: Realizar una adquisición de datos mediante la tarjeta de adquisición de datos de National

Instruments PCI 1200.

1. Seleccione en la paleta de funciones la opción "analog Input" y desplace el vi de "AI MULT PT". Este vi le

permite captura muestras del puerto de la tarjeta de forma continua.

2. Inicialice las entradas del vi de la siguiente forma

La figura anterior muestra un detalle importante en la configuración de la salida del vI, se puede seleccionar

el type de salida como un arreglo o una forma de onda "waveform". Escoja inicialmente el tipo "Scaled

Array"

La configuración de este VI es de la siguiente forma: Device : 1, significa que para un numero determinado

de tarjetas de adquisición y cualquier otra tarjeta de National Instruments, la herramienta Measurement and

Automatization Explorer MAX identifica todos los dispositivos y le asigna a cada uno un numero, para saber

que numero tiene la tarjeta se puede revisar en la herramienta MAX y en "Devices and Interfaces". Con esta

misma herramienta se deben configurar la forma de funcionamiento de la tarjeta en cuanto a cuales son los

niveles de voltaje a manejar y si los niveles de voltaje son bipolares o unipolares.

También dependiendo de la tarjeta esta puede tener un determinado numero de canales análogos de entrada,

dependiendo de nuestra conexión física a la tarjeta se puede escoger el canal por donde se reciben los datos,

para este ejemplo se ha tomado el canal de entrada numero 0 de la PCI1200.

Numero de muestras 1000, Significa en cada ciclo de captura se va ha tomar N muestras par representar la

se?al

Frecuencia de muestreo 1000. Importante. La frecuencia de muestreo escogida debe cumplir con el criterio

de Nyquist el cual dice que la frecuencia de muestreo debe ser por lo menos el doble de la máxima

componente de frecuencia de la se?al ha capturar, es decir, si la se?al ha capturar es de 100Hz, la frecuencia

de muestreo debe ser mayor que 200Hz. Esto no significa que sea una frecuencia muy lejana de esta

condición, es mejor utilizar esta frecuencia limite para evitar procesamientos excesivos en el caso de

implementar dentro de la aplicación filtros.

3. Por ultimo en el panel de control coloque un Waveform Graph, luego en el panel de programación realice

la correspondiente conexión.

PUERTO SERIAL

Objetivo: Manejo de puerto serial . se plantea el problema de controlar a un Fuente programable mediante

comandos por el puerto serial.

1. Inicializar el puerto serial. Numero de Puerto cero correspondiente al COM1

Otros números de puerto para windows son:

0: COM1 5: COM6 10: LPT1

1: COM2 6: COM7 11: LPT2

2: COM3 7: COM8 12: LPT3

3: COM4 8: COM9 13: LPT4

4: COM5

El VI serial port es el encargado de inicializar el puerto y las demás características correspondientes a cada

puerto

2. Envío del comando VOLT020 para programar la fuente a un voltaje de 2Voltios. Mediante el VI de Serial

Port Writer, se envía un string seguido de un carrier return. El string tiene un formato necesario para que el

comando se especifique de la forma adecuada. La herramienta de formato de string se encuentran en la paleta

de funciones.

3. Lea del puerto serial de la computadora la información de confirmación que envía la fuente.

El primer vi. corresponde a "Bytes at serial port" y es necesario para especificar al siguiente VI, Serail port read.

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PowerINSPECT hanging the Excel Template

Customising PowerINSPECT Excel Report Part B

SurfacePoint.ChartArea:

The GROUP Section

The EDGE POINT Section

The GUIDED POINT Section

Customising PowerINSPECT Excel Report Part A

Introduction

Before you start.

Creating a new template file.

Avoiding problem with hidden documents:

Some EXCEL prerequisites :

Using the Excel Tools to define Named Cells

span style='mso-ignore:vglayout;;z-index:1;left:0px;margin-left: -31px;margin-top:1px;width:215px;height:98px' span style=';mso-ignore:vglayout; left:0pt;z-index:1' Figure 4 PowerINSPECT Excel ToolBar Using the PowerINSPECT Tools to manage Named Cells

Process

Manuale Fanuc Nuovo senza motorizzato

Manejo De Puertos ConLabview

span style='mso-ignore:vglayout;;z-index:1;left:0px;margin-left: -31px;margin-top:1px;width:215px;height:98px'
span style=';mso-ignore:vglayout; left:0pt;z-index:1'

Figure 4 PowerINSPECT Excel ToolBar

Using the PowerINSPECT Tools to manage Named Cells