GEAR DESIGN SOLUTIONS

Transcription

1 GEAR DESIGN SOLUTIONS Release

2 Dontyne SyStems Dontyne Systems offers software and services aimed at the optimum production of gear components and their use in the transmission industry. Our range of products allows end-toend control of the gear manufacturing process by providing a common platform for design, machining and inspection software. The Gear Production Suite has been developed as a collection of individually licensed software tools (or modules). These can be applied at various points of the production process, and interface with existing software and equipment. This allows centralisation and analysis of project data, leading to improved efficiency, cost savings and better quality control. We also offer training for all our products, bespoke teaching courses and consultancy services for project work. We have completed development programs with various partners for applications ranging from ship building, wind turbines and mining, to small scale and specialist equipment. Over 100 active installations in 15 countries

3 Gearbox system model Gear Design Analysis AND Optimization Software Tools Training AND Support Dontyne Offices HQ, Newcastle, England The lead times and accuracy made possible by the introduction of the Optimal calculation would simply not have been possible without the software. Gaudlitz GmbH The gear metrology expertise from Dontyne and the applications experience of Renishaw was an ideal combination to produce software that offers a high level of functionality and exploits the benefits of Renishaw s coordinate measuring machine (CMM) scanning systems. Dontyne s software brought us a huge improvement in productivity: reducing hours of work to seconds. The visual representations make the software very intuitive to use and understand, and the results are quite accurate. The endeavour was so successful that more collaboration is inevitable. Renishaw plc Eaton Corporation

4 GEarbox Designer Gearbox Concept tool Drag and drop concept level layout of gearbox system for rapid development of transmissions to determine speed, torque, clutching, and power to analyse efficiency with live test for valid connections. This is a specialist module to help in the very earliest stages of gear box design. It allows a transmission layout to be constructed in several minutes, with no need to create a spreadsheet specific arrangement. A system model can then be constructed from the concept layout. 8 Speed Lepelletier Automatic 3D graphical interface Static Deflection Model This tool can create a gear box layout and uses a fully coupled matrix to determine the deformation through the gear, shaft, bearing and housing. It is possible to import a stiffness matrix from 3rd party software. Controls exist to indicate power through the system and emphasise The Advanced level of the tool links directly to detailed design and analysis tools within the Suite. Gearbox view of motor sport transmission Gearbox contains spur and spiral bevel gears

5 Standard Features include :- Spur, Helical and Bevel gears Shaft Assembly Designer The shaft sections, gear positions and supports are input Shaft Deflections Misalignments in Line of Action Forces Shaft Stresses Fully Coupled Housing Stiffness Matrix 3D Gearbox Graphics Deflected Plots Concept or Detailed Gears Power flow plot Shaft calculations for gear misalignment

6 PLANETARY DRIVE DESIGN Features include :- Single Stage Layout Involute spur and helical gear geometry Assembly check for equal spacing Single or double planet arrangement Interference checks for outer diameters Speed and torque of all components ISO 6336 rating (inc updates) Tolerances to ISO 1328 Cumulative damage and safety factor Standardized tooth proportions or calculate for maximum contact ratio Plots of gears in 2D and 3D DXF output of transverse tooth profile Co-ordinates output of tooth profile Measurement over balls and chordal pan including contact height Metric or Imperial(English) units Material database (user defined) Phasing calculation 3D display of designs Export DXF of tooth form

7 Design Gear design AND rating Features include :- Involute internal and external spur and helical gear geometry ISO 6336 rating (inc updates) AGMA 2001 D 04 rating Tolerances to ISO 1328 Tolerances to AGMA 2015 Standardized tooth proportions or calculate for maximum contact ratio Plots of gears in 2D and 3D DXF output of transverse tooth profile Co-ordinates output of tooth profile Measurement over balls and chordal span including contact height Metric or Imperial(English) units Gear sizing Flash temperature calculations Graphical plot of specific sliding Plot of theoretical path of contact Material database (user defined) SN fatigue curve plots Rating Inspection Bevel Geometry

8 connections Features include :- Detailed design of connecting elements - splines. ISO 4156 Splines DIN 5480 Splines ANSI B Splines Calculation of load distribution in the bearing Consideration of centrifugal forces for high speed ball bearings Subsurface stresses for large bearings with surface hardening Calculation for bearing sets like multiple angular contact bearings Load spectra Extension of contact ellipsis and contact angle under load Calculation with elastic outer ring for track rollers Full integration of bearing analysis including non-linear bearing stiffness in shaft tool Calculation of natural frequencies with gyroscopic effect Combined calculation of multiple coupled coaxial shafts Axial and shear deformations are taken into account Splines Produce spline designs to ISO 4156, DIN 5480 and ANSI B with an ANSI rating system. The side, inner and outer variants are considered. The root rounding can be arbitrarily adjusted to user preference. All profiles can be exported as DXF to wire erosion machines.

9 shaft and bearings Rolling Bearing Calculation Software Rolling bearing calculation according ISO/TS The bearing life calculation according ISO/TS (2008) is the latest standardized version of a bearing life calculation. The bearing life is calculated using the load distribution on each rolling element and is therefore not limited to an external force but can also consider tilting moments and the influence of clearance or pretension. For each of the five degrees of freedom either a load or a displacement/rotation can be specified. As in the calculation according ISO 281 (2007) the influence of the lubricant can be considered. Either the ratio or the specific film thickness can be used. The life with and without consideration of the lubricant will be provided as result. MESYS Shaft Calculation The shaft calculation allows the calculation of displacements, forces, strength according DIN 743 and bearing life for several connected coaxial shafts. The MESYS Rolling Bearing Calculation according ISO/ TS is included in the software and the nonlinear stiffness of rolling bearings in considered. Because of the nonlinear bearing stiffness shafts with more than two bearings can be calculated with accurate bearing forces as result. Pretension of bearings can be considered. Combinations of angular contact bearings can be easily considered as bearing set:

10 ADVANCED LOAD ANALYSIS MODEL The load analysis program calculates the deformation of gear tooth components and their consequences on properties such as stress and transmission error (accuracy of ratio) under load. Versatile graphics and reporting features offer a quick interpretation of the resulting analysis and formatting for customer reports. Links to metrology and manufacturing equipment enable evaluation of existing gear components as well as newly designed components. The Advanced level of this module incorporates the FE calculation GATES originally developed and experimentally validated at The Design Unit, Newcastle-Upon-Tyne, England. Already implemented by some of the most trusted gear design and manufacturing institutions in the UK, the program has been used in the development of an extensive range of marine, industrial and automotive applications. GATES, Gear Analysis for Transmission Error and Stress Specific film thickness calculation and ISO TR micro-pitting method A Features include :- Surface definition, (profile and flank line modification) Contact stress Root bending stress 3D FE model of tooth stiffness Power loss and efficiency Surface topological modification definition Multiple load cases Double helical gears Effect of gear misalignment Various graphical interfaces Import of measured gear surface Gear contact stress Bearing load pattern Power loss and efficiency

11 Micro-geometry definition Surface modifications defined by :- Normal pressure angle change Linear / parabolic profile modification 4th degree polynomial Simulated bias A user model exported to GPS format Measured data compatible to common manufacturing systems Surface modification can be applied to minimise transmissions error (and hence noise and vibration effects) at a specific load Nominal 3D surface modification / 3D surface with simulated or measured bias

12 ADVANCED LOAD ANALYSIS MODEL Micropitting Dontyne Systems has been working with Dave Barnett of Gears Made Easy to introduce a method for predicting micropitting over extended periods of time, analysing its effects on performance and if it will arrest. This empirically derived analysis has been corroborated against actual gear tests and it can be concluded that micropitting is primarily dependent on the following factors: 1. Contact stress 2. Sliding velocity 3. Oil film thickness 4. Oil temperature 5. Slide roll ratio (SRR) 6. Surface finish (the RMS parameter Ra is used in the calculations at present, but this may require modification) 7. Surface hardness 8. Number of contact cycles 9. Direction of sliding and the time that each surface is in contact with the corresponding gear in the pair. 10. Oil additive (Based on FZG micro-pitting oil test or based on actual gears) Analysis of the Modified FZG C type gears The modified C type gears were re-designed standard FZG gears with a mm tip relief, starting just above the highest point of single tooth contact. The amount of tip relief was chosen such that under a torque level of LS10, premature engagement was just avoided. LS 5 to LS 10 and Endurance Standard FZG Test Gear. LS 5 to LS 10 and Endurance Modified FZG Test Gear. To date, many different spur and helical gear sets have been analysed (from physical tests and field failures), with good correlation to the calculation procedures. Modified FZG at end of Load Stage 10 Actual / Predicted.

13 MicroErosion Profile change at each stage added to Tooth Contact Model to show change in performance over time. TE 0.85 after 10 hours 0.58 after 90 hours Conclusion - Comprehensive micro-pitting model originally developed by Dave Barnett based on results of a British Gear Association research program. - long term effects calculated beyond ISO limits including possible arrest of surface degradation - Profile changes linked to TCA - experimental validation (see AGMA paper 06FTM06) - Exclusive to Dontyne Systems The wear due to progressive mircopitting can be viewed in 3D at any stage.

14 ADVANCED LOAD ANALYSIS MODEL Convoloid Tooth Contact Analysis Dontyne Systems has completed several projects to develop customer specific applications or integrate functionality into the Gear Production Suite under licence. One example is an exclusive agreement on Convoloid gearing from Genesis Partners (US). Improvement over involute for same ratio and face width Reduced stress enables more power Low tooth numbers and optimized root forms (no undercut) Increase life potential Reduced weight Reduced centre distance Carrier Comparison between existing 750KW Gearbox and Convoloid Enhanced Gearbox Parameter Existing 750KW Planet Speed Planet Torque Bearing Type Bearing Configuration Bearing Loads Bearing L10 life Planet Carrier Weight Planet/Brg Assembly Ring Existing 750KW Gearbox rpm 34.9 kn-m Spherical Roller (2) Under Planet kn 129,900 hr 775 kg 225 kg 503 kg Convoloid Enhanced Gearbox rpm 34.9 kn-m Cylindrical Roller (4) Straddle Mount kn 124,900 hr 646 kg (-16.7%) 218 kg (-3.1%) 456 kg (-9.3%) With projected cost savings at 24,431/MW Annual Production Projected Total Savings 2,000MW 48,862,000 4,000MW 97,724,000 8,000MW 195,448,000 10,000MW 244,310,000 Based on data from 20% Wind Energy by 2030, US Department of Energy

15 Analysis of Involute/Convoloid Parameters Optimized Involute and Convoloid designs including tip relief Analysis shows typical 10-30% reduction in stress and improved loading condition. Improved Convoloid Centre relief Relief applied to the transition zone to improve contact conditions further. Centre distance tolerance mm Analysis used to establish envelope of operation where advantage is maintained mm

16 GEAR MANUFACTURE Tool Design Gear hobbing generated profile to check tool design Features include :- Tool design Tool database Simulation of profile generation and micro geometry Analysis of max/min tolerances on generated profile Protuberance and short lead hobbing techniques on profile Use tool generated profile in bending stress calculation for accurate rating Tool Database Define new tool Search and select tool

17 Machine Simulations Features include :- Calculate resulting gear profile using existing tooling and machine settings Model various machines and processes (Hob, Grind, Dress, Shape, Shave, Wire Erosion, Injection Mould, Forge) Import/export of co-ordinate files to machine tools Improved gear quality Reduced costs and resources Shorter lead times More efficient production Balancing contact forces for shaving Thread grinding Dressing and grinding Cavity (Injection Moulding) Profile error calculated from existing tooling Creating 3D models for formed gears produced by injection moulding or forging

18 Gear Inspection Co-ordinate Evaluation Direct from Gear Inspection and CMM Equipment Features include :- Interfacing to gear measuring machines and co-ordinate measuring machines Evaluation of linear errors Profile/flank/pitch to common standards (ISO, DIN, AGMA) 2D scan for full form inspection in root 3D Surface inspection Simulation of physical inspection(measurement over balls, tooth span) Simulation of contact testing Statistical analysis of production Definition of master surface Diagnostics and optimization of tool and machining process by compensation of errors Standard parameter evaluation Virtual testing tooth span, measurement over balls, transmission error

19 Advanced Analysis Functions Statistical evaluation of multiple measurements and creating a master surface Simulating dynamic tests such as contact marking with virtual master or other measured component optimal This module uses measurements to improve tool or machine process accuracy. Distorted gear due to shrinkage Invert errors on mould Improved quality gear

20 Gearbox system model Gear Design Analysis AND Optimization Software Tools Training AND Support UK info@dontyne.com Telephone : Dontyne Systems Limited is a company registered in England and Wales with company number Registered office: rotterdam house, 116 quayside, newcastle upon tyne NE1 3dy VAT Registration Number: