Romax Technology European User Forum 2015

Transcription

1 Romax Technology European User Forum 2015 Frank Seibicke Klingelnberg GmbH Paris, September30 th 2015

2 Frank Seibicke Klingelnberg GmbH Paris, September 30 th 2015

3 September 2015 Page 3 A New Challenge in CAE Agenda 1. Klingelnberg Group 2. ClosedLoop Manufacturing of Bevel Gears 3. Bevel Gear Design with KIMoS 4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer 6. Azimuth Thruster: Design example

4 September 2015 Page 4 A New Challenge in CAE Agenda 1. Klingelnberg Group 2. ClosedLoop Manufacturing of Bevel Gears 3. Bevel Gear Design with KIMoS 4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer 6. Azimuth Thruster: Design example

5 September 2015 Page 5 A New Challenge in CAE Klingelnberg Group Leading international company in gear technology Founded in 1863 Family business In the 7th generation, owner-management More than 1,300 staff in the KLINGELNBERG Group Equity capital approx. 50 % Turnover of KLINGELNBERG Group approx. 280 Mio

6 September 2015 A New Challenge in CAE Klingelnberg Group: Production Sites in Zurich, Hueckeswagen, Ettlingen, Gyoer (HU); Corporate Headquarters are located in Zurich Page 6 KLINGELNBERG AG, Zurich KLINGELNBERG GmbH, Hueckeswagen KLINGELNBERG GmbH, Ettlingen

7 September 2015 Page 7 A New Challenge in CAE Agenda 1. Klingelnberg Group 2. ClosedLoop Manufacturing of Bevel Gears 3. Bevel Gear Design with KIMoS 4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer 6. Azimuth Thruster: Design example

8 September 2015 Page 8 A New Challenge in CAE ClosedLoop Manufacturing of Bevel Gears Operating in ClosedLoop is the basis to get manufactured what is designed! KIMoS is a design suite for all types of spiral bevel gears The KIMoS results are stored as Neutral Data in a manufacturing database These data are the basis for: Tool preparation: Blade grinding and Cutter set-up Manufacturing of spiral bevel gears in soft and hard stage in ClosedLoop independent form manufacturing method Topography and spacing measurement Roll test for Bevel Gear Set

9 September 2015 A New Challenge in CAE ClosedLoop Manufacturing of Bevel Gears Blade grinding Cutter setting Page 9 KIMoS METEORIT corr. settings 3D checking Theoretical nominals Lapping Cutting Carburizing KOMET corr.settings 3D checking Grinding (also ClosedLoop)

10 September 2015 Page 10 A New Challenge in CAE Agenda 1. Klingelnberg Group 2. ClosedLoop Manufacturing of Bevel Gears 3. Bevel Gear Design with KIMoS 4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer 6. Azimuth Thruster: Design example

11 September 2015 Page 11 A New Challenge in CAE Bevel Gear Design with KIMoS KIMoS is the basis for ClosedLoop manufacturing KIMoS as an engineering tool covers the whole design process starting from the definition of Macro geometry until the Micro Geometry of a gear set is released for manufacturing KIMoS also assists the manufacturing process with a lot of functions in several modules, for example: Complete data for tool preparation Calculation for deburring process Calculation for arbor length The KIMoS program package consists of several different modules what allows to customize the package for each individual application

12 September 2015 A New Challenge in CAE Process Flow in Bevel Gear Design with KIMoS Page 12 Standards Database Dimensioning Stress Analysis Contact Pattern Development N E U T R A L D A T A Production Database GLEASON cage: spa-file Oerlikon CDS Previous KIMoS versions Import Interface

13 September 2015 Page 13 A New Challenge in CAE Agenda 1. Klingelnberg Group 2. ClosedLoop Manufacturing of Bevel Gears 3. Bevel Gear Design with KIMoS 4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer 6. Azimuth Thruster: Design example

14 September 2015 Page 14 A New Challenge in CAE System Based Limitations tooth is described by an elastic model manufacturing deviations can be considered load is calculated for each individual contact line multiple mesh is taken into consideration Hertzian pressure is calculated in steps for each individual contact line tooth root stress is calculated in steps for each individual contact line tooth pair 3 tooth pair 2 tooth pair 1 Limitation: Gear body and it s environment is assumed as infinite stiff!

15 September 2015 Page 15 A New Challenge in CAE Agenda 1. Klingelnberg Group 2. ClosedLoop Manufacturing of Bevel Gears 3. Bevel Gear Design with KIMoS 4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer 6. Azimuth Thruster: Design example

16 September 2015 A New Challenge in CAE Page 16 Consideration of whole gear box by interaction with Romax Designer 1 Designing the Gear Pair KIMoS 5 LTCA with BECAL 2 Export Gear Dimensions to RomaxDESIGNER 4 Import Load Cases from RomaxDESIGNER via Load Spectra Editor 6 Export Results to RomaxDESIGNER 3 Powertrain Simulation RomaxDESIGNER 7 Dynamic analysis

17 September 2015 A New Challenge in CAE Page 17 Consideration of whole gear box by interaction with Romax Designer RomaxDesigner Model Output rotation Input Rotation

18 September 2015 Page 18 A New Challenge in CAE Consideration of whole gear box by interaction with Romax Designer RomaxDesigner Model / KIMoS interface

19 September 2015 Page 19 A New Challenge in CAE Agenda 1. Klingelnberg Group 2. ClosedLoop Manufacturing of Bevel Gears 3. Bevel Gear Design with KIMoS 4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer 6. Azimuth Thruster: Design example

20 Azimuth Thruster: Design example RomaxDesigner model of Azimuth Thruster CAD model RomaxDesigner model Gears, shafts, bearings, housings

21 Azimuth Thruster: Design example 6 DOF Forces Desired: Thrust (x direction) Torque (roll direction) Undesired Side forces (y direction) Pitching moments (pitch direction) Yawing moments (yaw direction)

22 Azimuth Thruster: Design example System Analysis Static deflections, based on load conditions Gear and Bearing ratings, including system deflections Gear and Bearing static assessment (e.g. bearing and gear contact stress under crash-back condition) System vibration predictions System modes Vibration response to prop excitation (torque fluctuation) Vibration response to gear transmission error

23 Azimuth Thruster: Design example Model setup For each prop speed considered Apply torque, thrust (can apply full 6DOF forces and moments if desired) Loads must be calculated externally

24 Azimuth Thruster: Design example Static Assessment Deflections and gear/bearing ratings

25 Azimuth Thruster: Design example System deflections Torque and Thrust 140 KN Thrust, 30KNm torque Deflections can affect durability and sealing

26 Azimuth Thruster: Design example Gear / Bearing Analysis under loads and deflections

27 Azimuth Thruster: Design example Bevel gear contact patch analysis Zero misalignment With system deflections Target: Bevel Gear EaseOff specified such that patch centralises under true misalignment

28 Azimuth Thruster: Design example Bevel gear contact patch analysis With system deflections (nominal load) With system deflections (over-speed load) Target: Bevel Gear EaseOff specified such that patch centralises under true misalignment

29 Azimuth Thruster: Design example Gear / Bearing Duty Cycle Analysis Example: ISO bearing ratings (Loads on propeller calculated externally and prescribed in RomaxDesigner)

30 Azimuth Thruster: Design example Extreme static load assessment e.g. crash-back Nominal Peak loads during crash-back

31 Azimuth Thruster: Design example Extreme static loads crash-back Pinion shaft lower bearing stress contours Nominal Peak loads during crash-back

32 Azimuth Thruster: Design example Dynamic Assessment Modes and vibration response

33 Azimuth Thruster: Design example System modes 13 Hz 60 Hz 1023 Hz Global Local

34 Azimuth Thruster: Design example System modes 1023 Hz (external view) 1023 Hz (internal view) 1023 Hz mode - coupled mode of housing of shaft system

35 Azimuth Thruster: Design example Vibrational system response to bending excitation at propeller (5KNm) Response from all modes (Modal damping dry response) Response from 12 Hz only

36 Azimuth Thruster: Design example Operating deflected shape Response to torsional prop excitation 5KNm magnitude at 200 rpm

37 Summary: RomaxDesigner/KIMoS analysis Fast (much faster than classical FE) predictions of static deflections Analytical bearing contact models Multi-fidelity component representations (1D/3D) Combined gear and bearing analysis using system misalignments Gear life ratings /static strength Bearing life ratings / static strength Modal and vibration analysis of system Integration with KIMoS bevel gear analysis Load spectra s are taken over from ROMAX Designer Optimization of EaseOff under consideration of calculated deflections easy data exchange between booth systems