Whats New in 03 2011 Rev 1

EES KISSsoft GmbH P.O.
Box 121 Weid 10 6313 Menzingen Switzerland
++41 41 755 09 54 (Phone) ++41 41 755 09 48 (Fax) ++41 79 372 64 89 (Mobile) h.dinner@EES-KISSsoft.ch www.EES-KISSsoft.ch
KISSsoft & KISSsys Release 03-2011, Whats New
1 Whats new in release 03-2011 of KISSsoft

1.1 Most relevant new features
KISSsoft and KISSsys key improvements are - Improved tooth contact analaysis and micropitting analysis in KISSsoft - 3D geometry of bevel and worm gears in KISSsoft - Optimisation function for corrections - Animation and cut away in 3D view of KISSsys - Use of tabs in KISSsys
1.2 Annual maintenance (AMC)

The new release 03-2011 is shipped out to our customers now, provided that their investment in KISSsoft software is protected by AMC (maintenance and support). A valid AMC contract (maintenance and support contract) ensures that: You get updates of the software You are entitled to software and installation support You have confidence that the software is compatible to changing hardware and operating system requirements You may get hardware lock / dongle replacement in case of damage or hardware incompatibility You will get technical help from our gear engineers
EES KISSsoft GmbH Title: Release 03-2011 Weid 10 / P.O. Box No.: 6313 Menzingen Date: Switzerland Manager: HD www.EES-KISSsoft.ch Email: h.dinner@EES-KISSsoft.ch \\Diskstation\transfer\EES KISSsoft GmbH\Verwaltung\Update-to-03-2011\Whats-New-in-03-2011-Rev-1.doc
Public
Revision: 0 Autor: HD Date: 2011-06-09 Approved: HD Date: 2011-06-09 1 of 55
Your initial purchase of KISSsoft & KISSsys software was a substantial investment helping you to optimise your product. The annual maintenance protects this investment and we strongly recommend that you only work with the actual version of KISSsoft & KISSsys.
1.3 Table of content

1 Whats new in release 03-2011 of KISSsoft ....................................................................... 1 1.1 Most relevant new features ........................................................................................ 1 1.2 Annual maintenance (AMC) ...................................................................................... 1 1.3 Table of content.......................................................................................................... 2 1.4 Document change record............................................................................................ 3 New modules...................................................................................................................... 3 2.1 Synchronizer............................................................................................................... 3 2.2 Spindle drives............................................................................................................. 4 2.3 KISSsys model for sizing of gearboxes ..................................................................... 4 2.4 Optimisation function for corrections ........................................................................ 5 2.5 Calculation of clamped connection .......................................................................... 10 2.6 Calculation of single bearings with inner geometry................................................. 11 General ............................................................................................................................. 13 3.1 Training .................................................................................................................... 13 3.1.1 Trainings, India 2011 ....................................................................................... 13 3.1.2 Trainings, China 2011 ...................................................................................... 14 3.1.3 Trainings, Switzerland 2011 ............................................................................ 14 3.2 Support ..................................................................................................................... 14 3.3 Licencing.................................................................................................................. 15 3.4 i-Phone application................................................................................................... 15 KISSsoft ........................................................................................................................... 16 4.1 Bearing database ...................................................................................................... 16 4.2 Gear material, Databases.......................................................................................... 18 4.3 General, Databases ................................................................................................... 18 4.4 User Interface ........................................................................................................... 18 4.5 Helical gears ............................................................................................................. 21 4.6 Tooth contact analysis for helical gears ................................................................... 32 4.7 Bevel gears ............................................................................................................... 39 4.8 Worm gears .............................................................................................................. 42 4.9 Face gears ................................................................................................................. 43 4.10 Shaft calculation ....................................................................................................... 43 4.11 Bolts ......................................................................................................................... 48 4.12 Springs...................................................................................................................... 48 4.13 Various ..................................................................................................................... 48 KISSsys ............................................................................................................................ 49 5.1 General ..................................................................................................................... 49 5.2 User Interface ........................................................................................................... 49 5.3 GPK.......................................................................................................................... 50 5.4 Transfer of shaft system deformation....................................................................... 51 5.5 Graphics ................................................................................................................... 51 CAD Interfaces................................................................................................................. 54 6.1 3D gear graphics....................................................................................................... 54 6.2 Parasolid Kernel in KISSsoft ................................................................................... 55 6.3 SolidEdge interface .................................................................................................. 55 6.4 SolidWorks interface................................................................................................ 55
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6.5 6.6 6.7
Autodesk Inventor interface ..................................................................................... 55 ProEngineer interface............................................................................................... 55 NX interface ............................................................................................................. 55
1.4 Document change record

Revision Dated 0 2011-06-09 Who HD Comments Original document
2 New modules
2.1 Synchronizer
Synchronizer calculation is possible with the KISSsoft module A010. The calculation module is still under construction, but KISSsoft has released the first version for the testing.
Figure 2.1-1 Input of Synchronizer data
Current module allows calculation for the synchronization (and total) time based on the geometry, forces and application data defined in the interface. Some additional calculations for the heat development, frictional power and wear resistance are performed. Calculations can be performed for common type of synchronizer with number of cones. (single, double or triple cone). The calculation is based on formulas by Borg Warner and on Synchronizer Design: A Mathematical and Dimensional Treatsie by Syed T. Razzacki, Daimler Chrysler Inc. Three documents are available on request related to KISSsoft and synchronizer design - Instructions - A summary of the formulas - Original paper by T. Razzacki
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2.2 Spindle drives

This module allows for the calculation of spindles with trapezoidal thread as shown below. The buckling safety and contact pressure safety factors are calculated. Two configurations of spindle (moving hub or stationary hub) are possible as shown below.
Figure 2.2-1 Left: types of configurations. Right: thread type
Figure 2.2-2 Calculation of spindle drive.
2.3 KISSsys model for sizing of gearboxes

A new KISSsys model allows for the automatic optimisation (in terms of mass, cost and size) of complete helical gearboxes considering the gears, shafts and bearings. Inside KISSsys, different combinations of ratio per stage (giving the same required gearbox ratio) are proposed and for each combination of ratio in the individual stages, the gear sizes are optimised. For all gearbox solutions, then, the mass, cost and size is estimated. The user may then select the gearbox with e.g. the lowest cost for production.
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Studies with data from a customer have shwon that it is possible (in this case) to reduce the gearbox cost by 20% compared to the initial design. The gearbox variant generator is available for helical and planetary gearboxes
2.4 Optimisation function for corrections

Gear geometry corrections in profile and lead direction can be given in KISSsoft using the menu Calculation/Modifications. There, different modifications like tip relief, crowning or helix angle correction may be defined. These corrections, along with the gear misalignement, is then used in the tooth contact analysis (TCA) which may be used with the menu Calculation/Contact analysis. However, only one set of corrections can be analysed at one time. Similar to the rough and fine sizing function for the gear macro geometry (where many different gear geometry solutions are calculated and compared to find the best solution for a given application), a new sizing function for gear micro geometry is added. This functions allows to simultaneously calculate different combinations of gear corrections. This allows to study the robustness of the corrections as also the load level may be analysed. For example: the user wants to see what is the best amount of tip relief for a load range of 60%-80% of the nominal torque. Then, he can define that the tip relief is varied from e.g. 10um to 25um in steps of 5um. Furthermore, he can define that the torque level is taken as 60%, 70% and 80% of load. For each combination of amount of tip relief and amount of torque (in this simple example it is nine combinations), the tooth contact analysis is automatically run and relevant results like transmission error (peak to peak transmission error) or face load distribution (Khbeta) is calculated. The results for all calculations (in our example, for nine calculations) is listed in a report in tabular form. There, the robustness (how much changes e.g. the peak to peak transmission error for a given tip relief when the load varies) of the design can be assessed. To use the new module, proceed like this Define the nominal corrections in the tab Modifications, e.g. as shown below:
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You should also activate the tab Contact analysis and define e.g. the misalignement of the two gears there (in our case 10um inclination error and 15um deviation error)
Then, press the button Modification optimization and the window as shown below will appear
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As a default, the modifications are taken from the tab Modifications. However, using the . button , they may be deleted. The user can add his own corrections by using the button Note that there are three different modifictions, A, B and C. Inside each group, a minimum and a maximum value for the individual corrections can be given. Below, an example of a set up is shown. Note that additionally, end relief on the gear 1 has been added:
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Figure 2.4-1 Example set up of the modification optimisation tool
In the above, we have selected that three steps will be calcualted for each modification A, B, C. For example, in modification B, we have selected that the root relief in gear 1 starts at 2um, is then increased to 4um and then to 6um. Parallel to this, the root relief of gear 2 starts at 5um, is then increased to 7.5um and then to 10um. Furthermore, three load levels will be calculated (60%, 70%, 80% of nominal load). Therefore, the total number of calculations will be 3x3x3x3=81 different calculations (27 different gear micro geometry, for each of them, three different load levels). This calculation does take some time and yields the following results:
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Figure 2.4-2 Results report
In the results report, you can now find 81 different results, e.g. for the peak to peak transmission error as shwon above. There are 27 lines of results and 3 columns. The 27 lines correspond to the 27 different types of corrections calculated and the 3 columns correspond to the three different load levels. The results may for example be copied to Excel for analysis as shown below:
Peak to peak transmission error

3 Load=60% Load=70% Load=80%
2.5
2 PPTE in um
1.5
0.5
0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 Gear micro geometry (solution number)
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It can be seen that for solution No. 6, we have a very low PPTE and a low variation of the PPTE for the three different load levels. This means that this gear design has a) a good noise characteristic and b) the noise level will not change much with changing load. This means that the design is both of good quality and robust. In comparison, solutions No. 3 and 4 also have a low PPTE but it varies more compared to the solution No. 6.
2.5 Calculation of clamped connection

This module allows for the strength rating of a particular type of shaft-hub connection, a clamped connection. Two types of connections are possible, one as shwon below and one as shown in the second next figure
Figure 2.5-1 Slotted hub type connection
Figure 2.5-2 Clamped hub type connection
The calculations are as per the very popular German engineers handbook by Roloff and Matek. They allow for the calculation of the transmittable torque or the resulting safety factor in a given application.
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2.6 Calculation of single bearings with inner geometry

This module allows for the calculation of the bearing load distribution, the rolling element contact stress, the bearing lifetime (basic rating, modified rating, modified basic rating, modified reference rating) and the non-linear bearing stiffness. The inner ring is either tilted/moved with respect to the inner ring and the resulting forces are calculated. Or, more commonly, the external loads like tilting moments and forces may be given and the movement of the inner ring with respect to the outer ring is calculated. This allows for a detailed study of the contact stress as furthermore, the corrections on the rolling element are considered. As default, logarithmic corrections are used but the user can also define his own corrections in the bearing database. This calcualtion module may also be used for slewing bearings (four point bearings and double row four point bearings) and is therefore also used in the wind turbine design. A very new feature is that it is also possible to consider the ovalization of the bearing races (meaning that the bearing outer and inner ring are deformed and not ciruclare anymore, giving a different assembly clearance for each rolling element). This type of calculations to such level of detail is available only in a few commercial software packages globally.
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Figure 2.6-1 Calculation of single bearing with inner geometry
Figure 2.6-2 Types of bearings that can be analysed
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Figure 2.6-3 For rolling element bearings, the rolling element corrections and the deformation of inner and inner ring may be given
3 General
3.1 Training
A new training schedule has been set up. It covers two levels of KISSsoft trainings and three levels of KISSsys trainings and it is valid for trainings in Switzerland, China and India. A summary of the training schedule is given below. Detailed information on the training schedule may be obtain from our manager trainings, Mr. Thomas Ha, t.ha@ees-kisssoft.ch or from your local KISSsoft partner. 3.1.1 Trainings, India 2011
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3.1.2
Trainings, China 2011
3.1.3
Trainings, Switzerland 2011
3.2 Support
New staff is available at KISSsoft AG and EES KISSsoft GmbH providing technical support. Mr. Ioannis Kaliakatsos, responsible for shaft and bearing calculation Mr. Virgilio Schirru, responsible for user interface and gear modules
Mr. Benjamin Mahr, responsible for tooth contact analysis and graphics Mr. Thomas Ha, overall responsible for trainings in Asia
3.3 Licencing
Test version may now be requested using Wizard inside KISSsoft:
There is a new module list, listing all commercial modules, available.
3.4 i-Phone application

The hardness conversion from KISSsoft is now available as i-Phone application:
Figure 3.4-1 KISSsoft iPhone application
Check out your app store to find the KISSsoft hardness conversion tool for your iPhone!
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4 KISSsoft
4.1 Bearing database
Rolling element corrections: In the bearing database, the user can now introduce information about the correction (crowning) of the rollers:
Figure 4.1-1 Using a dat file (text file) to define the rolling element corrections
The text file showing the rolling element correction is of the following form: The first column defines the position along the rolling element. A total of 43 points along the rolling element length are used. The second colum defines the position, from the middle of the rolling element, normalised by the rolling element length. The third column defines the amount of correction, normalised by the rolling element diameter.
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Figure 4.1-2 Definition of the rolling element corrections
Depending on the correction defined, the contact stress (and the stress concentrations) may be modified as shown below:
Figure 4.1-3 Left: rolling element with crowning, the maximum stress is in the middle of the rolling element. Right: rolling element with no correction, giving a uniform stress distribution along the rolling element width and stress concentrations at the ends of the rolling element.
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4.2 Gear material, Databases

Material database: new plastic material data from SABIC (VERTON RVL36 now with root strength data, LUBRICOMP ECL36 with static and wear data) are available (on request).
4.3 General, Databases

Import / export of data sets: Note that single data sets may now be exported and imported to and from the database. This simplifies the collaboration between e.g. two engineers in a company or between customer and supplier. This approach allows e.g. that one engineer adds a new type of bearing to the databased. By using the export function, he can generate a text file with the bearing data. The other engineer can then import this text file into his database and he can then also use the new type of bearing:
Figure 4.3-1 Left: export button to export a single dataset. Right: single dataset as text file
4.4 User Interface

KISSsoft examples: The KISSsoft examples and tutorials may now be found in the tab Examples. Open the pdf documents to get tutorials on how to get started with KISSsoft. Alternatively, open KISSsoft files to study the data presented in these files:
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Figure 4.4-1 Examples window with Tutorials and KISSsoft example files
File explorer: For easy access to your directories and files, you can also add the Explorer view to KISSsoft:
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Figure 4.4-2 File explorer in KISSsoft
As a default, the file explorer is not active. By changing the kiss.ini file, the explorer will be activated:
Figure 4.4-3 Activating the file explorer in kiss.ini
Symbol size: Note that the symbols in KISSsoft user interface correspond to the symbols as used in the respective standard. In order to improve readability, use right mouse click to enlarge the symbols:
Figure 4.4-4 Use right mouse click to enlarge symbols
Copy and past graphics: The content of a graphics window may now be copied to the clipboard using the keys Ctrl+C. Then, the content of the window can e.g. quickly be pasted to a report written in e.g. MSWord by using Ctrl+V:
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Figure 4.4-5 Using copy-past to copy the content of a KISSsoft graphics to e.g. MSWord
4.5 Helical gears

Strength rating methods: The calculation method RINA 2010 for commercial ships is added.
Figure 4.5-1 Strength rating methods for commercial ships
Master gears: Optionally the total radial composite deviation according to AGMA2002 can be considered. Calculation of flank breakage: Flank breaking calculation for bevel gears and cylindrical gears is implemented according to Dr. Annast, TU Mnchen, 2002. The method was developed for bevel gears, but may give also approximation of flank breakage risk for cylindrical gears.
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Backlash calculation: The largest and smallest backlash case is now calculated from user temperature range input. Slight change in the calculation of the acceptance backlash for cases when the center distance tolerance is not symmetric (if Aa.e <> -Aa.i). Additionally in the report will be a proposition for tooth thickness tolerances to get exactly jtmin=0 under the worst conditions.
Figure 4.5-2 More detailed definition of operational temperature range in operational backlash calculation
Fine sizing function: In Fine Sizing the calculation of transmission error is added, including optional a sizing of profile modification (tip / root reliefs, with various transition types). For the sizing of profile modifications, the same function as for the layout of modifications in the tab Modifications is used.
Figure 4.5-3 Calculation of transmission error in fine sizing function. Connection of fine sizing function with sizing function for corrections.
Micropitting calculation according to ISO TR 15144:2010, Method B, is implemented. The more accurate calculation acc. to Method A is already available since Release 04-2010. The method Be along ISO TR 15144 calculates the safety factor against micropitting at seven points on the flank, A, B, C, D, E and halfway between A and B and D and E. Requirement for the calculation is that the lubricant load stage against micropitting is defined as shown
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below. The safety factor against micropitting is shown in the results summary and the report as shown below:
Figure 4.5-4 Input of FZG load stage against micropitting (lubricant data)
Figure 4.5-5 Left: results summary, showing safety factor against micripitting (method B). Right: report on micropitting calculation
Wear is calculated for metallic (steel) gears. The wear coefficient can be entered manually or calculated according to Plewe. The wear coefficient is to be entered at the material data as shown below:
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Figure 4.5-6 Use the "Plus" button for the materials and select "own input". Then, activate the flag Wear factor and either enter the wear factor or use the sizing factor to calculate it.
Note that the calculation of the wear factor is difficult and inaccurate as it for examples assumes a clean lubricant (abrasive wear due to debris in lubricant is not considered). Hence, this calclulation should mainly be considered as a qualitative calculation. Note that you have to give the wear coefficient for both gears / gear materials. Note that for the wear calculation, you have to run the tooth contact analysis. The results can then be retrieved in graphical form. Two graphics of the wear are shown, a 2D graphic in the middle of the face width and a 3D graphic.
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Figure 4.5-7 Run the tooth contact analysis and show the graphics for wear
Figure 4.5-8 Wear after 20'000hours. Left: 2D graphics showing wear distribution (blue area) and resulting gear geometry (red line). Right: wear distribution shown on the plane of action, note that along the facewidth, the wear is not uniform due to misalginement of the gears as defined above.
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Figure 4.5-9 Same results but after 2000'000h
Note that the wear calculation is also available for plastic gears. Tab Basic data: a proposition for the Oil-Viscosity following DIN51509 is added.
Figure 4.5-10 Sizing function for oil viscosity
Varying qualities: Different qualities may be given for individual errors. Activate this option in the module specific settings as shown below. Then, enter the quality levels that deviate from the default as shown below. Note that this my influence some calculations:
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Figure 4.5-11 Module specific settings, activate input of varying qualities
Figure 4.5-12 Input of qualities different to those in the main input
Kinematic oil viscosity: using the menu Graphics/Evaluation/Oil viscosity, the kinematic viscosity vs. tempererature is shown:
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Figure 4.5-13 Display of oil viscosity as a function of temperature
Tab Tolerances: Concentricity deviation Trk is calculated according to DIN58405 The tip and root diameter allowances can be determined from the diameter values. Herewith the drawing data can be entered without changing the reference profile data.
Figure 4.5-14 Input of tip diameter tolerance
Input of upper and lower tip diameter instead of tolerances:

Figure 4.5-15 Input of upper and lower tip diameter
Tab Modification: There are several changes in the list with modifications a comment can be added. 1) Modifications can be switched on and off (Status: active / inactive) 2) Comments can be added 3) The resulting helix angle in case of helix angle correctin is shown for information 4) New types of corrections are available
Figure 4.5-16 Active / inactive modifications. Comments. Resulting helix angle.
Figure 4.5-17 Additional types of modifications

The modifications tip / root relief, linear with transition radius as well as tip / root relief, progressive are added. Also the modification end relief, arc-like is available now. The modification helix angle modification, tapered or conical is added. This allows the definition for helix angle modification for left flank in the same philosophy as for the right flank (less material on side II). Note also the important addition of curved end relief as opposed to the linear end relief. This new type of curved end relief ensures that there are not stress concentrations at the location where the end relief starts
Figure 4.5-18 Upper: linear end relief. Lower: curved end relief.
Tab Tooth form: Data for Gear hobbing cutter can be introduced in factors or in mm (or inch). This helps a lot for the introduction of cutter data from drawings, when the data is given in inch or mm.
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Figure 4.5-19 Input of tool data in mm instead of mn
Tooth form modifications (i.e. tip relief, etc.) from the tab Modifications will be handled now in the graphics as a separate step. Additionally in the tab Tooth form the modifications can be selected to be considered or not.
Figure 4.5-20 Select in the tooth form calculation whether modifications as given in the tab "Modifications" should be considered or not
Module specific settings: Option for use alternative algorithms for the tooth form calculation is added. In some seldom cases this provides more useful results than the standard algorithm. Option for allow unsymmetrical profile modifications is added. This is to be used if the left and right gear flanks have different modifications.
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Figure 4.5-21 Activate modification side selection
Figure 4.5-22 Select side for modification (default is "both")
Report: the language of drawing data is now related to the language setting. User specific reports needs to be re-named with the corresponding letter (Z010gear1.rpt changed to Z010gear1d.rpt, etc.). The files for CAD remain as before (Z010gear1.out).
4.6 Tooth contact analysis for helical gears

Settings: You can select whether in the tooth contact analysis, only the tooth contact analysis is performed or the Khbeta calculation along ISO6336-2, Appendix E or both.
Figure 4.6-1 Select extent of tooth contact analysis
KHbeta calculation: Further to the tooth contact analysis, KHbeta is calculated along ISO6336-2, Annex E based on the gear misalignement and the gear corrections. KHbeta is reported in the results window in the tab Contact analysis
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Figure 4.6-2 Calculation of KHbeta from tooth contact analysis
Detailed calculation information on Khbeta calculation can be found in the report as shown below:
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Figure 4.6-3 Report on KHbeta calculation
Contact stress: the contact stress on the gear flank is now shown on the gear flank itself:
Figure 4.6-4 Left: open contact stress graphic. Right: contact stress distribution on tooth flank
Using this graphics, the effect of different corrections may be shown:
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Figure 4.6-5 Deformed system, stress distribution and KHbeta. No corrections on the gears
Figure 4.6-6 Deformed system, stress distribution and KHbeta. Crowning added to the gears
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Figure 4.6-7 Deformed system, stress distribution and KHbeta. Crowning and helix angle corrections added to the gears
Figure 4.6-8 Deformed system, stress distribution and KHbeta. Crowning, helix angle and end relief added to the gears
Shaft deformation in gear contact analysis: The user can select the shafts on which the gears are located. Then, the shaft deformation is calculated and automatically used to define the misalignement of the gears
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Figure 4.6-9 Select shaft files for calculation of gear misalgignement
A separate document on this calculation is available on request. Note that in the above calculation, e.g. the influence of the bearing clearance and its influence on the bearing stiffnes, the subsequent influence on the gear misalignement and the contact stress (and Khbeta) may be studied: Case 1, bearing clearance is -0.05mm
Figure 4.6-10 Shaft deformation, load distribution in the bearing, bearing roller stress and bearing nonlinear stiffness curve
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Figure 4.6-11 Resulting contact stress on gear tooth
So, for case 1, Khbeta is found as 1.23 Case 2, bearing clearance C3
Figure 4.6-12 Shaft deformation, load distribution in the bearing, bearing roller stress and bearing nonlinear stiffness curve
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Figure 4.6-13 Resulting tooth contact stress on gear tooth
So, for case 2, Khbeta is found as 1.33 (whereas it was 1.23 before) Graphics / Evaluations: FFT-analysis of transmission error and meshing stiffness are now provided.
Figure 4.6-14 Additional graphics based on transmission error
4.7 Bevel gears

Calcualtion methods: along AGMA2003 and Klingelnberg standards are updated. New calculation method AGMA2003-C10 added (additionally to AGMA2003-B97). Size factor Cs is different for face width b>79 mm. Klingelnberg-method KN3030 is updated to edition 1.2. There are changes in Y_bet, which cause significant differences for spiral angle beta > 30.
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Figure 4.7-1 New bevel gear calculation methods
Calculation of flank breakage: Flank breaking calculation for bevel gears and cylindrical gears is implemented according to Dr. Annast, TU Mnchen, 2002. The method was developed for bevel gears, but may give also approximation of flank breakage risk for cylindrical gears. Tab Geometry: Additional button for entering data according to Gleason data sheet is available. The dimensions (also the corresponding addendum and dedendum angles) are calculated for spur gears, spiral bevel duplex and standard, zerol duplex and standard.
Figure 4.7-2 Additional data input for Gleason bevel gears
Tab Modifications: Modifications can be defined for the 3D models.
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Figure 4.7-3 Definition of modifications for bevel gears
3D gear geometry calculation: Generation of 3D Bevel gears (straight, helical and spiral bevel) with no restriction on tooth cone type. Spiral bevel gears are currently restricted to epicycloidic lengthwise curvature (Face hobbing). Export in STEP or Parasolid format (with module CB1). Available modifications: lengthwise crowning, profile crowning, pressure angle modification and helix angle modification. Tip chamfer, tip rounding, and tooth end chamfer are not available.
Figure 4.7-4 3D spiral bevel gear geometry
Note:
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4.8 Worm gears

Tab Basic data: tooth thickness modification factor xs added. This allows to change directly the tooth thickness without changing of tip and root diameter. Herewith the same functionality as for the bevel gear calculation is provided. 3D geometry: of enveloping worm wheel is added. Generation of 3D models of worm gears (with enveloping wheel) based on the cutting simulation. Worm wheel cutter is supposed to duplicate the worm, but its possible to use bigger cutter by setting the cutter increasing factor in Module specific settings. Export in STEP or Parasolid format (with module CB1). The cutting model is available in order to check the result of virtual cutting simulation.
Figure 4.8-1 3D geometry of worm wheel
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4.9 Face gears

3D geometry: Generation of 3D models for face gear is enhanced for shaft angle 90, helix angle 0 and / or offset 0 mm. The cutting model is available in order to check the result of virtual cutting simulation.
Figure 4.9-1 3D face gear with shaft angle not equal to 90deg
4.10 Shaft calculation

Shaft editor: Face gears can be considered now as force elements for the shaft calculation (force element bevel gear, and change the type of gear in element editor). Cylindrical inner gears can now be defined with (-) diameter values (following the nomenclature in gear calculation). Force elements within the power flow (torque input or output) are indicated with dark blue color. Force elements without torque or power are displayed with light blue color. The bearing elements contain now sketches which shows the schematically bearing type.
Figure 4.10-1 Display of bearing type in editor
Tab Strength: Additional input for shaft materials (as e.g. raw diameter, etc.) is now moved to the element editor of the respective shaft. This allows defining these values specific for each shaft Bearing calculation (classical method): The calculation with rigid bearings having clearance is improved. The bearing deformation is now in accordance (same direction) with the applied load on the bearing. This is performed in all bearings for every shaft.
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Bearing losses: The bearing drag losses (oil bath and jet lubrication) are now calculated too. The oil level can be defined in module specific settings.
Figure 4.10-2 Resulting bearing friction torque in report
The calculation of this friction torque is based on SKF catalogue 2004:
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Bearing calculation (inner geometry method): Optionally the bearing preload can be defined now with force in [N] instead of offset in [mm]. The bearing outer ring rotation in X and Z can be given as input. This represents e.g. the housing deformation.
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Figure 4.10-3 Definition of pre-tension as a force
Campbell diagram: A campbell diagram is calculated and shown:
Figure 4.10-4 New tab for campbell diagram
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Figure 4.10-5 Campbell diagram of shaft
Non-linear bearing stiffness: The non-linear bearing stiffness is calculated based on the bearing inner geometry and the clearance. The course of the stiffness as a function of the external load applied is calculated and shown in graphics:
Figure 4.10-6 Show bearing stiffness curve
Figure 4.10-7 Left: bearing stiffness course without bearing clearance. Right: with clearance
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4.11 Bolts
Shearing load according to VDI 2230 (part R12) is implemented. Tab Basic data: the friction radius is now required instead of the diameter (previous releases). This is following the equation (5.4/1) of VDI 2230. Material and shearing strength of the nut is now directly defined in the main menu. The calculation of minimal required length of engagement for nut connected tpyes is now done in the main calculation too. Hexagon socket head cap screw with low head DIN 7984 is implemented. Geometry standards actualized: DIN EN ISO 4762, DIN EN ISO 4014, DIN EN ISO 4017, DIN EN ISO 1207, DIN EN ISO 8765, DIN EN ISO 8676, DIN EN 1662, DIN EN 1665 Module specific settings: Calculation of minimal required length of engagement with maximal tensile strength (factor Rmmax/Rm according to VDI2230) Option added in order to determine specific thermal expansion factor of washers. This allows defining a different thermal expansion factor for washers. Otherwise the value will be overtaken from the clamped parts.
4.12 Springs
Compression springs: the standard for tolerances DIN 2095 (1973) is now replaced by DIN EN 15800 (2009). The values are now calculated according to formulas, which can result in slightly different values. Tension springs: calculation of relaxation and spring force after 48h (EN 13906-1), several diagrams added in graphics: relaxation, time curve of relaxation and time curve of spring force.
4.13 Various
Menu extras: license file can be downloaded directly under Extras - License tool. Export and Import with US Customary Units is possible. The units can be set under Extras System of Units. Hardness conversion: Calculation of Hardness conversion is update and according to DIN EN ISO 18265. Previously it was according to DIN 50150. ISO 286 (tolerances as i.e. for diameters and bores) adapted to the new edition 2010 Graphics: the footer for the printed graphics can be defined now by the user, using the report templates graph?.rpt Calculation time is now available (per default off). Reports: Report templates can be Unicode 16bit Low Endian. This allows using non-Latin characters, such as Cyrillic, Greek or Asian CJK characters. A formatting tag <SUPER> and </SUPER> was added to the report generator for superscript characters, as i.e. x2 The function strlen(str) returns the length of str. This allows also an easy check for empty string variables in the report, as i.e. drawing part numbers. The function strcmp(str1;str2) allows the comparison of values, using an alphabetical order. It returns -1 if the string str1<str2, 0 if str1=str2 and 1 if str1>str2.
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KISS.ini: new option for calculation modes is available: CALCONOPEN. When the KISSsoft or KISSsys files are opened, the possibility is given to calculate (as before, default setting) or not to calculate the file automatically. New option for using the file explorer is available: USEFILEEXPLORER. The file explorer can be switched off (default setting) or on (as before).
5 KISSsys
5.1 General
Project folder: while starting the software, no project folder is required anymore. The project folder is set automatically when opening a file. Classes: version of ClassCAD changed. In seldom cases this may cause problems with some old user codes. Tables: are now arranged with tabs and can now easily be selected. Variables: for the roller bearings the Rotcad variables hasPretension, pretension, rotX and rotZ are now defined. Synchonizer and Face gears: the KISSsoft calculation and KISSsys element are now available. Model structure: coaxial shafts can be placed freely in the tree structure. Calculations: calculation function for the total efficiency, depending on the added losses in the model, is added in system. The calculation of contact analyses for helical gear pairs and planetary systems can be started from KISSsys and the results (as i.e. TE, etc.) shown in KISSsys tables. The shaft deformation can be considered as linear (as currently) or using the exact values from the shaft calculation.
5.2 User Interface

In the user interface, tabs are introduced. They allow for fast navigation between the different windows. The windows may then be shown using only the tabs or, if the menu Window/Cascaded order is used, in the usual fashion.
Figure 5.2-1 Using tabs instead of windows
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Figure 5.2-2 Using windows instead of tabs
5.3 GPK
Table User Interface: Export / import functionality of table settings and KISSsoft calculation files in order to use updated GPK Model templates. A check regarding the GPK Model type is performed in order to avoid wrong handling. Table Settings: method (standard) for gear strength calculation can be defined individually now. Number of bearings can be defined per shaft and shaft-end. Table Presizing: max. number of iterations for shaft / bearing can be entered. Shaft sizing with 3 shaft sections (1.2 * the biggest bearing inner diameter), shaft diameters are sized according to bearing diameter, improved sizing functionality in case of small diameters The number of bearings per side can now be selected
Figure 5.3-1 Defining the number of bearings per shaft
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5.4 Transfer of shaft system deformation

For the toot contact analysis on KISSsoft level, the deformation of the shafts as calculated in KISSsys is automatically transferred to h KISSsoft. So, the system deformation originating from the shaft deformation (taking into account the bearing deformation and if required the housing deformation) is automatically given to the gear calculation:
Figure 5.4-1 Automatic transfer of system deflections from KISSsys to KISSsoft
5.5 Graphics
It is now possible to show the deformed system in KISSsys
Figure 5.5-1 Display of deformed system
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Figure 5.5-2 Deformed system
A cut away view of the 3D graphics may be activated as shown below:
Figure 5.5-3 Activating the cut away view
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Figure 5.5-4 Cut away view
It is now also possible to animate the movement of the gearbox using the function shown below
Figure 5.5-5 Animation of the gearbox movement
Display of bevel spiral and double helical gears in KISSsys:
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Figure 5.5-6 Detailed gear geometry display in KISSsys
6 CAD Interfaces
6.1 3D gear graphics
Skin models now include corrections and the load free contact pattern can be simulated:
Figure 6.1-1 Activate the skin model in the graphics settings.
Figure 6.1-2 Load free contact patterns: spiral bevel gear, crossed axis helical gear, spur gear with crowning
Note that there is a separate document available on request on this function.

6.2 Parasolid Kernel in KISSsoft

The following changes took place: All gears: The skin model is available now in order to check the contact lines of meshing the tooth system. An rotating function (for one gear) is added in order to create a flank overlap. Control parameters are added in KISS.ini and setup dialog. The system model is now saved to single assembly file. Cylindrical gears: Generation of 3D cylindrical gears with tooth flank modification is available. Available modifications: All modifications except triangular end relief and twist are available. Planetary gear: assembly uses the center points from Calculation > Center points if regular assembly is not possible. Shaft: Shaft inner and outer contour export is available now. Shaft system with multiple shafts is now saved in a single assembly file.
6.3 SolidEdge interface

Interface to Solid Edge ST3 is added
6.4 SolidWorks interface

Interface to Solid Works 2011 is added
6.5 Autodesk Inventor interface

Interface to Autodesk Inventor 2012 is added
6.6 ProEngineer interface

Interface to ProEngineer: Added a new function, that you can cut a toothing on a existing shaft
6.7 NX interface
Interface to NX 7.5 32-/64bit (Interface to NX 4 will no longer be supported)
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EES KISSsoft GmbH P.O.

Box 121 Weid 10 6313 Menzingen Switzerland

KISSsoft & KISSsys Release 03-2011, Whats New

1 Whats new in release 03-2011 of KISSsoft

1.2 Annual maintenance (AMC)

Revision: 0 Autor: HD Date: 2011-06-09 Approved: HD Date: 2011-06-09 1 of 55

1.3 Table of content

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6.5 6.6 6.7

1.4 Document change record

Figure 2.1-1 Input of Synchronizer data

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2.2 Spindle drives

Figure 2.2-1 Left: types of configurations. Right: thread type

Figure 2.2-2 Calculation of spindle drive.

2.3 KISSsys model for sizing of gearboxes

2.4 Optimisation function for corrections

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Figure 2.4-1 Example set up of the modification optimisation tool

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Figure 2.4-2 Results report

Peak to peak transmission error

0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 Gear micro geometry (solution number)

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2.5 Calculation of clamped connection

Figure 2.5-1 Slotted hub type connection

Figure 2.5-2 Clamped hub type connection

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2.6 Calculation of single bearings with inner geometry

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Figure 2.6-1 Calculation of single bearing with inner geometry

Figure 2.6-2 Types of bearings that can be analysed

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Trainings, China 2011

Trainings, Switzerland 2011

There is a new module list, listing all commercial modules, available.

3.4 i-Phone application

Figure 3.4-1 KISSsoft iPhone application

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Figure 4.1-2 Definition of the rolling element corrections

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4.2 Gear material, Databases

4.3 General, Databases

4.4 User Interface

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Figure 4.4-2 File explorer in KISSsoft

Figure 4.4-3 Activating the file explorer in kiss.ini

Figure 4.4-4 Use right mouse click to enlarge symbols

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4.5 Helical gears

Figure 4.5-1 Strength rating methods for commercial ships

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Figure 4.5-9 Same results but after 2000'000h

Figure 4.5-10 Sizing function for oil viscosity