whats new kisssoft 032015

KISSsoft Release 03/2015

Changes from Release 03/2014 to Release 03/2015 Date: 02 April 2015

KISSsoft AG

Rosengartenstrasse 4

8608 Bubikon

Switzerland

Tel: +41 55 254 20 50

Fax: +41 55 254 20 51

[email protected]

www.KISSsoft.AG

02.04.2015 2 / 12

Contents

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

Base packages ............................................................................................................................................ 3 System modules .............................................................................................................................................. 6

KISSsys ....................................................................................................................................................... 6 Expert System KISSsys .................................................................................................................................. 7 Expert Modules Gears .................................................................................................................................... 7

Cylindrical gears .......................................................................................................................................... 7 Configuration / Dimensioning ................................................................................................................... 7 Methods for strength calculation .............................................................................................................. 8 Contact analysis ....................................................................................................................................... 8

Bevel gears .................................................................................................................................................. 9 Worm gears (Globoid) ............................................................................................................................... 10 Crossed helical gears or Worm gears (Cylindrical-Worm gear) ................................................................ 10 Beveloid gears ........................................................................................................................................... 11 Further gear specific modules ................................................................................................................... 11

Expert modules shafts and bearings ............................................................................................................. 11 Shafts......................................................................................................................................................... 11 Bearings..................................................................................................................................................... 11

CAD Interfaces .............................................................................................................................................. 12 3D Export ................................................................................................................................................... 12

COM Interfaces ............................................................................................................................................. 12

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

release.

NEW These new features are highlights of the release 03/2015, regarding new modules, calculation or

handling comfort.

02.04.2015 3 / 12

General

Modules Changes / Enhancements

General NEW the dynamic user interface is implemented allowing the modification of the KISSsoft

User interface, as i.e. edited and rearranged regarding parameters, tabs, parameter names,

etc. This feature is not yet available for all of the parameters in KISSsoft. More information are

available on request.

The hardness conversion is updated according to DIN EN ISO 18265:2014.

For imperial units, one or two additional digits are shown now in the American report.

Reports: a rounding functionality is now available (round (x,n)). The special reports

CADOR.rpu, DTS.rpu (both for cylindrical gears) and GLEASON_SPIRAL_BEVEL.rpu are

moved to the folder rpt/rps and .rps. Also, own reports can be created and opened very easily

in KISSsoft under Report Special Reports.

Settings: The paths for the directories of CADDIR, USERDIR, TMPDIR and EXTDIR can be

defined now under Extras Settings.

Database

Tool Materials: the properties for cast iron are updated according to DIN EN 1561:2012 and

DIN EN 1563:2012. Also, property data for cast steel are updated according to EN 10293:2005.

The materials for GS-52 are removed, as it isnt included in the standard anymore. Now, the

material core hardness can be defined in the table of material basic data.

Lubricants: some SHELL oils are updated. Also the properties for the Klber oils are

updated.

Roller bearing: Timken bearings for tapered roller bearings are added; the data for

single row bearings are updated, and the data for the paired bearings are added.

Base packages

Base packages


ZPK

Cylindrical gear basic package

Strength calculation: if the reference profile constructed involute is selected, the

factors tooth form factor YF and stress correction factor YS are derived from the root radius

directly.

ISO/TR15144 (Micropitting): Updated according ISO/TR 15144-1:2014. Additionally,

KISSsoft calculates Micropitting also for inner gears (for information only, as they are not part

of the ISO/TR).

02.04.2015 4 / 12

If profile grinding is applied, for the calculation of grinding notch tg/rg the radius rg is

not determined based on the generating grinding simulation anymore.

Tab Reference profile: For pinion type cutters, the tool is now always done with

constructed involute.

For non-topping hobbing cutters, the root radius of the tool is now considered with the exact

value.

Tab Modification: the maximum number of flank modifications definitions per flank is

increased from 10 to 20.

The chamfer / tooth end is now considered in the cylindrical gears 3D models. Note that the

Chamfer / tooth end modification are not considered as gear flank modification as i.e. crowning,

and hence does neither appear in flank line diagram, nor in the graph 3D geometry

Modifications Gear1, Gear 2.

Helix angle modification: Under Module specific settings the option for calculate control

dimension, taking into account helix angle modification is moved from tab calculations to the

tab Diagrams. Also, it is changed into a choice list: - Remove material on both sides - Manufacturing with modified helix angle

Based on this selection, the flank line diagram and 3D models are modified so that the flank

modifications dont exceed the unmodified flank (see also information graph).

Graphic: the structure of the tooth form is changed from point to curve elements. This allows

a significantly faster calculation i.e. in the contact analysis. A new graph Generating cuts

shows the cutting simulation created by the tool.

Report: in the section 1, with the reference profile data the theoretically biggest root radius factor rhofPmax* is now shown additionally. The reports for service life calculation and sizing of torque are based on RPT templates now and hence the report template can be customized by the user.

In case of oil injection lubrication, the required oil volume (for temperature increase of 10) is

reported (under section 8, additional data).

Tolerances: The tolerance for single flank composite fi and Fi according ISO1328

are slightly changed. Up to now an approximate value for total contact ratio was used,

now we use the exact value.

WPK Shaft and bearing basic package

Shaft editor: The option Display shadowed can be controlled now additionally from the

context menu.

The force element gears now allows to enter an offset of the load application to the centre

of the face width (option is to be activated under Module specific settings Calculations

activate force centre point offset). With this option a non-central load application can be

defined. This option results in different bearing forces, which also results in different bearing

life time.

02.04.2015 5 / 12

For the force element Bevel gear / Hypoid gear, the position of the gear on shaft can be

converted now exactly using several bevel gear geometry data.

Shaft calculation: the new shaft calculation solver is now recommended as the default solver.

However, the previous solver is still available (under module specific settings calculations

use 2013er solver). Careful comparisons between the two shaft solvers are recommended,

regarding bearing forces, etc.

The seal torque loss can be calculated now according to the methods SKF main catalogue

6000 EN or ISO/TR 13593 (Viton or Buna N). The methods can be selected under Module

specific settings roller bearing.

Tab Basic data: if the housing temperature is different than the reference temperature (see

Modul specific settings Calculations), the position for the shaft origin (reference point) can

be defined now, where the shaft thermal expansion starts. The axial expansion of the shaft is

visible in the graphic deformation.

The total weight of the shafts, including gears and additional masses, is now listed in the

main report, if the option in Basic data - Gears is set accordingly (gears considered as

masses, etc.).

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

(eigenfrequencies), the colours of the shafts as defined in the shaft editor, are overtaken now.

Report: a new report shaft speeds is available which shows the speeds of the individual

shafts. This is helpful especially for coaxial shafts (planetary systems, automotive shafts, etc.)

to check the several speeds of the shafts.

MPK Shaft-hub connections

Splines: the calculation of GO and NO-GO gauges according to DIN5480-15 is implemented

now, the results are shown in the Report Construction of Gauges.

Straight-sided splines, splines, Polygon, Woodruff key: The alternating load is updated to DIN 6892:2012; now the alternating torque does not have the options for slow

or fast increase anymore. Hence the factors fw, fL, k are slightly changed.

Cylindrical interference fit: The friction coefficient for press on and press off can be defined

by the user now (under Module specific settings). Before, the coefficients were defined in

KISSsoft directly.

Keys: the corrigendum for DIN 6892 is implemented, where the factor for torque input

and output is modified.

SPK Bolt calculation

VDI 2230, sheet 1 (2014): the new Guideline is implemented. The examples are

updated accordingly. A comparison document for the calculation between KISSsoft and VDI

2230 results is available on request.

02.04.2015 6 / 12

VDI 2230, sheet 2 (2014): the changes as per edition 2014 are implemented.

Tab Results from FEM calculation: a new option Model class III (only forces and torques,

without resiliences) is added. This option allows the input of FE results without resiliences, as

i.e. applied with the interface for Bolt Assessment inside ANSYS.

Material database: for the strength class of bolts, the Youngs Modulus and the coefficient of

thermal expansion are now implemented in the database.

System modules

KISSsys


SYS KISSsys

Templates: some new templates are now integrated: efficiency, damages and frequency

calculation. The Damages template shows the damage for each machine element within the

KISSsys model for nominal load or load spectras. The Frequency template calculates the

meshing frequencies as well as the bearing frequencies considering the inner geometry

(bearing defect frequencies i.e. for outer race, inner race, ..).

New icon shapes: for roller bearings, connection roller bearing and connection elements, new

icons shapes are created which can be distinguished more easily.

Elements: the elements kSysConnectionBearing and kSysCouplingConstraint can be

defined now as shifting elements. Furthermore, they are then recognized in the speed table

automatically.

GPK Gearbox calculation package

Tab UserInterface: the calculation for Calculate Torque Capacity is enhanced with two

options accurate and approximate now, as well as the possibility to calculate the gears,

bearings or shafts independently.

Tab PreSizing: The shaft and bearing sizing functionality is enhanced. There are now two

options available regarding the shaft diameter sizing strategy, adapt to bearing diameter or

not.

Tables: The new tables DamageResults and SystemResults are added to the GPK

models, under the table Result, where the total mass, kinetic energy, inertia and backlash are

shown.

New Calculations: new calculations are added in all GPK models in the model tree, as i.e.

the modal analysis (ShaftsSystem calculation) and Efficiency template.

Required safeties: the required safeties for all standards (ISO/AGMA/..) in each KISSsoft

calculation can be controlled now from KISSsys by the newly added variables.

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SYSweb

NEW

A web platform is available now for KISSsys application. The platform provides the user

interface for an external access to KISSsys and allows i.e. gearbox safety and lifetime

calculations for sales via online access.

Expert Modules KISSsys


KS2

NEW

Efficiency: The efficiency and thermal rating calculation is improved and enhanced now.

Regarding the efficiency calculation, the user has more possibility as i.e. to modify the power

losses by an own factor, and also the evaluation of thermal rating is enhanced by several

options.

KS3

NEW

Modal analysis: the eigenfrequencies and mode shapes of the transmission drive train

(calculation ShaftsSystem) are calculated using the modal analysis, also considering the gear

meshing stiffnesses. The results are the torsional as well as coupled (torsional bending

axial) vibrations.

KS4

NEW

Casing deformation: The deformation of the casing is calculated for each bearing position

based on the bearing forces and influences. This influences the gear meshing contact of the

corresponding gears. The calculation is based on the stiffness matrix of the housing, which is

to be determined by a FE calculation.

Expert Modules Gears

Cylindrical gears

Configuration / Dimensioning


ZA1 Planetary stages: for the load distribution coefficient K according to AGMA 6123, for

quality 7 now always Level 1 values are used.

ZA2 Rack: if no length of the rack is given, the default value is set to 10**d1. With this, the number

of load cycles for the pinion NL1 = 10*NL2 of the rack.

ZA3 Rough sizing: for micropitting and flank fracture, now the required safeties can be defined

(under module specific settings), which will be considered then in the sizing calculation.

The Rough sizing functionality is improved, especially for planetary gears. Now, the user

can specify the priority over the sizing parameters b/a, b/m, b/d. Also, the first 5 variants shown

are specific solutions for most exact ratio, biggest resp. smallest centre distance, etc.

ZA4 Fine sizing: in the graphical evaluation, the symbols are added before the parameter name.

Also, the safeties for Micropitting and flank fracture are displayed now, and solutions can

be eliminated, if required safeties are not achieved.

02.04.2015 8 / 12

Methods for strength calculation


ZA10 ISO 6336: Root stress calculation: in the stress correction factor YS: If the notch

parameter qs is bigger than 8, the value is not limited = 8 anymore. A message is given in the

report.

The maximum value for the face load factor KH according to ISO 6336-1 can be

restricted to a user defined value (under module specific settings Face load factor).

The work hardening coefficient Zw is now applied only for heat treatable steel

(ISO6336) resp. heat treatable steel alloyed, not alloyed (DIN 3990). For the other steels, it

will be set to 1. This was agreed in discussions in the ISO committee.

ZA12 AGMA 2001: the lead correction factor Cmc is now set as 1 for gears with unmodified

lead and 0.8 for gears with leads properly modified by crowning or lead correction.

ZA19 Lloyds: NEW the strength calculation according to Lloyds Register:2013 is implemented

now.

ZA20 AGMA: the new version of AGMA 6011-J14 is implemented.

ZA21 VDI2736: 7 more plastic materials for high temperature application are added to the database,

including the s-n curves data.

ZA22

NEW

GOST: strength calculation according to GOST 21354-87, including manufacturing

tolerances and tooth thickness allowances. The option for root rounding, ground is applied

only to the GOST calculation (under rating strength pair / gear data).

ZA23

NEW

ISO13691: strength calculation according to ISO13691 (High speed, special purpose gear

units) is implemented now.

Contact analysis


ZA30 Contact analysis cylindrical gears: the window is slightly rearranged, the input fields for the

number of slices etc. are moved to the Plus-button.

NEW The Tooth Flank Fracture calculation according to ISO/DTR 19042 (Draft) is

implemented in the contact analysis.

The factors application factor KA and dynamic factor KV are not considered

anymore in the contact analysis. If the additional load due to these factors should be

considered, the new sizing button is added, in order to increase the parameter partial load for

calculation wt manually.

The report for contact analysis is now based on a RPT template and hence the user can

customize the report template accordingly.

Graph: a new graphic Meshing is available which shows the efficiency, speed and torque

variation directly over the length of one gear meshing.

02.04.2015 9 / 12

ZA33 Modification sizing: several graphs from the contact analysis are shown now in the detailed

report file.

ZA34

NEW

Contact analysis planetary gears

The contact analysis is reworked and hence slight differences may appear.

NEW The flank fracture calculation according to ISO/DTR 19042 (Draft) is implemented into

the contact analysis. Herewith, the local stresses can be determined using the meshing

simulation.

NEW The contact analysis can consider now a floating sun gear if no shaft calculation file is

connected. Herewith, due to meshing stiffnesses the sun will be positioned according to the

meshing forces. The option can be activated in the tab Factors in the window Axis

alignment and the results are shown in the graphic Contact analysis System Position of

shaft.

The factors application factor KA and dynamic factor KV are not considered

anymore in the contact analysis. If the additional load due to these factors should be

considered, the new sizing button is added, in order to increase the parameter partial load for

calculation wt manually.

Graph: a new graphic Meshing is available which shows the efficiency, speed and torque

variation directly over the length of one gear meshing.

ZA35 KH calculation: for internal gears, a conical expansion (deformation) can be entered now.

A new graph shows the evaluation of the gap and the best tooth trace modification (under

Graphics evaluation Gap analysis, similar to RIKOR).

An additional evaluation is added which shows the line load and Hertzian pressure at both

tooth ends (under report section 10), also calculated for each bin if a load spectra is applied.

This information may be very useful in order to prevent the edge contact with pressure peaks.

ZA36

NEW

Planet carrier deformation: for the misalignment of the planet pin, the deformation of the

planet carrier can be entered of imported. Also, a parametrized geometry can be defined for

single- and double-walled planet carriers and the deformation are calculated automatically by

means of an (open source) FE library.

Bevel gears


ZC1 Tab Basic data: the geometry value pitch apex to front/back of gear blank is now calculated

by default, as long as no user input is given (under details).

The Conversion from GLEASON data sheets is enhanced with the input fields for tooth

thickness. This calculates the values for tooth thickness modification factor xs and the tooth

thickness allowances.

The adjacent pitch difference fu is added according to DIN3965.

Tab Manufacturing: the settings for manufacturing type generated or formate is moved to

the tab manufacturing.

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Graphic: the tooth form of the equivalent cylindrical gear is now additionally shown at the inner

and outer (toe and heel) position of the gear (settings for the position Le and Li under Module

specific settings Differential gears). The tooth form also considers now the tip alteration

(defined in the tab modification).

Report: the equivalent cylindrical gear of bevel and hypoid gears is available as own report

(under Report Special report Input file for equivalent cylindrical gear). This report can be

saved in the dat-format, renamed to .Z12 and opened as cylindrical gear pair calculation.

Herewith, further evaluations as i.e. micropitting are possible.

ZC10 3D model bevel gear: with the new option 3D spline the tooth form is calculated using the

winding-up of the involute on the cone (under Module specific settings Generation of 3D

Use interpolation with 3D splines). This results in a tooth form which is very close to the

spherical involute profile form. Also several new options are added regarding tooth thickness

modification, etc.

ZC12 Fine sizing: the contact analysis is optionally available within the variant calculation (similar

to cylindrical gears).

NEW For differential bevel gears, many more variations are now possible, as i.e. addendum

coefficient gear 1,2, addendum and dedendum angle (under Conditions II). As result,

additional parameters are shown in the result table of fine sizing.

ZC13

NEW

The sizing for topological modification is available for bevel gears. Based on measurement

grid data (in Klingelnberg or Gleason format), the modification will be calculated in order to

achieve the topology of the KISSsoft 3D model identically to the target bevel gear.

ZC30

NEW

Contact analysis: A contact analysis under load for bevel gears is available now. It considers

microgeometry as well as the mounting displacements VH, and calculates contact lines,

transmission error, stress distribution, etc.

Also wear and NEW flank fracture are calculated.

Worm gears (Globoid)


ZD1 Efficiency: the application factor KA is not considered anymore in the efficiency

calculation.

ZD10 3D Model worm gear: modifications for the tool etc. are available now.

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


ZE1 Plastic gears: the power-on time can be now lower than 100% (under Module specific

settings General). This influences the number of load cycles and also the gear flank

temperature, which is considered in the material strength properties.

02.04.2015 11 / 12

Beveloid gears


ZH1 The calculation for beveloid gears is available now.

ZH10 3D model beveloid gears: The model is also available now, including modifications.

Further gear specific modules


ZZ1 Load spectra: the damages are calculated a) referred to the nominal service life, b) referred

to the achieved service life, c) referred to root and flank service life. The results are shown in

the report in section 10.

Transmittable power and torque: the data are reported in section 11, if the option is activated

(under module specific settings - calculations).

ZZ4

NEW

Tooth Flank Fracture: The flank fracture calculation according Method B of ISO/DTR 19042

(Draft) is added. This method is currently under development in the ISO committee 60 for

cylindrical gears. In KISSsoft, it is available also for bevel gears, using the equivalent cylindrical

gear.

Expert modules shafts and bearings

Shafts


WA1 Bearing with inner geometry: the minimum EHL lubricant film thickness hmin is now

calculated. For ball bearings, the spin to roll ratio is calculated. Both are shown in the main

report and the roller bearing report.

WA4 Eigenfrequencies: A new report nodal points shows the position of the nodal points along

the shaft axis, for different eigenfrequency modes. Note: for Eigenfrequencies, the new shaft

calculation solver is recommended.

WA6 DIN 743: the corrigendum for DIN 743-2:2014-12 is implemented, as some materials

(unalloyed structural steels) have corrected admissible strength values.

The materials 15NiCr3 and 17NiCrMo6-4 are assigned now to the category of CrNiMo

steels, which results in slightly different value for technology size influence K1.

WA10

NEW

AGMA: the shaft strength calculation according to AGMA 6101-E08 / 6001-E08 is available

now.

Bearings


WB2

WB4

Rolling bearing ISO/TS16281: a new 3D graphic shows the forces which act on each rolling

element of roller bearings (under Graphics roller bearing load distribution 3D). An

02.04.2015 12 / 12

additional graphic shows the distribution of the Hertzian pressure along the bearing race

(under Graphics roller bearing Stress distribution on race).

Additionally to the static safety factor S0, the two parameters static safety factor S0w (based

on pressure values) and static safety factor S0ref (based on the load rating number) are

calculated and shown in the reports.

WB3 Hydrodynamic bearings: the standard DIN 31652 is withdrawn and replaced by the

ISO 7902. The calculation algorithm is almost identical to the DIN standard.

CAD Interfaces

3D Export


CB2 Interface to Solid Edge ST7 is implemented. The interface is also available now in Russian

language.

CB3 Interface to Solid Works 2015 is implemented. The interface is also available now in Russian

language.

CB4 Interface to Inventor 2016 is implemented. It is also available now in Russian language.

CB6 Interface to Creo Parametric 3.0 is implemented (only versions back to Wildfire 5 are

supported).

CB7 Interface to NX 10 is implemented (only versions back to NX 6 are supported). The ribbon bar

is implemented.

COM Interfaces


CC2 COM Interface expert: new functions GetDBName() and GetDBValue() are added to call

parameters from the database.

whats new kisssoft 032015

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