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Plastic
Gears
ProfileoptimisationKISSsoftPlasticgearprofileoptimisationWewilllook
at
the
following
profile
modificationsTipandrootreliefProfilecrowning/barelling(centricandeccentric)PressureanglemodificationWewilllearnaboutafunctionhowtofindthebestpossiblecombinationofprofilemodificationsNotethatyoushouldapplyatiproundingbeforeyouusethebelowfunctionbecausethetiproundingaffectsthetipformdiameterdFa!1)ProfilemodificationsProfilemodifications
BasicconsiderationsThebasic
task
isFindasuitableprofilemodificationThatgivesgoodresultsintermsofe.g.Lowpeak-to-peaktransmissionerrorLowwearrateLowcontactstress…UndertheconditionthatitworksfordifferentloadlevelsAndthenexporttheresultinggeometryfortoolingThekeydifficultyis:ONEmodificationshouldbesuitableforMANYloadlevels.Forexample,amodificationthatgiveslowvibrationataparticularloadlevelbuthighvibrationatanotherisNOTsuitable.Profilemodifications
DefinitionsinKISSsoftThedesignofgearmodifications(forplasticgears,mostlyprofilemodifications)isoneofthekeytasksforhighperformancegears,wherehighperformancemaybedefinedas,amaximizedtorquecapacity,minimizedvibrationlevelorlowestwearrisk.Gearmodifications,orthegearmicrogeometry,areassessedinthetoothcontactanalysisTCAwherethetruegeargeometry,consideringbothgearmacroandmicrogeometryandgearmisalignment.The
profile
modification
may
be
considered
asatoothformmodification
and
are
discussed
here.Thetooth
contact
analysis
isnotdiscussedhere.For
tolerance
bands
refer
toANSI/AGMA2000-A88,ISOTR10064-1.ForprofilemodificationsinKISSsoft,ISO21771isusedmostly.Profilemodifications
TipandrootreliefTip
and
root
reliefCαaCαf:Tipreliefmaybeaddedtogear1orgear2orbothinamesh.Ifyouwanttoconsiderthemodificationonbothgears,usetwolines.Selectthetypeof
tip
relieffromthelist„Typeofmodification“In„Value“,enterthevalueforCαaandCαfinum„Factor1“definesthelengthoftherelief/it‘sstartposition,asamultipleofthemodule,measuredfrompointAandErespectivelyUsing
the
flag„Status“,you
may
use/notuse
the
modificationinaparticular
calculation.Profilemodifications
Differenttypesoftip/rootreliefProfilemodifications
Differenttypesoftip/rootreliefProfilemodifications
Differenttypesoftip/rootreliefProfilemodifications
Differenttypesoftip/rootreliefProfilemodifications
Differenttypesoftip/rootreliefDifferenttypes
of
tip
and
root
relief:Therearefortypes:linear,curved(circular),progressive(polynom)andcurvedwithtransitionradiusProfilemodifications
ProgressivereliefThecurvature
of
theprogressive
relief
may
be
changed:Use„Factor2“todefinethe„factor“inthebelowformulaAgoodvalueis75->linearrelief 20->strongcurvatureProfilemodifications
PressureanglemodificationProfileslope
modificationCHαWiththis,thepressureangleofthegearismodified.ItmayalsobeunderstoodasatipreliefthatstartsattherootformdiameterdFfProfilemodifications
Profilecrowning/barrelling2)Sizingfunction
Sizingfunction
KISSsoftusageInKISSsoft,there
are
three
sizing
functions
for
geardesignThe„Roughsizing“The„Finesizing“The„Modificationssizing“TheyallworkonasimilarprincipleDefinebasicrequirementsofthegearsetDefineaparameterrangeKISSsoftwillsearchallpossiblesolutionswithintheparameterrangeTheuserwillfilterthesolutionsaccordingtohisrequirementsTofind„thebest“solutionLoaddata,material,…SizingFunctionMultiplesolutionsFilterBestsolutionParameterrangesfor…Sizingfunction
Tab„Conditions“Tab„Conditions“:hereyoudefinetheparametersfortheoptimisationrun.Youcandefinethreegroupsofmodificationsthatarevaried.YoumayconsiderarangeoftheloadForeachmodificationgroupandfortheloadrange,youmaydefinethestepnumberSizingfunction
Tab„Conditions“Youmaydefineseveralmodificationspergroup.Foreachmodification,enteraminimumandamaximumvalue.Betweenthisminimumandmaximumvalue,thevaluewillbevariedsuchthatanumber(=stepnumberasdefinedatlowerendofwindow=ofdifferentmodificationsarechecked.Ifyouhaveenteredmodificationsinthetab„Modifications“already,theyaretransferedhereautomatically.Sizingfunction
Tab„Conditions“
Thenumberofsolutionsgeneratedisns^i*nl+nlWhere: nsisthenumberofstepsforthemodifications nlisthenumberofstepsfortheload i=1ifmodificationsareingroupAonly,i=2ifinAandB, i=3ifinA,BandCNotethatinanycase,thecalculationisalsoperformedforagearsetwithoutanymodificationsforcomparison,forallloadlevels.Hencetheterm„+nl“.Sizingfunction
Tab„Conditions“
InthebelowexampleThetiprelief(inGroupA):fivestepsThelowesttipreliefis20um,thehighestis60umThetipreliefwillhencebe20um,30u,40um,50um,60umsimultaneouslyforbothgearsThestartoftipreliefandthecurvatureisnotvariedProfilecrowning(inGroupB):fivestepsThelowestprofilecrowningis0um,thehighestis20umTheprofilecrowningwillhencebe0um,5um,10um,15um,20umFourloadlevels:70%,80%,90%and100%load.Givingatotalof100combinationsSizingfunction
Tab„Results“
TheresultstableshowFirsttheresultswithoutmodificationsforthedifferentloadlevelsThentheresultswithmodificationsforthedifferentloadlevelsDifferentresultsarelistedUserightmouseclicktoaddandremovecolumnsUse„Shift“and„Ctrl“toselectmultiplerowsUse„Delete“todeletesomeresultsUse„Accept“tousethemodifications/transferthem intothetab„Modifications“Sizingfunction
Tab„Results“
Sizingfunction
Tab„Graphics“
ThegraphicsshowDifferentresultsforthedifferentmodifcations/differentloadlevelsRed:highestload,blue:lowestloadUsemultiplegraphstocomparedifferentpropertiessimulatneouslySelectresulttypeSelectindividualloadlevelsSelectnumberofgraphsUse„CtrlC“+“CtrlV“tocopy/pastgraphSizingfunction
Tab„Graphics“
ThegraphicsshowResultswithoutmodificationsThedifferentcombinationsofmodifcationsTheresult/valuesUsezoomandotherfunctionsthroughrightmousecl
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