1、 1 / 16 29 August 2011 Release 03/2011 KISSsoft AG - +41 55 254 20 50 Uetzikon 4 - +41 55 254 20 51 8634 Hombrechtikon - infoKISSsoft. AG Switzerland - www. KISSsoft. AG KISSsoft Tutorial: Bevel Gears 1 Starting KISSsoft 1.1 Starting the software Once you have installed and activated KISSsoft either
2、 as a test or licensed version, follow these steps to call the KISSsoft system. Start the program by clicking “StartProgram FilesKISSsoft 03-2011KISSsoft“. This opens the following KISSsoft user interface: Figure 1.1 Starting KISSsoft, initial window 1.2 Starting the calculation module Start the “Be
3、vel and hypoid gears“ calculation module by double-clicking the corresponding entry in the “Modules“ window in the top left-hand corner of the main window. Figure 1.2 Selecting the “Bevel and hypoid gears“ calculation module from the “Modules“ window KISSsoft Tutorial 015: Bevel Gears2 / 16 29 Augus
4、t 2011 Release 03/2011 2 Introduction There are various different types of bevel gears, and every design has special features that must be taken into consideration. This tutorial describes these various designs and provides information about how they can be analyzed in the KISSsoft system. 2.1 Diffe
5、rential bevel gears Differential bevel gears are usually straight toothed. For manufacturing reasons, their construction is usually very different from the theoretical design. Therefore, we recommend you use a different approach to analyze an existing set of bevel gears from a drawing. The drawings
6、for differential bevel gears often contain very little theoretical data. Usually, the drawing does not show a theoretical external tip diameter dae or an external reference diameter de. Instead it shows the finished external diameter so that the external reference diameter must be estimated. It is a
7、lso often not clear whether the module is the middle or external module. However, this can be checked quite easily with mte = de/z. The transverse and normal modules are identical because the gear is straight toothed. 2.2 Calculating geometry in KISSsoft 1. In the “Geometry“System data“ tab, select
8、the “Standard, fig 2 (Tip, Pitch and Root apex NOT in one point)“ option. This type allows you to input tip and root angles (see Figure ). Figure 2.1 Selecting “Standard, fig 2“ type 2. Input “Reference diameter gear 2 (outside)“ or “Normal module (in middle)“ according to the drawing. If the values
9、 are not specified on the drawing, use the graphics on the drawing to determine them. 3. Input the “Pressure angle“ and “Number of teeth“ in accordance with the drawing. 4. Input the “Facewidth“. If the facewidth is not predefined, you must measure it on the drawing. Here, use the reference cone len
10、gth. 5. Input the “Profile shift coefficient“ and “Tooth thickness modification factor“= 0. 6. Before you can input the “Tip and root angle gear 2“, you must first run the calculation with or press “F5“ to calculate the reference cone angle. Right-click on “Convert“ to input the tip and root angle.
11、Then click “Calculate“ to calculate the tooth angle and include this in the calculation (see Figure ). 3 / 16 29 August 2011 Release 03/2011 Figure 2.2 Input and convert tip and root angle 7. You do not need to enter anything under “Manufacturing data“ because this data will be ignored 8. Either cli
12、ck or press “F5“ to run the calculation. To generate and open the report, click or press “F6“. You can then compare the results in the report with the default data on the drawing, for example the angle (see Figure ). Figure 2.3 Bevel gear report, section 1 tooth geometry 2.3 Calculation of static st
13、rength Differential bevel gears are usually calculated with static load because they usually operate in static applications. The static calculation only takes root fracture due to bending into account. 1. In the “Strength“System data“ tab, select the “Differential, static calculation“ calculation me
14、thod (see Figure ) Figure 2.4 “Differential, static calculation“ strength calculation 2. Input performance/torque/rotation data using the default values 3. Differential bevel gears are normally used with several strands. Check and input the “Number of strands“ under “Pair data“Details“. The default
15、value is 2, because this is the most common situation. 4. Either click or press “F5“ to run the calculation. To generate and open the report, click or press “F6“. 2.4 Inputting an existing set of bevel gears from a Gleason data sheet To analyze an existing set of bevel gears (with spiral toothing) u
16、sing drawings or Gleason datasheets (“Gleason dimension sheets“), follow this procedure. Bevel gear drawings and the Gleason dimension sheet usually contain precise, comprehensive information about intermeshing. In KISSsoft, use the “Conversion from GLEASON data sheets“ function to input this data.
17、The required data is mte2 (or de2), m1, , av, rc0, z1, z2, b, dae, he, a 4 / 16 29 August 2011 Release 03/2011 2.4.1 Calculating the geometry 1. In the “Geometry“System data“ tab, select the “Constant slot width“ or “Modified slot width“ type (see Figure). Figure 2.5 Selecting “constant slot width“
18、type or “non constant slot width“ type 2. Click on “Conversion from GLEASON data sheets“ to the right of the type and input the data (see Figure and Figure ). Figure 2.6 Conversion from GLEASON data sheets Figure 2.7 Inputting data from Gleason datasheets Unfortunately, the cutter tip cutter radius
19、is often not specified on the drawings. However, this value is usually present on Gleason datasheets. 3. Click “Calculate“ and check the calculated values. Then click “Accept“ to transfer them to the main input screen. 4. Either click or press “F5“ to run the calculation. To generate and open the re
20、port, click or press “F6“. 2.5 Dimensioning a bevel gear set with “Rough sizing“ You can use the “Rough sizing“ function to dimension a new bevel gear set. Rough sizing uses formulae defined at Klingelnberg (in accordance with the Klingelnberg “Bevel gear“ book), no matter which calculation method y
21、ou select (ISO, DIN, AGMA:, Klingelnberg). 5 / 16 29 August 2011 Release 03/2011 Important note: This calculation process is designed for bevel gear sets without offset, and made of case-hardened steel, with a pressure angle of 20. Other conditions in the main input screen are ignored. Despite that,
22、 Rough sizing can also be used for other bevel gears and supplies good initial values for further developments. 1. In the “Geometry“ “System data“ tab, select the required type (standard, Klingelnberg, Gleason). 2. Then input the performance data in the “Strength“ tab (see Figure ). Figure 2.8 Input
23、ting performance data 3. Select Rough sizing via “Calculation“Rough sizing“ or click on 4. Input the data to meet your requirements (see Figure ) - Face width to normal module ratio: 8 to 12 Values closer to 8 lead to higher modules and resistance to bending, and values closer to 12 lead to smaller
24、modules and a higher contact ratio - Ratio of length of reference cone to tooth width: Re/b = 3.5. To avoid manufacturing problems using standard machines, the ratio should not be less than 3. - Helix angle: usually in the range 20 to 35 for the bevel gear (Gear 2) Figure 2.9 Rough sizing 5. Click “
25、Calculate“ to calculate the values. 6. If the calculated data cannot be output as required (e.g. the bevel gear reference circle is too large), you can predefine the value by setting the input flag and clicking “Calculate“ again. 7. Click “Accept“ to transfer the data to the main input screen. 2.6 G
26、leason spiral bevel gear and hypoid bevel gear Gleason bevel gears are usually manufactured in a single part process (face milling). Due to their arc-shaped tooth length form, these gears can be ground after being heat treated. In the automobile industry, bevel gears are also lapped. However, Gleaso
27、n also uses a continual hobbing process (face hobbing). 6 / 16 29 August 2011 Release 03/2011 In the examples that follow, dimensioning has already been performed using Rough sizing so that the majority of the required data is already present (see section 2.5). For this reason only the specific entr
28、ies for each method are described. However, if Rough sizing has not already been performed, you must input all the values manually. 2.6.1 Gleason, 5-section method 1. In the “Geometry“ “System data“ tab, select “Modified slot width“ type (see Figure ). The pinion space width changes due to the diffe
29、rent machine settings for each flank. Figure 2.10 Selecting “Modified slot width“ for 5-section bevel gears 2. Input the “pressure angle“. 3. Click on the “Plus button“ to the right of “Pressure angle“. Under “Additional data hypoid gears“ you can input values for the “Nominal pressure angle“ and th
30、e “Influencing factor limit pressure angle“ (usually 1 for “Modified slot width“). If an offset (hypoid gear) is predefined, the influence of the “generated and effective contact angle“ is included in the calculation. 4. Input the “spiral direction“ for the pinion. 5. Click on the “Plus button“ to t
31、he right of “Helix angle“. Then go to “Additional data for spiral teeth“ and activate spiral toothing. If the Rough sizing function was used, spiral toothing is active. 6. Input the “Offset (Center dist.)“ using the default conditions. 7. You can either input the “Profile shift coefficient“ manually
32、 or click the Sizing button to calculate it automatically. If the KISSsoft software determines an undercut, the profile shift coefficient is set to prevent undercut. All the other criteria (optimal specific sliding, etc.) are listed in the report and can be entered manually. 8. We recommend you use
33、the Sizing function to calculate the tip and root angle. As the angles are affected by the cutter head radius, the reference profile and the profile shift, you must run the sizing function again if you want to change one of these values at a later point in time (see Figure ). Figure 2.11 Sizing func
34、tion for tip and root angle 9. Under “Manufacturing data“, select “Face milling“ as the manufacturing process and then input the “Cutter radius“. We recommend you use the sizing function to the right of the “Cutter radius“ input field to get a suggested value for the minimum cutter tip size (in acco
35、rdance with Klingelnberg “Bevel gears“, page 70) and then enter the cutter tip radius that was actually used during production. In addition, the system displays a warning message if the milling tip radius is smaller than the recommended value. This is because the meshing may not be correct for a pra
36、ctical application (see Figure ). 7 / 16 29 August 2011 Release 03/2011 Figure 2.12 Warning if the cutter radius is smaller than the recommendation The cone length (for hypoid gears) and the external and internal spiral angles are affected by the cutter tip radius. KISSsoft therefore checks whether
37、the values are suitable. 10. In the “Reference profile“ tab, either select a suitable reference profile or click “Own input“. The recommended tip clearance factor for a “modified slot width“ is 0.3 (in accordance with Klingelnberg “Bevel gears“, page 72), which is why you should input 1.3/0.3/1 manu
38、ally. 11. In the “Strength“ tab, select the required “Calculation method“ (ISO, DIN, AGMA, VDI, or ISO proposition for hypoid gears). Under “Materials, manufacturing types and lubrication“, select the “For generated gears“ or “Made by form cutting“ settings to influence the tooth thickness at root.
39、As a rule of thumb, for conversions i2.5 the “Made by form cutting“ process is selected for bevel gears because they can be manufactured more quickly with this process. The pinion is always generated. (See Figure ). Figure 2.13 “For generated gears“ and “Made by form cutting“ manufacturing types 12.
40、 In the “Tolerances“ tab, select tooth thickness deviation “ISO23509“ to ensure the flank clearance and the appropriate tooth thickness allowance can be set automatically in accordance with the module. The “No backlash“ option is also often selected because the clearance value is not set until the g
41、ear is assembled by changing the assembly dimensions. 13. Either click or press “F5“ to run the calculation. To generate and open the report, click or press “F6“. 2.6.2 Gleason, duplex method 1. In the “Geometry“System data“ tab, select “Modified slot width“ type (see Figure ). The pinion has a cons
42、tant space width because both flanks are created in the same manufacturing run. Figure 2.14 Selecting “Constant slot width“ type for duplex bevel gears 2. Input the “pressure angle“. 3. Click on the “Plus button“ to the right of “Pressure angle“. Under “Additional data hypoid gears“ you can input va
43、lues for the “Nominal pressure angle“ and the “Influencing 8 / 16 29 August 2011 Release 03/2011 factor limit pressure angle“ (usually 0 for “Constant slot width“). If an offset (hypoid gear) is predefined, the influence of the “generated and effective contact angle“ is included in the calculation.
44、4. Input the “spiral direction“ for the pinion. 5. Click on the “Plus button“ to the right of “Helix angle“. Then go to “Additional data for spiral teeth“ and activate spiral toothing. If the Rough sizing function was used, spiral toothing is active. 6. Input the “Offset (Center dist.)“ using the de
45、fault conditions. 7. You can either input the “Profile shift coefficient“ manually or click the Sizing button to calculate it automatically. If the KISSsoft software determines an undercut, the profile shift coefficient is set to prevent undercut. All the other criteria (optimal specific sliding, et
46、c.) are listed in the report and can be entered manually. 8. We recommend you use the Sizing function to calculate the tip and root angle. As the angles are affected by the cutter head radius, the reference profile and the profile shift, you must run the sizing function again if you want to change o
47、ne of these values at a later point in time (see Figure ). Figure 2.15 Sizing function for tip and root angle 9. Under “Manufacturing data“, select “Face milling“ as the manufacturing process and then input the “Cutter radius“. We recommend you use the sizing function to the right of the “Cutter rad
48、ius“ input field to get a suggested value for the minimum cutter tip size (in accordance with Klingelnberg “Bevel gears“, page 70) and then enter the cutter tip radius that was actually used during production. In addition, the system displays a warning message if the milling tip radius is smaller th
49、an the recommended value. This is because the meshing may not be correct for a practical application (see Figure ). Figure 2.16 Warning if the cutter radius is smaller than the recommendation The cone length (for hypoid gears) and the external and internal spiral angles are affected by the cutter tip radius. KISSsoft therefore checks whether the values are suitable. 10. In the “Reference profile“ tab, either select a suitable reference profile or click “Own input“. The recommended tip clearance factor for a “Constant slot width“ is 0.35 (in accordance with Klingelnberg
