Tendenze attuali nei metodi di

calcolo per progettare gearbox

Dr. Ulrich Kissling
KISSsoft AG, Bubikon, Svizzera
Tendenze attuali nei metodi di calcolo per
progettare gearbox

- Standardized Gear Calculation Procedures (for Gear Failure Modes)

- Actual trends: ‘Old’ and ‘new’ Gear Types
- Non-conventional Gear Calculation Procedures
- Bearings, Shafts, Screws, Connections, …
- System view: Gearboxes, Power Transmission
Standardized Gear Calculation
Procedures
(for Gear Failure Modes)
Predicting Gear Failure Modes of Cylindrical Gears
by Classic Calculation Methods in Standards
Year Method (DIN 3990-3) First ISO
edition
published
in
1970 Bending (DIN 3990-3) 1996
1970 Pitting (DIN 3990-2) 1996
1985 Scoring (DIN 3990-4) 2000
2003 Subsurface fatigue (DNV 41.2) - 2003 by DNV

2010 Micropitting (ISO 15144) 2010

2113 Wear (VDI 2736) - 2014 by VDI

2015 Flank breaking (Draft, WG6)

???? Next phenomena …

‘Old’ and ‘new’ Gear Failure Modes
Failure by fatigue
- Bending fatigue / Tooth (root) breakage (ISO6336-3)
- Pitting (ISO6336-2)
- Micropitting (ISO TR 15144)
- Tooth flank fracture (TFF) (ISO DTS 19042)
- Tooth interior fatigue fracture (TIFF)

Failure by overload
- Scoring (ISO TR 13989)
- Static tooth root breakage
Gear Failure Modes
Consequences of failure by fatigue
- Tooth (root) breakage Breakdown
- Pitting Increased noise/vibrations
- Micropitting Slightly increased vibrations
- Tooth flank fracture (TFF) Breakdown
- Tooth interior fatigue fracture Breakdown

Can failure be prevented by inspection ?

- Tooth (root) breakage Crack can be seen, Magnaflux
- Pitting Easy to see
- Micropitting Easy to see
- Tooth flank fracture (TFF) Not detectable (only by Ultrasonic)
- Tooth interior fatigue f. (TIFF) Not detectable (only by Ultrasonic)
Gear Failure Modes: Tooth Flank Fracture
What is TFF?

 Only in surface hardened gears;

 Tooth fracture due to a crack located in the

active flank area, often at approximately half the
height of the tooth;

 Primary crack initiation is at a considerable

depth below the surface of the loaded gear
flank, typically at or below the case-core
interface;

 The primary crack starter is often but not always

associated with a small non-metallic inclusion;
Gear Failure Modes: Tooth Flank Fracture
What is TFF?

 The primary crack propagates from the initial

crack starter in both directions – towards the
surface of the loaded flank and into the core
towards the opposite tooth root section;

 Due to the high hardness in the case, the crack

propagation towards the surface is smaller as
through the core;

 Angle between primary crack and flank surface

is approx. 40-50°;
Gear Failure Modes: Tooth Flank Fracture
What is TFF?

 Final breakage of the tooth is due to forced

rupture; typically developing according to local
bending stress;

 Fractured surfaces show typical fatigue

characteristics with a crack lense around the
initiation point and a residual zone of forced
rupture;

 In many cases no indications of surface related

failures such as pitting or micro-pitting are
observed on the gear flanks.
Gear Failure Modes: Tooth Interior Fatigue Fracture
Similar phenomena, not to be confounded with TFF

Tooth Interior Fatigue Fracture (TIFF):

Occurs (mostly) on idler gears; caused by
alternating bending; crack is horizontal

TIFF (from Diss. Witzig)

Gear Failure Modes: Wear
- Dry running Gears in plastic
- Big low speed Gears in steel

VDI 2736:

Wear distribution on Flank

 Actual trends
‘Old’ and ‘new’ Gear Types
Gear pairs

External gears Internal gears Bevel gears Face gears

Spiral bevel gears
Cylindrical gears

Parrallel axes Intersect axes

Hypoid gears Crossed helical gears Worm gears

Skewed axes
Beveloid gears Face gears
Special Gear Geometry:
Low loss gears, Cycloid Gears, ...

Low Loss Gears

mn small
z1, z2 high
ea 1.0-1.1
Non-conventional
Gear Calculation Procedures
 Contact Analysis
Non loaded contact pattern analysis (TCA)
Loaded Tooth Contact Analysis (LTCA)
Contact pattern analysis (Non loaded)
Easy to handle, if a true 3D model is available!

 Produce a ‘skin’-model of both gears

 Rotate one gear against the other
 The contact pattern shows up
 Considering shaft alignment and mounting position error
Loaded Tooth Contact Analysis (LTCA)

by specific semi-numeric approach by FEM

(as RIKOR, … since 1977) (as ANSYS, NASTRAN,…)
Helical gear contact analysis
Main results: Stress distribution,
Transmission error, Losses, ….
Bevel gear contact analysis
- For straigth, helical and spiral bevel gears
- For Klingelnberg and Gleason bevel gears
- Allows the analytical evaluation of flank contact with TE, H. Pressure, ..

Klingelnberg, with profile modification Gleason, without profile modification

 Bevel gear contact analysis
Comparison of modification (Klingelnberg 11:54, D2=360mm)

Modification:
LB=150mm
HB=60mm
Contact Analysis
Flank and Profile Modification Optimization:
Transmission Error and KHb at 60, 80, 100% load with different
modifications.
Contact Analysis in Gear Configurations
Deformation of planet carrier
Shafts are calculated (including bearing stiffness) using conventional methods
Carrier deformation (torsion) by FE
Carrier 3D is builded and processed automatically

FE software
Code-Aster used
Bearings, Shafts, Screws,
Connections, …
Bearing calculation methods
Conventional method Non-conventional method
ISO 281 ISO 16281

Generally used in: Generally used in:

Industrial gear drives Automotive
Wind
 System view:
Gearboxes, Power Transmission
System view
Power flow definition
Duty cycles
Lifetime analysis
Running virtual tests
Damage Calculation of all Components

> Finding the weakest element

Total Power Losses: Automotive

Reduce losses in Gear meshing, clutches, synchronization,

lubrication system, sealing

Double Clutch
Transmission
Thermal Capacity: Industrial Gear Reducers

(ISO 14179 and others)

Contact Analysis including Housing Stiffness
Stiffness Matrix

Bearing Loads

sH-distribution
from LTCA:
Eigenfrequencies on System level
(Torsional and bending)
System: Integration with
Multibody Dynamic Simulation

ADAMS

Gear Calculation Dynamic Simulation

Gear meshing stiffness >> Simulation

Stresses, Lifetime << Torque behavior

Noise Prediction
Transmission Error Vibration propagation
is known is hard to predict

Noise (dB(A)) prediction

is not yet possible

dB(A) ??
Who we are
 Company KISSsoft AG
1980: Software development for personal use from Kissling Gear AG
1986: Sale of the first KISSsoft license to company Saurer AG, Switzerland
1998: KISSsoft AG Switzerland, Founder Dr. Kissling
2005: KISSsoft USA LLC, Chicago
2015: Partners in Korea, China, India, South Africa, Italy, France,
Germany, Argentina, Turkey, Belarus, Czech Republic,
Slovakia, Russia, Brazil
Over 2700 clients worldwide, 30 members of staff

For over 30 years KISSsoft AG has been the driving force behind
developments in the machine elements sector.

Its activities in committees that define international calculation

standards ensure first-hand knowledge.
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