Simulation modeling of transmission

mechanisms
Cite as: AIP Conference Proceedings 2077, 020051 (2019); https://doi.org/10.1063/1.5091912
Published Online: 21 February 2019

Anna Šmeringaiová, and Zuzana Murčinková

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© 2019 Author(s).
 Simulation Modeling of Transmission Mechanisms
Anna Šmeringaiová1, a) and Zuzana Murčinková1, b)
1
Faculty of Manufacturing Technologies of the Technical University of Košice with a seat in Prešov,
Bayerová 1, 08001 Prešov, Slovakia
a)
Corresponding author: anna.smeringaiova@tuke.sk
b)
zuzana.murcinkova@tuke.sk

Abstract. The aim of this paper is to highlight the possibilities of efficient designing of gear mechanisms in the Autodesk
Inventor Professional graphical system. Using the various special software tools, techniques and work methodology has a
significant impact to the overall performance of the designer. The article describes the methodology that has been
developed specifically for designing different types of gears. An example of the design of a combined transmission which
consist from a single-stage gearbox and a belt drive gear is described in the using the application of the recommended
work procedure.

INTRODUCTION
Designing drives is a creative mental activity. Engineering designs for transmission mechanisms must meet a
number of requirements, such as functional reliability, operational efficiency, the choice of suitable construction
materials, design with the lowest possible demands on production technology, low costs and ecological disposal. All
design activities in designing different types of mechanisms (Engineering calculations, 3D model, drawing
documentation) are now supported by various CA systems. However, their use still requires control of the
computational practices that the SW products contain. Based on these theoretical knowledge and practical
experiences, computer-generated solutions need to be critically evaluated. In the design process, each designer
chooses his own work procedure. Using the various special software tools, techniques and work methodology
available for component modeling, assembly creation, and functional simulation, it is possible to influence the
overall performance and performance of the designer. If we want to make the most of the CAD software really
effective, we need to know certain Best Practices Workflow.

WORK TOOLS AND METHODICS OF DESIGNING MECHANISMS

IN AUTODESK INVENTOR PROFESSIONAL
For efficient design and simulation of gear mechanisms, Autodesk Inventor Professional offers these working
tools:
∂ Design Accelerator allows you to create models of standard types of engineering components based on
technical calculations. Designs and calculations of functional parts of gears are made using component
generators. The use of Design Accelerator in the design process simplifies the design process, automates
design and geometry creation, improves the quality of the initial design by comparing design requirements,
increases the standardization rate by selecting the same components for the same tasks.
∂ Stress analysis is an instrument designed to calculate the stresses and deformations that are occurring in the
designed components and assemblies under a defined load and design alternative.
∂ Dynamic simulation. The intent of the dynamic simulation is to build a functional mechanism. Dynamic
simulation adds to functional mechanism the real, dynamic influences of various kinds of loads to create a
true kinematic chain. The advantage of designing with the help of kinematic and dynamic analysis is the

Scientific Session on Applied Mechanics X

AIP Conf. Proc. 2077, 020051-1–020051-8; https://doi.org/10.1063/1.5091912
Published by AIP Publishing. 978-0-7354-1805-9/$30.00

020051-1
 ability to monitor kinematic variables of all members of the mechanism at any point in time and in any
position. The depiction of the monitored quantities can be displayed in graphical tabular or in vector form.
From kinematic analysis, it is possible to go directly to dynamic simulation and strength analysis.

Demands in every area of the industrial production, are today made to maximize the reduction of all activities
related to the development, design and production of products to meet specific customer requirements. When
designing transmission mechanisms using CAD software, we recommend using the following workflow:
∂ Calculation of input parameters needed for solution.
∂ Design and modeling of the components of the mechanism directly in the assembly model environment
using the Design Accelerator.
∂ Constructing the model of the mechanism assembly.
∂ Setting conditions for kinematic analysis in "Dynamic Analysis" environment - defining kinematic links,
drive, extreme positions, monitored variables.
∂ Start of the simulation, record and results processing - output in tabular and graphical form (functional
dependencies of output variables over time, values of monitored variables for defined position of the
mechanism).
∂ Evaluation of results, verification of results by another solution method.

Using the above-mentioned work tools and the Best Practic Workflow recommended in Autodesk Inventor
Professional, it is possible to quickly and easily transform your customers' vision into practical design ideas. In the
following text a recommended workflow is described in detail, which was applied when designing a single-stage
gearbox with straight toothed wheels and belt drive gear.

DESIGN OF A TRANSMISSION MECHANISM

In the example described it was designed the transmission mechanism of the drive station. The combined
transmission consists of belt drive and spur gears. – Fig. 1a. Input parameter values Pi, n i, MKi are listed in Tab. 1.
The above design methodology was used for the solution.

PIII, MKIII
nIII, ωIII

PII, M K II
nII, ω II

P I, M K I
nI, ω I

(a) (b)
FIGURE 1. Kinematic Scheme (a) and Design (b) of the Transmission Mechanism.

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 Calculation of Input Parameters Needed for Solution
For the calculations of the input parameters and control values which are necessary for verification of the
correctness of the simulation were in accordance to Ζ1, 2, 9, 10∴ used relationships listed below. The kinematic
values of the individual shafts were determined for two different motion alternatives (ω21 = const.; α21 = const.).

Calculation of velocity ratios, speed (rpm) and angular velocity

ninput nI nI
iOVR < < ⇑ n III < (1)
n output n III iOVR
iOVR
i BTR < (2)
u HGR
nI n II
n II < ; n III < (3)
i BTR u HGR
ϖi < 2ο √ ni ; i < I , II , III (4)

ni ; i = I, II, III are speed the shafts I, II, III,

ϖi ; i = I, II, III is the angular velocity of the shaft I, II, III,
iOVR - overall velocity ratio,
iBTR - velocity ratio of the belt transmission,
uHGR - gear ratio of helical gears.

Total drive efficiency

γOE < γCE √ γ SGE √ γ2RBE √ γ BTE (5)

γ CE is coupling efficiency,
γ SGE - spur gear efficiency,
γ RBE - the effectiveness of one pair of rolling bearings,
γ BTE - the efficiency of the belt transmission.

Calculation of power

PI < PM √ γCE
PII < PI √ γ RBE1 .γ BTE (6)
PIII < PII √ γ SGE √ γ RBE 2
Pi ; i = I, II, III are power of the shafts I, II, III.

Calculation of Torques

Pi
Pi < M K i √ ϖi ⇑ M Ki < ; i < I , II , III (7)
ϖi

MKi ; i = I, II, III are the torques acting on the shafts I, II, III.

Calculation of angular acceleration

d ωi
αi < < konšt. (8)
dt

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 t ωi
ωi , ωi 0
〉
αi d t <
0
〉 dω ;
ω0
αi t < ωi , ωi 0 ⇑ αi <
t
; i < I , II , III (9)

αI αI α II α II
i BTR < ⇑ α II < ; u HGR < ⇑ α III < (10)
α II i BTR α III u HGR

i ; i = I, II, III is the angular acceleration of the shaft I, II, III,

t - the acceleration time.

Calculation of shaft diameter

16M K i
di ″ 3 (11)
ο σD

σD is permitted the shaft torsional stress,

di ; i = I, II, III - the diameter of the shaft I, II, III.

Design Calculation of Spur Gear Module by Bach

2 M K cos α
mn < 3 (12)
ο c ξ m z1
mn is normal module,
Ψm - gear width coefficient,
z1 - number of teeth (pinion),
β - reference cylinder helix angle,
c - permitted flexural stress coefficient for the material.

Design and Modelling of Mechanism Components

When creating the model of the mechanism assembly, the principle "from the functional basis to the details" [5]
was applied in the modeling process. The actual transmission station was implemented directly in the model
assembly environment where Design Accelerator tools are available. As the starting point for the design of the
shafts, the belt transmission and the gearwheels has been given and calculated values of the input parameters. Using
the Design Accelerator commands, the major functional parts of the gear mechanism were designed and modeled in
a simplified form containing the basic functional shapes. The bindings were precisely defined by their mutual
position, the positioning of the mechanism with respect to the fixed base and the kinematic pair. The design and
dimensioning of functional parts of the mechanism were realized using engineering calculators. Engineering
calculators use standard mathematical formulas and physical theories in design and validation of mechanical
systems.
The current design of the components modeled in the assembly environment were continuously verified in the
design process, modified as needed and simultaneously defined in kinematic analysis conditions in the dynamic
simulation environment. With the dynamic simulation and the assembly environment, the intent is to build a
functional mechanism. Dynamic simulation adds to that functional mechanism the dynamic, real influences of
various kinds of loads to create a true kinematic chain. Though both have to do with creating mechanisms, there are
some critical differences between the dynamic simulation and the assembly environment. The most basic and
important difference has to do with degrees of freedom. By default, components in Autodesk Inventor Simulation
have zero degrees of freedom. Unconstrained and ungrounded components in the assembly environment have six
degrees of freedom. [6]
Required kinematic parameters of the proposed transmission mechanism were verified using a functional
simulation. After verification of the correct operation, the mechanism was supplemented by other shapes and
components.

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 Modeling of the Functional Model of the Gear Mechanism. Working Procedure
"Assembly environment" - The base is in the virtual space defined by the basic coordinate system. With respect
to this base, the position of the gear mechanism was set.
"Shaft Component Generator" - Input shaft I modeling. The shaft was anchored to the basic coordinate system
with one degree of mobility - rotation around the axis. Using engineering calculators, shaft I was dimensioned with
respect to the assumed load.
"V-Belts Component Generator" - Belt transmission modelling. The belt transmission consists of 2 belt pulleys
and the appropriate number of belts according to the program calculation. In the "Design" tab, it is selected the type
of pulley, type and number of belts. Belt pulley II was mounted and fixed to the shaft I. Interconnections of the
functional parts of the belt drive have been defined automatically. After entering the rated values for power and
angular velocity of the engine and other transmission parameters, a control calculation was made - the "Calculation"
tab. Depending on the result, we will make changes to the parameters and repeat the control calculation, respectively
the design will be confirmed. In terms of dynamic simulation, it is necessary to change "iProperties" from
"Grounded" to "Flexible".

(a) (b)
FIGURE 2. „Mechanism Status“.
"Environments tab / Dynamic simulation"- Define the kinematic dependencies of the belt transmission by
"Automatically Convert Constraints to Standard Joints" and "Insert Joint / Rolling: Belt" command - Fig. 3a. By
"Mechanism Status" command, it is checked that the created model corresponds to the mechanical system with one
degree of mobility - Fig. 2a.
"Shaft Component Generator" – Design of the shaft II. The initial value of shaft diameter is calculated from the
equation (11). The design and check calculation of shaft II were realised.
"Environments tab / Dynamic simulation" - With command "Mechanism Status" was verified number of degree
of mobility again - Fig. 2a.

(a) „Rolling: Belt“ (b) „Rolling: Cylinder on cylinder“

FIGURE 3. Command „Insert Joint“.

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 "Spur Gears Component Generator" - Design of spur gears through Spur Gears Component Generator dialog
box. The design scenario is based on the specified distance of the axes, the calculated transmission and the module.
For the module calculation, the recommended procedure was chosen [1, 9]. Through the dialog box, it is possible to
repeat thegear assembly design and stress calculations. Several methods of strength calculation are available. In the
case described, the "Strength calculation method" according to ISO 6336:1996 was used. Generated was spur gear
wheel with helical gearing was generated. The drive gear 3 has been modeled as a fixed member of shaft II. The
correct position and movement restriction were defined by the links only in the case of the toothed wheel 4. For the
reciprocal rolling movement is from a functional point of view, necessary to define the bond "Motion" in the
assembly environment.
"Environments tab / Dynamic simulation" - By command "Automatically Convert Constraints to Standard
Joints" and by command "Insert Joint" / Rolling: Cylinder on cylinder" were defined kinematic dependencies of gear
transmission components – Fig. 3b. Command "Mechanism Status" checked, if the mechanism mobility was
delimited to one degree of mobility by chosen bonds – Fig. 2b.
"Shaft Component Generator" - Design and strength calculation of shaft III.
"Environments tab / Dynamic simulation" Already in the design process, the basic functional part of the
transmission mechanism was defined as a mechanical assembly with one degree of mobility – Fig. 2b. The next step
is defining the external loads - in our case, it is the driving moment acting on the input shaft I. Its point of action,
direction and size were determined. In next step were defined properties of actuating shaft drive, the conditions for
starting the simulation of motion and the conditions of the simulation course were defined. The results of the
functional simulation were generated in tabular and graphical form (Fig. 4, Fig. 5). By the standard calculation of
the monitored variables it was verified, if the gearbox functional simulation was set correctly. Table 1 lists the
values of monitored parameters obtained by calculation and simulation. Differences in numeric values are caused by
the fact that Inventor uses multiple factors for the design. For example, in the standard efficiency calculation, the
clutch and bearing efficiency were neglected. Fig. 4 and Fig. 5 shows the progress of monitored parameters.
Numerical angular velocity and acceleration values obtained from the simulation, expressed in [↓.s-1], resp. [↓.s-2]
were in accordance to (13) converted to [rad.s-1], resp. [rad.s-2].

Ζ ∴ 180
ϖi rad √ s ,1 √
ο
< ϖ Ζ↓ √ s ∴
ν
i
,1
(13)

Table 1. Values of monitored variables. Calculation results / simulation results.

ϖi [rad.s-1] i [rad.s-2] n i [ot.min -1] Pi [kW] M Ki [Nm]
306,83 30,68 2930 7,50 24,40
SHAFT I
306,83 30,68 2930 7,50 24,40
122,73 12,27 1172 7,20 58,67
SHAFT II
126,54 12,65 1208 7,18 56,90
30,68 3,07 293 7,06 229,97
SHAFT III
31,63 3,16 302 7,02 223,05

Finishing the Modelling of the Elements

"Shaft Component Generator" - is linked to the "Content Center", that enables efficient modeling - generating
standardized structural and technological shape elements and automatically loading standardized parts (key, gaskets,
retaining rings, etc.) from content center.
Gear and shaft design modifications - the standard modeling of shape gears was used.
"Bearing Component Generator" – allows bearing design for required durability. Selects the bearing from the
"Content Center" bearing list that matches all criteria specified in the "Design" and "Calculation" tabs and its
calculated Adjusted Bearing Life value is equal or close to Bearing Required Life value. Through the bonds, the
exact position of the bearings in the assembly and the number of degrees of mobility were defined directly in the
design process.
Gearbox design - It is the designer's job to choose the procedure. In our case, we used standard modeling
procedures. In the assembly model, the positioning of the gearbox is correct with respect to the shafts, respectively
gear bearings. At the same time, the gearbox was fixed to the basic coordinate system.

020051-6
 Design of an electric motor - The model of the electric motor used in the assembly is taken from GrabCAD.
"Bolted Connection Component Generator" – Enables efficient design procedure, modeling and calculation
control of screw connections. After design confirmation, the link components of the proposed screw connections
were retrieved from the content center. Screw connections have been created automatically. Similarly, the shape of
the jointed components was automatically supplemented with standardized screw holes at the joint point.

FIGURE 4. Simulation results – alternative A.

FIGURE 5. Simulation results – alternative B.

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 CONCLUDING REMARKS
The introduction of CA technology into all areas of engineering has created the need for new forms and design
methods. When designing and constructing transmission mechanisms, the design engineer, in addition to general
technical know-how, also anticipates an understanding of the basic principles of 3D CAD systems and an overview
of the possibilities of using different software applications.
Autodesk's Inventor Professional application includes a special Design Accelerator tool designed to design drive
gear. It provides engineering calculation and decision support to identify standard components or create standards-
based geometry. The Design Accelerator commands simplify the design process. They automate the selections and
geometry creation, improve initial design quality by validating against design requirements, and increase
standardization by selecting the same components for the same tasks. In the design process, it is also possible to use
a computer simulation enabling stress analysis and functional analysis of motion of mechanical systems. It is
possible to use the recommended work procedure for design of all basic types of gear mechanisms.

ACKNOWLEDGMENTS
This research was supported by the Ministry of Education of the Slovak republic, through grants VEGA
1/0910/17 “Research of Hybrid Composite Material Structures in the Context of Their Applications for Improving
the Performance of Belt Gears”.

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