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11.2 Generation of 3D gears

You must first perform a gear calculation to ensure that the results are consistent.
Select Graphics > Settings to choose the CAD system to which you want
to export the selected element.

Then, in the Graphics > 3D export menu option, you can select which indi-
vidual gear and the configuration (only possible as individual gears) you want to
generate.
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In the case of Unigraphics NX, generation is only possible if you have started
KISSsoft from the NX add-in menu, then run the gear calculation and pressed the
required generation button. In the case of Creo Parametric (ProEngineer) and CA-
TIA, you must run the CAD interface so that you can start the gear generation pro-
cess from KISSsoft. In the SolidWorks, Solid Edge and Inventor CAD systems,
press a generation button to start the CAD process, if it is not already open.

The default setting runs the gear generation process with a permitted tooth form
deviation (tolerance band) of 1 m. If this tolerance is too large, you can open the
Tooth form tab to change the tolerance. Once this is changed, you must click
Calculate again (Tooth form tab active), to transfer the inputs and recalculate
the tooth form.
Changing the generation type in the Tooth form tab (polylines, circular pitch ap-
proximation, arc estimation, splines) only affects the 2D display. In NX,
SolidWorks and Solid Edge, the part is generated with splines. In Inventor, Creo
Parametric (ProEngineer) and CATIA, it is created with arcs of circles. SolidWorks
and Solid Edge also support other generation types, which you can change by
entering a value in the additional APPROXIMATION=1 parameter, in the
kiss.ini (see page I-59) file, in the relevant CAD system.
In the case of the gears, the transverse section of the tooth space is usually cut out
from a cylinder, and then duplicated as a pattern. For worms with a helix angle of >
50o and number of teeth < 4, the tooth space is cut out in the axial section and then
duplicated.
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11.3 Generating 3D shafts

Until now it has only been possible to generate shafts in 3D in the SolidWorks,
Solid Edge, Autodesk Inventor and NX CAD systems.
First, a shaft analysis must be performed to ensure the results are consistent. Select
Graphics > Settings to choose the CAD system to which you want to ex-
port the selected element.

Then click Graphics > 3D Export to select the shaft(s) and configuration (if
you want to generate more than one shaft) that you require. In a configuration, each
shaft is created individually, in sequence, in its own part.
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You can therefore create a 3D shaft in the CAD system at the click of a button,
using the data from a KISSsoft shaft analysis.
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11.4 Viewer with neutral format interface

KISSsoft provides a 3D viewer for displaying individual gears or a gear system.
The viewer is activated from the Graphics > 3D Geometry menu.
In the 3D viewer, you can export the solid model in STEP and Parasolid formats
(text and binary). Supported gears (see page I-192) and for operating the viewer
(see page II-655). You can change the settings by selecting Calculation > Settings
> 3D Generation.

11.4.1 Parasolid Export of 3D Shafts

Parasolid can be used to generate the solid model of the shaft. The available for-
mats for export are STEP, Parasolid text (X_T) and binary (X_B).
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Select File > Export > Shaft > 3D Geometry to generate the model.
If the calculation model contains a number of shafts, you can export them by
selecting File > Export > Geometry 3D System.

11.4.2 Face gear - 3D geometry

The 3D model of a face gear is generated by simulating the cutting process, and has
no limitations affecting the helix angle, shaft angle and offset. The reference coor-
dinates of the model are defined in accordance with Roth [79], and the correspon-
ding positions of pinion and gear are defined by equations (1) and (2).

(1)

(2)
Here, rtS is the pinion reference radius and xS is the pinion profile shift coefficient.
Here, rtS is calculated from the number of teeth of the pinion type cutter.
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The shaft angle and radial offset (θ and a) are defined in Geometry >
Details…..
The face gear model is generated by simulating the cutting process, and the tooth
flank is approximated as a spline surface.
The manufacturing process is based on the Parasolid core, where the quality of the
model depends on the settings made in Parasolid modeling (see Calculation > Set-
tings > Parasolid).
NOTE:

The strength calculation is performed with the assumption that the shaft angle is
90° and the radial offset is 0. The shaft angle and radial offset are only used for 3D
model generation, so the strength calculation result may not be valid.

11.4.3 Bevel gear - generating a 3D model

The 3D geometry model for straight, helical and spiral bevel gears is defined
according to ISO 23509 and the tooth form is calculated for several sections along
the facewidth. The tooth form is placed across the planar involutes of the virtual
spur gear, at ninety degrees. Then, the tooth flank surface is generated by sweeping
the tooth forms of the sections (Figure 10.1). The tooth forms in the individual sec-
tions are transformed by the angle  into the relevant position. The angle of each
section  is calculated both for the generating and face milling processes by using
the auxiliary angles  and . Therefore, the final tooth form along the facewidth is
an extended epicycloid (face hobbing) or circular (generating) form, as shown in
Figure 10.2.
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Figure 11.1 Definition of the sections for tooth form calculation

Figure 11.2 Transformation angle of generating (left) and face milling (right) processes

Machine tool manufacturers (such as Klingelnberg and Gleason) also have their
own processes for generating tooth forms, that differ slightly from the procedures
mentioned above. The tooth form is called an octoid and may differ slightly from
our tooth form. However, we have ascertained that the difference between the tooth
forms is much less than the tolerance range, and will not give rise to any problems
in practical use.
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11.4.4 Worm wheel - generating a 3D model

The 3D model of the enveloping worm wheel is generated by simulating the actual
cutting process. The tooth forms at several sections along the facewidth are calcu-
lated, and the tooth flank is approximated as a spline surface. The model is genera-
ted using the best possible tool to manufacture the worm. Theoretically, the tool
generates the worm, in regard to arc of circle, pressure angle, and tooth form. Ho-
wever, if the tool itself was manufactured to these specifications, it would no lon-
ger be usable after resharpening, because it would be smaller than the worm. The
tools used to manufacture worm wheels are therefore slightly larger than the worm
they are to create so that they can be resharpened several times, as required [91].
To generate the model using the larger tool, you can set the oversize factor in the
module-specific Settings window.

Figure 11.3 Oversize factor for worm wheel cutter

In this case, the tool will have a larger tooth thickness, and therefore generate a
smaller tooth thickness on the gear. The cutting distance between the tool and the
gear will then be changed accordingly, to ensure a consistent result for the root and
tip diameters on the gear.

11.4.5 General information about 3D modeling in Par a-

solid
If the model could not be generated correctly, you can improve it by modifying the
Parasolid settings (see Calculation > Settings > 3D Generation)
or, if gears are involved, by reducing the permitted deviation (Tooth form >
Approximation for export > Permissible deviation tab).
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11.5 3D interface to SolidWorks

Manufacturer: KISSsoft AG
The interface between SolidWorks and KISSsoft creates the direct integration into
the 3D CAD system. Use this to start all KISSsoft calculation modules directly
from within SolidWorks. Cylindrical or bevel gears calculated in KISSsoft can be
generated directly in SolidWorks as a 3D part (see page I-193) with a real tooth
form. Shafts calculated with KISSsoft can be generated as a 3D part comprising
cylinder and cone elements (see page I-195) directly in SolidWorks. From within
KISSsoft, you can start SolidWorks with one click on a button. The system opens a
new part, and generates the appropriate part. You can create cylindrical gears with
straight or helical teeth, which are outside or inside, racks with straight or helical
teeth, or straight-toothed bevel gears, as defined in DIN 3971, Figure 1, and shafts.
Furthermore, you have the option of adding toothing to existing shafts (see page I-
202) at a later point in time. In addition, with the interface in the 2D range, you can
automatically insert gear manufacturing data (see page I-207) as a text field. The
gear manufacturing data is attached to the relevant cutout (tooth space).

11.5.1 Gear teeth in the case of an existing b asic solid

11.5.1.1 Procedu re for toothing creation

1. Select the required area in CAD