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عدد المساهمات : 18984 التقييم : 35458 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب KISSsoft User Manual الخميس 18 نوفمبر 2021, 11:38 am | |
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Table of Contents I General .43 1 Installing KISSsoft 44 1.1 Basic installation 44 1.2 Downloading a license file .44 1.3 Licensing 45 1.3.1 Test version .45 1.3.2 Student version 45 1.3.3 Single user version with dongle (protection key) .46 1.3.4 Single user version with license code 46 1.3.5 Network version with dongle (protection key) 46 1.3.6 Network version with a license code .47 2 Setting Up KISSsoft 48 2.1 Directory structure 48 2.2 Language settings 48 2.3 Systems of units .49 2.4 Defining your own template files 49 2.5 Rights .49 2.6 Global settings - KISS.ini .50 2.6.1 Definitions in [PATH] .50 2.6.2 Definitions in [SETUP] .51 2.6.3 Definitions in [REPORT] 53 2.6.4 Definitions in [GRAPHICS] 54 2.6.5 Definitions in [LICENSE] 54 2.6.6 Definitions in [CADEXPORT] .542.6.7 Definitions in [INTERFACES] 54 2.6.8 Definitions in [SOLIDEDGE] 55 2.6.9 Definitions in [SOLIDWORKS] .55 2.6.10 Definitions in [INVENTOR] 56 2.6.11 Definitions in [CATIA] 56 2.6.12 Definitions in [PROENGINEER] 57 2.6.13 Definitions in [HICAD] 57 2.6.14 Definitions in [VIDEOENCODING] 57 2.7 User-defined settings .59 2.7.1 Configuration tool 59 2.8 Rules 62 3 Running KISSsoft . 65 3.1 Start parameters 65 3.2 Disconnect license from the network .65 4 Elements of the KISSsoft User Interface . 67 4.1 Menus, context menus and the tool bar .67 4.2 Docking window .68 4.2.1 The module tree 69 4.2.2 The project tree .69 4.2.3 The Results window 70 4.2.4 The Messages window 70 4.2.5 The info window .70 4.2.6 Manual and Search .70 4.3 Graphics window 71 4.3.1 Tool bar and context menu 71 4.3.2 Comment field .73 4.3.3 Context menu 734.3.4 Properties 73 4.3.5 Toothing .75 4.4 Main input area 76 4.4.1 Report Viewer 76 4.4.2 Helptext Viewer .77 4.5 Tooltips and status bar .77 5 KISSsoft Calculation Modules . 78 5.1 Standard and special tabs .78 5.2 Input elements .78 5.2.1 Value input fields .79 5.2.2 Formula entry and angle input .79 5.2.3 Unit switch .80 5.2.4 Tables 80 5.3 Calculating and generating a report .80 5.4 Messages .81 6 Project Management 82 6.1 Generating, opening and closing projects .82 6.2 Adding and deleting files 83 6.3 The active working project .83 6.4 Storage locations .83 6.5 Project properties .83 7 Dynamic User Interface 84 7.1 Modified tabs and dialogs supplied with the system 84 7.2 Adding additional tabs and dialogs 84 7.3 Formatting 85 7.3.1 Elements 857.3.2 Columns 86 7.3.3 Groups .86 7.3.4 Tabs .87 7.3.5 Attributes .87 7.3.6 Comments .89 7.3.7 Special elements .89 8 Results and Reports . 90 8.1 Results of a calculation 90 8.1.1 Add your own texts in the results window 90 8.2 Calculation reports .90 8.3 Drawing data 91 8.4 Report settings .91 8.4.1 General 91 8.4.2 Page layout 91 8.4.3 Header and footer 92 8.4.4 Start and end block 92 8.5 Report templates 93 8.5.1 Storage locations and descriptions 93 8.5.2 Scope of a report .95 8.5.3 Formatting .95 9 Database Tool and External Tables 103 9.1 Viewing database entries .104 9.2 Managing database entries .106 9.2.1 Creating a database entry .106 9.2.2 Deleting a database entry 107 9.2.3 Restoring a database entry .107 9.3 Import and export data from the database tool 1079.4 External tables .108 9.4.1 Functions tables 109 9.4.2 Range tables .111 9.4.3 List tables 112 9.4.4 List of key words used .114 9.5 Description of database tables .115 9.5.1 Center distance tolerances 115 9.5.2 Machining allowance for cylindrical gear .115 9.5.3 Reference profiles .115 9.5.4 Compression springs standard 115 9.5.5 Hobbing cutter selection 116 9.5.6 Basic material Glued and Soldered joints 116 9.5.7 Manufacturing process for bevel and hypoid gears .116 9.5.8 V-belt standard 116 9.5.9 Spline Standard .117 9.5.10 Chain profiles ISO 606 117 9.5.11 Adhesives 117 9.5.12 Modifications 117 9.5.13 Load spectra 117 9.5.14 Solders 118 9.5.15 Surface roughness of shafts and shaft-hub connections .118 9.5.16 Key standard .119 9.5.17 Polygon standard .119 9.5.18 Woodruff key standard 119 9.5.19 Bolts/pins .119 9.5.20 Lubricants 119 9.5.21 Bolts: Tightening factor 121 9.5.22 Bolts: Bore .1219.5.23 Bolts: Strength grade .121 9.5.24 Bolts: Nut strength grade .122 9.5.25 Bolts: Coefficients of friction classes .122 9.5.26 Bolts: Thread type .122 9.5.27 Bolts: Nuts .123 9.5.28 Bolts: Type .123 9.5.29 Bolts: Washer 123 9.5.30 Selection of pinion type cutters 123 9.5.31 Disc spring standard 123 9.5.32 Tolerances standard 123 9.5.33 Beam profiles .124 9.5.34 Multi-Spline standard .124 9.5.35 Materials 124 9.5.36 Material of gears 128 9.5.37 Rolling bearings .129 9.5.38 Rolling bearing tolerance .139 9.5.39 Rolling bearing fit (tolerance) classes 140 9.5.40 Tooth thickness tolerances 140 9.5.41 Toothed belt standard 140 10 Description of the Public Interface 142 10.1 Interfaces between calculation programs and CAD - Overview .142 10.1.1 Efficient interfaces .142 10.1.2 Open interfaces concept in KISSsoft .143 10.2 Defining input and output .144 10.2.1 Preamble .144 10.2.2 Requirements placed on the third party program 145 10.2.3 Used files .146 10.2.4 Rating life of files .14610.2.5 Explicitly reading (importing) and generating data 147 10.3 Example: Interference fit calculation 147 10.4 Geometry data .149 10.5 COM interface 149 10.5.1 Registering the server .149 10.5.2 Server functionality 150 10.5.3 Example of a call from Excel .152 11 3D Interfaces 157 11.1 Overview of the available CAD interfaces and their functionality 157 11.2 Generation of 3D gears 158 11.3 Generating 3D shafts .159 11.4 Viewer with neutral format interface .160 11.4.1 Parasolid Export of 3D Shafts .161 11.4.2 Face gear - 3D geometry .162 11.4.3 Bevel gears - generating a 3D model 162 11.4.4 Worm wheel - generating a 3D model .163 11.4.5 General information about 3D modeling in Parasolid 164 11.5 3D interface to SolidWorks 164 11.5.1 Gear teeth in case of an existing basic solid .165 11.5.2 Integrating the KISSsoft Add-in (menu options in CAD) 166 11.5.3 Add-in functions (calls) 169 11.6 3D interface to Solid Edge .171 11.6.1 Change to the parameter for generation .171 11.6.2 Gear teeth in case of an existing basic solid .172 11.6.3 Integrating the KISSsoft Add-in (menu options in CAD) 173 11.6.4 Add-in functions (calls) 177 11.6.5 Opening the calculation file for the created gear .178 11.6.6 Simplified view of the gears .17811.7 3D interface to Autodesk Inventor .179 11.7.1 Gear teeth if existing shaft data is present 179 11.7.2 Add-in (menu options in the CAD system) 180 11.7.3 Add-in functions (calls) 183 11.7.4 Opening the calculation file for the created gear .184 11.8 3D interface to Unigraphics NX 184 11.8.1 Add-in (menu options in the CAD system) 186 11.8.2 Running KISSsoft via the Add-in .189 11.9 3D interface to Creo Parametric (ProEngineer) .196 11.9.1 Integrating the KISSsoft Add-in .200 11.9.2 Cutting gear teeth on an existing shaft 204 11.9.3 Modifying the selected 3D model 205 11.9.4 Modifying the teeth on an existing shaft 206 11.9.5 Changing base settings in the interface 207 11.9.6 Save the files to the PTC Windchill working directory .208 11.10 3D interface to CATIA 209 11.10.1 Registering the interface 209 12 Answers to Frequently Asked Questions 211 12.1 Changing the output of angles in reports .211 12.2 Input materials for gear calculations in the database .211 12.3 How can I test the software? 212 12.4 What licenses are available? .212 12.5 Add your own texts in the results window 212 12.6 Restoring a previous stage in the calculation 213 II Gear Teeth 214 13 Introduction . 21513.1 Underlying principles of calculation 215 14 Cylindrical gears . 217 14.1 Basic data 218 14.1.1 Hand of gear for gear teeth .219 14.1.2 Normal module 219 14.1.3 Pressure angle at normal section 219 14.1.4 Helix angle at reference circle .219 14.1.5 Center distance .220 14.1.6 Number of teeth .221 14.1.7 Facewidth 221 14.1.8 Profile shift coefficient 222 14.1.9 Tooth thickness modification factor .225 14.1.10 Quality .225 14.1.11 Geometry details .227 14.1.12 Material and lubrication .229 14.2 Rating (load) 234 14.2.1 Calculation methods 235 14.2.2 Rating life .244 14.2.3 Reliability .245 14.2.4 Application factor .246 14.2.5 Power, torque and speed 247 14.2.6 Strength details 247 14.2.7 Strength details (AGMA) 261 14.2.8 Define load spectrum .262 14.3 Factors .265 14.3.1 Transverse coefficient .265 14.3.2 Dynamic factor .265 14.3.3 Mesh load factor 26614.3.4 Alternating bending factor 266 14.3.5 Load spectrum with alternating torque 268 14.3.6 Face load factor .270 14.3.7 Taking into account shaft bending (face load factor and contact analysis) .290 14.3.8 Z-Y factors and the technology factor 292 14.3.9 General calculation procedure for KHbeta as specified in ISO 6336-1, Annex E 294 14.4 Reference profile 295 14.4.1 Configuration .295 14.4.2 Pre-machining and grinding allowance 304 14.4.3 Tip alteration 305 14.5 Manufacture .305 14.5.1 Details about the grinding process 305 14.5.2 Power skiving 306 14.6 Tolerances .307 14.6.1 Tooth thickness tolerance 308 14.6.2 Tip diameter allowances 310 14.6.3 Root diameter allowances .310 14.6.4 Center distance tolerances 310 14.6.5 Settings 310 14.7 Modifications 311 14.7.1 Type of modification 311 14.7.2 Individual modifications per tooth 312 14.7.3 Profile modifications 313 14.7.4 Tooth trace modifications 322 14.7.5 Sizing modifications .329 14.7.6 Notes about profile modification 332 14.7.7 Using diamond dressing wheels and grinding worms .332 14.8 Tooth form 33514.8.1 Context menu 336 14.8.2 Operations .337 14.9 Asymmetric gears 354 14.10 Contact analysis .355 14.10.1 Theory of contact analysis .357 14.10.2 Asymmetrical gear teeth in the contact analysis .360 14.10.3 Discretized model 361 14.10.4 Smoothing the tooth form curvature to calculate Hertzian pressure in the contact analysis .361 14.10.5 Reduced stiffness on the side edges .362 14.10.6 Coupling the individual slices 363 14.10.7 Contact analysis model for planetary systems 364 14.10.8 Base pressure angle of contact analysis .365 14.10.9 Wear iteration 366 14.10.10 Contact analysis with load spectra 367 14.11 Gear pump .367 14.12 Operating backlash 369 14.12.1 Temperatures 371 14.12.2 Relative water absorption during swelling .371 14.12.3 Coefficient of thermal expansion for housing 372 14.12.4 Take into account the bending of the shafts and width modifications .372 14.12.5 Tooth deformation .372 14.13 Master gear 373 14.14 AGMA 925 .374 14.15 Root stress FEM 375 14.16 Rough sizing 376 14.17 Fine sizing 380 14.17.1 Necessary entries in the input window 382 14.17.2 Conditions I 38214.17.3 Conditions II .383 14.17.4 Conditions III 384 14.17.5 Results .388 14.17.6 Graphics 390 14.17.7 Geometry fine sizing for 3 gears 390 14.17.8 Geometry-Fine Sizing for 4 gears 391 14.17.9 Additional strength calculation of all variants .392 14.18 Sizing modifications .392 14.18.1 Conditions I/II .393 14.18.2 Results .394 14.18.3 Graphic I 394 14.18.4 Graphic II .395 14.18.5 Report 395 14.19 Measurement grid 395 14.20 Settings 397 14.20.1 General 398 14.20.2 Plastic 401 14.20.3 Planets .405 14.20.4 Sizings .406 14.20.5 Calculations .407 14.20.6 Required safeties .412 14.20.7 Contact analysis/face load factor .413 14.20.8 Contact analysis 413 14.20.9 Summary .415 14.20.10 Diagrams .416 14.20.11 Generate a 3D model 416 14.21 Tooth thickness 419 14.22 Tooth form export .42015 Bevel and Hypoid Gears . 421 15.1 Underlying principles of calculation 421 15.1.1 General 421 15.1.2 Overview of the bevel gear manufacturing process and the terminology used in it 421 15.1.3 Calculation according to Klingelnberg, Gleason and Oerlikon 422 15.2 Basic data 423 15.2.1 Mean normal module .423 15.2.2 Pitch diameter gear 2 423 15.2.3 Pressure angle at normal section 423 15.2.4 Pressure angle driving/driven flank: Hypoid gears 424 15.2.5 Spiral and helix angle 425 15.2.6 Shaft angle 426 15.2.7 Offset .426 15.2.8 Number of teeth .427 15.2.9 Facewidth 427 15.2.10 Profile shift coefficient 427 15.2.11 Tooth thickness modification factor .428 15.2.12 Quality .428 15.2.13 Addendum angle and root angle .429 15.2.14 Angle modifications .430 15.2.15 Geometry details .430 15.2.16 Manufacturing process 432 15.3 Type .432 15.3.1 Converting or inputting Gleason toothing data 435 15.4 Manufacturing 437 15.4.1 Cutter radius 437 15.4.2 Number of blade groups 438 15.5 Rating (load) 43815.5.1 Methods used for strength calculation .438 15.5.2 Required rating life 441 15.5.3 Power, torque and speed 442 15.5.4 Strength details 442 15.5.5 Application factor .444 15.6 Reference profile 445 15.6.1 Default values for tip clearance .445 15.6.2 Default values for addendum coefficients 446 15.7 Contact analysis .446 15.8 Modifications 446 15.9 Rough sizing 450 15.9.1 Facewidth ratio 450 15.9.2 Module ratio .451 15.10 Fine sizing 451 15.10.1 Required entries in the standard tabs 452 15.10.2 Conditions I 452 15.10.3 Conditions II .453 15.10.4 Conditions III 454 15.10.5 Results .458 15.10.6 Graphics 459 15.11 Notes about calculations according to the Klingelnberg standard .459 15.11.1 Bevel gears with cyclo-palloid gear teeth .459 15.11.2 Hypoid gears with cyclo-palloid gear teeth 460 15.11.3 Normal module ranges for Klingelnberg machines (cyclo-palloid) 460 15.11.4 Bevel gears with Palloid gear teeth .462 15.11.5 Definitions and dimensions of standard cutters for palloid gear teeth .463 15.11.6 Minimum safeties .463 15.11.7 Surface roughness at tooth root 46315.11.8 Manufacturing quality for bevel gears 464 15.11.9 Characteristic number .464 15.12 Settings 465 15.12.1 General 465 15.12.2 Calculations .465 15.12.3 Differential gears .465 15.12.4 Helpful information about the Generation of 3D model tab .466 15.12.5 Factors .466 15.12.6 Contact analysis 468 15.12.7 Display .469 16 Face Gears . 470 16.1 Underlying principles of calculation 470 16.2 Basic data 473 16.2.1 Normal module 473 16.2.2 Pressure angle at normal section 475 16.2.3 Helix angle at reference circle .475 16.2.4 Axial offset .476 16.2.5 Profile shift coefficient 476 16.2.6 Quality .477 16.2.7 Geometry details .478 16.2.8 Material and lubrication .479 16.3 Rating (load) 480 16.3.1 Methods used for strength calculation .480 16.3.2 Service life .482 16.3.3 Power, torque and speed 482 16.3.4 Application factor .483 16.3.5 Strength details 483 16.4 Factors .48816.4.1 Face load factor .488 16.5 Modifications 488 16.5.1 Addendum reduction .488 16.5.2 Type of modification 489 16.6 Settings 489 16.6.1 General 490 16.6.2 Sizings .491 16.7 Notes on face gear calculation .491 16.7.1 Dimensioning .491 16.7.2 Pinion - Face gear with Z1 > Z2 492 17 Worms with enveloping worm wheels . 493 17.1 Underlying principles of calculation 493 17.2 Basic data 495 17.2.1 Axial/transverse module 495 17.2.2 Pressure angle at normal section 495 17.2.3 Lead angle at reference diameter 496 17.2.4 Center distance .496 17.2.5 Number of teeth .496 17.2.6 Facewidth 496 17.2.7 Profile shift coefficient 497 17.2.8 Tooth thickness modification factor .497 17.2.9 Quality .498 17.2.10 Geometry details .498 17.2.11 Material and lubrication .499 17.3 Rating (load) 500 17.3.1 Methods used for strength calculation .501 17.3.2 Rating life .501 17.3.3 Application factor .50117.3.4 Permissible decrease in quality .502 17.3.5 Power, torque and speed 502 17.3.6 Strength details 503 17.4 Tolerances .506 17.5 Settings 506 17.5.1 General 507 17.5.2 Reference gearing .508 17.5.3 Calculations .509 17.5.4 Required safeties .511 18 Crossed helical gears, precision mechanics worms and crossed helical gear with rack . 512 18.1 Underlying principles of calculation 512 18.2 Basic data 513 18.2.1 Normal module 513 18.2.2 Pressure angle at normal section 513 18.2.3 Helix angle reference circle gear 1 513 18.2.4 Center distance .514 18.2.5 Facewidth 514 18.2.6 Profile shift coefficient 514 18.2.7 Quality .514 18.2.8 Define geometry details .515 18.2.9 Material and lubrication .516 18.3 Rating (load) 517 18.3.1 Methods used for strength calculation .517 18.3.2 Rating life .522 18.3.3 Application factor .522 18.3.4 Power, torque and speed 523 18.3.5 Strength details 52318.4 Settings 529 18.5 Notes 529 18.5.1 Checking the contact pattern .529 18.6 Crossed helical gear with rack .529 19 Beveloid Gears . 531 19.1 Underlying principles of calculation 531 19.2 Basic data 532 19.2.1 Normal module 532 19.2.2 Normal pressure angle 532 19.2.3 Helix angle .532 19.2.4 Shaft angle 532 19.2.5 Number of teeth .533 19.2.6 Width .533 19.2.7 Cone angle 533 19.2.8 Profile shift coefficient (center) 533 19.2.9 Quality .533 19.2.10 Material and lubrication .533 19.3 Reference profile 533 19.4 Modifications 534 19.5 Factors .534 19.6 Dimensioning .534 19.7 Manufacturing Data and Working Data 534 20 Non-Circular Gears . 536 20.1 Input data .536 20.1.1 Geometry .536 20.1.2 Tolerances .538 20.1.3 Reference profile .53820.2 Notes on how to operate KISSsoft .539 20.2.1 Angle error .539 20.2.2 Checking the meshing .539 20.2.3 Improving the tooth form 540 20.2.4 Accuracy of the tooth form .540 20.2.5 Exporting individual teeth 541 20.2.6 Report 542 20.2.7 Temporary files 542 21 Report Menu . 544 21.1 Drawing data 544 21.2 Manufacturing tolerances .544 21.3 Summary 545 21.4 Rating life .545 21.5 Sizing of torque 545 21.6 Proposal for the hardening depth EHT 545 22 Graphics Menu . 547 22.1 AGMA 925 .550 22.1.1 Lubricant film thickness and specific oil film thickness 550 22.2 Geometry 2D 551 22.2.1 Gear tooth forms 551 22.2.2 Gear tool 552 22.2.3 Manufacturing a gear .552 22.2.4 Meshing .552 22.2.5 Profile and tooth trace diagram .553 22.2.6 Drawing .556 22.2.7 Assembly .556 22.2.8 Manufacturing drawing 55622.3 Geometry 3D 559 22.3.1 Tooth system .559 22.3.2 Tooth form .560 22.4 Evaluation 560 22.4.1 Specific sliding .560 22.4.2 Contact temperature 560 22.4.3 Flash temperature .560 22.4.4 Hardening depth 560 22.4.5 Theoretical meshing stiffness 561 22.4.6 S-N curve (Woehler lines) for material 562 22.4.7 Safety factor curves .562 22.4.8 Oil viscosity 562 22.4.9 Gap analysis 562 22.4.10 face load distribution 562 22.4.11 Backlash with actual tooth form .563 22.4.12 Tooth flank fracture 563 22.4.13 Sliding velocity (face gear) 563 22.4.14 Contact line (face gear) .563 22.4.15 Stress curve (face gear) 563 22.4.16 Scuffing and sliding velocity (face gear) 563 22.5 Contact analysis .564 22.5.1 Axis alignment .565 22.5.2 Transmission error .565 22.5.3 Transmission error acceleration 565 22.5.4 Amplitude of transmission error .567 22.5.5 Normal force curve 567 Normal force distribution .568 22.5.6 Torque curve .568Single contact stiffness 568 22.5.7 Stiffness curve .568 22.5.8 Amplitude spectrum of the contact stiffness 569 22.5.9 Bearing force curve and direction of the bearing forces 569 22.5.10 Kinematics .570 22.5.11 Specific sliding .570 22.5.12 Power loss .570 22.5.13 Heat development .570 22.5.14 Stress curve .570 22.5.15 Flash temperature .571 22.5.16 Micropitting (frosting) .571 22.5.17 Wear 573 22.6 Gear pump .575 22.7 3D export .575 22.8 Settings 575 22.9 Graphics list .575 23 Answers to Frequently Asked Questions 576 23.1 Answers concerning geometry calculation .576 23.1.1 Precision engineering 576 23.1.2 Deep tooth forms or cylindrical gears with a high transverse contact ratio .576 23.1.3 Pairing an external gear to an inside gear that has a slightly different number of teeth 577 23.1.4 Undercut or insufficient effective involute 577 23.1.5 Tooth thickness at tip .577 23.1.6 Special toothing .578 23.1.7 Calculating cylindrical gears manufactured using tools specified in DIN 3972 578 23.1.8 Composites as defined in DIN 58405 579 23.1.9 Automatic change of reference profiles .57923.1.10 Non-identical (mirrored symmetry) tooth flanks .580 23.1.11 Internal teeth - differences in the reference profile if you select different configurations 580 23.1.12 Effect of profile modifications .581 23.1.13 Number of teeth with common multiples .582 23.1.14 Allowances for racks 583 23.2 Answers to questions about strength calculation .583 23.2.1 Differences between different gear calculation programs .583 23.2.2 Difference between cylindrical gear calculation according to ISO 6336 or DIN 3990 .584 23.2.3 Calculation using Methods B or C (DIN 3990, 3991) .584 23.2.4 Required safeties for cylindrical gear units 584 23.2.5 Insufficient safety against scuffing .585 23.2.6 Material hardening factor (for strengthening an unhardened gear) .586 23.2.7 Defining the load stage scuffing (oil specification) .586 23.2.8 The effect of the face load factor KHß for the tooth trace deviation fma is due to a manufacturing error. .586 23.2.9 Load spectrum with alternating torque 587 23.2.10 Strength calculation with several meshings on one gear 588 23.2.11 Bevel gears: – Determine permitted overloads .591 23.2.12 Taking shot peening data into account when calculating gear strength 591 23.2.13 Calculation according to AGMA 421.06 (High Speed Gears) 592 23.2.14 Comparison of an FEM calculation with the crossed helical gear calculation .592 23.2.15 Determine the equivalent torque (for load spectra) .593 23.2.16 Check changes in safeties if the center distance changes 593 23.2.17 Warning: "Notch parameter qs …. outside RANGE (1.0 to 8.0) ." .594 23.2.18 Tooth root stresses in the contact analysis and stress according to FEM – is there a difference? 594 23.3 Abbreviations used in gear calculation 595III Shafts and Bearings .602 24 Defining Shafts . 603 24.1 Input window 605 24.1.1 Shaft Editor 606 24.1.2 Element Tree .606 24.1.3 Element List .607 24.1.4 Element Editor .608 24.2 Element overview .608 24.2.1 The shaft element 608 24.2.2 Outer contour .613 24.2.3 Inner contour .620 24.2.4 Forces 620 24.2.5 Bearings 625 24.2.6 Connection elements .629 24.2.7 Cross sections .631 24.3 Basic data 632 24.3.1 Position of shaft axis in space .632 24.3.2 Number of eigenfrequencies .633 24.3.3 Number of buckling cases .633 24.3.4 Speed 633 24.3.5 Direction of rotation .634 24.3.6 Reference temperature 634 24.3.7 Housing temperature .635 24.3.8 Lubricant temperature .635 24.3.9 Load spectra 636 24.3.10 Gears .636 24.3.11 Rolling bearings .63724.3.12 Tolerance field .638 24.3.13 Modified rating life according ISO 281 .640 24.3.14 Consider weight .640 24.3.15 Consider gyroscopic effect 640 24.3.16 Housing material 641 24.3.17 Lubrication .641 24.3.18 Contamination .641 24.4 Module specific settings .641 24.4.1 Non-linear shaft .641 24.4.2 Take into account deformation due to shearing and shear correction coefficient .642 24.4.3 Activating offset of the load application center point .642 24.4.4 Using the 2013 solver 642 24.4.5 Saving temporary results in CSV format with .tmp file extension 643 24.4.6 Standard radius at shoulders .643 24.4.7 Node density 643 24.4.8 Iterative calculation of load distribution 644 24.4.9 Input different numbers of load cycles for bending and torsion (for limited life calculations) 644 24.4.10 Save user defined bearings in calculation file .644 24.4.11 Read user-defined rolling bearings from calculation file 645 24.4.12 Enter contamination in each bearing separately .645 24.4.13 Axial clearance 645 24.4.14 Failure probability 645 24.4.15 Required rating life 645 24.4.16 Maximum life modification factor .646 24.4.17 Display critical bearings .646 24.4.18 Surface roughness of housing .647 24.4.19 Calculation method for friction .647 24.4.20 Grease lifetime 64724.4.21 Oil level 647 24.4.22 Type of oil lubrication .647 24.4.23 Moment of friction, seals 648 24.4.24 Bearing manufacturer 648 24.4.25 Show coordinates system 648 24.4.26 Show automatic dimensioning .648 24.4.27 Equivalent stress for sizings 649 24.4.28 Maximum deflection for sizings .649 25 Calculating Shafts . 650 25.1 Deflection and Bearing Forces, Distribution of Force and Torque .651 25.1.1 Calculating force on bearings with a contact angle .653 25.2 Eigenfrequencies .654 25.2.1 Bending critical speed .655 25.2.2 Torsion critical speed .655 25.3 Buckling .655 25.4 Rough sizing of shafts 655 25.5 Strength .656 25.5.1 Calculation method 658 25.5.2 Type of calculation .662 25.5.3 Rating life .664 25.5.4 Strength parameters according to Hänchen and Decker 664 25.5.5 Strength parameters according to FKM .665 25.5.6 Strength parameters according to DIN 668 25.5.7 Strength parameters according to AGMA 669 25.5.8 Stress 670 25.5.9 Stress ratio 671 25.5.10 Load factor for static analysis 671 25.5.11 Load factor endurance calculation .67225.5.12 Cross sections .672 25.5.13 Sizing .674 25.5.14 Cross-section types .674 25.5.15 General entries 679 25.5.16 Thermally safe operating speed 679 25.6 Tooth trace modification .680 25.7 Campbell diagram 682 25.8 Forced vibrations .684 25.8.1 Calculation procedure 684 25.8.2 Results .684 26 General Bearing Calculation . 685 26.1 Classification of bearings .685 26.1.1 Properties 685 27 Rolling Bearings (Classic Analysis) 687 27.1 Selecting the type of rolling bearing .688 27.1.1 Properties of the most important bearing types .688 27.1.2 Comparing types .690 27.1.3 Hybrid bearings .692 27.2 Load capacity of rolling bearings .693 27.2.1 Dynamic load capacity .693 27.2.2 Static load capacity 693 27.2.3 Rolling bearing calculation with inner geometry 694 27.3 Thermally safe operating speed .695 27.3.1 Thermal reference speed 696 27.3.2 Process for calculating thermally safe operating speed (DIN 732-2) 697 27.4 Moment of friction 699 27.4.1 Calculation according to SKF Catalog 1994 69927.4.2 Calculation according to SKF Catalog 2018 700 27.4.3 Calculation according to Schaeffler 2017 (INA, FAG) .703 27.5 Grease lifetime .704 27.5.1 Calculation according to Schaeffler 2014 (INA, FAG) .704 27.5.2 Calculation according to SKF Catalog 2018 704 27.6 Maximum Speeds 705 27.7 Rating life .705 27.7.1 Modified rating life calculation according to the Supplement to DIN ISO 281 (2007) 705 27.7.2 Rating life calculation with load spectra .707 27.8 Failure probability .708 27.9 Bearing with radial and/or axial force .708 27.10 Calculating axial forces on bearings in face-to-face or back-to-back arrangements .709 27.11 Oil level and lubrication type 710 28 Rolling Bearings (Internal Geometry) 711 28.1 Bearing data tab .711 28.1.1 File interface 712 28.1.2 Bearing data 713 28.2 Rating (load) tab 717 28.2.1 Rating (load) 717 28.2.2 Modified rating life calculation in accordance with ISO 281 718 28.3 Tab Elastic Rings .718 28.3.1 Basic data 718 28.3.2 Details 719 28.4 Graphics .721 28.5 Fine sizing 721 29 Hydrodynamic Plain Journal Bearings 723 29.1 Calculation methods 72329.2 Module specific entries 724 29.3 Thermal expansion coefficients .724 29.4 Average surface pressure 725 29.5 Geometries according to DIN 31657 .725 29.6 Stiffness .728 29.7 Lubrication arrangement 728 29.8 Heat transfer coefficient .730 29.9 Heat transfer surface .730 29.10 Oil temperatures 731 29.11 Mixture factor .731 29.12 Sizing the bearing clearance 731 29.13 Sommerfeld number 732 29.14 Bearing width .733 29.15 Permissible lubricant film thickness .733 30 Hydrodynamic Plain Thrust Bearings 734 30.1 Calculation .736 30.2 Sizings .737 30.3 Calculation of volume-specific heat .738 30.4 Limiting values in the calculation .738 31 Answers to Frequently Asked Questions 739 31.1 Intersecting notch effects .739 31.2 Notch effects on hollow shafts .739 31.2.1 Notches on the outer contour 739 31.2.2 Notches on the inner contour 740 31.3 Fatigue Limits for New Materials 740 31.4 Taking double helical gearings into account in the shaft calculation .741IV Connections .742 32 Cylindrical Interference Fit 743 32.1 Inputting Tolerances 745 32.2 Coefficients of friction .746 32.3 Variable external diameter of the hub 748 32.4 Convert external pressure with multiple interference fit .748 32.5 Materials 750 32.6 Settings 751 32.7 Sizings .752 33 Conical Interference Fit . 754 33.1 Calculation .756 33.2 Application factor .757 33.3 Axial spanning with nut 757 33.4 Variable external diameter of the hub 759 33.5 Conicity 759 33.6 Materials 760 33.7 Settings 761 33.8 Sizings .761 34 Clamped Connections 763 34.1 Calculations .763 34.2 Sizings .765 34.3 Settings 766 34.4 Materials 767 35 Keys . 768 35.1 Main window 76835.1.1 Additional inputs for DIN 6892 Method B 770 35.2 Application factor .772 35.3 Contact coefficient .773 35.4 Own inputs .774 35.5 Permissible pressure .774 35.6 Materials 774 35.7 Settings 774 35.8 Sizings .775 36 Straight-sided splines . 776 36.1 Standard profiles 776 36.2 Application factor .777 36.3 Torque curve/Number of changes of load direction .778 36.4 Occurring contact stress 778 36.5 Length factor 778 36.6 Share factor .779 36.7 Permissible pressure .779 36.8 Materials 780 36.9 Settings 780 36.10 Sizings .781 37 Splines (Strength) . 782 37.1 Standard profiles 782 37.2 Application factor .783 37.3 Torque curve/Number of changes of load direction .784 37.4 Occurring contact stress 784 37.5 Length factor 784 37.6 Share factor .785 37.7 Permissible pressure .78637.8 Materials 787 37.9 Settings 787 37.10 Sizings .787 38 Splines (Geometry and Strength) . 789 38.1 Underlying principles of calculation 789 38.1.1 General 789 38.1.2 Calculation of spline connections as described in DIN 5480 with diameter centering.789 38.1.3 Calculating spline connections according to DIN 5480 with flank centering 790 38.2 Basic data 791 38.2.1 Geometry standards 791 38.2.2 Normal module 792 38.2.3 Pressure angle at normal section an .792 38.2.4 Number of teeth .792 38.2.5 Profile shift coefficient 792 38.2.6 Quality .793 38.2.7 Niemann geometry data 794 38.2.8 Geometry details .794 38.2.9 Define details of strength .795 38.2.10 Materials 801 38.3 Tolerances .801 38.3.1 Tooth thickness tolerance 801 38.3.2 Effective/Actual 802 38.3.3 Shaft/hub: diameter of ball/pin .803 38.4 Gauges 803 38.5 Tooth form 804 39 Polygons . 805 39.1 Standard profiles 80539.2 Application factor .806 39.3 Torque curve/Number of changes of load direction .806 39.4 Occurring contact stress 806 39.5 Permissible pressure .808 39.6 Materials 809 39.7 Settings 809 39.8 Sizings .809 39.9 Graphics .810 40 Woodruff Keys 811 40.1 Standard profiles 811 40.2 Application factor .812 40.3 Torque curve/Number of changes of load direction .812 40.4 Occurring contact stress 813 40.5 Length factor 813 40.6 Share factor .814 40.7 Permissible pressure .814 40.8 Materials 815 40.9 Settings 815 40.10 Sizings .815 41 Bolts and Pins . 816 41.1 Influence factors .817 41.2 Materials 818 41.3 Settings 819 41.4 Permitted values 819 41.5 Sizings .820 42 Bolts . 82142.1 Special features in KISSsoft 821 42.2 Inputs for Basic data 822 42.2.1 Operating data .822 42.2.2 Bolt data 834 42.2.3 Type of bolted joint 837 42.2.4 Washers 838 42.2.5 Extension sleeves without external forces .839 42.2.6 Tightening technique .839 42.3 Data input for clamped parts 840 42.3.1 Geometry of clamped parts (connecting solids) 840 42.3.2 Distances for eccentric clamping/load .842 42.3.3 Load introduction .843 42.4 Constraints data .844 42.4.1 Technical Explanations 846 42.4.2 Coefficients of friction 847 42.4.3 Rotation-angle controlled tightening 848 42.5 Stripping strength .849 42.6 Settings 849 43 Welded Joints . 853 43.1 Welded joints .853 43.2 Seam length .854 43.3 Welded seam equivalent stress .855 43.4 Weld seam boundary stress 855 43.5 Part safety coefficient .855 43.6 Boundary safety coefficient 855 43.7 Materials 856 44 Glued and Soldered Joints . 85744.1 Basic materials .858 44.2 Settings 858 44.3 Sizings .859 44.4 Bracket connection 859 44.5 Shaft connections 859 45 Retaining rings (self-locking rings, snap rings) 860 45.1 Basic data 860 45.2 Automatic calculation of load factor q 862 45.3 Automatic calculation of the dishing angle ψ .863 45.4 Module specific settings .864 46 Answers to Frequently Asked Questions 865 46.1 Adding new bolt types to the database 865 46.1.1 Extending an existing bolt series .865 46.1.2 Creating a new bolt type 868 V Springs 870 47 Compression Springs . 871 47.1 Strength values 872 47.2 Shear stress values .872 47.3 Bearings coefficient 873 47.4 Materials 874 47.5 Tolerances .874 47.6 Relaxation 875 47.7 Drawing data 876 47.8 Sizings .877 48 Tension Springs 87848.1 Strength values 879 48.2 Shear stress values .879 48.3 Manufacturing type 880 48.4 Eyes window 880 48.5 Materials 882 48.6 Settings 883 48.7 Tolerances .883 48.8 Relaxation 883 48.9 Drawing data 884 48.10 Sizings .885 49 Leg Springs 886 49.1 Strength values 887 49.2 Bending stress values 887 49.3 Spring design .888 49.4 Assumptions made for the calculation .889 49.5 Materials 890 49.6 Tolerances .890 49.7 Drawing data 891 49.8 Sizings .891 50 Disc Springs . 892 50.1 Strength values 893 50.2 Stress values .893 50.3 Materials 895 50.4 Calculate number .895 50.5 Limit dimensions 896 51 Torsion-Bar Springs 897 51.1 Tip forms 898 51.2 Strength values 898 51.3 Shear stress .899 51.4 Limiting values .899 51.5 Sizings .900 VI Belts and chain drives 901 52 V-Belts 902 52.1 V-belts data 903 52.2 V-belt standards .903 52.3 Configuring tensioning pulleys .904 52.4 Application factor F1 904 52.5 Center distance 904 52.6 Belt length 905 52.7 Effective number of V-belts 905 52.8 Tensioning pulley diameter 905 52.9 Position of tensioning pulley (x/y) 905 52.10 Inspecting V-belts 905 53 Toothed Belt . 906 53.1 Technical notes (toothed belts) 906 53.2 Toothed belt standard 908 53.3 Possible sizings/suggestions .909 53.4 Configuring tensioning pulleys .909 53.5 Application factor and summand for operational behavior .910 53.6 Center distance 910 53.7 Belt length and number of teeth on belt .910 53.8 Effective belt width .91153.9 Tensioning pulley tooth number .911 53.10 Position of the tensioning pulley x/y .912 54 Chain Drives . 913 54.1 Sizings .913 54.2 Tensioning pulleys .914 54.3 Standard 914 54.4 Chain type 914 54.5 Number of strands .914 54.6 Application factor .914 54.7 Speed/number of teeth/ratio 915 54.8 Configuration 915 54.9 Center distance 916 54.10 Polygon effect 916 54.11 Number of links 917 54.12 Sprocket geometry .917 VII Automotive 919 55 Synchronization 920 55.1 Geometry .920 55.2 Operating data .921 56 Friction couplings 922 56.1 Calculation .923 56.2 Definition of spring forces 926 56.3 Definition of the coefficients of sliding friction and velocities .927 56.4 Graphics .927 56.5 Settings 927VIII Various .929 57 Tolerance Calculation . 930 58 Proof of strength with local stresses . 931 58.1 General 931 58.1.1 Software functionality 931 58.1.2 Areas of application for the FKM Guideline .931 58.2 Background 932 58.2.1 The FKM Guideline: Rechnerischer Festigkeitsnachweis für Maschinenbauteile .932 58.2.2 Usefulness of the rating life calculation .933 58.3 Implementation in KISSsoft 935 58.3.1 Main screen .935 58.3.2 Stress cases 937 58.3.3 S-N curve (Woehler lines) .938 58.3.4 Number of load cycles .938 58.3.5 Temperature 938 58.3.6 Temperature duration 938 58.3.7 Protective layer thickness, Aluminum, section 4.3.4, Figure 4.3.4 938 58.3.8 Stress ratios .938 58.3.9 Spectra 939 58.3.10 Surface factor KV, section 4.3.3, Table 4.3.7 940 58.4 Materials 940 58.4.1 Surface roughness 940 58.5 Settings 941 58.5.1 General settings 941 58.5.2 Required safeties .943 58.6 Estimation of the endurance limit for surface-treated parts (section 5.5) .944 59 Hertzian Pressure . 94659.1 Settings 948 60 Hardness Conversion . 949 61 Linear Drive Train . 951 61.1 Calculation .952 61.2 Sizings .956 61.3 Settings 957 61.4 Materials 957 62 Deformation of the Gear Body 959 62.1 Calculation procedure 959 62.2 Results .960 63 Plastics Manager 961 63.1 Gear test results .962 63.1.1 Case I. Test results measured on identical test gears .962 63.1.2 Case II. Test results available from gears with different gear geometry 963 63.2 Additional settings in the "Test data" tab .963 63.3 Settings in the Module specific settings .965 63.4 Extrapolation of the calculated permissible root and/or flank stresses 966 63.5 Other calculation options .966 63.6 Writing material data to the KISSsoft database .967 63.7 Graphics .967 63.8 Import material files from mBase .967 IX KISSsys 968 64 KISSsys: Calculation Systems 969 64.1 General 96964.1.1 Structure of KISSsys .969 64.1.2 Ways in which KISSsys can be used 969 64.1.3 The user interface 970 64.2 Creating Models in KISSsys 974 64.2.1 Classic method 974 64.2.2 Element Assistant 974 64.2.3 System Assistant .974 64.2.4 Setup with icon 975 64.2.5 Creating and modifying tables .975 64.2.6 Adding variables to tables .975 64.2.7 Individual names for elements .976 64.3 Extended functionality for developers 977 64.3.1 Properties dialog 977 64.3.2 Table view .979 64.4 The following elements are available .979 64.4.1 Variables 979 64.4.2 Calculation elements .981 64.4.3 Elements for shafts 983 64.4.4 Connection elements .983 64.4.5 Displaying elements in a 3D graphic .984 64.4.6 System settings .985 64.5 Programming in the Interpreter 985 64.5.1 Expressions in variables 985 64.5.2 Functions .987 64.5.3 Important service functions 989 64.5.4 Variable dialogs .990 64.5.5 Defining 2D graphics .999 64.6 Specific functions .100264.6.1 Load spectrum calculation .1002 64.6.2 Efficiency Calculation 1003 64.6.3 Taking into account housing deformation in static KISSsys calculations 1003 64.6.4 Modal analysis of shaft systems 1006 64.6.5 Campbell diagram for shaft systems .1007 64.6.6 Analysis of unbalance response of shaft systems .1008 X Bibliography and Index 1010 65 Bibliography 1011
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