Cylindrical gear basis modules Configurations Spur and helical gear, double helical, herringbone, with or without face width offset Grease or oil lubricated or dry running gears Metallic and plastic gears Involute and non-involute gears Any number of teeth, any type of tooth height, internal or external gears Symmetrical and asymmetrical profile Gear geometry calculation Gear geometry along ISO 21771, DIN 3960 Reference profile along ISO 53, DIN 867, JIS B 1701, GOST 13755, DIN 3972, DIN 58400, BS 5482 Tooth thickness tolerances along DIN 3967, ISO 1328, DIN 58405, GOTS 1643 Centre distance along ISO 286, DIN ISO 2768, DIN 7168, DIN 58405, GOST 1643 Gear quality along ISO 1328, AGMA 2015, DIN 3961-3963, AGMA 2000, GOST 1643, JIS B 1702 Own input Gear rating DIN 3990 method B, DIN 3990 method B with YF along method C, DIN 3990 Part 41 (vehicles) ISO 6336:2006 and ISO 6336:2019 Static rating against yield AGMA 2001-C95, AGMA 2101-D04, AGMA 2001-D04 AGMA 6004-F88, AGMA 6011-J14, API 613 :2021, AGMA 6014-B15, AGMA 6015-A13, GOST 21354-87 Plastic gears along Niemann, VDI 2545, VDI 2545 modified, VDI2736 BV / Rina FREMM3.1, Rina 2010, DNV41.2, Loyds Register 2013 ISO 13691:2001 (high speed gears) For nominal load or load spectrum Reports Default report or user specific template Geometry and strength reports Tooth scuffing, micropitting and wear Tooth thickness dimensions, tooth tolerances Modifications, manufacturing X-Y coordinates of tooth profile Cylindrical gear general modules Gear geometry calculation Based on gear or tool reference profile with protuberance, buckling root, reference thickness, semi- non- full topping Or based on *.dxf import of tool geometry Calculation based on mating gear geometry Import and export of gear or tool geometry from CAD system Calculation of theoretical, acceptance and operating backlash for metallic and plastic gears and housings Load spectrum calculation Direct input of load spectrum or import from text or Excel file or time series Calculation of lifetime based on required safety factor, safety factors based on required lifetime and permissible torque based on required safety factor and lifetime Calculation of partial damages Calculation of equivalent torque For DIN 3990, ISO 6336 and AGMA 2001 rating AGMA925 calculations Calculation of scuffing safety Calculation of contact stress, lubricant film thickness Micropitting and scuffing calculation Micropitting rating along ISO/TS 6336-22 Specific lubricant film thickness calculation along AGMA 925 Lubricant film thickness calculation along ISO/TS 6336-22 based on true contact stress Scuffing rating along ISO 6336-20, ISO 6336-21, DIN 3990-4 Flank fracture calculation Along ISO/TS 6336-4 method Along method A (based on LTCA) or method B (based on formulas) Case crushing calculation along DNV 41.2 Master gear calculation Calculation of master gear geometry Meshing of master gear with workpiece Sizing function for form diameters Cylindrical gear sizing modules Configurations Sizing functions to find optimized gears (in terms of mass, power density, stiffness, space, … requirements) Functions to reverse engineer gears Functions to optimize gear properties Rough sizing Proposal of several gear solutions for required power rating, required ratio, given material Considers gear quality, permissible ratio error For single load level or load spectrum Fine sizing Define permissible ranges for module, pressure angle, helix angle, center distance, face width, gear quality, profile shift, … Define target ratio and permissible deviation Define maximum number of solutions Set maximum permissible tip diameter and minimum permissible root diameter For pre-defined number of teeth or varying number of teeth Different filter and sorting functions Report with assessment of solutions for different criteria Profile shift sizing Sizing from gear pair data Sizing for target profile shift sum For balanced specific sliding / speed increaser To avoid pointed tooth or undercut For maximized strength on flank or root or maximized scuffing strength Sizing of tooth height / reference profile Sizing of reference profile for target transverse contact ratio Sizing of maximum possible root radius Sizing of profile and lead modifications Sizing of tip and root relief Sizing of end relief and crowning Automatic search for optimum modifications Cylindrical gear modifications Configurations Combine modifications in profile and lead direction, combined and topological modifications Create K chart and lead diagram Define tolerances range based on AGMA 2000, using constant band width or import tolerance bands from GAMA ® Display each modification separately in 2D diagram, display resulting combination Show flank modifications in 3D, combining all modifications Gear 3D geometry includes modifications Tip chamfer, tip rounding in different sections Face chamfer, tip face chamfer Modifications manager using variants of sets of modifications Root modifications Root with pre-machining and or final machining, independent root diameter tolerances Grinding notch, partial final machining of root Root geometry optimization for minimized root stresses Manufacturing errors as modifications Flank waviness with wavelength, amplitude and angle Natural twist from generating grinding Profile and helix form and slope deviation Lead and profile modifications End relief (left and right end), flank line crowning (centrical, eccentrical) Helix angle modification Linear and progressive tip / root modification Profile crowning (barreling), also in combination with tip relief, roll length or diameter centered Pressure angle modification Tip chamfer or rounding Flank twist Triangular end relief (left and right end) Topological modification … Gear body influence Modelling and FEM Hub / web / rim arrangement Parametrized geometry Automatic meshing, parabolic tet elements Automatic meshing, parabolic prism elements Modeling of local radii Automatic defeaturing capabilities Geometry preview, mesh preview Import of *.stp files Multibody modelling (separate materials for rim and body) Result review per body Calcualtions and integration Calculation of deformation and reduced stiffness matrix Stiffness matrix connected to shaft calculation In combination with LTCA 2D and 3D-gear body deformation Tooth geometry export Options With or without profile / lead modifications Modifications may be different per tooth Modifications may be different per flank Output in transverse, normal and axial section Output of tooth or gap, single or half tooth Output as x,y format to use e.g., in spreadsheet calculations Output as x, y, z format in line with Gleason or Klingelnberg format for measuring machines Rating with time series Import and conversion Import time series of speed and torque from text file Convert to load duration distribution load spectrum (LDD), save LDD for gear rating Considers changes in torque direction Considers changes in speed direction Graphical display of resulting load and speed distribution Configurations Rain flow count method according to Amzallag or ASME Simple count method Loaded tooth contact analysis Configurations Considers all modifications in profile and lead direction and topological modifications Calculation over one or several pitches Pitch errors may be considered in part or fully Calculation for nominal or operating center distance Calculation for nominal or partial load level Meshing friction considered in calculation Considers true gear geometry from manufacturing simulation For internal and external gears User defined resolution in calculation Line load calculation along ISO 6336-1, Annex E with consideration of manufacturing errors Mesh stiffness calculation Calculation of transmission error TE for spur and helical gears, showing peak to peak transmission error PPTE, average and standard deviation Calculation of normal force, torque variation, contact stiffness, bearing forces, kinematics, specific sliding, and local heat generated over meshing cycle Results displayed vs. roll angle, pinion diameter, length on path of action, pinion angle of rotation Calculation has been verified in benchmarks against reference software, practical experience in full load tests and FEM calculations Different methods for slice linking spring stiffness Output Graphics, exportable as graphic format or *.dxf Report including calculation settings and results summary Report including all graphics True contact ratio calculation Calculation of true transverse contact ratio under load Calculation of true total contact ratio under load Detailed backlash calculation Backlash from true tooth form Backlash is calculated as an angular backlash. Theoretical backlash is calculated based on true tooth form. Tooth form may be involute, involute with modifications or non-involute. For non-involute tooth form or involute tooth form with modifications, backlash is not constant over the meshing cycle. Backlash is calculated for highest, lowest and mean tooth thickness / diameter / center distance combination, resulting in three curves. Collisions and tip to root interferences are indicated by zero backlash condition Gear modifications in lead direction are considered, backlash is calculated for a number of slices along the face width Tooth deformation and temperature influence are not considered Works also for tooth form from imported *.dxf files Backlash, acceptance backlash, operating backlash Theoretical backlash in transverse and normal section, chordal and arc value, considering tooth thickness and center distance tolerances. Acceptance backlash considering runout, manufacturing errors and axis misalignment. Operating backlash considering housing and gear temperatures and moisture absorption. Contact and collision check in 2D graphic in transverse section for any tooth thickness, diameter and center distance tolerance combination. Recommendation of tooth thickness tolerances in case of gear jamming. Backlash definition through manufacturing profile shift or tooth thickness tolerances. Calculation of tooth thickness / backlash from span measurement or from diameter over pins. Strength calculation on theoretical gear or on gear with backlash. 2D FEM of virtual spur gear FEM models 2D plane stress model using parabolic triangular elements with variable mesh density Mesh density is maximized for critical area in the root Resulting stress levels are calculated for contact point of 30° (60°) tangent to theoretical tooth form, for contact point of 30° (60°) tangent to actual tooth form and for point with highest stress Stress levels are reported and compared to nominal stress calculated along ISO 6336 FEM pre-processor (Salome) and solver (Code Aster) are remote controlled requiring no interaction. Pre- and post-processor may be opened after calculation to check mesh, boundary condition and results Different stress values like von Mises, max and min principal and others may be shown. Different color bars may be used. Root stress calculation For standard gear geometry with trochoidal fillet based on circular tip of tool For non-standard gear root geometry including machining notches / grinding notches For non-trochoidal, e.g., circular, or elliptic root shape Also, for cycloidal and circle shaped (non-involute) gears For asymmetrical involute gears 3D FEM FEM model For spur and helical gears Using parabolic tetraeder elements
