advanced load analysis module v 4 - dontyne systems ... · link to iso6336 design and rating . ......

© Dontyne Systems Limited 2008Dontyne Systems Limited is a company registered in England and Wales with company number 05973058Registered office: 1 Simonside, Prudhoe, Northumberland, ENGLAND, NE42 6LJVAT Registration Number: 902 9027 45

© Dontyne Systems Limited 2012

27th April 2012

27th April 2012

GATES Advanced Load Analysis

Module V 4.6

History And Overview

© Dontyne Systems Limited 2012GATES 4.6 - History and Overview

Introduction Background & Development

Application

Experimental Validation

Analysis Features

Advantages of GATES Program

Summary


GATES – Gear Analysis for Transmission Error and Stress

It is an FE based analysis package that calculates;

– Transmission Error (T.E.)– Load sharing between teeth– Surface Contact Stress and Root Bending Stress– Efficiency

Introduction


Background1990- 1992 The Design Unit (Newcastle Upon Tyne U.K.) identify the need

for a sophisticated loaded tooth contact analysis for gears

1992- 1997 A large number of different gears tested at many torques and alignments. Some of the results of which have been published

1997- 2006 Program is implemented using FEA by project founders and collaborators

2006- 2007 Dontyne Systems take over the development and marketing of GATES calculation as part of Load Analysis Model

2007- 2009 Development programs defined and implemented for the expansion of the GATES analysis and scope


ApplicationInitial Development in Marine propulsion systems

– GATES has been used to design gears for British Royal Navy


Contact Model

Link To ISO6336 Design and Rating


Contact Model

Flexible Profile and Lead Definition of 2D

and 3D Surface Topography


Contact Model

Links To Metrology Equipment To Define

Surface From Measured Data

3D Surface Measurement


Contact ModelMeasured Data Allows Effect of Bias on Measured Surface

to be Examined

Designed topology 3D Measured Topology inc bias


Contact Model

•Misalignment due to assembly or deflection

•Bearing Compliance

•Case Compliance

Operating Conditions


Analysis OptionsAnalysis Types:

– Contact stress– Contact load– Bending stressTensile and compressive – Transmission errorGeometric / Total– Power Loss


Analysis OptionsGraphic Presentation:

– 2D chart / 3D chart / Gear surface


Analysis OptionsMultiple Load Levels:

Detailed Tooth-To-Tooth(Plot can be used to derive FFT

Spectrum)

Harris Map Plot(Illustrates Change in Amplitude through load to identify optimum)


Analysis OptionsPower Loss On Tooth:


Analysis OptionsVariant #1 : Spur


Analysis OptionsVariant #2 : Helical


Analysis OptionsVariant #3 : Double Helical


Advantages of GATES Program– FEM calculation of tooth stiffness– Takes into account effect of increases of stress at gear tip– Exhibits change in behaviour due to twist of tooth– Extended contact that increases effective EAP and contact

ratio– Effect of manufacturing on root stress– Gear power loss and efficiency– Link to measured data– Validated results


ExamplesCase #1 - Analyse increased stress at entry and exit


ExamplesCase #2 - Tip Stresses (Inadequate Tip Relief)


ExamplesCase #3 - Twist (dependent on where torque applied)


ExamplesCase #4 - Increase efficiency with surface modifications


Same 20° spur gear cut with different pressure angle hob (short lead hob)

20 degree 11 degree

ExamplesCase #5 – Effect of manufacturing on root strength


Deflected tooth

Un-deflected position

End of active profile

Contact continues beyond end of active profile off line of action as tooth releases load and rolls round on tip

Theoretical end of active profile

Actual end of active profile

Contact Stress

ExamplesCase #6 – Extended contact for tip loaded gears


Validation 1The following data is from an experimental study to validate the application of the GATES contact model:

– Marking patterns on actual gears are shown compared to predicted bearing load from GATES

– Good correlation is shown

Experimental data courtesy of:


Validation 1Gear Centres 91.5 mm

Gear Ratio 1.5:1

Wheel Ref Diameter 108.08

Pinion Ref Diameter 72.05

Face Width ~ 25 mm

Pinion Torque 100 – 373 Nm



Validation 1


Pinion 100 Nm Wheel 100 Nm


Validation 1




Validation 2The following data is from an experimental study to validate the application of the GATES Transmission error model:

– The aim was to reduce noise levels that arise from the transmission error (T.E.) at the gear mesh

– The T.E. Causes forces that propagate through the system and radiate noise

– A comparison is provided between single, double helical gears and optimised gears using the GATES program



Validation 2Gear Centres 400mm

Gear Ratio 3:1

Wheel Ref Diameter 600

Pinion Ref Diameter 200

Face Width ~ 200mm

Max Pinion Speed 6000rpm

Max Pinion Torque 15000rpm

Max Power 8 MW



Validation 2



Validation 2

33Specified AccuracyISO 1328-1/95 Grade

400400Centre Distance, a573.15183.15Root Diameter, df

612222Tip Diameter, da599.839199.946Ref. Diameter, d

200200Face Width, b28.728.7Ref. Helix Angle, βn

17.5°17.5°Ref Pressure Angle, αn

6.056.05Normal Module, mn87 29No of teeth, z

WheelPinion



Validation 2

None15μm CrowningNone20μm CrowningLead

Tip Relief – 10μmx5mm extentRoot Relief - none

Tip Relief – 10μmx5mm extentRoot Relief - none

Tip Relief – 10μmx10.5mm extentRoot Relief - none

Tip Relief – 10μmx10.5mm extentRoot Relief - none

Profile

WheelPinionWheelPinion

Flank BFlank A



Validation 2

Pinion Speed (rpm)

Pinion BearingLoad[N]rms

Flank A

Optimised

Single Helical

DoubleHelical



Validation 2Pinion BearingLoad[N]rms

Pinion Speed (rpm)

Flank B

Single Helical

Double HelicalOptimised



Summary Experimentally validated FE model FE analysis is a practical development tool

- Graphical view of analysis- Integration to other Dontyne software design tools- Integration to metrology equipment for increased

accuracy- Failure investigation and reverse engineering

Proven results for noise and vibration reduction Significant advantages over other calculation methods Continued development and experimental validation


SummaryPublished literature- “Ultra-Low Noise Gearbox” Hofmann D. & Haigh J, Transactions of INEC 2000, Atkins, Hamburg, 14-16 March 2000

- “High Speed Gears for Extreme Applications in Industrial and Marine Fields” Weiss T. & Hoppe F., Gear Technology, Sep-Oct 2007 p 68-74

- “Practical Production of Low Noise Gears”, Penning G., BGA Congress 2008, 20 November 2008

- “Optimisation of Gear Performance Through Surface Engineering”, Aylott C., BGA Congress 2008, 20 November 2008

- “Optimizing Gear Geometry for Minimum Transmission Error, Mesh Friction Losses and Scuffing Risk Through Computer Aided Engineering”, Fraser R., Shaw B, Palmer D. & Fish M. AGMA FTM09, 13-15 September 2009

- “Evaluation of Methods for Calculating Effects of Tip Relief on Transmission Error, Noise and Stress in Loaded Spur Gears”, Palmer D. & Fish M. AGMA FTM10, 2010


Contact UsEurope

+44 1661 833 828Asia

+61 35 975 0816

www.dontyne.com

advanced load analysis module v 4 - dontyne systems ... · link to iso6336 design and rating . ......

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