productpresentation gates 4.6

7/30/2019 ProductPresentation GATES 4.6

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Dontyne Systems Limited 2008

Dontyne Systems Limited is a company registered in England and Wales with company number 05973058

Registered office: 1 Simonside, Prudhoe, Northumberland, ENGLAND, NE42 6LJ

VAT Registration Number: 902 9027 45

Dontyne Systems Limited 2012

27th April 2012

27th

April 2012

GATESAdvanced Load Analysis

Module V 4.6

History And Overview


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Dontyne Systems Limited 2012GATES 4.6 - History and Overview

Introduction Background & Development

Application

Experimental Validation

Analysis Features

Advantages of GATES Program

Summary


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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


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


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ApplicationInitial Development in Marine propulsion systems

GATES has been used to design gears for British Royal Navy


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Contact Model

Link To ISO6336

Design and Rating


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Contact Model

Flexible Profile and

Lead Definition of 2Dand 3D Surface

Topography


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Contact Model

Links To Metrology

Equipment To DefineSurface From Measured

Data

3D Surface Measurement


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Contact ModelMeasured Data Allows Effect of Bias on Measured Surfaceto be Examined

Designed topology 3D Measured Topology inc bias


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Contact Model

Misalignment due to assembly or

deflection

Bearing Compliance

Case Compliance

Operating Conditions


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Analysis OptionsAnalysis Types:

Contact stress

Contact load Bending stressTensile and compressive

Transmission error

Geometric / Total Power Loss


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Analysis OptionsGraphic Presentation:

2D chart / 3D chart / Gear surface


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Analysis OptionsMultiple Load Levels:

Detailed Tooth-To-Tooth

(Plot can be used to derive FFTSpectrum)

Harris Map Plot

(Illustrates Change in Amplitudethrough load to identify optimum)


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Analysis OptionsPower Loss On Tooth:


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Analysis OptionsVariant #1 : Spur


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Analysis OptionsVariant #2 : Helical


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Analysis OptionsVariant #3 : Double Helical


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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 contactratio

Effect of manufacturing on root stress

Gear power loss and efficiency

Link to measured data

Validated results


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ExamplesCase #1 - Analyse increased stress at entry and exit


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ExamplesCase #2 - Tip Stresses (Inadequate Tip Relief)


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


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ExamplesCase #4 - Increase efficiency with surface modifications


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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


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Deflected tooth

Un-deflected position

End of active profile

Contact continues

beyond end of activeprofile off line of action

as tooth releases load

and rolls round on tip

Theoretical end of

active profileActual end of

active profile

Contact Stress

ExamplesCase #6 Extended contact for tip loaded gears

Experimental data courtesy of:


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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 topredicted bearing load from GATES

Good correlation is shown



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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



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Validation 1Pinion 100 Nm Wheel 100 Nm



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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 thetransmission error (T.E.) at the gear mesh

The T.E. Causes forces that propagate through the system andradiate noise

A comparison is provided between single, double helical gears andoptimised gears using the GATES program



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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



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Validation 2



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Validation 2

33Specified Accuracy

ISO 1328-1/95 Grade

400400Centre Distance, a

573.15183.15Root Diameter, df

612222Tip Diameter, da

599.839199.946Ref. Diameter, d

200200Face Width, b

28.728.7Ref. Helix Angle, n

17.517.5Ref Pressure Angle, n

6.056.05Normal Module, mn

8729No of teeth, z

WheelPinion



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Validation 2

None15m CrowningNone20m CrowningLead

Tip Relief

10mx5mm

extent

Root Relief -

none

Tip Relief

10mx5mm

extent

Root Relief -

none

Tip Relief

10mx10.5mm

extent

Root Relief - none

Tip Relief

10mx10.5mm

extent

Root Relief - none

Profile

WheelPinionWheelPinion

Flank BFlank A



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Validation 2

Pinion Speed (rpm)

Pinion

Bearing

Load

[N]rms

Flank A

Optimised

Single Helical

DoubleHelical



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Validation 2PinionBearing

Load

[N]rms

Pinion Speed (rpm)

Flank B

Single Helical

Double Helical

Optimised


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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 increasedaccuracy

- Failure investigation and reverse engineering Proven results for noise and vibration reduction Significant advantages over other calculation methods Continued development and experimental validation


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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 FieldsWeiss 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 FrictionLosses 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 TransmissionError, Noise and Stress in Loaded Spur Gears,Palmer D. & Fish M. AGMA FTM10, 2010


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Contact UsEurope

+44 1661 833 828Asia

+61 35 975 0816

www.dontyne.com

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