single product model for transmission design & analysis romaxdesigner

Single Product Single Product Model for Model for

Transmission Transmission Design & AnalysisDesign & Analysis

RomaxRomaxDesigDesignerner

Copyright © Romax Technology Limited Copyright © Romax Technology Limited 2000 - 20052000 - 2005

About this Presentation

Aims of the presentationAims of the presentation Modelling the components:Modelling the components:

• shaftsshafts

• bearingsbearings

• gearsgears

Assembling the gearboxAssembling the gearbox Defining the loads and Defining the loads and

powerspowers Running the analysisRunning the analysis Review of the results and Review of the results and

further RomaxDesigner further RomaxDesigner capabilitiescapabilities


Introduction

Aims of this presentation are to Aims of this presentation are to show how:show how:

To model an existing transmission To model an existing transmission in just one day in just one day

To analyze the model for shaft, To analyze the model for shaft, bearing and gear performance and bearing and gear performance and lifelife

To use the analysis results to To use the analysis results to optimize an existing designoptimize an existing design


Modelling the Transmission

Definition of componentsDefinition of components

Mounting the gears on to shaftsMounting the gears on to shafts

Definition of gearbox internal geometryDefinition of gearbox internal geometry

Powerflow definition and analysisPowerflow definition and analysis

Review of resultsReview of results

Options for further analysis and Options for further analysis and optimizationoptimization

Key Stages for Creating a RomaxDesigner ModelKey Stages for Creating a RomaxDesigner Model


Modelling the TransmissionModelling the Transmission

RomaxDesigner Modelling stages:RomaxDesigner Modelling stages:









The first step is to create a shaft The first step is to create a shaft by simply selecting it from the by simply selecting it from the menu:menu:



Specify the approximate shaft outer Specify the approximate shaft outer dimensions:dimensions:



To create shaft sections of To create shaft sections of different sizes, use the cutter icon different sizes, use the cutter icon to define steps:to define steps:



Specify the dimensions of each Specify the dimensions of each section including any tapers and section including any tapers and bores if needed:bores if needed:



The user need only input the The user need only input the geometrygeometry

RomaxDesigner will generate static RomaxDesigner will generate static and dynamic models from this data and dynamic models from this data instantaneouslyinstantaneously



RomaxDesigner automatically RomaxDesigner automatically generates a solid model and 3-D generates a solid model and 3-D view for easy visualization: view for easy visualization:



To add bearings, select the bearing To add bearings, select the bearing icon and click at the approximate icon and click at the approximate position:position:



RomaxDesigner has complete bearing RomaxDesigner has complete bearing database catalogues for SKF and FAG database catalogues for SKF and FAG to choose from - as well as a Custom to choose from - as well as a Custom specification option:specification option:



View the details of a range of View the details of a range of bearings and accept the most bearings and accept the most suitable:suitable:



Every bearing is a fully specified Every bearing is a fully specified engineering object ready for engineering object ready for analysis:analysis:

Virtual Component has :

- Dimensions

- Engineering Properties



Specify its Specify its exact position exact position on the shaft, on the shaft, and conditions and conditions such as axial such as axial constraints and constraints and pre-load:pre-load:



Repeat the procedure to add Repeat the procedure to add further bearings:further bearings:



The 3-D view is updated The 3-D view is updated automatically:automatically:



To add gear pairs there are two To add gear pairs there are two options for defining gear options for defining gear geometry:geometry:

Concept gear pairConcept gear pair• Basic gear data required for the Basic gear data required for the

calculation of forces on the shafts calculation of forces on the shafts and bearingsand bearings

Detailed gear pairDetailed gear pair

• Requires additional macro-geometry Requires additional macro-geometry data for gear ratingdata for gear rating



Create a new concept gear pair:Create a new concept gear pair:



Detail the concept pair if full Detail the concept pair if full analysis results are required:analysis results are required:



A completed detailed gear pair:A completed detailed gear pair:



Mount the gear on the shaft with the gear icon:Mount the gear on the shaft with the gear icon:



Create and connect more gears to Create and connect more gears to complete the shaft:complete the shaft:



The completed solid The completed solid model of the shaft in 3-model of the shaft in 3-D:D:



RomaxDesigner automatically RomaxDesigner automatically produces a static model:produces a static model:



And a dynamic model to And a dynamic model to completely simulate the completely simulate the behaviour of the shaft:behaviour of the shaft:



RomaxDesigner Modelling Areas:RomaxDesigner Modelling Areas:








Modelling Overview Modelling Overview Gear mounting Gear mounting

definitiondefinition

There are four options for defining There are four options for defining gear mounting in the model:gear mounting in the model:

Integral with shaftIntegral with shaft• The gear is manufactured into the The gear is manufactured into the

shaftshaft Rigidly mounted to shaftRigidly mounted to shaft

• The gear is permanently attached to The gear is permanently attached to the shaftthe shaft

Synchronizer or clutch connectionSynchronizer or clutch connection• The gear is free to rotate on the shaft The gear is free to rotate on the shaft

unless the synchroniser/clutch is unless the synchroniser/clutch is engagedengaged

Free RotationFree Rotation• The gear is free to rotate on the shaftThe gear is free to rotate on the shaft



Selection of gear mounting method: Selection of gear mounting method:



Define the details of the gear blank Define the details of the gear blank for inertia calculations:for inertia calculations:



Once the other shafts have been generated, Once the other shafts have been generated, their relative positions need to be specified:their relative positions need to be specified:



The completed gearbox:The completed gearbox:



The completed solid model is ready The completed solid model is ready for analysis:for analysis:


Defining the Load ConditionsDefining the Load Conditions

Add input and output power loads Add input and output power loads with the power load icon:with the power load icon:



Define the time and clutch/synchro Define the time and clutch/synchro for each speed:for each speed:



Define the loads for each speed:Define the loads for each speed:



The The completed completed duty cycle duty cycle with six with six defined defined speeds, speeds, ready to ready to run: run:



The duty cycle results on all components are The duty cycle results on all components are calculated in under a minute on a standard PC:calculated in under a minute on a standard PC:


Review of ResultsReview of Results

RomaxDesigner calculates complete RomaxDesigner calculates complete duty cycle results, in under a minute, duty cycle results, in under a minute, on a standard PCon a standard PC

The results for each load case The results for each load case include:include:

• Forces, moments, displacements and Forces, moments, displacements and stresses for all shaftsstresses for all shafts

• Deflections, tilts and displacements on Deflections, tilts and displacements on all bearingsall bearings

• Mesh misalignment for all gear meshesMesh misalignment for all gear meshes

• Life rating for all bearings and gears Life rating for all bearings and gears including misalignment effectsincluding misalignment effects


Review of ResultsReview of Results

The results for a single load case The results for a single load case will be examined first:will be examined first:

• Shaft loadings and deflections Shaft loadings and deflections leading to bearing rating and gear leading to bearing rating and gear mesh misalignmentmesh misalignment

Then the cumulative effect of the Then the cumulative effect of the duty cycle will be shownduty cycle will be shown

This gives a final assessment of This gives a final assessment of gear and bearing performance for gear and bearing performance for the specified duty cyclethe specified duty cycle


Results for a Single Load Results for a Single Load CaseCase

The input shaft forces in 1st The input shaft forces in 1st speed in the x-direction:speed in the x-direction:



The input shaft shear force diagram The input shaft shear force diagram in 1st speed in the x-z plane:in 1st speed in the x-z plane:



Input shaft moments in 1st speed Input shaft moments in 1st speed in the x-z plane:in the x-z plane:

Moment from the bearing arises from the calculated tilt stiffness



Input shaft displacements in 1st Input shaft displacements in 1st speed in the x-direction:speed in the x-direction:

The bearing displacement is non-zero



Input shaft bending stresses in 1st speed:Input shaft bending stresses in 1st speed:



Bearing results showing the life, as well as Bearing results showing the life, as well as the relative and absolute displacements:the relative and absolute displacements:



Bearing results showing the Bearing results showing the bearing stiffnesses:bearing stiffnesses:



Shaft deflections are converted Shaft deflections are converted into gear mesh misalignment:into gear mesh misalignment:



The life rating for the gear pair is then The life rating for the gear pair is then calculated to ISO 6336 or AGMA 2001:calculated to ISO 6336 or AGMA 2001:



The user can choose to include the effect The user can choose to include the effect of misalignment in the gear rating:of misalignment in the gear rating:


Cumulative Damage Based On Gearbox Duty Cycle

0

20

40

60

80

100

120

1 2 3 4 5Speed

Per

cent

age

Dam

age

Damage

Cumulative Damage

Duty Cycle Results

For each component, the duty cycle For each component, the duty cycle result includes a contribution from result includes a contribution from each load case:each load case:


Duty Cycle Results

Complete ISO life and the Adjusted life (which Complete ISO life and the Adjusted life (which includes the effect of misalignment on bearings):includes the effect of misalignment on bearings):


Duty Cycle Results

Also duty cycle results for the gear pair :Also duty cycle results for the gear pair :


Further Analysis (i)Further Analysis (i)

Examples of additional work possible Examples of additional work possible using the RomaxDesigner software:using the RomaxDesigner software:

The influence of Housing Stiffness on The influence of Housing Stiffness on the system deflections the system deflections

The misalignment of synchronized The misalignment of synchronized gears mounted on needle roller gears mounted on needle roller bearingsbearings

Stress concentration factors and shaft Stress concentration factors and shaft fatigue analysis.fatigue analysis.


Further Analysis (ii)Further Analysis (ii)

Examples of additional work possible Examples of additional work possible using the RomaxDesigner software:using the RomaxDesigner software:

A more detailed duty cycle, e.g. for A more detailed duty cycle, e.g. for different driving styles and different driving styles and conditionsconditions

Gear micro-geometry definition and Gear micro-geometry definition and transmission error calculationtransmission error calculation

Synchronizer sizing and simulation.Synchronizer sizing and simulation.


Further Analysis (iii)Further Analysis (iii)

Examples of additional work Examples of additional work possible possible

using the RomaxDesigner software:using the RomaxDesigner software:

Driveline dynamic analysis and Driveline dynamic analysis and NVHNVH

Perpendicular shafts, hypoid, Perpendicular shafts, hypoid, spiroid and bevel gearsspiroid and bevel gears

In-depth analysis of bearings.In-depth analysis of bearings.


ConclusionsConclusions

RomaxDesigner allows:RomaxDesigner allows:

Modelling of a complete gearbox …Modelling of a complete gearbox …in less than 1 dayin less than 1 day

Duty cycle analysis of a gearbox …Duty cycle analysis of a gearbox …in under 1 minutein under 1 minute

World-leading analysis in an easy-to-use World-leading analysis in an easy-to-use interfaceinterface

This speed-of-use allows rapid iterative design This speed-of-use allows rapid iterative design optimization for the first timeoptimization for the first time


Your Next Step!Your Next Step!

Start using RomaxDesignerStart using RomaxDesigner

Take one of the Romax in-depth Take one of the Romax in-depth training courses on training courses on transmissions, or gear design transmissions, or gear design using RomaxDesigner (email us using RomaxDesigner (email us - see next slide)- see next slide)

Contact Romax for more details Contact Romax for more details on Romax software solutions on Romax software solutions (see next slide)(see next slide)

Thank you for reviewing RomaxDesigner.Thank you for reviewing RomaxDesigner.You may now wish to:You may now wish to:

For more information contact:

Romax Technology Limited

Rutherford House

Nottingham Science and Technology Park

Nottingham

England, NG7 2PZ

Tel: +44 (0)115 951 8800

Fax: +44 (0)115 951 8801

e-mail: [email protected]

http://www.romaxtech.com

single product model for transmission design & analysis romaxdesigner

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