KISSsoft 2022 – Tutorial 9

Cylindrical Gear Fine Sizing

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A Gleason Company F. +41 55 254 20 51
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Switzerland www.KISSsoft.com
Contents

1 Task ........................................................................................................................................ 3
1.1 Task ........................................................................................................................................................ 3
1.2 Starting gear pair calculation (cylindrical gear pair) ................................................................................ 3

2 Rough Sizing of a Cylindrical Gear Pair .................................................................................. 5

2.1 Preparing the calculation......................................................................................................................... 5
2.2 Call the rough sizing function .................................................................................................................. 6
2.3 Modifications ........................................................................................................................................... 9

3 Fine Sizing ............................................................................................................................ 11

3.1 Starting the fine sizing function ............................................................................................................. 11
3.2 Results of the fine sizing function.......................................................................................................... 15
3.3 Sizing a deep tooth form ....................................................................................................................... 17
3.4 Further details about strength analysis ................................................................................................. 21

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1 Task
1.1 Task
A cylindrical gear pair is to be designed such that it has a service life of 5,000 h when transmitting a power of 5
kW at an input speed of 400 rpm (application factor = 1.25). The ratio shall be 1:4 (reducing speed) and
18CrNiMo7-6 is to be used as the gear material. The cylindrical gear pair is to be optimized to achieve the best
possible noise/contact ratio. Strength verification is to be performed as specified in ISO 6336 Method B.

1.2 Starting gear pair calculation (cylindrical gear pair)

You can call KISSsoft as soon as the software has been installed and activated. Usually you start the program by
clicking «Start→Program Files→KISSsoft AG →KISSsoft». This opens the following KISSsoft user interface:

Figure 1. Starting KISSsoft, initial window

In the «Modules» tab, click on the «Cylindrical gear pair» calculation in the module tree window:

Figure 2. Call the cylindrical gear calculation

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To open the example used in this tutorial, click on «File/Open» and select «Tutorial-009-Step1» (to «Tutorial-009-
Step5») or select it from the «Tutorials» tab. Each section in this tutorial describes which file you need to open
(as shown below).

Figure 3. Options for opening the example files used in this tutorial at different stages of progress

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2 Rough Sizing of a Cylindrical Gear Pair
2.1 Preparing the calculation
Before you can start the rough sizing process, you must enter the basic toothing parameters to the Basic data
and Rating tabs. In the Basic data tab, input the material 18CrNiMo7-6 in the Material and lubrication group.

Figure 4. Materials in the Basic data tab

The safety factors that are to be achieved can be specified in the module specific settings dialog in the «Safety
factors» tab.

Figure 5. Module specific settings – Specified safeties

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Then click «Calculation»→ «Strength» to open In the Rating tab where you input the data for service life,
power, and input speed, along with the calculation method for the strength verification.

Figure 6. Toothing data in the Rating tab

To access this stage of the calculation directly, open the «Tutorial-009-Step1» file.

2.2 Call the rough sizing function

Use the Rough sizing function to create a sensible initial layout for a cylindrical gear stage. To do this, input the
required key data after you call the Rough sizing function by clicking «Calculation»→ «Rough sizing macro
geometry» in the Rough sizing screen.

Figure 7. Call Rough sizing

The most important is to define the required ratio (including the permitted variation as a percentage – here 5%).
You can also predefine the required helix angle or center distance. The helix angle depends on the type of
bearing used with the shaft. The helix angle may be larger or smaller, depending on how much axial force the
bearings can support. The helix angle can be optimized later on during fine sizing. Here, in the rough sizing
function, you should only input an approximate value for the helix angle, or «zero» for spur gear. In the lower part

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of the «Rough sizing» input window you can enter additional data such as the range of number of teeth on the
pinion, the geometry proportions, and the center distance.

Figure 8. Rough sizing input window - Specifying the number of teeth, gear 1 and 2

When you click the Calculate button in rough sizing, KISSsoft calculates a number of different solutions for a gear
pair that meets the specified conditions. These solutions are then displayed in the list shown below.

Figure 9. Cylindrical gear - rough sizing, results

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Right-hand mouse click in the results list to select the criteria you want to use, such as center distance a, width b, etc.

Figure 10. Show columns

To select a particular solution (in this case with a center distance of 91.5 mm), select it from the list and click the
«Accept» button to transfer it, and then click «Close» to close the window.

Figure 11. Normal module, number of teeth, width, profile shift and center distance shown as suggested by KISSsoft

To access this stage of the calculation directly, open the «Tutorial-009-Step2» file.

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2.3 Modifications
You can now modify the proposed values. For example, for the gear width you can input a pinion width of 30 mm
and a gear width of 29 mm (directly in the appropriate fields).
In the tab «Reference profile» you can modify the reference profile in the drop-down list.

Figure 12. «Reference profile» tab, information about the reference profile

You can modify the profile shift of gear 1 (gear 2 is then sized accordingly) as follows: Click the Sizing button
in the figure below to open the «Sizing of profile shift coefficient» dialog window that displays proposed values
for a number of profile shift coefficients (see Figure 14):

Figure 13. Open dialog window; Size profile shift coefficients

▪ Various methods for sizing the profile shift

coefficient
▪ Sensible suggestions for the profile shift
coefficient
▪ Maximum and minimum (minimum topland
without undercut)

Figure 14. Dialog window; Size profile shift coefficients

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If you use different criteria, the KISSsoft system proposes suitable profile shift coefficients. In this example you
want to balance specific sliding. Click the «Radio Button» to display the required proposal on the right-hand side
and then click «OK» to accept it.
The profile shift coefficient x is then transferred to the input window of the «Basic data» tab, «Geometry» group.
Then, either click on the icon in the tool bar or press «F5» to calculate the complete geometry, the root and
flank safeties, the safety against scuffing, and the resulting contact ratio (see Figure 15 below). The results
should now look like this (however, minor variations are possible, for example in the calculated profile shift
coefficient):

Figure 15. Modified profile shift coefficient, results overview after calculation has run

To access this stage of the calculation directly, open the «Tutorial-009-Step3» file

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3 Fine Sizing
3.1 Starting the fine sizing function
Now that you have used the rough sizing function to define a gear pair that can transmit the required power, you
can optimize this gear's noise emission and strength characteristics. Just as for rough sizing, go to
«Calculation», then select «Fine Sizing macro geometry» to open the «Fine Sizing» screen, where you can
perform the fine sizing functions.

Figure 16. Starting «Fine Sizing»

Here you can define ranges (and intervals) for the following parameters. The KISSsoft system will then search
these ranges for a suitable gear pair solution.

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 2

Figure 17. Input window - Fine sizing, input parameter ranges

(1)
(2) Set to 300
(3) Define the required ratio (4) and permissible error (2%)
(4) Click the Sizing buttons to have KISSsoft propose sensible ranges for the «Normal module», «Helix
angle», «Center distance» and «Range for profile shift coefficient» parameters
(5) Specify whether the center distance is to be fixed or variable

▪ Range for normal module (1.25 …4.5)

▪ Range for helix angle (5°…15°)
▪ Range for center distance (select «variable center distance» option here)
(A note about the sizing of this value has already been output as the result of the rough sizing process.)

You can also predefine these parameters:

▪ Upper limit for the tip diameter
▪ Minimum active root diameter
▪ Fix the number of teeth for one or both gears (enable the checkbox for the relevant gear; if 0: number of
teeth is variable)
▪ Specify the profile shift for one or both gears (enable the checkbox for the relevant gear)

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For this example, make the settings shown in Figure 17. Then click «Calculate» (button at the bottom) to call the
sizing function. The algorithm then finds all possible gear combinations that match the values you have input.
Once the calculation process has finished, you see a list of all the solutions the system found (see
Figure 18). In this example, the aim is to find a gear pair with low noise emissions. You can now sort the results
by the required criterion (e.g. ɛα, ɛß, or ɛγ), to find the best solution (depending on the selected strategy ɛα and ɛß if
possible as whole numbers or ɛγ if possible as a whole number). Double-click on the required variant or click
«Accept» to transfer and calculate the result. If the result produced is not the optimum solution, you can always
select a different variant until you find the best possible result.
In this case, solution 48 has been selected.

Figure 18. List of all the solutions found in the particular parameter range

Press the «Report» button to evaluate the most important properties of this solution in a report.

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Analysis of the results (Assessment of important characteristics)

Comment:
No. = Number of the variant
diff_i = Deviation from the nominal ratio in %
kg = Weight in kg
Slide = Specific sliding (maximum value)
v.Slide = Sliding velocity (m/s, maximum value)
AC/AE = Begin working depth AC / working depth AE
(Friction)
del_cg = Variant on the stiffness during rolling (N/mm/mym)
1-eta = Losses in % (1.0-total efficiency)
Safety = Safety (Tooth root and flank, 0 = high, 1 = medium, 2 = low)
(SF-min: 0.60/ 1.20/ 1.40 SH-min: 0.60/ 0.90/ 1.00)
Summary = Overall assessment (weighted)
(50.0%:del_cg 20.0%:diff_i 100.0%:kg 35.0%:Slide 0.0%:v.Slide
0.0%:AC/AE 10.0%:1-eta 100.0%:Safety)

(For this table it can be said in general: the smaller the value the better!)
No. diff_i kg Slide v.Slide AC/AE del_cg 1-eta Safety Summary
1 0.000 4.128 0.772 0.156 0.476 0.990 0.958 1.408 0.643
2 0.000 4.119 0.641 0.169 0.427 0.990 0.978 1.424 0.649
3 0.862 4.145 1.067 0.163 0.514 0.989 1.071 1.371 0.636
…
139 0.000 4.036 2.328 0.379 0.419 0.978 2.152 1.412 0.653
140 0.000 4.009 1.595 0.406 0.367 0.977 2.257 1.380 0.635
141 0.000 3.990 2.087 0.456 0.347 0.974 2.575 1.362 0.627

Analysis of the results

(with the variant index in decreasing order)
Best variants for accurate ratio 1 2 16 17 18 34 41 42 43 50
Best solutions for weight 138 141 137 140 135 131 108 132 134 126
Best variants relative to friction (AC/AE) 138 129 132 108 141 135 137 123
102 118
Best solutions for stiffness 141 138 140 139 137 132 136 135 131 130
Best variants for strength 32 33 22 29 47 19 30 41 48 44
Best overall variants (summary) 32 33 41 42 19 47 29 43 20 48
Figure 19. Evaluation of the solutions

Important note: The description of the method of approach here has deliberately been kept as short as possible.
In practice it is very important that you carefully read through the «Analysis of results» list in the fine sizing
function. It is quite likely that the second or third best solution (in terms of noise emission) should be preferred for
other reasons. Displaying the variants as graphics in the «Graphics» tab can also help you make the right
decision:

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 Figure 20. Graphic display of all the solutions

This graphic can help you find the best possible solution more easily (in this case, in terms of tooth root/flank
safety). You can then select it under «Results» and transfer it to the calculation.

3.2 Results of the fine sizing function

The total contact ratio is now barely above 3, i.e. the variations in stiffness across the contact are very small (see
Figure 21). The gear will therefore generate fewer vibrations.

Figure 21. Results of fine sizing (profile shift, helix angle, number of teeth)

To access this stage of the calculation directly, open the «Tutorial-009-Step4» file.

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The resulting tooth form is then displayed in a graphics window under «2D geometry». Here, you can either click
the button or double-click the left-hand mouse button in the gray area to make it into a floating window and
enlarge it:

Figure 22. Resulting tooth form (base circles and path of contact shown in red)

To display the stiffness curve above the meshing, click «Graphics»→ «Evaluation»→Theoretical contact
stiffness»:

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 Figure 23. Course of theoretical meshing stiffness

3.3 Sizing a deep tooth form

In the next step you can further improve the selected solution. To do this, increase the transverse contact ratio 𝜀𝛼
to 2. If you want to calculate a tip relief later on, you will need a higher contact ratio because this will be reduced
by the tip relief. You should now also increase the resulting contact ratio by sizing a deep tooth form (you can
define the target size in the «Module specific setting», in the «Sizings» tab).

Figure 24. Module specific settings

To size a deep tooth form, call the Fine Sizing function again and then set the flag in the «Sizing of deep tooth
form» checkbox under «Conditions III». Then click the Calculate button to calculate new values.

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 Figure 25. Settings in Fine Sizing, select «Sizing of deep tooth forms»

We choose solution 50. You can now select this variant by clicking «Accept» to transfer the gear data for this
variant. When you now size a deep tooth form, the reference profiles have been changed.

The gear data now appears again in the main screen (changed number of teeth, helix angle, profile shift) and the
new results calculated immediately when they are accepted:

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 Figure 26. New gear data and results, in particular contact ratio

To access this stage of the calculation directly, open the «Tutorial-009-Step5» file.

The resulting tooth form is then displayed in a graphics window under «2D geometry». Here, you can either click
the button or double-click the left-hand mouse button in the gray area to make it into a floating window and
enlarge it:

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 Figure 27. Resulting deep tooth form

Figure 28. Viewing the reference profile for a deep tooth form in the «Reference profile» tab

The resulting contact ratio is now very close to 3, which results in very even contact stiffness:

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 Figure 29. Theoretical contact stiffness curve across the contact

3.4 Further details about strength analysis

For a final gear strength analysis, you must input values for lubrication and for the face load factor:

Figure 30. Inputting lubrication data

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 Figure 31. Calling the input window for the face load factor

You can select the lubrication type as well as the lubricant itself directly in the drop-down list (shown here on the
left and right). You can also use the database tool to add to the list of lubricants.
Click the Plus button (lower right-hand marking in the Materials and Lubrication group, see Figure 31) to
specify the lubricant temperature.
Input the operating and ambient or housing temperature in the «Operating backlash» tab (see the marked texts
in the next figure).

Figure 32. Operating backlash

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 The face load factor can be
determined using Methods A, B
or C.

However, you do not usually

need to make any changes
here.

Figure 33. Entering other parameters, especially values for setting the face load factor

Important note:
If the strength analysis or service life calculation is relevant for evaluating the variant calculated by the fine sizing
function, you must input the values listed above before you perform fine sizing.

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