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HypoidFaceMilled User`s Manual

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1. Tooth 1 nge 0 000000E 000 8 546703E 005 Each Div 1 000000E 005
2. 0 000000 000 4 482542 003 Each Div 1 000000E 003 Time 5 000000E 003 Ran Figure 7 29 The histogram of grid separation after contact generated by the SEPAFTHIST menu Pre and Post processing iv 2 EXIT SPROFBEGIN 0 000000 000 TU ECEE 000000e 0 CLEAR AT 600000e 001 COMPONENT MaXPPLSTRESS NUMSPROF 51 AXIS sPROF v TFACEBEGIN 1 000000e 000 BEGINSTEP 1 TFACEEND PELA ere 000000 000 ENDSTEP E NUMTFACE 51 d EELEE START DEPTHBEGIN 0 0000000000 000 ii DEPTHEND 0 0000000000e 000 41 1 121 SURFACE FILL_SURFACE1 NUMDEPTH 1 TOOTHBEGIN a XI ELELEE DISTMIN 0 0000000000e 000 TOOTHEND 22 ELELEE IDUTPUTTOFILE Figure 7 30 The SEARCHSTRESS menu 7 13 The SEARCHSTRESS command The SEARCHSTRESS command of the post processing menu Figure 7 3 leads to the menu shown in Figure 7 30 This menu is us
3. OS BH ge 1 086244 003 4 798848E 003 Each Div 1 000000E 003 5 000000E 003 Ran Figure 7 27 The histogram of grid separation before contact generated by the SEPBEFHIST menu Pre and Post processing PINION_SURFACE1_GEAR_SURF PINION SURFACEPAIR MEMBER TOOTHBEGIN 14141 151 12 TOOTHEND 2 4141 151 121 1 TIMESTEP fi 141 151 121 1 z OUTPUTTOFILE Figure 7 28 The SEPAFTHIST menu 7 12 The SEPAFTHIST command 121
4. Time 5 000000E 003 Rat Figure 7 25 The grid pressure histogram generated by the GRIDPRHIST menu 118 Pre and Post processing QUIT START SURFACEPAIR PiNION SURFACE1 GEAR SURF v MEMBER PINION TOOTHBEGIN 20 SIX D PESE TOOTHEND 2 ganana TIMESTEP 1 LELEII 2 Figure 7 26 The SEPBEFHIST menu 7 11 The SEPBEFHIST command The SEPBEFHIST command in the post processing menu Figure 7 3 leads to the menu shown in Figure 7 26 This menu is used to to generate a histogram of the distribution of normal separation over individual contact grid cells in the unloaded and undeformed state The SUR FACEPAIR item selects the surface pair and the MEMBER parameter selects one of the two bodies in this pair The items TOOTHBEGIN and TOOTHEND are used to select a range of surface instances tooth numbers There can be at most 7 teeth in this range The item TIMESTEP selects a time step number Figure 7 27 shows an example of a histogram of separation in the unloaded state Negative separation values are possible in this histogram 7 12 The SEPAFTHIST command The SEPAFTHIST command in the post processing menu Figure 7 3 leads to the menu shown in F
5. 5 E E 1 3 8 3 8 8 2 2 1 3 3 a lt E 2 Koi By 8 E E 8 a 4 8 RE vt 8 li 8 E 4000 000000 3000 000000 2000 000000 1000 000000 0 000000 Figure 7 13 The tooth load vs time graph generated by TOOTHLOAD menu 7 6 The CONTACT command 105 7 6 The CONTACT command The CONTACT command in the post processing menu Figure 7 3 leads to the menu shown in Figure 7 14 This menu is used to generate a graph of contact pressure vs time The SURFACEPAIR item selects the contact surface pair for which the pressure is of interest Each surface pair has two contacting members or bodies The MEMBER parameter selects one of these two bodies and the TOOTHBEGIN and TOOTHEND items select a range of instance numbers or tooth numbers within that body If TOOTHBEGIN is greater than TOOTHEND then the range wraps around the last tooth of the surface This range must contain 7 teeth or less BEGINSTEP and ENDSTEP are used to select a range of time steps for which results have been stored in the post processing file The items SPROFBEGIN SPROFEND TFACEBEGIN and TFACEEND are used to restrict the search to a part of the contact surface Contact occurring outside this range is not considered for display in this graph Figures 7 15 and 7
6. 1 Max Ppl normal stress 81 on PINION SURFACEI 140000 000000 120000 000000 100000 000000 80000 000000 60000 000000 40000 000000 0 000000 Figure 7 32 The graph of root stress vs profile generated by the SEARCHSTRESS menu 7 13 The SEARCHSTRESS command 125 3 8 8 4 8 B z 2 2 2 8 5 8 2 E 140000 000000 100000 000000 80000 000000 60000 000000 40000 000000 20000 000000 0 000000 Figure 7 33 The graph of root stress vs face generated by the SEARCHSTRESS menu 126 Pre and Post processing MultyX PostProc 1 21 Fatique EXIT QUIT CLEAR BEGINSTEP 1 1 1 1 1 151 1 ENDSTEP 21 ELELEE CRITERION STRESS VELD STRENGTH 15150000000000 ULTIMATE_STRENG 7g95 0000000000 ENDURANCE START PINION 2141 alae SURFACE 14 TOOTHBEGIN 1 141 1515151 1 TOOTHEND pmo y 4141 151 121 1 2 Figure 7 34 FATIGUE menu 7
7. 5 7 Machine settings for the pinion 5 8 Machine settings for the generated type gear 5 9 Machine settings for the 5 10 Cutter Specifications for the pinion 5 10 1 Use new cutter m xum y wow Rom eed 5 10 2 Use old cutter 1222 xo bets oo eo om RR OS S 4 8 5 11 Cutter Specifications for the generated type gear 5 12 Cutter Specifications for the formate type gear 5 13 Surface Modifications xi Daw lt lt gt 4 j 13 15 15 15 15 16 16 17 iv 5 14 Modelling the Rim 5 15 Modelling the 5 16 Modelling a Differential Carrier 5 161 Pinionholesmenu 5 16 2 Conical and Cylindrical Races 5 17 Modeling the Housing 5 17 1 Connecting a Bearing to the Housing 6 Running an Analysis 6 1 Surfacegages 6 2 Finite element probes 0 9 Load sensors beste gis dx 6 4 Specifying a contact 6 5 The setup memi 222245220005 bah ah eS 6 6 Other output 7 Pre and Post processing 7 1 Selecting bodies isa c
8. A1 must less a A2PINIONHOLE duas STIFFNESSPINIONHO S088 Gell E Spring Stiffness AXIALORDERPINIONH 8 5 e o3 5 2 23 NPINIONHOLES les 9920288 IPINIONHOLE Ed e ed ANGPOSNPINIONHOLE 0 0000000000e 000 t ed 15 12 amp Figure 5 54 Pinion holes menu 5 16 1 Pinionholes menu The PINIONHOLES menu Figure 5 54 requests all the necessary information to properly lo cate the pinion holes within the imported model ZAPEXPINIONHOLE refers to the Z posi tion of the intersection of the pinion hole axis with the carrier axis This is measured in the gear reference frame after the carrier models have been translated by DELTAZ and rotated by DELTATHETAZ CONEANGLEPINION is the half cone angle of the cone passing through the pinion hole axes Figure 5 55 shows the ZAPEXPINIONHOLE and CONEANGLEPINION in put details A1IPINIONHOLE and A2PINIONHOLE define the distance of the close and far side respectively of the pinion hole from the pinion hole apex A2PINIONHOLE must be a larger value than AIPINIONHOLE as shown in Figure STIFFNESSPINIONHOLE defines the linear stiffness of a spring that is used to connect the differential carrier to the rigid body at the pinion holes The circular order axial order number of pinion holes and the position of each pinion hole must also be entered 5 16 Modelling a Differential Carrier Differential P
9. 28 Assembly error calculation 2 28 Assembly error calculation Method 3 29 Assembly error output file format 29 The pinion data menu saoe os bx RS PRES 30 The gear data Menu PRR EG SOR A ee 31 The common design and blank data 31 Thickness measurement at an arbitrary point es 34 The Pinion Common 35 The Gear Common 36 The Concave tooth side data menu 37 The Convex tooth side data menu 37 Machine parameters 2222 222 2 4 eee ee 38 Machine parameters for 40 Cutter specifications for the pinion 43 Cutter specifications with USENWCUTTER flag checked 44 vi 5 24 5 25 5 26 5 27 5 28 5 29 5 30 5 31 5 32 5 33 5 34 5 35 5 36 5 37 5 38 5 39 5 40 5 41 5 42 5 48 5 44 5 45 5 46 5 47 5 48 5 49 5 50 5 51 5 52 5 53 5 54 5 55 5 56 5 57 5 58 5 59 5 60 5 61 5 62 5 63 5 64 5 65 5 66 5 67 5 68 LIST OF FIGURES Cutter description for Straight Blade with Straight Toprem New Cutter 45 Cutter description for Straight Blade with Blended Toprem New Cutter 45 Cutter description for
10. is set up centered around this closest point of slice 7 The number M NPROFDIVS in Figure 6 9 is user selectable The dimension of the grid cells in the profile direction As DSPROF in Figure 6 9 is also user selectable Here s is the curve length parameter measured along the profile The number M is referred to as the number of grid cells in the profile direction NPROF DIVS and N is referred to as the number of grid cells in the face width direction NFACEDIVS As is referred to as the width of the grid cell in the profile direction DSPROF The width of the grid is 2M 1 8 Choosing the correct width is crucial in obtaining correct contact pressures Using too wide a grid for a fixed M Figure 6 4 Computational grid in the contact zone of the gears 88 Load grid cell 2 1 0 l 1 2 Profile direction Running an Analysis Figure 6 5 Contact pressure distribution across the width of contact obtained when the contact grid is too wide Load on grid cell i 2 1 0 41 l 2 Profile direction Figure 6 6 Contact pressure distribution across the width of contact obtained when the contact grid is too narrow 6 4 Specifying a contact grid Load on grid cell 2 i 1 0 2 Profile direction 89 Figure 6 7 Contact pressure distribution across the width of contact obtained when the contact grid is correct 90 Running an Analysis 6 5 Th
11. 2i UYCONSTRAINT s UZCONSTRAINT 2 THETAXCONSTRAINT 2 THETAYCONSTRAINT 21 YOUNGSMOD 3 0000000000 007 POISSON 0 3000000000 EELEE DENSITY 7600 0000000000 ERE RALEIGHALPHA RTT T3T 0 0010000000 RALEIGHBETA 1 0000000000 007 ECE OUTERCONNECTIONT BEARINGFLEXIBLE NNERSHAPE CYLINDRICAL ad DINNER 0 1000000000 INNERCONNECTIONT FREE QUADRATIC lt gt 114151 121 1 CIRCORDER 8 OE Oa Oe AXIALORDER fi 41 14151 121 1 Figure 5 45 The menu for specifying shaft data 5 15 Modelling the shaft SEG OUTERBRG 63 64 Building a Model LENGTH LEN AXIS AXIS DINNER D2INNER DIINNER lo CYLINDRICAL b CONICAL Figure 5 48 The dimensions of the outer surface of a shaft segment Transverse Bending Deflection Axis of Rotation Torsion AT Ku Ux Ty Ky Kyoy Kyo Uy fy Koy Ky Koo Ke Kg _ Kay Kex My _ Key _ Kee Kee Kee Figure 5 49 The bearing stiffness matrix format 5 15 Modelling the shaft 65 2 Hnion Bearing Reference Frame 5 Global Ground Reference Frame Figure 5 50 The pinionstiffnessbearingreferenceframe 66 Building a Model
12. TOOTHBEGIN 1 1 1515121 1 TOOTHEND 8151 SPROF 0 0000000000 000 0 0000000000 000 REFDIRECTION TFACE 218 ANGLE 90 0000000000 START CLEAR BEGINSTEP y I D TH ENDSTEP p y OUTPUTTOFILE M e FILENAME output txt APPEND Te Figure 7 35 The POINTSTRESS menu The surface is selected by specifying the body in the BODY box and a surface in the SUR FACE box A range of teeth with up to 7 teeth is selected through the TOOTHBEGIN and TOOTHEND items A profile and face location on this surface is specified through the SPROF and TFACE parameters The direction is specified by an angle in the item ANGLE This angle is the angle between the normal direction of interest and the profile direction if the REFDIRECTION option is SPROF or the face direction if the REFDIRECTION option is TFACE The angle is measured using the right hand rule about the outward normal to the surface The range of time steps is specified by the BEGINSTEP and ENDSTEP items File output is controlled by the OUTPUTTOFILE FILENAME and APPEND items Figure 7 36 shows an example of the graph generated by this menu 7 16 The PATTERN command The PATTERN command of the post processing menu Figure 7 3 leads to the menu shown in Figure 7 37 This menu is used to create a drawing of the contact pattern on a tooth The surface is selected by specifying the body in the BODY box and a surface in t
13. 158 List of Tables 4 1 Common buttons 4d Pe Y US S EUR Poe ee aa 16 51 System configuration parameters 20 5 2 Common design and blank parameters 32 5 3 Common design and blank parameters 33 5 4 Machine parameters for concave and convex tooth side for the pinion 39 5 5 Machine parameters for concave and convex tooth side for the generated type gear 41 5 6 Machine parameters for the 42 5 7 Cutter specifications for concave and convex tooth side of a pinion 51 5 8t v et06 2 t06 2e 32 6 r 33956 s9 8 p 1895 eci 437 8 5 2 c32 6a t06 2ci 437 0 167 n 526 s 32 24 f 827 o 5 LIST OF TABLES Preface In developing the HypoidFaceMilled computer program we have received active support and en couragement from many people We would especially like to thank Timothy Krantz of the Army Research Laboratory at the NASA Glenn Research Center for his support and encouragement Sandeep Vijayakar Hilliard OH Samir Abad Hilliard OH February 2003 222 Chapter 1 Introduction In some applications gears are needed to connect shafts which are neither parallel nor intersecting For this purpose a variation of the spiral bevel gear called a hypoid gear has been developed The unusual geometry of the hypoid gear allows the pinion to be large and strong even though it has on
14. Figure 5 51 The carrier 5 16 Modelling a Differential Carrier The ability to import differential carrier models like the one shown in Figure 5 62 is included within HypoidFaceHobbed by checking ENABLEDIFFCARRIER in the GEAR menu Figure 22 Within the DIFFCARRIER menu Figure 5 53 the number of models to be imported must be specified along with the model file type model file name nodal tolerance and any positional translations to be done to the model within HypoidFaceHobbed The model file dff 53647_Q fem1 0 OUPDATED inp is copied into the working folder of the model Information for the PINIONHOLES CONICALRACES and CYLINDRICAL RACES for each model must be specified by opening the appropriate menu 5 16 Modelling a Differential Carrier 67 GENERATED ENABLESHAFT ENABLEDIFFCARRIER 2 Figure 5 52 The EDIT GEAR menu Number of Models NMODELS Model File Type And IMODEL n z Model Filename MODELFETYPE 48005 ABAQUS ABAQUSFILENAME dff 53647_Q fem1 O OUPDATED inp dff 53647_Q fem1 0 OUPDATED inp Nodal Tolerance NODE TOLERANCE 0030000000 4 COORDXFM identity Transformation Identity_Transformation ee vel Positional 25 0000000000 MODELDELTATHET 5 0000000000 000 ELE i Figure 5 53 The menu for importing a differential carrier ee ZAPEXPINIONHOLE 0 0000000000 000 DIAPINIONHOLE
15. MACHINE CUTTER and MODIFICATIONS All three data submenus are similar for both the concave and convex side data except that the data comes from a different part of the Special Analysis File For the generated type gear the data menus for concave and convex side gear tooth are similar to those for the pinion They are slightly different for the formate type gear 5 7 Machine settings for the pinion The MACHINE command in Figures 5 18 amp 5 19 leads to the details of the face milling operation settings used for the manufacturing of the hypoid pinion gear shown in Figure 5 20 Table 5 4 explains all the machine parameters in this menu The values for Tiltangle Swivelangle Rootangle and the Cradleangle are given in radians in the Special Analysis File The user should convert them in to degrees before entering them in to their respective menus 38 Ses 707 ROOTANGLE 168670000 B CRADLEANGLE 5395000 121 1 BRL M ELE 121 1 L2 NNNM 121 0 0000000000 00 00 as 0 000000 00 Bae i reece 1210 pe 1 Figure 5 20 Machine parameters Building a Model 5 7 Machine settings for the pinion 39 Table 5 4 Machine parameters for concave and convex tooth side for the pinion Item Special Analyis File Details RADIALSETTING Float Distance between the cra dle axis and
16. The choices are CAPP type and CALYX3D type If the MODELTYPE option in the main menu is set to CAPP then the name of the configuration file can be specified in the item CONFIGFILE This file is created by the program CAPP is an older analysis and post processing package You are only able to generate the model if you select the CAPP type model The preproc postproc setup startanal probes loadsensors surfgages menus cannot be accessed for the CAPP type model The HANDPINION switch controls whether the pinion is lefthanded or righthanded If the Special Analysis Record value for this item is 1 then the pinion is lefthanded and if the value is 2 the pinion is righthanded The shaft offset value is specified in the OFFSET menu Offset is the perpendicular distance between the axes of the hypoid gear and the pinion Refer to Figures 5 3 and 5 4 for the sign convention for the offset menu The shaft ANGLE is the angle between the axes of the gear and the pinion It is measured in degrees The Special Analysis File Record and Item numbers specified in Table 5 1 has value for this angle in radians Conversion to degrees is done before specifying it in the ANGLE menu The LOADEDSIDE switch controls whether the convex side or the concave side of the gear tooth is going to carry the load The DRIVER switch defines which member is the input member Power will enter the gear pair at this member The angular velocity and the torque for the pinion are entered
17. 0 000200 L RB 0 000100 Y i 3 tfi 8 8 8 8 8 8 8 8 8 8 8 8 8 E E E E E 8 8 8 8 El 8 8 8 8 8 8 E 8 8 8 8 8 8 8 E Figure 7 20 The subsurface shear graph generated by the SUBSURFACE menu showing large errors when DEPTHBEGIN 0 7 8 The SUBSURFACE command 0 000500 0 000400 0 000300 a Depth P 0 000200 E DN 5 s 900000 000000 800000 000000 700000 000000 600000 000000 400000 000000 300000 000000 200000 000000 100000 000000 Figure 7 21 The subsurface shear graph generated by th
18. 4 6 5 1 5 2 5 8 5 4 5 6 5 7 5 8 5 10 5 11 5 12 5 13 5 14 5 15 5 16 5 17 5 18 5 19 5 20 5 21 5 22 5 23 The hypoid gear 2 The computer programs the HypoidFaceMilled analysis package 4 The menu presented to the user by Guide 5 multi body system 2 8 Reference frame degrees freedom 9 The reference frames set up for a pair of face milled hypoid gears 10 The mai mien 225 ve eee Pope m 11 HypoidFaceMilled s user interface 2A 14 An integer data entry box s oe go ehe e OW ICE 15 An floating point data entry box 15 An boolean data entry box 15 A string data entry DOK o soos o RA A ERE S 15 An switch type data entry box 16 The EDLC mente domuum duy ge 19 The system data menus 2 224426 5856 BEE Reese dee Pee ee RE 4 21 Sign convention for offset menu for lefthanded gear 22 Sign convention for offset menu for righthanded 23 The assembly errors menu 25 Sign convention for modelling assembly errors for a lefthanded 26 Sign convention for modelling assembly errors for a righthanded gear 27 Assembly error calculation 1
19. DELT PRESSURE 0 0000000000 000 DELTA_CONE_ANGLE DELTA COI 0 0000000000 000 ILINEARTIPRELIEF QUADRATICTIPRELIEF IDOTOPOMODFN Figure 5 37 Surface Modification menu AConeAngle Figure 5 38 Angle Modifications 5 14 Modelling the Rim MultyX Edit Gear Concave Modifications m EMT OUT DELTA SPIRAL AN 0 0000000000e 000 sis DELTA PRESSURE 0 0000000000e 000 Boneg DELTA CONE ANGLE 0 0000000000 000 LINEARTIPRELIEF 8 MAGILINEAR 0 0000000000e 000 TIPDIST1LINEAR 1 1 121 1 AXPEXDISTILINEAR Konar monar MAG2LINEAR 0 0000000000 000 TIPDIST2LINEAR s T 9 AXPEXDIST2LINEAR MAG3LINEAR 0 0000000000 000 TIPOISTSINEAR EEEH AXPEXDIST3LINEAR s m T 9 QUADRATICTIPRELIEF 2 DOTOPOMODFN 2 Figure 5 39 Linear Tip Relief menu 57 58 Building a Model DELTA SPIRAL OPERE 0 0000000000 000 DELTA_PRESSURE 0 0000000000 000 DELTA_CONE_ANGLE 0 0000000000 000 LINEARTIPRELIEF QUADRATICTIPRELIEF D DOTOPOMODFN TOPOMODTYPE aa ZEISSCOORDS ZEISSFILE ZEISSCCVGEAR DAT SCALEFACTOR ME fi 0000000000 PROFORDER 2 2 FACEORDER 2 x 41 DP ET ISTABILIZEFIT iv Figure 5 40 Surface Modification applied on the gear concave
20. HOUSING DOMODELHOUSING Figure 5 63 DOMODELHOUSING checked in the EDIT menu 5 17 Modeling the Housing The Abaqus condensed stiffness matrix of housing model is included in HypoidFaceHobbed model The housing is included by checking the DOMODELHOUSING menu in the EDIT menu as shown in Figure 5 63 The housing stiffness file location of bearing nodes transformation ma trix to Abaqus reference frame from HypoidFaceHobbed reference frame are the required inputs of the HOUSING menu shown in Figure 5 64 The stiffness matrix JLR PLA frt7 Carrier mtx is copied into the working folder of the model The file is referenced in FILENAME menu The COORDXFM lists the transformation matrix for the model The orientation of the reference frame in the two system in shown in Figure The nodal locations of the bearing origins used in the stiffness condensation are given next The coordinate location of the nodes is in Housing reference frame For this model 5 nodes are given The node locations given in the sample session file is approximate and needs to be updated First three nodes are on pinion shaft and differential flange and button bearing are the rest 76 Building a Model 5 21 8 4 T Stiffness Matrix FILENAME ROUSING mtc 3434 FileName _ RALEIGHALPHA 0000000 Figure 5 64 Housing Menu HypoidFaceHobbed Reference Frame Abaqus Reference Frame COORD
21. Note that the IglassViewer graphics window is independent of the guide graphics window The advantage of using IglassViewer over guide program for pre and postprocessing is that it is more faster efficient and more simple to operate Also you can visualise the models in their dynamic mode which is not possible using the Guide program Following sections gives a detailed explanation of the procedure for creating the pre and postprocessing iglass files and also the various functions associated with the iglass program 8 1 Generating an Iglass file for preprocessing The GENIGLASSFILE command in Figure 7 1 will lead to a menu shown in Figure 8 1 using which you can generate a preprocessing file for Iglass The filename is specified in the IGLASS FILENAME menu The time at which the user wants to visualise the model can be specified in the TIME menu The user can also visualise the model at a sequence of time steps by entering the number of steps in the NTIMESTEPS menu The DELTATIME menu is the value of time increment between successive writes to the iglass file The POPUPIGLASS menu if turned on will automatically open up the Iglass graphical window after the Igass file is generated If it is not turned on only the data file for iglass will be created and iglass will have to be started manually Using the SELECT menu in Figure 8 1 the user can select the bodies to be displayed in the Iglass graphical window Click on the START button in Figure 8 1 to g
22. Running an Analysis The analysis is started by using STARTANAL command of Figure 3 4 Before starting an analysis sensor locations have to be set up to measure stress and loads in the model This is done through the SURFGAGES FEPROBES and LOADSENSORS com mands in the main menu Figure 3 4 Additional analysis parameters and settings are controlled through the SETUP command 6 1 Surface gages A surface gage is used to measure the critical stress along tooth surfaces The reading of each gage is the most critical stress measured over a user defined range of teeth profile face and depth along a specific surface Figure 6 1 shows the Surface Gage setup menu The number of gages NGAGES has to be entered first Then the gage number for a particular gage can be entered into the GAGE box and the gage information can be typed into the remaining boxes For each gage the BODY item selects which of the individual components in the system the gage is attached to For a HypoidFaceMilled gear analysis there are two bodies the pinion and the gear After the Body is selected the surface on which the gage should be attached should be selected The gear teeth typically have four surfaces SURFACE1 and SURFACE2 cover the entire involute and fillet areas of the two sides Side 1 and Side 2 respectively of the teeth FILLET1 and FILLET2 cover only the fillet region of Side 1 and Side 2 respectively When there are multiple copies of a surface on a body
23. will increase the effective cone angle you can provide a scale factor of 25 4 The order of this polynomial in the profile direction is PROFORDER and that in the face width direction is FACEORDER The Surface Modifications menu for the gear tooth is similar to that of the pinion 5 14 Modelling the Rim The RIM command in Figure 5 12 leads us to the Rim data menu for the pinion shown in Figure 5 43 The DORIM flag controls whether the rim model will be generated in addition to the model of the contacting tooth If it is not generated then the tooth finite element model will be constrained at the base TYPE defines how the rim will be created WEBBED or EXTERNALFE The RIM menu for the gear is same as that for the pinion If WEBBED the rim is specified by sequence of line segments in order to define the rim cross section The first segment is closest to the tooth and the last segment is the farthest Each segment i has two endpoints A and B A is the end that is closer to the crossing point as shown in Figure 5 42 Each end point is specified by its radial coordinate r and axial coodinate z The Rim data parameters are explained in Table 5 11 If EXTERNALFE the rim is imported using either a Nastran or Abaqus mesh file The CYCLICSYMMETRY flag allows for the model to be of only a sector of the rim the nodes Building a Model X Edit Gear Concave Modifications QUIT DELTA SPIRAL AN 0 0000000000 000
24. 16 show graphs of contact pressure vs time over the entire surface of a pinion tooth Very high contact pressures are observed near the tips of the pinion and gear teeth This high contact pressure near the edges can be filtered out by restricting the search range using the SPROFBEGIN and SPROFEND commands 106 Pre and Post processing MultyX PostProc 1 21 Contact EXIT QUIT START CLEAR FINDPITCHPOINT SURFACEPAIR GEAR_SURFACE1_PINION_SURF MEMBER 1 TOOTHBEGIN 141 1 151 121 1 TOOTHEND 41 1 151 121 1 BEGINSTEP 41 1 151 121 1 ENDSTEP 4141 151 121 1 SPROFBEGIN 41 1 121 1 SPROFEND ganan TFACEBEGIN LELEH TFACEEND XAXIS TIME EDGECONTACT PRESSURETYPE SLIDING VELOCITY ROLLING VELOCITY 8 Figure 7 14 The CONTACT menu 107 7 6 The CONTACT command 0000900 0000500 00008070 oun 00006070 00002070 0000100 0000000 61 ADVAL 100 38 100
25. 6 HypoidFaceMilled Software Package 2 2 Installation of the software package on windows plat form The procedure for installing the HypoidFaceMilled software analysis package on Microsoft Win dows NT 2000 XP Vista Win7 Win8 platforms is as follows e Obtain the self extracting file HypoidFaceMilled msi from us e Before installing anything make sure that there are no previous copies of guide exe mul tyz exe or calyz exe in your path If these files are present then you either have to move the old programs elsewhere or change the path so that they don t conflict with the new programs e Now you are all set to install the software package Close all the other programs and run HypoidFaceMilled msi It wil ask you questions about where to install the program and where to keep the working directory e After you answer these questions it will display the Computer ID and ask for a license key Copy the Computer ID and click the button skip or install key later It will proceed with the installation and will install icons under Start Programs HuwypoidFaceMilled Send the Computer ID via email to support ansol com and we will send you the License Key Click on the skip button You can return to this license key dialog by using the icon at Start Programs HypoidFaceMilled Register e After you receive the License Key from Ansol run Start Programs HypoidFaceMilled Register again and paste the License Key in the respective box Now click
26. 8809C0 C HO V3 10097 1 4 8 amp 96L dO dS 132 VITIS 32 VeIDIS EVO ed uo 1971009 Y 0000000 0000007000001 000000000007 000000 00000 00000000000 000000000005 000000000009 0000007000001 0000007000006 0000000000001 Figure 7 15 The tooth contact pressure vs time graph generated by the CONTACT menu processing 00009070 0000500 00008070 00006070 00002070 0000100 0000000 Pre and Post NOINId 132 VeDEDIS VAD amd sona 61 ADVAL 1003865607 IONAS 100 1 8092072 7HO VA 100 ASEE96L P AONAS 108 0000000 0000007000001 000000000007 00000000000 000000000005 0000007000001 0000007000008 0000007000006 Figure 7 16 The tooth contact pressure vs time graph generated by the CONTACT menu 7 7 The TOOTHLDHIST command 109 EX
27. BLADE ANGLE EDGE RADIUS CUTTER FOR THE CONVEX SIDE Z A POINT RADIUS 4 ES DEPTH R OF MODFN EDGE RADIUS MODIFIED CUTTER FOR THE CONVEX SIDE Figure 5 33 Cutter description for Convex side Old Cutter 5 10 Cutter Specifications for the pinion 51 Table 5 7 Cutter specifications for concave and convex tooth side of a pinion Item Special Analyis File Details POINTRADIUS Float Radius of the cutter Concave side Record 17 Item 5 amp Convex side Record 20 Item 5 BLADEANGLE Float Cutter blade angle Deg Concave side Record 17 Item 4 amp Convex side Record 20 Item 4 EDGERADIUS Float Radius of the cutter Concave side Record 16 Item 15 amp edge Tip radius Convex 1 19 15 Switch Type of cut Concave side Record 17 Item 1 amp ter STRAIGHT TOPREM Convex side Record 20 Item 1 o Z A NS P 4 d d POINT RADIUS ra d 4 E R EDGE RADIUS LADE ANGLE Figure 5 34 Curved cutter description for Concave side Old Cutter 52 Building a Model PERICA lr gt POINT RADIUS B A ec Mob ect a et ee ee pee R BLADE ANGLE __ EDGE RADIUS Figure 5 35 Curved cutter description for Convex side Old Cutter 5 11 Cutter Specifications for the
28. Each surface pair has two contacting members or bodies The MEMBER parameter selects one of these two bodies and the TOOTHBEGIN and TOOTHEND items select a range of instance numbers tooth numbers within that body If TOOTHBEGIN is greater than TOOTHEND then the range wraps around the last tooth of the surface This range must contain 7 teeth or less BEGINSTEP and ENDSTEP are used to select a range of time steps for which results have been stored in the post processing file Figure 7 13 shows a graph of tooth load vs time generated by the TOOTHLOAD command The OUTPUTFILENAME item is used to write the tooth load data into an ASCII file The name of the ASCII file is entered into the item OUTPUTFILENAME If the APPEND box is checked and if this file already exists then the data is appended at the end of the file Otherwise a new file is created 102 Pre and Post processing 7 5 The TOOTHLOAD command 103 SURFACEPAIR PINION_SURFACE1_GEAR_SURF MEMBER 1 TOOTHBEGIN LEELLE BEGINSTEP 4141 1519121 ENDSTEP 1 4141 1519121 1 OUTPUTTOFILE Iv 2 FILENAME 0202020 APPEND ra 20 TOOTHEND 2 q 4141 151 121 1 N Figure 7 12 The TOOTHLOAD menu 104 Pre and Post processing
29. Finite Element Mesh Show Front Side Show Back Side 9 Curent Reference Frame Relerence Frame Pre and Post processing using Iglass Viewer es rea x Figure 8 10 Iglass in post processing mode 8 5 Features specific to iglass post processing The time switch processing iglass shown in Figure 8 11 is used to run the simulation of the model in the post window You can look at the simulation at a particular time step by dragging the slider along the scale The Defmn deformation slider shown in Figure 8 12 is used to view the deformed shaped of the gear bodies The Rigid and the F E Defl shows the rigid body deflection and the finite element deflection of the bodies The magnification scale of deformation can be adjusted using the slider Time SS Time 000273 sec Figure 8 11 The time slider 8 5 Features specific to iglass post processing 145 Attribute NONE z Figure 8 13 The attribute switch Rigid Dell Superimpose Undeformed Defmn 0 Figure 8 12 The deformation slider The Attribs menu is shown in Figure 8 14 The attribute menu shown in Figure 8 13 is used to check for contours for different component of results The available options are DISPLVEC TOR MAXPPLNORMAL S2PPLNORMAL MINPPLNORMAL MAXSHEAR VONMISES and ERRORESTIMATE The DISPLVECTOR will pop up a component switch using which the contour f
30. LEFTROATE box and press enter on Keyboard you will see 0 in the box This means that the program has incorporated that change of 30 degrees rotation in the model even though you are not able to visualise that change To see the new rotated drawing you will have to clear the one present on your screen and click on the DRAWBODIES button in the pre and the postprocessing menus Pre and Post processing EXIT QUIT WINDOW AUTOWINDOV VIEWPORT XPROJECTION YPROJECTION ZPROJECTION ISOMETRIC LEFTROTATE 0000 RIGHTROTATE 2000000000000 UPROTATE 000 0 0000000000 000 CCwR TATE 0 0000000000 000 2 REFFRAME e FIXED m HIDDENREMOVE e OUTLINE Iv 2 ELEMENTS Figure 7 5 The view menu pre processing mode 7 2 View parameters QUIT WINDOW AUTOWINDOW _ r E I 1 YPROJECTION ZPROJECTION ISOMETRIC LEFTROTATE 0 0000000000 000 UPROTATE 0 0000000000 000 0 o c000000000e 000 CCWROTATE 0 0000000000 000 2 FIXED HIDDENREMOVE OUTLINE ELEMENTS COLORS 2 RESOLUTION 4595952 LOADS E EREEL 0 00000000006 000 CONTOURS Figure 7 6 The view menu in post processing mode with the LOADS option disabled Pre and Post processing e
31. Post processing p M on EXIT QUIT START CLEAR SELECT BEGINSTEP 4141 151 121 1 ENDSTEP SIL D FILENAME LEH Figure mo 0 0 0 m 0 0 0 internal force inertial press body f mo m f mo mass amp damping force contact force bearing force reaction force Residual force error Uf mo OUTPUTTOFILE 21 APPEND Joutput tt 7 39 The AUDIT menu 2456 413213 2265 730626 435 0533685 3787 851508 2604 563245 7809 750003 3787 851508 2604 563245 7809 750003 0 0 0 0 0 0 0 0 0 2456 413213 2265 730626 435 0533685 3787 851508 2604 563245 7809 750003 1 364242053e 012 9 094947018e 013 5 684341886e 014 1 364242053e 012 4 547473509e 013 0 1 364242053e 012 4 547473509e 013 0 The forces and moments are broken down into contact forces bearing forces internal forces mass and damping forces and reaction forces The reaction forces are the forces exerted by the reference frame constraints Two values for the moments are displayed In the above example mo refers to the moments computed about the origin of the pinion shaft body m stands for the moment computed about the origin of the fixed reference frame The moments about the fixed reference frame are more useful in comparing the action and reaction acting on diffe
32. Straight Blade with Straight Flankrem New Cutter 46 Cutter description for Straight Blade with Blended Flankrem New Cutter 46 Cutter description for Curved Blade with Straight Toprem New Cutter AT Cutter description for Curved Blade with Blended Toprem New Cutter AT Cutter description for Curved Blade with Straight Flankrem New Cutter 48 Cutter description for Curved Blade with Blended Flankrem New Cutter 48 Cutter description for Concave side Old Cutter 49 Cutter description for Convex side Old 50 Curved cutter description for Concave side Old Cutter 51 Curved cutter description for Convex side Old Cutter 52 Cutter specifications for the formate gear 54 Surface Modification 56 Angle Modifications sea ders xx 56 Linear Tip Relief menu 57 Surface Modification applied on the gear concave side 58 tip relief input 58 The Rim geometry Webbed een 59 The Rim data Men 5i 30328046 SUE Tm mox EIE E TER 60 The Rim geometry 60 The menu for specifying shaft 62 Ehe shatt model 5 Re RR Sb EU
33. be visualized by using the appropriate sliders The magnification scale of the forces and the moments can be adjusted using the respective sliders The EXIT button will take you out of the iglass post processing window 8 5 Features specific to iglass post processing 149 View Bodies Attibs Contact Reactions e s s Contact Load Intensity o Contact Pressure 1 72822 003 1 0887 003 amp 85820 002 4 3204e 002 2 7217 002 1 714 002 3 402164001 0 0000e 000 Contact Pressure Figure 8 17 The iglass postprocessing Contact menu 150 Pre and Post processing using IglassViewer Figure 8 18 The contact pressure distribution on the pinion teeth 8 5 Features specific to iglass post processing 151 View Bodies Contact Reactions Body Reaction Moment Constraints Figure 8 19 The iglass postprocessing Reactions menu 152 Pre and Post processing using Iglass Viewer Appendix Tooth Mesh Templates The finite element meshes in the HypoidFaceMilled package are created with very little input from the user The user does not need to provide any of the node numbering and element connectivity information to the model generator This information is read by the program from pre existing files called template files Figures A 1 through A 4 show the element connectivity and element numbering scheme use
34. cutter spindle tilt with respect to the gear being generated Deg Float Offset between the work spindle axis and the cradle axis Float Angle between the element of the root cone and its axis Deg Float Axial distance from the root apex of the gear to the spin dle mounting surface Float Position of the sliding base with respect to the machine plane Float Angular position of the cradle axis with respect to the gear generated Float Ratio of the number of teeth on the imaginary gear to the number of teeth on the gear being cut Float Modified roll 2nd order co efficient Float Modified roll 3rd order co efficient Float Modified roll 4th order co efficient Float Modified roll 5th order co efficient Float Helical motion 1st order coefficient Float Helical motion 2nd order coefficient Float Helical motion 3rd order coefficient Float Vertical motion 1st order coefficient Float Vertical motion 2nd order coefficient Float Vertical motion 3rd order coefficient Concave side Record 25 Item 1 Convex side Record 21 Item 1 Concave side Record 25 Item 2 Convex side Record 21 Item 2 Concave side Record 25 Item 3 Convex side Record 21 Item 3 Concave side Record 25 Item 4 Convex side Record 21 Item 4 Concave side Record 25 Item 5 Convex side Record 21 Item 5 Concave side Record 25 Item 6 Convex side Record 21 Item 46 Concave side Record 25 Item 7 Convex side Record 21 Item 7 Concave side Recor
35. difference is that it uses contact pressure instead of contact load Figure 7 25 shows an example of a grid pressure histogram 7 10 The GRIDPRHIST command 2e 0 000000E 000 1 613570E 002 Each Di v 2 000000E 001 ne 5 000000E 003 Ran Figure 7 23 The grid load histogram generated by the GRIDLDHIST menu 116 Pre and Post processing TOOTHEND APPEND Figure 7 24 The GRIDPRHIST menu 7 10 The GRIDPRHIST command 117
36. dy dete bn 63 The dimensions of the outer surface of a shaft segment 63 The dimensions of the outer surface of a shaft segment 64 The bearing stiffness matrix format 64 The pinionstiffnessbearingreferenceframe 65 Phe Caitie aunke Rege es ee Bunk ek ae 66 The EDIT GEAR menu lees 67 The menu for importing a differential carrier 67 Pinion EEE SEG SS 68 2 position and 69 1 A2 and angular position of pinions 69 Conical races Menus he eem ee de eee 70 Comical Race Diagram ee A ee UA d 71 Conical cna a s ko ee ee ROROROR we eee e EMER A 71 Cylindrical races menu les 72 Cylindrical Paces Ron ee RR 73 The diff carrier stiffness bearing reference frame 74 DOMODELHOUSING checked in the EDIT menu 75 Housing sorai erea a Ge ee 44 76 Reference frame 76 Bearing Origin Locations In Abaqus Reference Frame 77 Pinion Bearing Menu se eee ER Rae Re 78 Differential Bearings DIF
37. generated type gear 53 5 11 Cutter Specifications for the generated type gear The CUTTER menu for the generated type gear is similar to that of the pinion cutter menu Figure 5 22 except for the Special Analysis File details Table 5 8 explains all the parameters associated with the Cutter menu for the generated type gear Table 5 8 Cutter specifications for concave and convex tooth side of a generated type gear Item Special Analyis File Details POINTRADIUS Float Radius of the cutter Concave side Record 25 ltem 8 amp Convex side Record 21 Item 8 BLADEANGLE Float Cutter blade angle Deg Concave side Record 27 Item 4 amp Convex side Record 23 Item 4 EDGERADIUS Float Radius of the cutter Concave side Record 26 Item 15 amp edge Tip radius Convex side Record 22 Item 15 TYPE 54 Building a Model Figure 5 36 Cutter specifications for the formate gear 5 12 Cutter Specifications for the formate type gear If you select the gear type as formate gear then the CUTTER command in the Concave Convex menus leads to the menu shown in Figure 5 36 Table 5 9 explains all the terms associated with this menu 5 13 Surface Modifications MODIFICATIONS command in Figure 5 18 leads to the Surface modification menu shown in Figure 5 37 The modifications for Spiral Pressure and Cone angles all lead to increases in the their respective angles shown in Figure 5 38 The sign convention for each of the angles is positive as shown
38. in the figure Note the DELTA CONE ANGLE parameter is dependent upon the the DELTA PRESSURE ANGLE DELTA SPIRAL ANGLE inputs therefor DELTA_CONE_ANGLE value should not be input if also entering values for the remaing two parameters Table 5 10 provides a more detailed description of each of the 3 angle modifications The LINEARTIPRELIEF flag controls whether or not linear tip relief will be applied and expands the menu to Figure 5 39 Tip relief is specified in three locations and for each location the Magnitude Tip Distance and Distance from the face cone axis must be specified The QUADRATICTIPRELIEF flag controls whether or not quadratic tip relief will be applied and has similiar menu and inputs to linear tip relief A graphical depiction of the inputs is shown in Figure 5 41 The DOTOPOMODEYN flag controls whether or not surface modifications based on numerical data such as from CMM will be applied If you check the DOTOPOMODEN box then the Surface Modifications menu applied on the Gear Concave side shown in Figure 5 40 becomes available The Surface Modifications menu applied on the Convex side of the tooth is similar to that on the Concave side The TOPOMODTYPE specifies which type of modification file is to be used The data file name containing the surface modifications should be entered in the ZEISSFILE textbox SCALEFACTOR allows for the data points within the modification file to by multiplied by this scale factor If the file i
39. is the assembly error of the gear with respect to the pinion in the plane of rotation of the gear in a direction perpendicular to the pinion axis Assembly error H is the error in the axial direction of the pinion It is positive when the pinion is moved out of mesh relative to the gear Assembly error R is the error in the axial direction of the gear It is positive when the gear is moved out of mesh relative to the pinion Assembly error BETA is the difference in the shaft angle from the design shaft angle It is positive when the actual shaft angle is larger than the design shaft angle Figures 5 6 and 5 7 shows the sign convention used to model the assembly errors for the left handed and right handed gear respectively Figures 5 8 through 5 10 show the three methods used to calculate the assembly errors Method 1 calculates displacement values at the base surfaces method 2 calculates displacement at the base surfaces of contacting teeth and method 3 calculates the displacement within the contacting teeth underneath of the contact zone The preferred method and the method employed within the HypoidFaceMilled software package is method 2 Figure 5 11 shows the output file format for the assembly error file The E P G and parameters are synnonomous with the V R and 8 parameters described previously 5 3 Assembly errors MODELTYPE HANDPINION LEFT id OFFSET 0 0000000000e 000 anna ANGLE 90 0000000000
40. object that is capable of rigid body motion and interacts with other bodies through surface contact and bearing connections Figure 3 1 There is a special body called the fixed body which refers to ground In HypoidFaceMilled the hypoid pinion and hypoid gear are treated as separate bodies The interaction between the hypoid gear and the hypoid pinion is through contact Preliminaries Figure 3 1 A multi body system 3 3 Reference frames 9 3 3 Reference frames Each of the bodies in the system has a reference frame to which it is rigidly attached The reference frame has 6 rigid body type degrees of freedom three translation components Uz Uy and U and three rotation components 9 0 and and 6 Figure 3 2 Theta N P d Theta x 7 Theta z 277 Figure 3 2 Reference frame degrees of freedom In addition to the body reference frames there is a special reference frame called the fixed reference frame that is considered as ground and does not move It is used as the reference for defining the locations of all other reference frames Figure 3 3 show how HypoidFaceMilled sets up the pinion and gear reference frames relative to the fixed reference frame in Hypoid gear set Its Z axis is parallel to the axes of rotation of the gear The pinion and gear reference frames have their origins at their crossing points with the Z axis being the axis or rotation At time t 0 the gear X Y and Z axes
41. rotate the model using the left mouse button Drag the left mouse button in the direction you want to rotate the model in the iglass graphics window Also the model can be moved in the graphics window in any directions you want using the right mouse button Drag the right mouse button in the direction you want to move the model in the iglass graphics window 8 2 1 Finite element mesh The finite element mesh model can be visualised if the Finite Element Mesh item is selected Figure 8 4 shows the finite element mesh model of the gear bodies in iglass preprocessing 8 2 2 Cutting plane Using the cutting plane switch shown in Figure 8 5 you can visualise the model along a section This feature is especially useful in pre and post processing of complicated models with a large number of internal gears The cutting plane can be selected along the ve and ve X Y and Z axes Using the button below the cutplane switch you can select the cutting plane at various points along the axis chosen by the cut plane switch option 8 2 3 Selecting the time step User can visualise the model at a particular timestep in iglass pre processing using the Time slider shown in Figure 8 6 140 Pre and Post processing using Iglass Viewer Table 8 1 Common buttons in Iglass pre and postprocessing window Button Purpose Zoom In E Zoom Out Move the model upwards If Spin is turned OFF Move the model downwards If Spin is turned OFF
42. the cutter The value of this angle given in the Special Analysis File is in radians The user should convert in to degress before entering it in the TOPREMANGLE menu TOPREMLENGTH Record 17 Item 2 for Concave side and Record 20 Item 2 for Convex side is the distance from the cutter point of the start of the modified part of the cutter If the Special Analysis File Record shows a non zero value for the TYPE item Refer to the Table 5 7 for details then the Cutter type is TOPREM or else it is STRAIGHT type or CURVED type Figures 5 32 and 5 33 show the various terms associated with the modified cutter for Concave side and Convex side respectively If the CURVED type cutter is selected then a parameter called RHO Special Analysis File Record 15 Item 12 for Concave side and Record 18 Item 12 for Convex Side is added to the cutter menu RHO is the spherical radius for the curved blade If the Special Analysis File Record shows a non zero value for the RHO item then the cutter type is CURVED or else it is STRAIGHT A CURVED type cutter for concave and convex side tooth is shown in Figure 5 34 and Figure 5 35 respectively 5 10 Cutter Specifications for the pinion 45 ZA ___ RADIUS EDGE RADIUS TOPREM ANGLE LADE ANGLE Figure 5 24 Cutter description for Straight Blade with Straight Toprem New Cutter 7 POINT RADIUS TOPREM EDGE RADIUS BLEND RADIUS BLADE ANGLE Te Figure 5 25 Cutt
43. the cutter axis when they are parallel Float Tilt of the cutter axis with respect to the direction of the cra dle axis Deg TILTANGLE SWIVELANGLE BLANKOFFSET ROOTANGLE MACHCTRBACK SLIDINGBASE CRADLEANGLE RATIOROLL 2C 6D 24 120 H1 H2 H3 V1 V2 V3 Float Direction of the cutter spindle tilt with respect to the gear being generated Deg Float Offset between the work spindle axis and the cradle axis Float Angle between the element of the root cone and its axis Deg Float Axial distance from the root apex of the gear to the spin dle mounting surface Float Position of the sliding base with respect to the machine plane Float Angular position of the cradle axis with respect to the gear generated Float Ratio of the number of teeth on the imaginary gear to the number of teeth on the gear being cut Float Modified roll 2nd order co efficient Float Modified roll 3rd order co efficient Float Modified roll 4th order co efficient Float Modified roll 5th order co efficient Float Helical motion 1st order coefficient Float Helical motion 2nd order coefficient Float Helical motion 3rd order coefficient Float Vertical motion 1st order coefficient Float Vertical motion 2nd order coefficient Float Vertical motion 3rd order coefficient Concave side Record 15 Item 1 Convex side Record 18 Item 1 Concave side Record 15 Item 2 Convex side Record 18 Ite
44. 0 060000 0 050000 ge 3 043801 0040000 THETAZ Ran 0 030000 0 020000 0 010000 0 000000 Body Fram 0 002900 0 002920 0 002940 0 002960 0 002980 0 003000 0 003020 0 003040 0 003060 Figure 7 41 The graph generated by the BODYDEFLECTION menu 7 19 The BODYREACTION command 135 BODY aa PINION COMPONENT MZ 213 BEGINSTEP Tz D TH EST ENDSTEP 4141 1519121 1 Figure 7 42 The BODYREACTION menu 186 Pre and Post processing E T T dq T d d d Ce 0 000000 0 100000 0 200000 Time Figure 7 43 The graph generated by the BODYREACTION menu 8 Pre and Post processing using Iglass Viewer IglassViewer is a very powerful tool for pre and postprocessing gear models and results Sev eral features have been added to the Multyx program so as to enhance the compatability with IglassViewer Thus it can be considered as a program which enables the user to view pre and postprocessing files generated by an external code
45. 14 The FATIGUE command The FATIGUE command of the post processing menu Figure 7 3 leads to the menu shown in Figure 7 34 This menu is used to track fatigue within the tooth at the critical point The range of timesteps must be set using BEGINSTEP and ENDSTEP CRITERION is used to determine the method for finding the critical point The method is either ALTERN_STRESS or EQUIV_PURE_STRESS Values must then be set for YIELD STRENGTH ULTIMATE_STRENGTH and ENDURANCE_LIMIT NTOOTHCYCLES specifies the number of tooth cycles over which to calculate damage In order to get tooth cycles out of revolutions multiply the number of gear teeth by the number of teeth The surface is selected by specifying the body in the BODY box and a surface in the SUR FACE box A profile and face location on this surface is specified through the SPROF and TFACE parameters with the number of points to be evaluated specified by NUMSPROF and NUMTFACE The depth is specified by DEPTHBEGIN and DEPTHEND with the number of points to be evaluated specified by NUMDEPTH 7 15 The POINTSTRESS command The POINTSTRESS command of the post processing menu Figure 7 3 leads to the menu shown in Figure 7 35 This menu is used to track normal stresses in a specific direction at a specific point on a surface 7 16 The PATTERN command 127 MultyX PostProc 1 21 PointStress EXIT QUIT BODY NON PINION COORD_TYPE SURFACE_COORDS x 219 SURFACE SURFACED SE SURFACE1
46. 4 65670531 mo 3732 561763 2613 33 7814 037462 m 3732 561763 2613 33 7814 037462 Total contact force f 2457 605255 2268 267637 414 6567053 3732 561763 2613 33 7814 037462 m 3732 561763 2613 33 7814 037462 Bearing forces Total bearing force f 0 0 0 mo 0 0 0 m 0 0 0 otal internal force inertialt presstbody f 0 0 0 mo 0 0 0 m 0 0 0 otal mass amp damping force f 0505014 mo 0 0 0 m 0 0 0 otal contact force f 2457 605255 2268 267637 414 6567053 mo 3732 561763 2613 33 7814 037462 m 3732 561763 2613 33 7814 037462 otal bearing force f 0 0 0 mo 0 0 0 m 0 0 0 otal reaction force f 2457 605255 2268 267637 414 6567053 mo 3732 561763 2613 33 7814 037462 m 3732 561763 2613 33 7814 037462 Residual force error f 0 1 364242053e 012 5 684341886e 013 mo 4 547473509e 013 1 182343112e 011 9 094947018e 013 m 4 547473509e 013 1 182343112e 011 9 094947018e 013 Body no 2 GEAR Origin at 0 0 0 Contact forces Exerted by PINION Total f 2456 413213 2265 730626 435 0533685 mo 3787 851508 2604 563245 7809 750003 m 3787 851508 2604 563245 7809 750003 Total contact force f 2456 413213 2265 730626 435 0533685 mo 3787 851508 2604 563245 7809 750003 m 3787 851508 2604 563245 7809 750003 Bearing forces Total bearing force f 0 0 0 182 Tota Tota Tota Tota Tota Pre and
47. 58 10 FRONT ANGLE 1 271058 11 DELTA R 0 540584 12 GR 0 063690 13 BO 1 352146 14 BI 0 881508 15 PABCP 0 136397 160 Special Analysis File Bibliography 10 11 12 13 14 Planetary Gear Train Ring Gear and Support Structure Investigation Mark Valco Ph D Dissertation Cleveland State University 1992 Gear Tooth Stress Measurements of Two Helicopter Planetary Stages Krantz T L NASA Technical Memorandum 105651 AVSCOM Technical Report 91 C 038 1992 A combined surface integral and finite element solution for a three dimensional contact problem S Vijayakar International Journal for Numerical Methods in Engineering vol 31 pp 525 545 1991 Nonlinear and dynamic programming G Hadley Addison Wesley Publishing company 1964 Linear programming George Hadley Addison Wesley 1962 Linear and Combinatorial Programming Katta G Murty John Wiley 1976 ISBN 0 471 57370 1 Linearization of multibody frictional contact problems 5 Vijayakar Busby and Houser Computers and Structures vol 29 no 4 pp 569 576 1987 Natural Frequency Spectra and Vibration Modes of Planetary Gears Jian Lin and Robert Parker 1998 ASME Design Engineering Technical Conference September 1998 Atlanta Georgia Gear Dynamics Experiments Part I Characterization of Forced Response Blankenship and Kahraman ASME 7 International Power Transmissions and Gearing Conference San Diego October 1
48. 996 Gear Dynamics Experiments Part II Effect of Involute Contact Ratio Blankenship and Kahraman ASME 7 International Power Transmissions and Gearing Conference San Diego October 1996 Gear Dynamics Experiments Part III Effect of Involute Tip Relief Blankenship and Kahra man ASME 7 International Power Transmissions and Gearing Conference San Diego October 1996 The use of boundary elements for the determination of the geometry factor Vijayakar and Houser 1986 AGMA Fall Technical Meeting Paper no 86 F TM 10 Finite element analysis of quasi prismatic structures S Vijayakar H Busby and D Houser International Journal for Numerical Methods in Engineering vol 24 pp 1461 1477 1987 Edge effects in gear tooth contact S Vijayakar ASME 77 International Power Transmis sions and Gearing Conference San Diego October 1996 162 BIBLIOGRAPHY 15 Vibration Measurements on Planetary Gears of Aircraft Turbine Engines M Botman AIAA Journal vol 17 no 5 1980 16 Dynamic Tooth Loads in Epicyclic Gears Cunliffe J D Smith and Welbourn J Eng Ind Trans ASME May 1974 17 Effect of Internal Gear Flexibility on the Quassi Static Behavior of a Planetary Gear Set Kahraman S Vijayakar Transactions of the ASME September 2001
49. FCARRIER CYLINDRICALRACE menu 79 The surface cage menu Re ee Pe as 83 The finite element probe menu 84 The load sensor menu 85 Computational grid in the contact zone of the gears 87 Contact pressure distribution across the width of contact obtained when the con tact grid 15 wide decr sia a Wa bE Ee XX 88 LIST OF FIGURES vii 6 6 Contact pressure distribution across the width of contact obtained when the con tact grids DaffOW ose vh m or 88 6 7 Contact pressure distribution across the width of contact obtained when the con tact Prid COIPeGL EROR 7 080808 89 6 8 example of a contact grid set up on a pair of contacting teeth 89 0 0 Th setup Menu 2 25 8 Rae 91 7 1 The pre processing menu 93 7 2 The post processing file name dialog box 93 7 3 The post processing 94 7 4 body selection menu 95 7 5 The view menu in pre processing mode 96 7 6 The view menu in post processing mode with the LOADS option disabled 97 7 7 view menu in post processing mode with the LOADS option enabled 98 7 8 example of drawing made in the post
50. HypoidFaceMilled User s Manual Contents Preface 1 Introduction 2 HypoidFaceMilled Software Package 2 1 HypoidFaceMilled analysis 2 2 Installation of the software package on windows platform 2 3 Upgrading of the software package on windows platform 3 Preliminaries ek OF WIGS oerte 3 2 Bodies uo 2254 Eo ee eee Rb RR se 3 3 Reference frames 22522 X Lo ex we ud S EUROS Se UR RUN UE Eo 3 34 Ree ee Rok da x 4 4 The Graphical User Interface 4 1 Menu command items 42 lutegermenu itemg e Rok RUM RO a ee 4 3 Floating point menu items o e ss 2222 44 Boolean menu items ee BOX ere 402 deep Rom 40204 4 5 String menu Jiems 55 aa OS E 4 6 Switch type menu items 4 7 Commonly occurring buttons 2 25 3 IU RECEN MCCC Ge DELE 5 Building a Model 5 1 jSpecial Analysis File poe s osos esce bec E EG a RO Reb PUER 4 5 2 SysbemLlevel data key TO EPOR Y PUR mew 5 3 Assembly b ee AE E n 5 4 Pinion and gear dala 5 s Rose 8 4 2 Foe ba Oe eb e ed 5 5 Common design and blank 5 6 Concave and Convex side data
51. IT QUIT START CLEAR hif PINION_SURFACE1_GEAR_SURF MEMBER INI M PINION LL TIMESTEP 2201211 HISTCOLOR BLACK AUTOSCALE DUTPUTTOFILE 1 FILENAME LLH APPEND ral output txt Fs Figure 7 17 The TOOTHLDHIST menu 7 7 The TOOTHLDHIST command The TOOTHLDHIST command in the post processing menu Figure 7 3 leads to the menu shown in Figure 7 17 This menu is used to to generate a histogram of tooth loads at the different teeth in the pinion or gear at a particular time step The SURFACEPAIR item selects the surface pair and the MEMBER parameter selects one of the two bodies in this pair The time step number is selected by the TIMESTEP item If the AUTOSCALE box is checked then the vertical scale is automatically computed Otherwise the user can specify a maximum load value to be used for scaling the vertical axis The color of the histogram is specified in the HISTCOLOR item example of a tooth load histogram is shown in Figure 7 18 7 8 SUBSURFACE command The SUBSURFACE command in the post processing menu Figure 7 3 leads to the menu shown in Figure 7 19 This menu is used to to generate a graph of subsurface stresses vs depth under the most critical point in the contact zone The SURFACEPAIR item selects the surface pair and the MEMBER parameter selects one of the two bodies in this pair The time step numbe
52. IUM MESHFILE pinioncalemsh 000 Figure 5 14 The common design and blank data menu 31 32 Building a Model Table 5 2 Common design and blank parameters Special Analyis File Details Item NTEETH NFACEELEMENTS COORDORDER DISPLORDER SPIRALANGLE SPECIFYMSRPT MEASADDENDUM THICKNESS OUTERCONEDIST FACEWIDTH FACEANGLE BACKANGLE FRONTANGLE PITCHANGLE PITCHAPEX FACEAPEX ROOTAPEX Integer Number of teeth on the pinion gear Integer Number of elements across the face width of the pin ion gear Integer Limit on the order of coordinate axodes for the ion gear Integer Limit on displ order of axodes Float Angle between the tooth trace and an element of the pitch cone Deg Boolean Whether to specify the thickness measuring point Float The measuring addendum Float Mean transverse tooth thickness Float Distance from the apex of the pitch cone to the outer ends of the tooth Float Face width of the tooth Float Angle between the element of the face cone and axis Deg Float Angle between the element of the back cone and the plane perpendicular to the axis of rota tion Deg Float Angle between the element of the front cone and the plane perpendicular to the axis of rota tion Deg Float Angle between the element of the pitch cone and axis Deg Float Pitch apex beyond cross ing point distance Float Face apex beyond crossing point distance Float
53. NAME and APPEND items Fig ure 7 31 shows an example of stress as a function of time Figure 7 32 shows stress as a function of profile position Sharp oscillations can be seen in this graph in the vicinity of the concentrated contact loads Figure 7 33 shows a graph of stress vs face 7 13 The SEARCHSTRESS command 123 0 060000 0 050000 i 2 45 8 A 2 3 2 E A 3 140000 000000 100000 000000 80000 000000 60000 000000 40000 000000 20000 000000 0 000000 Figure 7 31 The graph of root stress vs time generated by the SEARCHSTRESS menu 124 Pre and Post processing 1 FE i E 1 20 000000 10 000000 i N 2222225 7471 xL i X
54. Palette menu Double clicking on the Background button will popup the Color window shown in Fig ure 8 16 using which you can change the background color of the iglass graphics window 8 5 Features specific to iglass post processing 147 Figure 8 15 Picking a nodal point to examine stresses 148 Pre and Post processing using IglassViewer View Bodies Attis lt gt i x 2 Altibute Basic colors MAXPPLNORMAL Palette Mode mmm POSITIVE 5033455008 1 258365004 mmmumr mr 3387564003 Custom colors 0 0000e 000 Hue 160 Red 255 Pick TEM 11111111 SU Backa Define Custom Colors gt gt ius 40 Blue 255 Lost ee 11 1005545 Contact Pressure 2 2111e 005 5 52772 004 Exit Figure 8 16 The background color popup window switch The Contact menu is shown in Figure 8 17 The Contact pattern legend is used to read the contact pressure on the contacting surfaces The contact pressure slider is used to show the contact pressures on the bodies Figure 8 18 The Reactions menu is shown in Figure 8 19 The directions of the bearing forces and moments can be visualised using the Bearing Force and Bearing moment sliders The directions of the body reaction force and the body reaction moment can also
55. Root apex beyond the crossing point distance amp amp Pinion Record 1 Item 1 Gear Record 1 Item 2 Pinion Record 1 Item 10 Gear Record 8 Item 4 Pinion Record 47 27 Gear Record 47 8 Pinion Record 3 Item 9 Gear Record 3 Item 10 Pinion Record 1 Item 6 Gear Record 1 Item 45 Pinion Record 5 Item 6 Gear Record 7 Item 6 5 9 7 9 amp Pinion Record 5 Item 10 Gear Record 7 Item 10 Pinion Record 5 Item 5 Gear Record 7 Item 5 Pinion Record 5 Item 15 Gear Record 7 Item 15 Pinion Record 4 Item 3 Gear Record 4 Item 4 Pinion Record 5 Item 12 Gear Record 7 Item 12 5 5 Common design and blank data 33 Table 5 3 Common design and blank parameters Item Special Analyis File Details BASESURFACETYPE Switch Kind of surface to be used as the sur face CYLINDER CONE BASECYLINDERDIAME Float Diameter of the cylin der used as the base of the tooth mesh IF BASESURFACE TYPE CYLINDER BASECONEANGLE Float Angle Deg between the element of the base cone and the axis IF BASESURFACE TYPE CONE BASECONEAPEX Float Inner cone apex be yond crossing point distance IF BASESURFACETYPE CONE ISRACERIGID Boolean Whether the bearing race is a rigid surface AXIALORDER Integer Polynomial order in the face direction CIRCORDER Integer Fourier series order in the circular direction YOUNGSMOD Float Youngs modulus for the pi
56. UMDEPTH of points ranging in depth from DEPTHBEGIN to DEPTHEND below the surface This is an expensive computation and should not be used unless necessary The surface gage will measure the stress at the critical depth The depth is in physical length units Because finite element stresses computed very close to the highly concentrated contact loads can have a large amount of error we need a way to screen out points that are too close The parameter DISTMIN is the minimum allowed distance of a stress calculation point from a contact point Stresses will not be calculated at any point whose distance from a contact point is less than this value This distance is in physical length units During the analysis all the surface gage readings are written to a file called GAGES DAT Each row in this file corresponds to a time instant The first column in the file contains the value of the time The remaining columns contain the readings of the surface gages There are four columns of data for each gage The first column for a gage contains the critical maximum principal normal stress 81 over its search range The second column contains the value of the critical minimum principal normal stress s3 The third column contains the critical maximum shear stress and the fourth column contains the critical Von Mises shear stress Sym The columns are separated by tabs 6 2 Finite element probes Finite Element Probes can be used to output stresses a
57. XEM Translate 5 e1 Rotate 0 e3 Rotate 0 e1 Figure 5 65 Reference frame orientation 5 17 Modeling the Housing 77 rims 2 _______ 679965 26 0 148 885797 3 ________ 679966 26 10 7 161385797 Figure 5 66 Bearing Origin Locations In Abaqus Reference Frame 78 Building a Model OFFSET_TYPE THRUSTCENTER BRGOFFSET 0 0000000000 000 al CONNECTHOUSING iv Turn ON for all bearing Figure 5 67 Pinion Bearing Menu 5 17 1 Connecting a Bearing to the Housing To connect bearings to the condensed stiffness housing the CONNECTTOHOUSING flag is turned ON within the pinion bearing menu 5 67 and the diff carrier gt cylindrical race menu 5 68 5 17 Modeling the Housing NCYLINDRICALRACES s 81112123 DIACYLINDRICALRACE s 23 23 2 Z1CYLINDRICALRACE Z2CYLINDRICALRACE 81 5 ICYLINDRICALRACE 1 H 1 CIRCORDERCYLINDRI onnan AXIALORDERCYLINDR m s 3 16101 21 5 CONSTRAINCYLINDRICALRACE a m 2 Ny DOBRGCYLINDRICALRACE _ THRUSTCENTER 8 ZPOSNBRG v lt CONNECTBRGHOUSING cum TYPE STIFFNESS oa BRGFILE cina carrier brg IUNLOADEDDEFM B Figure 5 68 Differential Bearings DIFFCARRIER CYLINDRICALRACE menu Turn ON for all bearing 79 80 Building a Model 6
58. a is being displayed Float Vector indexed by ISEG Radial coordinate at side A Float Vector indexed by ISEG Radial coordinate at side B Float Vector indexed by ISEG Z coordinate at side A Float Vector indexed by ISEG Z coordinate at side B 61 match the inner diameter of the gear or its rim The axial extent must overlap that of the pinion or gear If the segment connects to a bearing then OUTERCONNECTIONTYPE must be set to BEARINGRIGID for a rigid bearing or BEARINGFLEXIBLE for a flexible bearing The OUTERBRG menu is enabled upon selecting one of the abovementioned bearing types and the name of the file containing the bearing stiffness matrix is entered into the BRGFILENAME field Figure If the torque flows through the outer surface then OUTERCONNECTIONTYPE should be made CONSTRAINEDRIGID or CONSTRAINEDFLEXIBLE If the outersurface neither connects to the pinion or gear or bearing and is not constrained then the OUTERCONNECTIONTYPE should be set to FREE A similar set of options is available for the inside surface of the shaft segment through the item INNERCONNECTIONTYPE At least one segment must have its inner surface or outer surface constrained RALEIGHBETA F EXIT Anna 1 0000000000e 007 QUIT NSEGS OE 011214 ISEG 5 OUTERBRG LENGTH 1 0000000000 ECEE SHAFTOFFSET 5 5199900000 EEEH OUTERSHAPE CYLINDRICAL NTHETA 64 2 Mid bbe DOUTER 1 8000000000 141 1 121 1 UXCONSTRAINT
59. am without saving any data in the session file The EXIT command first writes data to the session file and then terminates the program All data entry occurs in a hierarchy of submenus accessed through the EDIT command on this main menu After data entry is completed the GENERATE command may be used to generate the model At this point a consistency check is carried out If any errors or inconsistencies are detected in the user s inputs then error messages are displayed and the model is not generated If the program detects something that it thinks is questionable but is still able to proceed then it 12 Preliminaries displays warning messages but proceeds with generating the model The REPORT command is used to generate an ASCII file called report txt describing all the inputs the user has supplied to the program The PREPROC command allows the user to graphically inspect the latest model If the user has changed some parameters after the last GENERATE action then the PREPROC command detects this and calls the GENERATE command itself The SETUP command is used to set up an analysis and the FEPROBES SURFGAGES and LOADSENSORS commands are to control the data created by the analysis The POSTPROC command is used to graphically inspect the results of the analysis 4 The Graphical User Interface HypoidFaceMilled s user interface is presented by Guide in graphical form as shown in Figure 4 1 HypoidFaceMilled als
60. are parallel to the corresponding axes of the fixed reference frame Manufacturing and assembly errors applied to the system might perturb the location of these reference frames slightly from their nominal location Preliminaries Yo Yg Xo Xg E 4 Zo Zg Xp i CMS bs x amp X Zo zg 72 4 227 o FIXED d p PINION g GEAR Xo Xg Figure 3 3 The reference frames set up for a pair of face milled hypoid gears 3 4 The main menu 11 OPTIONS SESFILENAME misses 00 0 LOADSESSION SAVESESSION EDIT SETUP GENERATE PREPROC SURFGAGES FEPROBES LOADSENSORS STARTANAL POSTPROC DOPOSTSCRIPT 2 DOMETAFILE 181 REPORT Figure 3 4 The main menu 3 4 The main menu The HypoidFaceMilled package is started by clicking on an icon created during the installation process After the HypoidFaceMilled package is started the main menu shown in Figure 3 4 comes up All user provided data is saved in a file called the session file The name of this session file can be changed by typing the name in the SESFILENAME box Changing the file name does not actually write the data to the new file nor does it read data from the new file Data is written to the session file through the SAVESESSION command Data can be loaded from an existing session file using the LOADSESSION command The QUIT command terminates the progr
61. ave side of the cutter profile with the appropriate parameters on a STRAIGHT blade type If the CURVED type cutter is selected then a parameter called RHO is added to the cutter menu RHO is the spherical radius of the blade If the STRAIGHT Toprem or Flankrem option is selected then a new parameter called DEDENDUM is added to the cutter menu DEDENDUM is the distance from the mean point to the cutter tip measured along the cutter axis Z direction Figures 5 28 and 5 30 show the concave side cutter profile for STRAIGHT Toprem and Flankrem on a CURVED blade type Figures 5 29 and 5 31 show the concave side of the cutter profile for 44 Building a Model POINTRADIUS BLADEANGLE 41112 EDGERADIUS E D 21 1 USENEWCUTTER 2 TYPE STRAIGHT TOPREM OPTION FLANKREM_OPTION gt NONE Figure 5 23 Cutter specifications with USENWCUTTER flag checked BLENDED Toprem and Flankrem on a CURVED blade type 5 10 2 Use old cutter The default type of cutter is the STRAIGHT type but if the TOPREM type is used then two more parameters TOPREMANGLE and TOPREMLENGTH are added to the cutter menu TOPREMANGLE Special Analysis File Record 17 Item 1 for Concave side and Record 20 Item 1 for Convex Side is the angle that the modified part of the cutter makes with the unmodified part When it is zero modification has no effect A positive angle implies that the material is being added to the tip of
62. d in the four standard templates The orientation of the element coordinate system is indicated by the notch in one of the corners of each element The range of the surface profile coordinate s for the two contact surfaces is also shown The element orientation for the rim sector is shown in Figure A 5 154 Tooth Mesh Templates ement Coordinates Side 2 Side 1 Figure 1 The MEDIUM TPL template file 155 156 Element Coordinates n MN 101 89 7 Tooth Mesh Templates Side 1 157 Element Coordinates Side 2 Figure A 4 The THINRIM TPL template file Tooth Mesh Templates Figure A 5 Element orientation for the rim sector Appendix Special Analysis File If the hypoid gear is manufactured using the Gleason s manufacturing process then the finite element analyst is given a special analysis file by the gear manufacturer This file contains the design data used for the manufacturing of the hypoid gear An example of a special analysis file record is shown in Table B 1 Table B 1 An example of Special Analysis File Record ITEM RECORD 7 GEAR DATA 1 ADDENDUM 0 129287 2 DEDENDUM 0 366338 3 CLEARANCE 0 058615 4 WHOLE DEPTH 0 495625 5 PITCH ANGLE 1 271058 6 FACE ANGLE 1 291448 7 ROOT ANGLE 1 216421 8 OUT DIA 10 508751 9 BACK ANGLE 1 2710
63. d 26 Item 9 Convex side Record 22 Item 9 amp amp amp Concave side Record 25 Item 13 amp Convex side Record 21 Item 13 Concave side Record 25 Item 14 amp Convex side Record 21 Item 14 Concave side Record 25 Item 15 amp Convex side Record 21 Item 15 Concave side Record 26 Item 1 Convex side Record 22 Item 1 Concave side Record 26 Item 2 Convex side Record 22 Item 2 Concave side Record 26 Item 3 Convex side Record 22 Item 3 Concave side Record 26 Item 4 Convex side Record 22 Item 4 Concave side Record 26 Item 5 Convex side Record 22 Item 5 Concave side Record 26 Item 6 Convex side Record 22 Item 6 Concave side Record 26 Item 7 Convex side Record 22 Item 7 Concave side Record 26 Item 8 Convex side Record 22 Item 8 amp m me m me g 42 Building a Model Table 5 6 Machine parameters for the formate gear Item Special Analyis File Details HORIZONTAL Float Horizontal setting of the Concave side Record 28 Item 2 amp cutter Convex side Record 24 Item 2 5 10 Cutter Specifications for the pinion 43 MultyX Edit Pinion Concave Cutter POINTRADIUS E D TET BLADEANGLE ganan EDGERADIUS D D ET USENEWCUTTER STRAIGHT Figure 5 22 Cutter specifications for the pinion 5 10 Cutter Specifications for the pinion The CUTTER command in Figures 5 18 amp 5 19 leads to the cutter menu shown in Figure 5 22 Table 5 7 gives the Special Analysis File details fo
64. d by the BEGINSTEP and ENDSTEP items The contact pattern can be displayed in color if the COLORS box is checked or with contour lines if the CONTOURS box is checked If both options are selected then a contact pattern like the one shown in Figure 7 38 will be created The contact pattern drawing is not three dimensional It is a projection of the contact surface in the r z coordinate plane If the SMOOTH box is checked then the contact pressures will be smoothed by fitting a polynomial surface to the raw data 180 Pre and Post processing 7 17 The AUDIT command 131 7 17 The AUDIT command Frequently the user needs to obtain the force and moment balance for the individual bodies in the system The AUDIT command of the post processing menu Figure 7 3 generates an equilibrim audit of all the forces and moments acting on each body Figure 7 39 shows the AUDIT sub menu The list of bodies for which this audit is to be generated is selected through a sub menu accessed through the SELECT button in this menu The range if time steps is specified in the BEGINSTEP and ENDSTEP boxes The START button then displays the audit statement in the Information window It can also be sent to an ASCII file by using the OUTPUTTOFILE FILENAME and APPEND boxes A sample equilibrium audit for the pinion shaft is shown below Time 0 05 Body no 1 PINION Origin at 0 0 0 Contact forces Exerted by GEAR Total f 2457 605255 2268 267637 41
65. dow 138 Iglass preprocessing view menu 139 Finite element mesh model of the gear bodies 141 The cutting plane Switch 2522 480104 ee ee Ro x X 141 The time slider as a Ba 2 6 141 The reference frame switch 142 Iglass preprocessing Bodies menu 142 The generate iglass file menu for post processing 143 Iglass in post processing mode 144 ee mede er A iod OR E 144 The attribute switch mm kon boom ee 145 The deformation slider 145 The iglass postprocessing Attribute menu 146 Picking a nodal point to examine 147 The background color popup window switch 148 The iglass postprocessing Contact 149 The contact pressure distribution on the pinion teeth 150 The iglass postprocessing Reactions 151 The MEDIUM TPL template 154 The FINEROOT TPL template file 155 The FINEST TPL template file 156 The THINRIM TPL template file 157 Element orientation for the rim sector
66. e ELEMENTS checkbox controls whether or not the individual finite elements should be drawn The COLORS option controls whether or not the bodies will be filled with color In pre processing mode all bodies are painted Gray The OUTLINE box controls whether or not an outline drawing of the body will be made The view menu in post processing mode Figure 7 6 has a few additional parameters There is CONTOURS option to draw stress contours If the COLORS or CONTOURS option is selected then the menu also asks for the values of the lowest contour level MINSTRESS and the highest contour level MAXSTRESS The colors used in the drawing are based on the stress level If the LOADS option is selected then the contact loads acting on the components will be drawn using the scale factor entered in the LOADSCALE box Figure 7 7 If the LOADS option is not checked Figure 7 6 then an additional box EXAGGERA TION appears where an exaggeration factor can by entered for deformed geometry plots An exaggeration factor of 0 0 will draw the bodies in their undeformed state The axes of rotation are aligned with the screen axes So if you enter a particular angle for any of the LEFTROTATE RIGHTROTATE UPROTATE DOWNROTATE CWROTATE CCWROTATE items then the model is rotated by that angle with respect to the screen axes The value in all the rotate items is always going to be 0 degrees after a change in the rotate angle is applied For instance if you enter 30 in the
67. e PostProc iy EXIT QUIT WINDOW AUTOWINDOW VIEWPORT XPROJECTION YPROJECTION ZPROJECTION ISOMETRIC LEFTROTATE 0 0000000000 000 Te TTE RIGHTROTATE 0 0000000000 000 UPROTATE 0 0000000000 000 EEEE DOWNRO Figure 7 7 The view menu in post processing mode with the LOADS option enabled 7 3 The DRAWBODIES command 99 7 3 DRAWBODIES command After an appropriate view and objects have been selected the DRAWBODIES command in the pre and post processing menus Figures 7 1 and 7 3 will generate a drawing Figures 7 8 and 7 9 show examples of drawings generated Multyx in the post processing mode 100 Pre and Post processing 7 4 The NUMBER command 101 7 4 The NUMBER command The NUMBER command in the pre and post processing menus Figures 7 1 and 7 3 lead to the numbering menu shown in Figure 7 10 This menu is used to to generate tooth and surface numbering as shown in Figure 7 11 IIn EXIT QUIT BODY e NUMBERTYPE MESHES 5 oc uu TOOTHBEGIN 1 DP ET TOOTHEND fi ananas START Figure 7 10 The NUMBER menu 7 5 The TOOTHLOAD command The TOOTHLOAD command in the post processing menu Figure 7 3 leads to the menu shown in Figure 7 12 This menu is used to to generate a graph of tooth load vs time The SUR FACEPAIR item selects the contact surface pair for which the load is of interest
68. e SUBSURFACE menu 114 Pre and Post processing SURFACEPAIR GEAR_SURFACE1_PINION_SURF ee MEMBER GEAR I we ee lt TOOTHBEGIN 1 1 1 1 19151 E a ________ _ TOOTHEND 38 ELELEE TIMESTEP 1 ELELEE E o EDGECONTACT 2 OUTPUTTOFILE 8 FILENAME output t APPEND Figure 7 22 The GRIDLDHIST menu 7 9 The GRIDLDHIST command The GRIDLDHIST command in the post processing menu Figure 7 3 leads to the menu shown in Figure 7 22 This menu is used to generate a histogram of the distribution of contact load over individual contact grid cells This figure is useful in determining whether the contact grid cell has been properly sized and whether it has adequate resolution The SURFACEPAIR item selects the surface pair and the MEMBER parameter selects one of the two bodies in this pair The items TOOTHBEGIN and TOOTHEND are used to select a range of surface instances tooth numbers There can be at most 7 teeth in this range The item TIMESTEP selects a time step number Figure 7 23 shows an example of a grid load histogram 7 10 The GRIDPRHIST command The GRIDPRHIST command in the post processing menu Figure 7 3 leads to the menu shown in Figure 7 24 This menu is used to to generate a histogram of the distribution of contact pressure over individual contact grid cells This command is very similar to the GRIDLDHIST command The only
69. e dz RR x Ge ee eS 7 2 View parameters 7 3 The DRAWBODIES command 7 4 The NUMBER command 7 5 TOOTHLOAD command 7 6 The CONTACT 7 7 The TOOTHLDHIST command 7 8 SUBSURFACE command 7 9 The GRIDLDHIST command 7 10 GRIDPRHIST command 7 11 The SEPBEFHIST command 7 12 The SEPAFTHIST command 7 13 The SEARCHSTRESS command 7 14 The FATIGUE command 7 15 The POINTSTRESS command 7 16 The PATTERN command 7 17 The AUDIT command 7 18 The BODYDEFLECTION command 7 19 The BODYREACTION command 8 Pre and Post processing using IglassViewer 8 1 Generating an Iglass file for preprocessing 8 2 View menu SY OE OG vv xa 8 2 1 Finite element mesh 8 2 2 Cutting plane aee 8 2 3 Selecting the time step 8 24 Reference frames 8 3 The Bodies s s Ro m Rog S 8 4 Post processing using iglass 8 5 Features specific to iglass post processing A Tooth Mesh Templates B Special Analysis File CONTENTS List of Figures 1 1 2 1 2 2 3 1 3 2 3 3 3 4 4 1 4 2 4 3 4 4 4 5
70. e setup menu Figure 6 9 shows the analysis setup menu accessed by using the SETUP command at the main menu The parameters SEPTOL NPROFDIVS NFACEDIVS and DSPROF are the grid spec ification parameters described earlier The initial state of the system can be specified as the undeformed state by enabling the ZEROINITIAL flag The time at which to start the analysis is specified in the INITIALTIME box If the ZEROINITIAL flag is not checked then a restart file has to be specified from which the deformed state and the value of time will be loaded The analysis time is divided into a user specified number NRANGES of time ranges The time step DELTATIME solution method SOLMETHOD and the number of time steps NTIMESTEPS can be specified separately for each time range It is possible to control the operating speed in each time range by specifying a speed factor at the beginning of the range by using the parameter STARTSPEEDFACTOR A speed factor of 1 0 implies that the system is at its nominal speed The speed factor at the end of a time range is the same as the speed factor at the beginning of the next time range The speed at the end of the last range is always assumed 1 0 The speed is assumed to vary as a linear function of time within a time range The torque in a time range can be controlled by setting the STARTTORQUEFACTOR and ENDTORQUEFACTOR for each range Again a factor of 1 0 means that the system is operating at its nominal torque The torque i
71. each individual copy of that surface is called an instance of that surface and is given a unique instance number In the case of gear tooth surfaces the instance number is the same as the tooth number The parameters TOOTHBEGIN and TOOTHEND define a range of teeth over which the gages will be placed The reading of the gage is the stress at the most critical tooth If the value of TOOTHBEGIN is greater than TOOTHEND then the search range will wrap around the last tooth There are two parameters that identify a point on a surface We refer to these two parameters as 5 which varies in the profile direction and T which varies in the face width direction The profile parameter 5 increases from fillet to the tip on Side 1 of a tooth and from the tip to the fillet on Side 2 as shown in Appendix A The parameters SPROFBEGIN and SPROFEND define a range over which the stress will be calculated These are in surface local units as shown in Appendix A The GAGE will read out the critical value of stress in this range The NUMSPROF parameter controls how many search points should be used over this range The face parameter T varies from 1 0 to 1 0 over the face of the tooth The face width range parameters TFACEBEGIN control TFACEEND range over which the search is carried out and NUMTFACE controls the number of search points within this range 82 Running an Analysis The DEPTHBEGIN DEPTHEND and NUMDEPTH parameters extend the search range to a number N
72. ears in a box in the dialog box If the value of the data item is undefined then the box appears blank RESOLUTION 4141 41519121 Figure 4 2 An integer data entry box 4 3 Floating point menu items Floating point data is entered through the dialog box shown in Figure 4 3 151 151 1 Figure 4 3 An floating point data entry box 4 4 Boolean menu items Boolean data items are those that can only take a YES NO or TRUE FALSE type of value Their value is set by checking or clearing the box as shown in Figure 4 4 HiDDENREMOVE 3 Figure 4 4 An boolean data entry box 4 5 String menu items String data items contain ASCII strings The dialog box shown in Figure 4 5 allows the user to enter string type data SESFLENAME meses 0000 Figure 4 5 A string data entry box 16 The Graphical User Interface 4 6 Switch type menu items The last kind of data item is of the switch type This item can be switched between a fixed set of valid choices The choice is made through a drop down list as shown in Figure 4 6 BACKCOLOR TH Figure 4 6 switch type data entry box 4 7 Commonly occurring buttons The data entry dialog boxes use a few small buttons as short cuts for common tasks as shown in the Table 4 1 Some of these buttons may be disabled depending upon the particular item and its value Table 4 1 Common buttons Button Purpose 9 Select the minimum allowable value si D
73. ecial analysis file by the gear manufacturer This file contains the design data used for the manufacturing of the hypoid gear An example of a special analysis file record is shown in Appendix B This file contains many such records We will need records 1 through 47 for analysis The special anaylsis files can be automatically read by using the SPAFILE menu and providing a filename and selecting the units to use for the system 20 Building a Model Table 5 1 System configuration parameters Item Special Analyis File Details MODELTYPE Switch Type of mesh to generate CALYX3D CAPP CONFIGFILE String Configura tion file for CAPP if MODELTYPE CAPP HANDPINION Switch Hand of the pinion Left Record 6 Item 8 handed Righthanded OFFSET Float Shaft offset distance Record 1 Item 7 ANGLE Float Shaft angle Deg Record 1 Item 4 LOADEDSIDE Switch Side of the gear to be loaded Convex Concave DRIVER Switch Member that is driving Pinion Gear MU Float The coefficient of Coulomb friction TORQUE Float The pinion torque magni tude always positive RPM Float Pinion angular velocity in RPM DOASSEMBLYERRORS Boolean Whether or not to in clude assembly errors 5 2 System level data The SYSTEM command in the EDIT menu of Figure 5 1 leads to the SYSTEM menu shown in Figure 5 2 The parameters in this menu are summarized in Table 5 1 The kind of mesh the mesh generator will create is controlled by the MODELTYPE switch
74. ecrement the value by 1 Select the default value sj Increment the value by 1 gt Select the maximum allowable value E Accept the value just typed in x Discard the value just typed in Get additional information Change the current graphics page Change the zoom level 4 8 Graphics 17 4 8 Graphics Guide directs the graphical output from HypoidFaceMilled to a graphics window The graphics are stored as separate pages A new page is started when HypoidFaceMilled clears the graphics screen The user can move between screens using the buttons on the toolbar Double clicking anywhere in the graphics window with the left mouse button or dragging the mouse in the graphics window with the left button depressed lets you zoom in To zoom out double click with the right mouse button The buttons on the toolbar can also be used to zoom in zoom out and to return to the original view It is possible to save sequence of graphics pages in a metafile a MET file using the Home Graph Write command This file can later be replayed in Guide using the Home Graph button command The graphics currently displayed can be saved in Windows Metafile format a WMF file by using the Home Graph Write command This WMF file can subsequently be loaded by another application such a word processor encapsulated PostScript file a EPS file can be created by using the Home Graph Write command This command creates an EPS file con
75. ed from the GEAR reference frame and the pinion orbits around it If the PINION option is selected then the reference frame origin aligns itself to the origin of the pinion 8 3 The Bodies menu The Bodies menu is shown in Figure 8 8 The body member can be turned on or off by clicking on the member name in the Bodies menu User can view the tooth and the rim sector separately for each gear body View Bodies Attibs Selected Bodies amp z PINION amp v Pinion 1 Tooth amp v Pinion Rim 1 Sector Pinion with rim amp v Gear 1 Tooth amp v Bear Rim 1 Sector Gear with rim Figure 8 8 Iglass preprocessing Bodies menu 8 4 Post processing using iglass 143 8 4 Post processing using iglass The GENIGLASSFILE command in Figure 7 3 leads to the generate iglass file menu shown in Figure 8 9 for post processing in iglass BEGINSTEP and ENDSTEP menus shown in Figure 8 9 define the range for which you want to check for results Note that these menus are independent of the GOTOPOSN menu shown in Figure 7 3 An example of an iglass post processing window is shown in Figure 8 10 IGLASSFILENAME BEGINSTEP ENDSTEP PATTERN SMOOTHPATTERN NODALFORCES POPUPIGLASS UATESTVERSION Figure 8 9 The generate iglass file menu for post processing 144 View Bodies Attibe Contact Reactions 525452 PEDE T Perspective T
76. ed to locate the most critical stresses in the system The COMPONENT box is used to select the stress component of interest Available choices are MAXPPLSTRESS the maximum principal normal stress 1 MINPPLSTRESS the min imum principal normal stress 53 MAXSHEAR the maximum shear stress Tmax and VON MISES the Von Mises octahedral shear stress sy Depending on selection in the XAXIS box the stress can be displayed as a function of time TIME profile SPROF face TFACE or depth DEPTH The stress values are computed over a range of time steps specified by BEGINSTEP and ENDSTEP teeth specified by TOOTHBEGIN and TOOTHEND location along the profile specified by SPROFBEGIN SPROFEND and NUMSPROF location along the face specified by TFACEBEGIN TFACEEND and NUMTFACE and depth specified by DEPTHBEGIN DEPTHEND and NUMDEPTH If the number of teeth in the range defined by TOOTHBEGIN and TOOTHEND is 7 or less and if the SEPTEETH box is checked then a separate graph is drawn for each tooth Otherwise a single graph is drawn showing the most critical stress among all the teeth in the range Searching for stresses in the depth direction is very compute intensive operation so the number of points in the depth direction should be kept at 1 if possible If a graph of stress vs depth is desired then the range of the other parameters should be restricted as much as possible File output is controlled by the OUTPUTTOFILE FILE
77. enerate the Iglass preprocessing file After the file is generated and if the POPUPIGLASS menu is turned on a separate Iglass window will open showing the reference axes and the gear bodies selected in the SELECT menu An example of the Iglass preprocessing window for a Hypoid gear pair is shown in Figure 8 2 As shown in Figure it has 3 menus View Bodies and Attributes The Attributes menu is used more commonly in the postprocessing mode The Exit button in each menu will close the Iglass graphics window 188 Pre and Post processing using Iglass Viewer IGLASSFILENAME 59090 IE Figure 8 1 The generate Iglass file menu View Bodies Contact Reactions ielvIe Perspective T Finite Element Mesh T Cutaway fV Show Front Side Show Back Side Time sec F Reference Frame Reference Frame Figure 8 2 example of an Iglass preprocessing window 8 2 View menu 139 View Bodies Contact Reactions EDUE Perspective Finite Element Mesh Show Front Side Show Back Side Time 0 000000 Current Reference Frame Reference Frame FIXED Figure 8 3 Iglass preprocessing view menu 8 2 View menu The View menu is shown in Figure 8 3 Table 8 1 shows the common tasks performed by some of the buttons displayed in the Iglass window Apart from all the features shown in Table 8 1 you can also
78. er description for Straight Blade with Blended Toprem New Cutter 46 Building a Model le POINT RADIUS _y EDGE RADIUS FLANKREM DEPTH FLANKREM ANGLE BLADE ANGLE Figure 5 26 Cutter description for Straight Blade with Straight Flankrem New Cutter Z POINT RADIUS FLANKREM BLEND RADIUS BLADE ANGLE Figure 5 27 Cutter description for Straight Blade with Blended Flankrem New Cutter 5 10 Cutter Specifications for the pinion 47 Z A TOPREM ANGLE Figure 5 28 Cutter description for Curved Blade with Straight Toprem New Cutter 7 EDGE RADIUS BLEND RADIUS BLADE ANGLE Figure 5 29 Cutter description for Curved Blade with Blended Toprem New Cutter 48 Building a Model BLADE ANGLE Figure 5 30 Cutter description for Curved Blade with Straight Flankrem New Cutter ZA MEE RHO FLANKREM BLEND RADIUS FLANKREM DEPTH Figure 5 31 Cutter description for Curved Blade with Blended Flankrem New Cutter 5 10 Cutter Specifications for the pinion 49 POINT RADIUS EDGE RADIUS BLADE ANGLE CUTTER FOR THE CONCAVE SIDE POINT RADIUS DEPTH OF MODFN EDGE RADIUS BLADE ANGLE MODIFIED CUTTER FOR THE CONCAVE SIDE Figure 5 32 Cutter description for Concave side Old Cutter 50 Building a Model POINT RADIUS
79. ganat LOADEDSIDE E DRIVER INION qp 0 0000000000 000 TORQUE 2613 3300000000 Hanas 100 0000000000 1 121 HEERE fonem LI ET Figure 5 5 The assembly errors menu 25 26 Building a Model Pinion Movement Pinion Pinion rotation Movement about origin G R alpha beta 7 Pinion J Movement P H Figure 5 6 Sign convention for modelling assembly errors for a lefthanded gear 5 3 Assembly errors 27 BN N N N 1 Pinion Movement V E Y Pinion Pinion rotation Movement about origin G R alpha beta Pinion Movement P H Figure 5 7 Sign convention for modelling assembly errors for a righthanded gear 28 Building a Model In Method 1 displacement mesurements are made at all the Finite Element nodes that lie on the base cone of the pinion and gear Measuretent Figure 5 8 Assembly error calculation Method 1 In Method 2 displacement mesurements are made at the Finite Element nodes that lie on the pase cone of the pinion and gear only of the teeth that are in contact Points Figure 5 9 Assembly error calculation Method 2 5 3 Assembly errors 3 Sa In Method 3 displacement lt mesurements are made inside the contacting teeth Figure 5 10 Assembl
80. gear are simi lar to those of the pinion Figure 5 20 except for the record numbers in the Special Analyis File Table 5 5 explains all the parameters for the Machine menu for the generated type gear Again the values for Tiltangle Swivelangle Rootangle and the Cradleangle are given in radians in the Special Analysis File The user should convert them in to degrees before entering them in to their respective menus 5 9 Machine settings for the formate type gear Figure 5 21 shows the machine parameters for the concave side of the formate type gear The parameters for the convex side are similar to those of the concave side The Root angle value is given in radians in the Special Analysis File The user should convert it in to degrees before entering it in the Rootangle menu Table 5 6 explains all the machine parameters associated with the manufacturing of the formate gear 5 9 Machine settings for the formate type gear Table 5 5 Machine parameters for concave and convex tooth side for the generated type gear Item 41 Special Analyis File Details RADIALSETTING Float Distance between the cra dle axis and the cutter axis when they are parallel Float Tilt of the cutter axis with respect to the direction of the cra dle axis Deg TILTANGLE SWIVELANGLE BLANKOFFSET ROOTANGLE MACHCTRBACK SLIDINGBASE CRADLEANGLE RATIOROLL 2C 6D 24 120 H1 H2 H3 V1 V2 V3 Float Direction of the
81. gt Move the model towards right If Spin is turned OFF Move the model towards left If Spin is turned OFF 2 Rotate the model upwards If Spin is turned ON Rotate the model downwards If Spin is turned ON gt Rotate the model towards right If Spin is turned ON Rotate the model towards left If Spin is turned ON Rotate the model clockwise If Spin is turned ON A Rotate the model counterclock wise If Spin is turned ON B View the model in an isometric view s View the model in the Y Z plane E View the model in the X Z plane N View the model in the X Y plane 8 2 View menu Figure 8 4 Finite element mesh model of the gear bodies Figure 8 5 The cutting plane switch Time N Time 6000273 Figure 8 6 The time slider 141 142 Pre and Post processing using Iglass Viewer Reference Frame Figure 8 7 The reference frame switch 8 2 4 Reference frames The default reference frame is the FIXED reference frame Both the pinion and the gear appear to move when observed from the FIXED frame The model will align itself to this reference frame when the iglass window pops up The reference frame can be aligned to a body member using the reference frame switch shown in Figure 8 7 If you select the GEAR as the reference frame the reference frame origin will coincide with the origin of the gear The gear appears stationary when observ
82. he SUR 128 Pre and Post processing 0 070000 0 060000 Le 0 050000 0 040000 0 030000 E Pai 8 T s Ni 8 4 E 14000 000000 12000 000000 8000 000000 6000 000000 4000 000000 000 000000 0 000000 000000000 4000 000000 6000 000000 Figure 7 36 The graph of root stress vs face generated by the POINTSTRESS menu 7 16 The PATTERN command 129 FINDPITCHPOINT SURFACEPAIR GEAR_SURFACE1_PINION_SURF 219 MEMBER GEAR TOOTHBEGIN TOOTHEND SIL DP ET BEGINSTEP 4141 151 121 ENDSTEP 41 1 151 121 COLORS CONTOURS FLIP SMOOTH GRID EDGECONTACT CALYX SLIDING VELOCITY ROLLING VELOCITY OUTPUTTOFILE v FILENAME output Figure 7 37 The PATTERN menu FACE box A range of teeth with up to 7 teeth is selected through the TOOTHBEGIN and TOOTHEND items The range of time steps is specifie
83. he position along the Z axis of the race Z2 must be greater than Z1 The CONSTRAINCYLINDRICALRACE check box is available to apply a flexible constrain to the race The DOBRGCYLINDRICALRACE check box is available to add a stiffness bearing to the race REFrY PE has drop down menu that has two options for bearing center location ROLLERCENTER and THRUSTCENTER ZPOSNBRG specifies the Z location of the origin of the bearing CONNECTBRGHOUSING enables the bearing to be connected to the housing if this option is not checked the bearing will be connected to the ground TYPE specifies the type of finite element to be used for the splines STIFFNESS or ROLLER If STIFFNESS is chosen a BRGFILE must also be specified The orientation of the differential carrier stiffness bearing matrix reference frame is shown in Figure 5 16 Modelling a Differential Carrier 71 CONE ANGLE Figure 5 58 Conical Race Diagram Figure 5 59 Conical races 72 Building a Model to connect housing UNLOADEDDEFM LOAD Figure 5 60 Cylindrical races menu 5 16 Modelling a Differential Carrier 73 Diameter Race 2 45 325 _Diameter Race 1 50 07 Z2 Race 2 37 00 Figure 5 61 Cylindrical races 74 Building a Model Gear Bearing Reference Fame You Y 250 Z Figure 5 62 The diff carrier stiffness bearing reference frame 5 17 Modeling the Housing 75 _______________ EXIT QUIT SPAFILE
84. id separation before contact generated by the SEPBEFHIST un _ 119 7 28 The SEPAFTHIST menu 120 7 29 The histogram of grid separation after contact generated by the SEPAFTHIST inp Wend Gee ae Gt Pc EE 121 7 30 The SEARCHSTRESS menu 122 7 31 The graph of root stress vs time generated by the SEARCHSTRESS menu 123 7 32 The graph of root stress vs profile generated by the SEARCHSTRESS menu 124 7 33 The graph of root stress vs face generated by the SEARCHSTRESS menu 125 7 04 The FATIGUE menu ammo o RR RR x RR EA OR Yee dae dhe bh 126 7 35 The POINTSTRESS menu 127 7 36 The graph of root stress vs face generated by POINTSTRESS menu 128 1 37 The PATTERN menu o cress dor ym vor e EUR ARA ee 129 7 38 The contact pattern generated by the PATTERN menu 130 7 39 The AUDIT 132 7 40 The BODYDEFLECTION menu 4 uos a ae ae ees 133 7 41 The graph generated by the BODYDEFLECTION menu 134 viii 7 42 7 43 8 1 8 2 8 19 LIST OF FIGURES The BODYREACTION menu 135 The graph generated by the BODYREACTION menu 136 The generate Iglass menu 138 An example of an Iglass preprocessing win
85. idual surface instance number within that body The outputs of all the sensors are put into file called LOADS DAT This file has one row for each instant of time The first column contains the time Each subsequent column contains the reading of one load sensor Figure 6 3 The load sensor menu 86 Running an Analysis 6 4 Specifying a contact grid This feature is still available but can now be automated with the ADAPTIVEGRID flag If the adaptive grid is not used this procedure must still be followed Figure 6 4 shows a computational grid that has been set up in the contact zone of a gear tooth The entire face width of the tooth is divided into 2N 1 slices N is a user selectable quantity NFACEDIVS in Figure 6 9 If is a parameter that goes from 1 at one end of the face width of a tooth to 1 at the other end then the thickness of each slice in the parameter space is A 2 2N 1 For each slice 7 N N across section of the tooth is taken at the middle of the slice and a point is located on this slice that approaches the surface of the mating tooth the closest This selection is carried out using the undeformed geometry If the separation between the two gears at this closest point is larger than a user selectable separation tolerance SEPTOL in Figure 6 9 then the entire gear slice is eliminated from further consideration Otherwise a set of grid cells identified by the grid cell location indices i j i
86. igure 7 28 This menu is used to to generate a histogram of the distribution of normal sepa ration over individual contact grid cells in the loaded and deformed state The SURFACEPAIR item selects the surface pair and the MEMBER parameter selects one of the two bodies in this pair The items TOOTHBEGIN and TOOTHEND are used to select a range of surface instances tooth numbers There can be at most 7 teeth in this range The item TIMESTEP selects a time step number Figure 7 29 shows an example of a histogram of separation in the loaded state These sepa ration values must be either zero or positive 7 12 The SEPAFTHIST command 119
87. illed analysis package Calyx is a powerful contact analysis code capable of analyzing a variety of contact problems including 2D and 3D dynamic and static analysis of systems such as gears compressors and brakes Because Calyx has to be capable of handling a variety of problems it communicates with the outside world through a programming language The programming language interface of Calyx brings flexibility at the expense of ease of use Such an interaction is appropriate for an advanced Calyx user but not for a gear design engineer In order to address this issue the program is used Multyx is capable of commu nicating with the user through an easy to use menu based interface It translates the user s commands into the appropriate programming language statements and sends them on to Calya A typical user does not even need to know that Calyx is running in the background In addition to the user interface Multyx also has built in model generators The hypoid gear tooth models described in this manual are all generated by Multyr It also has post processing and data extraction code to help the user extract the results of analysis from Calyz Multyx and are designed as portable code and can run any system that supports standard C In order to keep it portable Multyx s menu system is command line based and does not use any of the GUI features such as buttons windows or mouse interaction The following dialog sh
88. in the RPM and TORQUE items respectively 5 2 System level data 21 EXIT QUIT HANDPINION OFFSET 0 0000000000e 000 ANGLE 30 0000000000 LOADEDSIDE MU dd 000000000006 000 TORQUE _ 2613 3300000000 INE 100 0000000000 DOASSEMBLYERRORS Figure 5 2 The system data menu 22 Building a Model OFFSET gt 0 1 ger ee i Pa Sy P 2 1 p 29 3 2 wf d N N 1 X N 2 i N x S ue T A aoe 2 J p di 1 es d mm AE A 7 4 P d E 1 12 2 RH PINION LH GEAR Figure 5 3 Sign convention for offset menu for lefthanded gear 5 2 System level data OFFSET gt 0 e pem M ee 23 i 04 ko A N SAX E 7 f 29 LH PINION RH GEAR Figure 5 4 Sign convention for offset menu for righthanded gear 24 Building a Model 5 3 Assembly errors If you set the DOASSEMBLYERRORS flag shown in Figure 5 2 then the assembly errors will also be included in the analysis Figure 5 5 Assembly error V
89. inion CONEANGLEPINIONHOLE Z Figure 5 55 Z position and cone angle ANGPOSNPINIONHOLE1 Figure 5 56 Al A2 and angular position of pinions 69 70 Building a Model Number of Conical Races NCONICALRACES r d ci 5 gt 23 ICONICALRACE ZAPEXCONICALRACE B88 CONEANGLECONICAL 900000000 AICONICALRACE j A2CONICALRACE CIRCORDERCONICAL 8 ed ed 9 2 gt 2 z RADIALORDERCONIC ed d 2 2 0 2 A must be less haa Figure 5 57 Conical races menu 5 16 2 Conical and Cylindrical Races The CONICALRACES menu Figure 5 57 is for any races that are not cylindrical ZAPEXCON ICALRACE is the distance of the apex of the cone from the Z axis in the gear reference frame CONEANGLECONICAL is the cone angle for the race When the CONEANGLECONICAL is 90 degrees the cone will be the same as a plane transverse to the axis and A2CONICALRACE describe the distance from the apex along the cone to the start and end of the race respectively The conical race parameters are explained graphically in Figures 5 58 and 5 59 The CYLINDRICALRACES menu Figure 5 60 is used to define any cylindrical surfaces that require a race Figure 5 61 shows the CYLINDRICALRACES menu input parameters graphically DIACYLINDRICALRACE is the diameter of the race ZICYLINDRICALRACE and Z2CYLINDRICALRACE defines t
90. ltyz Guide trans lates each of Multyx s dialogs and presents them to the user in a graphical form The command line menu described above is presented to the user as shown in Figure 2 2 In addition Guide provide the user with convenient ways of viewing the graphics and helps the user convert the graphics into Microsoft formats and into Encapsulated PostScript EPS files Although Guide enhances the friendliness of Multyz it is not required All the features of Multyz can be accessed without Guide The connection between Guide and Multyx is based on the TCP IP telnet protocol when they are running on different computers When running on the same computer they communicate through named pipes Guide is a heavy user of advanced operating system features including GUI support multi threading support and inter process communication support Guide now runs on Windows 95 98 NT 2000 XP Vista Win7 Win8 systems only 2 1 HypoidFaceMilled analysis package EXIT QUIT START CLEAR SURFACEPAIR PINION SURFACE1 GEAR SURF MEMBER nan sj TOOTHBEGIN 40 5 EELEE 2 4141 1519121 1 BEGINSTEP 1 MELELEH 11 COLORS Iv 2 CONTOURS 2 MINPRESS 40000 0000000000 Doe ee MAXPRESS 42000 0000000000 DELTAPRESS 40000 0000000000 ECEE SMOOTH 2l GRID IQUTPUTTOFILE Figure 2 2 The menu presented to the user by Guide
91. ly a few teeth Hypoid gears resemble bevel gears in some aspects They are used on crossed axis shafts and there is a tendency to parts to taper as do bevel gears They differ from true bevel gears in that their axes do not intersect The distance between a hypoid pinion axis and the axis of a hypoid gear is called the offset Figure 1 1 shows offset and other terms Hypoid pinions may have as few as five teeth in a high gear ratio Since the various types of bevel gears do not often go below 10 teeth in a pinion it can be seen that it is easy to get high ratios with hypoid gears They do not have pitch diameters which are in proportion to their numbers of teeth This makes it possible to use a large and strong pinion even with a high ratio and only a few pinion teeth They are used in various applications such as passenger cars industrial drives tractors trucks etc Several manufacturing processes are available for hypoid gears The HypoidFaceMilled pack age is meant for analyzing hypoid gears cut using the face milling process Introduction F Hypoid of er mounting stance Ainon mounting _ distance Finion mounting distance Crossing point Gear Mounting ee E 2 distance Gear mounting distance Figure 1 1 The hypoid gear arrangement Chapter 2 HypoidFaceMilled Software Package This chapter explains the various features of the HypoidFaceMilled software package 21 HypoidFaceM
92. m 2 Concave side Record 15 Item 3 Convex side Record 18 Item 3 Concave side Record 15 Item 4 Convex side Record 18 Item 4 Concave side Record 15 Item 5 Convex side Record 18 Item 5 Concave side Record 15 Item 6 Convex side Record 18 Item 46 Concave side Record 15 Item 7 Convex side Record 18 Item 7 Concave side Record 16 Item 9 Convex side Record 19 Item 9 amp amp amp Concave side Record 15 Item 13 amp Convex side Record 18 Item 13 Concave side Record 15 Item 14 amp Convex side Record 18 Item 14 Concave side Record 15 Item 15 amp Convex side Record 18 Item 15 Concave side Record 16 Item 1 Convex side Record 19 Item 1 Concave side Record 16 Item 2 Convex side Record 19 Item 2 Concave side Record 16 Item 3 Convex side Record 19 Item 3 Concave side Record 16 Item 4 Convex side Record 19 Item 4 Concave side Record 16 Item 5 Convex side Record 19 Item 5 Concave side Record 16 Item 6 Convex side Record 19 Item 6 Concave side Record 16 Item 7 Convex side Record 19 Item 7 Concave side Record 16 Item 8 Convex side Record 19 Item 8 amp m me m me g 40 Building a Model EXIT QUIT How 1 1 121 1 VERTICAL ROOTANGLE 67 6833000000 ECEE MACHCTRBACK 0 0000000000 000 EEEE Figure 5 21 Machine parameters for formate gear 5 8 Machine settings for the generated type gear All the parameters for the machine details specifications for the generated type
93. mn contains the readout of an individual probe 6 2 Finite element probes TOOTHBEGIN 5 SPROFBEGIN NI ganas 0000000000 000 SPROFEND 1 48 0000000000 R SPHUF 51 I gt PEL m TFACEBEGIN 0 0000000000 000 EH 0 2 TFACEEND 0 0000000000 000 FACEE LP bI NUMTFA 2 4141 151 1211 DEPTHBEGIN 0 0000000000 000 I 0 0000000000 000 ND LELEL U PTH IL E D N PTHE MDE E PD PEL STMIN ENAM D 131111 F 0 0000000000 000 GAGES DAT Figure 6 1 The surface gage menu 83 84 PROBE 1 EELEE BODY Anon 1 a MESH homn TOOTH 1 2 ELELEE z ELEM 1 141 1515151 1 z Perre po ___ ZETA o oo00000000e 000 BERGE ________ PROBES DAT Dee Figure 6 2 The finite element probe menu Running an Analysis 6 3 Load sensors 85 6 3 Load sensors Load sensors are used to measure the contact loads generated at the contact surfaces Figure 6 3 shows the load sensor menu used to set up the sensors The SURFPAIR item selects the contact surface pair for which the contact load is of interest Each surface pairing has two contacting members or bodies The MEMBER parameter selects one of these two bodies and the TOOTH item selects the indiv
94. nion gear POISSON Float Poisson s ratio for the pin ion gear DENSITY Float Density of the pinion gear ALPHA Float Damping constant alpha for the pinion gear BETA Float Damping constant beta for the pinion gear TPLFILE Switch Template file for the pin ion gear Refer to appendix for details MESHFILE String Mesh file name for the pinion gear 34 Building a Model FRONT ANGLE BACK ANGLE THICKNESS MEASURING POINT G X MEAN POINT MEASURING ADDENDUM N 35 5 5 Common design and blank data XHdVHOVH X8dV LOOM 5 FTONVLOON 5 NVH 7 TIDNVSSVE ATONV LNOWA NVA Wnawaadv Figure 5 16 The Pinion Common Parameters Building a Model 36 Wwnanaday NVHIN ISITHNOOWRLDO Figure 5 17 The Gear Common Parameters X dvasvsa XHdVLOOM XddVHOLId XHdV8OVH 5 6 Concave and Convex side data 37 MACHINE CUTTER MODIFICATIONS Figure 5 18 The Concave tooth side data menu EE EXIT QUIT MACHINE CUTTER MODIFICATIONS Figure 5 19 The Convex tooth side data menu 5 6 Concave and Convex side data The CONCAVE and CONVEX command in the pinion menu Figure 5 12 leads to the con cave and convex side data menus shown in Figures 5 18 amp 5 19 There are three submenus
95. o sends out a stream of informational error and warning messages to the user These messages are separated by Guide and presented in separate windows as shown The user activates these message windows by hitting the appropriate Error Information or Warning tab Graphical information sent by HypoidFaceMilled is directed to a graphics window 4 1 Menu command items In the example shown in Figure 4 1 the large buttons such as those labeled EXIT QUIT OP TIONS LOADSESSION EDIT send commands to HypoidFaceMilled when hit by the user In response to the command HypoidFaceMilled might carry out an action as in the case of the LOADSESSION command or lead the user to a different menu as in the case of the EDIT com mand Moving the mouse over a button without depressing it will cause Guide to momentarily pop up a balloon a tool tip containing a short description of the use of that button The tool tips can be disabled by the View DisableToolTips item in the Guide main menu 14 The Graphical User Interface vm EXIT QUIT OPTIONS SESFILENAME LOADSESSION SAVESESSION IDOMETAFILE NTHREADS zi zi REPORT pu Figure 4 1 HypoidFaceMilled s user interface 4 2 Integer menu items 15 4 2 Integer menu items Integer data items are entered through a dialog box of the kind shown in Figure 4 2 The current value app
96. on the button nstall License Key e Now you are all set to run the analysis Start the program by using the icon Start Programs HypoidFaceMilled HypoidFaceMilled 2 3 Upgrading of the software package on windows plat form The procedure for upgrading HypoidFaceMilled software analysis package on Microsoft Windows NT 2000 XP Vista Win7 Win8 platforms is as follows e Obtain the current HypoidFaceMilled msi installation file e Uninstall old version Go to Control Panel Add Remove Programs Select HypoidFaceMilled and press Uninstall e Run installation file HypoidFaceMilled msi Chapter 3 Preliminaries The previous chapter gave an overview of the software architecture This chapter provides some information to help you get up and running with the program 3 1 System of units Any system of units can be used provided that all the inputs provided by the user are consistent with this system of units The user is free to choose any units for force time and length All the inputs should then be in units that are consistent with this choice For example if the user chooses Kgf as the unit for force seconds as the unit for time and cm as the unit for length then the input torque should be in Kgf cm the Youngs modulus in cm the Diametral pitch in 1 cm and the mass density in Kg f s cm Outputs will also appear in consistent units 3 2 Bodies In multi body contact analysis the term body is used to refer to an
97. or displacement vector in the X Y and Z directions can be displayed MAXP PLNORMAL S2PPLNORMAL MINPPLNORMAL MAXSHEAR VONMISES menus show their respective stress contours The ERRORESTIMATE menu is used to display the stress error estimate This error estimate is computed from the magnitude of the inter element stress discontinuity 146 Pre and Post processing using IglassViewer View Bodies ttibs Contact Reactions Attribute MAXPPLNORMAL Palette Mode POSITIVE 6 1390e 002 3 8673e 002 6 0906e 001 3 8369e 001 241 71 001 _ 10 0000 000 Rescale Pick 2 5044 001 0 0000 000 Legend Banded Solos Figure 8 14 The iglass postprocessing Attribute menu The colors for minimum and maximum stress contours can be controlled using the palette mode menu shown in Figure 8 14 A POSITIVE mode will align the scale from 0 minimum stress to a maximum positive value maximum stress A NEGATIVE mode will align the scale from 0 to a negative value The BOTH type mode will align the scale from the maximum negative value minimum stress to a maximum positive value maximum stress So as to find the stress at a node double click on the gear body The finite element nodes are now visible as shown in figure 8 15 Clicking once on the node will show the stress at that nodal point in the pick item of the
98. ows some of the command line interface of Multyz E gt multyx MultyX v 1 06 Copyright Advanced Numerical Solutions Dec 21 2000 MultyX gt post ok patt MultyX PostProc 1 11 Pattern gt HELP MENU Show menu Show menu HELP Show menu EXIT Return to main menu QUIT Return to main menu START Draw the contact pattern CLEAR Clear the graphics page SURFACEPAIR Surface pair Currently GEAR_SURFACE1_PINION_SURFACE1 4 HypoidFaceMilled Software Package Windows 95 98 NT 2000 Server running any O S System User Graphical Mesh Generator Contact amp Finite User Interface amp Post Processing Element Analysis Figure 2 1 The computer programs in the HypoidFaceMilled analysis package MEMBER Member Currently PINION TOOTHBEGIN 12 Tooth no or instance no of surface TOOTHEND 2 Tooth no or instance no of surface BEGINSTEP 1 Time Roll angle step at which to begin search ENDSTEP 10 Time Roll angle step at which to end search COLORS Whether to render the model in color Enabled CONTOURS Whether to draw pressure contours Enabled MINPRESS 4 000000E 004 Level of lowest press contour MAXPRESS 4 200000E 005 Level of highest press contour DELTAPRESS 4 000000 004 Spacing between press contours SMOOTH TRUE Whether to smooth the pressure contours OUTPUTTOFILE Whether to write data to file Disabled MultyX PostProc 1 20 Pattern gt START Guide is a program that provides a Graphical User Interface GUI to Mu
99. processing mode 99 7 9 example of drawing made in the post processing mode 100 AO The NUMBER mente kom mcm eo ee 101 7 11 Surface numbering superimposed a pinion drawing using the NUMBER com ke a 102 7 12 The TOOTHLOAD menu 9 9 Re 103 7 13 The tooth load vs time graph generated by TOOTHLOAD menu 104 7 14 The CONTACT s s si eias eee 106 7 15 The tooth contact pressure vs time graph generated by the CONTACT menu 107 7 16 The tooth contact pressure vs time graph generated by the CONTACT menu 108 TEL The TOOTHLDHIST meiu s aat ex RR 109 7 18 The tooth load histogram generated by TOOTHLDHIST menu 110 7 19 The SUBSURFACE menu 0 111 7 20 The subsurface shear graph generated by the SUBSURFACE menu showing large errors when DEPTHBEGIN 0 S ER S 112 7 21 The subsurface shear graph generated by the SUBSURFACE menu 113 1 22 The GRIDEDHIST menu SUE 114 1 23 The grid load histogram generated by the GRIDLDHIST menu 115 1524 The GRIDPRHLDST menus zx oso REOR Rm 116 7 25 The grid pressure histogram generated by the GRIDPRHIST menu 117 7 26 The SEPBEFHIST menu 118 7 27 The histogram of gr
100. r is selected by the TIMESTEP item The items TOOTHBEGIN and TOOTHEND are used to select a range of surface instances tooth numbers There can be at most 7 teeth in this range The items DEPTHBEGIN and DEPTHEND define a depth range and NUMDEPTH specifies the number of points over this range Very close to the surface the subsurface stresses have a large error because of the concentrated nature of the load as shown in Figure 7 20 5o DEPTHBEGIN should never be set to zero The stress component is selected in the COMPONENT box Options available are MAXP PLNORMAL the maximum principal normal stress 51 MINPPLNORMAL the minimum principal normal stress s3 MAXSHEAR the maximum shear stress and VONMISES the Von Mises octahedral shear stress sys Figure 7 21 shows an example of a graph of sub surface stress vs depth Pre and Post processing Tooth No irface pair GEAR SURFACEI PINION SURFACEI Load on sui 0 2000 0 1000 0 0 Figure 7 18 The tooth load histogram generated by the TOOTHLDHIST menu 7 8 The SUBSURFACE command 111 MultyX PostProc 1 21 SubSurface Figure 7 19 The SUBSURFACE menu 112 Pre and Post processing 0 000600 0 000500 0 000400 SS SS 1 da HB H 0 000300 Depth a
101. r the Cutter menu Cutter point radius is the radius of the cutter in a plane perpendicular to the cutter axis of rotation and passing through the tips of the blades The special analysis file gives the blade angle angle between the cutting edge of the cutter and the cutter axis of rotation in radians The user should convert that value in to degrees before entering it in to the BLADEANGLE menu The value to be entered should always be positive The sign for this item in the Special Analysis File can be disregarded 5 10 1 Use new cutter If the USENEWCUTTER flag in Figure 5 22 is checked then the menu will update to display the new cutter options Figure 5 23 The new cutter menu has three sets of options Type Toprem Option and Flankrem Option The default type of cutter is the STRAIGHT type and the default type of Toprem and Flankrem is NONE A cutter can have any combination of Toprem and Flankrem options For both the choices are NONE STRAIGHT and BLENDED If a STRAIGHT Toprem or Flankrem is chosen then two new parameters TOPREM_DEPTH or FLANKREM_DEPTH and TOPREMANGLE or FLANKREM_ANGLE are added to the cutter menu Figures 5 24 and 5 26 show the concave side cutter profile for STRAIGHT Toprem and Flankrem on a STRAIGHT blade type If a BLENDED Toprem or Flankrem is chosen then two new parameters TOPREM DEPTH or FLANKREM DEPTH and TOPREM BLEND RADIUS or FLANKREM BLEND RADIUS are added to the cutter menu Figures 5 25 and 5 27 show the conc
102. rent bodies Regardless of the origin about which the moments are computed the X Y and Z components of each force and moment always refer to the fixed reference frame 7 18 The BODYDEFLECTION command 133 MultyX PostProc 1 21 BodyDef Figure 7 40 The BODYDEFLECTION menu 7 18 The BODYDEFLECTION command The BODYDEFLECTION command of the post processing menu Figure 7 3 leads to the menu shown in Figure 7 40 This menu is used to generate a graph Figure 7 41 of a component of the rigid body type motion of a body as a function of time The six components of motion that can be graphed are the 3 translation motions uz and uz and the three rotation components 9 and 0 These components are calculated in the reference frame attached to the body The rotation components are displayed in Radians The 0 component of the body deflection is used to study the transmission error 7 19 The BODYREACTION command The BODYREACTION command of the post processing menu Figure 7 3 leads to the menu shown in Figure 7 42 This menu is used to generate a graph Figure 7 43 of a component of the body frame reaction as a function of time The six force components that can be graphed are the three forces Fy Fy and F and the three moments and M These components are calculated in the reference frame attached to the body The moments are computed about origin of this reference frame 184 Pre and Post processing
103. required Similarly the shape INNERSHAPE of the innersurface can be CYLIN DRICAL or CONICAL Accordingly only one diameter DINNER two diameters DIINNER and D2INNER will need to be specified Figure 5 48 If the outer surface of the segment connects to the pinion or gear then OUTERCONNEC TIONTYPE should be set to GEAR The diameter of the outer surface of the segment must 60 MultyX Edit Pinion Rim ET DORIM 8 WEBBED aa ______ 4 5 4 32 1 ELEMTYPE LINEAR AXIALORDER mM GI D PIT CIRCORDER s c gt ee NTHETA ELELEE NSEGS TIERE ELS ISEG 41415151 121 NELEMS SEI D DH ES Emm 1 ZB 151 3 Figure 5 43 The Rim data menu Building a Model ZAINNER Y Y CROSSING POINT RAINNER RBINNER Figure 5 44 The Rim geometry Externalfe 5 15 Modelling the shaft Table 5 11 The rim parameters Item Description DORIM NELEMS ELEMTYPE AXIALORDER CIRCORDER NSEGS ISEG RA RB ZA ZB Boolean Whether to build a rim model Integer Number of rim elements across the face Switch Type of finite element Available options are LINEAR QUADRATIC and CUBIC Integer Polynomial order in the face direction Integer Fourier series order in the circular direction Integer Number of segments used to define the rim Integer Segment number for which dat
104. s assumed to vary as a linear function of time within a time range The SAVEPERIODICALLY option saves the state of the system in a restart file after every NSTEPSSAVE number of steps The state is saved in the restart file named in the SAVEFILE NAME box This restart file can be used to restart another analysis The OUTPUTRESTART option saves the state of the system in a restart file at the end of the analysis The file named in the OUTPUTFILENAME box is used This file can also be used to start a subsequent analysis Finally a finite element post processing data file can be emitted once every NSTEPSWRITE number of time steps by enabling the POSTPROCWRITE option The file used is selected in the POSTFILENAME box The post processing file can be used subsequently to make drawings and stress contour diagrams of the deformed system 6 6 Other output files Several tabular output files are created during the analysis The displacements and reaction forces generated by the reference frames of the individual bodies in the system are saved in data files during analysis These data files are named after the bodies The file PINIONRES DAT contains the results for the pinion GEARRES DAT contains results for the gear Each data file has one row for each instant of time analyzed The first column contains the time The next 6 columns contain the six components of reference frame deflection uz Uy Uz 02 and 0 The last 6 columns contain the 6 componen
105. s in inches and your analysis is in mm 5 14 Modelling the Rim 55 Table 5 9 Cutter specifications for concave and convex tooth side of a formate type gear Item Special Analyis File Details POINTRADIUS Float Radius of the cutter Concave side Record 25 ltem 8 amp Convex side Record 21 Item 8 BLADEANGLE Float Cutter blade angle Deg Concave side Record 27 Item 4 amp Convex side Record 23 Item 4 EDGERADIUS Float Radius of the cutter Concave side Record 26 Item 15 amp edge Tip radius Convex side Record 22 Item 15 POINTWIDTH Float Difference between the Concave side Record 28 Item 10 amp point radii of the outside and in Convex side Record 24 Item 10 side blades of an alternate blade cutter TYPE Switch Type of cut Concave side Record 27 Item 1 amp ter STRAIGHT TOPREM Convex side Record 23 ltem 1 Table 5 10 Angle Modification Descriptions Item Description DELTA_SPIRAL_ANGLE Increase in spiral angle This angle is in Degrees Provide a non zero value to this variable to indtroduce a surface modification which will increase the effective spiral angle DELTA_ PRESSURE_ANGLE Increase in pressure angle This angle is in Degrees Provide a non zero value to this variable to indtroduce a surface modification which will increase the effective pressure angle DELTA_CONE_ANGLE Increase in cone angle This angle is in Degrees Provide a non zero value to this variable to indtroduce a surface modification which
106. side Figure 5 41 Hypoid tip relief input parameters 5 15 Modelling the shaft 59 Figure 5 42 The Rim geometry Webbed and elements at the two sectoral cuts must match up exactly NSECTORS is the number of identical sectors RAINNER and ZAINNER is the location closest to the crossing point that would connect to the shaft RBINNER and ZBINNER is the point furthest Figure 5 44 5 15 Modelling the shaft When the pinion or gear rides on a flexible shaft the shaft deflection can also affect the gear contact significantly In such a situation it may become necessary to incorporate a finite element model of the shaft When the ENABLESHAFT item is checked in the pinion or gear menu Figures 5 12 and 5 13 the submenu SHAFT appears This submenu is shown in Figure 5 45 The shaft is built of a number NSEGS of segments as shown in Figure 5 46 The same material properties YOUNGSMOD POISSON and DENSITY are used for all the segments in the shaft The shaft is positioned with respect to the gear or pinion mid face plane by specifying the offset value TOOTHOFFSET A specific segment is selected through the index ISEG The segment s axial length is specified through the item LENGTH The shape OUTERSHAPE of the outer surface of the segment can be set to CYLINDRICAL or CONICAL Figure 5 47 For a cylindrical outer shape only one outer diameter DOUTER is needed For a conical outer shape two diameters DIOUTER and D2OUTER are
107. sing menu and the post processing menu are used to make drawings of the sys tem and its components The CLEAR command clears the graphics screen The DRAWBODIES draws all the selected bodies using the current view settings The DRAWBODIES command 94 Pre and Post processing MultyX PostProc 1 21 58 585 IDOPOSTSCRIPT IDOMETAFILE GOTOPOSN 41 1 151 121 1 DRAWBODIES Figure 7 3 The post processing menu does not clear the screen before it makes the drawing In the post processing menu the FIRST POSN PREVPOSN NEXTPOSN and LASTPOSN commands allow the user to move from one time step saved in the post processing file to another Entering a position number directly in the GOTOPOSN box takes the user directly to that time step 7 1 Selecting bodies 95 7 1 Selecting bodies The object selection menu which appears when the SELECT command is invoked from the pre and post processing menus is shown in Figure 7 4 The objects that should be drawn are selected from this menu XPosiP 1 21 electObject Figure 7 4 The body selection menu 7 2 View parameters The VIEW menu controls the appearance of the drawings In the pre processing view menu shown in Figure 7 5 the user can enter any value of time into the TIME box The next drawing will show the system as it would appear at this instant of time The resolution level controls the degree of detail with which the drawing is made Th
108. t a particular point when its element number and local coordinates are known The Element numbering used in the gear tooth finite element meshes is shown in Appendix A Figure 6 2 shows the finite element probe input menu The BODY parameter selects the particular body or component to be probed Each body can have many finite element meshes The MESH parameter selects which finite element mesh should be probed There may be many copies or instances of the finite element mesh Each copy is given an instance number In the case of a gear tooth mesh this instance number is the same as the tooth number The TOOTH parameter selects the instance number The ELEM parameter selects the finite element number within the mesh The XI ETA and ZETA values are the local coordinates within the finite element XI ETA and ZETA vary between 1 and 1 over the element Appendix shows the orientation of the local coordinate axes for each finite element in the various mesh templates The COMPONENT parameter selects which stress component should be measured by the probe Available options are Maximum principal normal stress 81 minimum principal normal stress 53 maximum shear stress Tmas Von Mises octahedral shear stress Sym and the displacement magnitude u The data measured by the finite element probes is written to a file called PROBES DAT The data file has a row for each time instant The first column contains the value of time Each subsequent colu
109. taining only the visible part of the current graphics page Parts of the page that are not visible because of the zoom level will be cropped from the EPS file The Home Clipboard Copy command will copy the graphics in Windows Metafile format onto the clipboard Graphics pages can be printed by using the File Print command on G uide s main menu 18 The Graphical User Interface Chapter 5 Building a Model All data describing the model is entered in sub menus of the EDIT menu Figure 5 1 shows the EDIT menu In this EDIT menu and in all sub menus under it the QUIT command takes the user back to the parent menu after discarding all changes made in the sub menu and all sub menus under it The EXIT command takes the user back to the parent while keeping changes There are four sub menus under this EDIT menu The SPAFILE command leads to a menu for reading special analysis files The SYSTEM command leads to a menu for entering system level data The PINION and GEAR commands lead to separate sub menus for entering data specific to the pinion and gear respectively The DOMODELHOUSING flag enables a fifth sub menu that allows you to import an outside housing mesh file MultyX Edit EXIT QUIT SPAFILE SYSTEM PINION GEAR IDDMODELHDUSING 8 Figure 5 1 The EDIT menu 5 1 Special Analysis File If the hypoid gear is manufactured using the Gleason s manufacturing process then the finite element analyst is given a sp
110. ts of reference frame reaction Fy Fy Fz and Mz 6 6 Other output files SEPTOL 0 0100000000 NPROFDIVS 34 ELELEE NFACEDIVS g ELELEE DSPROF 0 0015000000 EEE EROINITIAL INITIALTIME 050000000 noses NRANGES 21 RANGE TT Figure 6 9 The 91 SOLMETHOD NTIMESTEPS LAELLE DELTATIME IL E 12 STARTSPEEDFACTOR amaa STARTTORQUEFACTC amaa STATIC 11 0 1000000000 0000000000 0000000000 ENDTORQUEFACTOR 0000000000 gogga SAVEPERIODICALLY QUTPUTRESTART POSTPROCWRITE 2 ISPLITPOSTPROCFILE Bi POSTFILENAME Le NSTEPSWRITE 1 41414151 12 postproc dat setup menu 92 Running an Analysis Chapter 7 Pre and Post processing The PREPROC command in the main menu leads to the pre processing menu shown in Fig ure 7 1 The POSTPROC command leads to the dialog box shown in Figure 7 2 where Multyx asks for the name of the post processing data file created in the analysis step When a valid name is entered the post processing menu shown in Figure 7 3 comes up DOPOSTSCRIPT DOPDF Ta DOMETAFILE YROBTEFEMODEL GENIGLASSFILE Figure 7 1 The pre processing menu CANCEL POSTPROCFILENAME postproc dat Figure 7 2 The post processing file name dialog box The pre proces
111. y error calculation Method 3 Method 1 Method 2 Method 3 Time t Figure 5 11 Assembly error output file format 29 30 Building a Model IENABLESHAFT Figure 5 12 The pinion data menu 5 4 Pinion and gear data 5 5 Common design and blank data MultyX Edit Gear SHAFT DIFFCARRIER FORMATE ENABLESHAFT 2 ENABLEDIFFCARRIER iv Figure 5 13 The gear data menu NTEETH 85 1 1 151 121 1 NFACEELEMS M D COORDORDER o TD 21 DISPLORDER P yy 1 151519 1211 SPIRALANGLE 5 000000 SPIRALANG 35 0000000000 SPECIFYMSRPT MEASADDENDUM THICKNESS 025200000 DUTERCONEDIST 3691000000 00 EEEE FACEWIDTH ooo 7 EEEE FACEANGLE 0 0 BACKANGLE 84990000 7 MELEE FRONTANGLE 18433300000 PITCHANGLE PITCHAPEX 0000000000000 FACEAPEX 0 0000000000 00 ROOTAPEX 0020 BASESURFACETYPE CYLINDER 54 BASECYLINDERDIAME 1380000000 LELEH ISRACERIGID 8 AXIALORDER LLELLE CIRCORDER 4 414141 1 121 1 YOUNGSMOD 3 0000000000 007 4151 121 1 _ POISSON 6300000000 00 0 630000000 00 0 ELEH DENSITY EEH 0010000000 TPLFILE 1000000000 007 MED

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