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KISSSOFT
RELEASE 03/2015
USER MANUAL

Issue 1.4

Copyright Notice
2015 KISSsoft AG
Rosengartenstrasse 4
CH-8608 Bubikon Schweiz

All rights reserved

This documentation may not be copied without the express written approval of KISSsoft AG.

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Table of Contents
I General

I-40

1 Installing KISSsoft ............................................................................ I-41

1.1 Basic installation.......................................................................................... I-42
1.2 Downloading a license file .......................................................................... I-43
1.3 Licensing ..................................................................................................... I-44
1.3.1

Test version .................................................................................. I-44

1.3.2

Student version ............................................................................. I-44

1.3.3

Single user version with dongle (protection key) ......................... I-44

1.3.4

Single user version with license code........................................... I-45

1.3.5

Network version with dongle (protection key) ............................. I-45

1.3.6

Network version with the license code......................................... I-46

2 Setting Up KISSsoft ........................................................................... I-47

2.1 Directory structure ....................................................................................... I-48
2.2 Language settings ........................................................................................ I-49
2.3 System of units ............................................................................................ I-50
2.4 Defining your own default files ................................................................... I-51
2.5 Rights ........................................................................................................... I-52
2.6 Global settings - KISS.ini ............................................................................ I-53
2.6.1

Definitions in [PATH] .................................................................. I-53

2.6.2

Definitions in [SETUP] ................................................................ I-54

2.6.3

Definitions in [REPORT] ............................................................. I-56

2.6.4

Definitions in [GRAPHICS] ........................................................ I-56

2.6.5

Definitions in [LICENSE] ............................................................ I-56

2.6.6

Definitions in [CADEXPORT] .................................................... I-57

2.6.7

Definitions in [INTERFACES] .................................................... I-57

2.6.8

Definitions in [SOLIDEDGE] ...................................................... I-58

2.6.9

Definitions in [SOLIDWORKS] .................................................. I-58

2.6.10 Definitions in [INVENTOR] ........................................................ I-58

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2.6.11 Definitions in [CATIA] ................................................................ I-59

2.6.12 Definitions in [PROENGINEER] ................................................ I-59
2.6.13 Definition in [COCREATE] ......................................................... I-60
2.6.14 Definitions in [THINK3] .............................................................. I-60
2.6.15 Definitions in [HICAD]................................................................ I-60
2.7 User-defined settings ................................................................................... I-61
2.7.1

Configuration tool ........................................................................ I-61

2.8 Rules ............................................................................................................ I-65

3 Starting KISSsoft ............................................................................... I-68
3.1 Initial parameters ......................................................................................... I-69
3.2 Disconnect license from the network........................................................... I-70
4 Elements of the KISSsoft User Interf ace ........................................ I-71
4.1 Menus, context menus and the Tool bar ...................................................... I-72
4.2 Docking window .......................................................................................... I-74
4.2.1

The module tree ............................................................................ I-74

4.2.2

The project tree............................................................................. I-75

4.2.3

The Results window ..................................................................... I-75

4.2.4

The Messages window ................................................................. I-75

4.2.5

The info window .......................................................................... I-75

4.2.6

Manual and Search ....................................................................... I-76

4.3 Graphics window ......................................................................................... I-77

4.3.1

Tool bar and context menu ........................................................... I-78

4.3.2

Comment field .............................................................................. I-80

4.3.3

Context menu ............................................................................... I-80

4.3.4

Properties...................................................................................... I-80

4.3.5

Toothing ....................................................................................... I-82

4.4 Main input area ............................................................................................ I-84

4.4.1

Report Viewer .............................................................................. I-84

4.4.2

Helptext viewer ............................................................................ I-85

4.5 Tooltips and status bar ................................................................................. I-86

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5 KISSsoft Calculation Modules ........................................................ I-87

5.1 Standard and special tabs ............................................................................. I-88
5.2 Input elements.............................................................................................. I-89
5.2.1

Value input fields ......................................................................... I-89

5.2.2

Formula entry and angle input...................................................... I-89

5.2.3

Unit switch ................................................................................... I-90

5.2.4

Tables ........................................................................................... I-90

5.3 Calculating and generating a report ............................................................. I-91

5.4 Messages ...................................................................................................... I-92
6 Project Management ......................................................................... I-93
6.1 Creating, opening and closing projects ........................................................ I-94
6.2 Adding and deleting files ............................................................................. I-95
6.3 The active working project .......................................................................... I-96
6.4 Storage locations.......................................................................................... I-97
6.5 Project properties ......................................................................................... I-98
7 Dynamic user Interfac e .................................................................... I-99
7.1 Modified tabs and dialogs supplied with the system ................................. I-100
7.2 Adding additional tabs and dialogs ............................................................ I-101
7.3 Formatting.................................................................................................. I-103
7.3.1

Elements ..................................................................................... I-103

7.3.2

Columns ..................................................................................... I-104

7.3.3

Groups ........................................................................................ I-104

7.3.4

Tabs ............................................................................................ I-105

7.3.5

Comments................................................................................... I-105

8 Results and Reports ........................................................................ I-106

8.1 Results of a calculation .............................................................................. I-107
8.1.1

Add your own texts in the results window ................................. I-107

8.2 Calculation reports ..................................................................................... I-108

8.3 Drawing data.............................................................................................. I-109
8.4 Report settings ........................................................................................... I-110

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8.4.1

General ....................................................................................... I-110

8.4.2

Page layout ................................................................................. I-110

8.4.3

Header and footer ....................................................................... I-110

8.4.4

Start and end block ..................................................................... I-111

8.5 Report templates ........................................................................................ I-113

8.5.1

Storage locations and descriptions ............................................. I-113

8.5.2

Scope of a report ........................................................................ I-114

8.5.3

Formatting .................................................................................. I-114

9 Database Tool and External Tables .............................................. I-124

9.1 Viewing database entries ........................................................................... I-126
9.2 Managing database entries ......................................................................... I-129
9.2.1

Generating a database entry ....................................................... I-129

9.2.2

Deleting a database entry ........................................................... I-130

9.2.3

Restoring a database entry .......................................................... I-130

9.3 Import and export data with the database tool ........................................... I-131
9.4 External tables ........................................................................................... I-132
9.4.1

Functions tables .......................................................................... I-133

9.4.2

Range tables ............................................................................... I-135

9.4.3

List tables ................................................................................... I-136

9.4.4

List of key words used................................................................ I-138

9.5 Description of database tables ................................................................... I-140

9.5.1

Center distance tolerances ......................................................... I-140

9.5.2

Machining allowance for cylindrical gear ................................. I-140

9.5.3

Reference profiles ...................................................................... I-140

9.5.4

Compression springs standard ................................................... I-140

9.5.5

Selection of hobbing cutters ....................................................... I-141

9.5.6

Basic material Glued and Soldered joints ................................. I-141

9.5.7

Manufacturing process for bevel and hypoid gears ................... I-141

9.5.8

V-belt Standard ......................................................................... I-141

9.5.9

Spline Standard ......................................................................... I-142

9.5.10 Chain profiles ISO606 ............................................................... I-142

9.5.11 Adhesives .................................................................................. I-142

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9.5.12 Modifications ............................................................................. I-142

9.5.13 Load spectra .............................................................................. I-142
9.5.14 Solders ....................................................................................... I-143
9.5.15 Surface roughness of shafts and shaft-hub connections ............ I-144
9.5.16 Key standard .............................................................................. I-144
9.5.17 Polygon standard ....................................................................... I-144
9.5.18 Woodruff Key standard ............................................................. I-144
9.5.19 Bolts/pins.................................................................................... I-144
9.5.20 Lubricants .................................................................................. I-144
9.5.21 Bolts: Tightening factor ............................................................. I-146
9.5.22 Bolts: Bore ................................................................................. I-146
9.5.23 Bolts: Strength class .................................................................. I-146
9.5.24 Bolts: Nuts strength class ........................................................... I-147
9.5.25 Bolts: Coefficients of friction classes ......................................... I-147
9.5.26 Bolts: Thread type ..................................................................... I-147
9.5.27 Bolts: Nuts ................................................................................. I-148
9.5.28 Bolts: Type ................................................................................ I-148
9.5.29 Bolts: Washer ............................................................................ I-148
9.5.30 Selection of pinion type cutters ................................................. I-148
9.5.31 Disc spring standard .................................................................. I-148
9.5.32 Tolerances standard ................................................................... I-149
9.5.33 Beam profiles ............................................................................ I-149
9.5.34 Multi-Spline standard ................................................................ I-149
9.5.35 Materials .................................................................................... I-149
9.5.36 Roller bearing ............................................................................ I-154
9.5.37 Roller bearing tolerance ............................................................ I-162
9.5.38 Roller bearing Tolerance classes ............................................... I-162
9.5.39 Tooth thickness tolerances ........................................................ I-162
9.5.40 Toothed belt standard ................................................................ I-163
10 Description of the p ublic interf ace ............................................. I-165
10.1 Interfaces between calculation programs and CAD - Overview................ I-166
10.1.1 Efficient interfaces ..................................................................... I-166

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10.1.2 Open interfaces concept in KISSsoft .......................................... I-167

10.2 Defining input and output .......................................................................... I-169
10.2.1 Preamble ..................................................................................... I-169
10.2.2 Requirements placed on the third party program ....................... I-170
10.2.3 Used files .................................................................................... I-170
10.2.4 Service life of files ..................................................................... I-171
10.2.5 Explicitly reading (importing) and generating data.................... I-171
10.3 Example: Interference fit calculation ......................................................... I-172
10.4 Geometry data............................................................................................ I-174
10.5 COM Interface ........................................................................................... I-175
10.5.1 Registering the server ................................................................. I-175
10.5.2 Server functionality .................................................................... I-175
10.5.3 Example of a call from Excel ..................................................... I-178
11 3D interfaces ................................................................................... I-184
11.1 Overview of the available CAD interfaces and their functionality ............ I-185
11.2 Generation of 3D gears .............................................................................. I-186
11.3 Generating 3D shafts ................................................................................. I-188
11.4 Viewer with neutral format interface ......................................................... I-190
11.4.1 Parasolid Export of 3D Shafts .................................................... I-191
11.4.2 Face gear - 3D geometry ............................................................ I-191
11.4.3 Bevel gear - generating a 3D model ........................................... I-193
11.4.4 Worm wheel - generating a 3D model ....................................... I-194
11.5 3D interface to Solid Works ...................................................................... I-195
11.5.1 Gear teeth in the case of an existing basic solid ......................... I-195
11.5.2 Integrating the KISSsoft Add-in (menu options in CAD) .......... I-197
11.5.3 Add-in functions (calls) .............................................................. I-200
11.6 3D interface to Solid Edge ......................................................................... I-203
11.6.1 Changes of the parameters for generation .................................. I-203
11.6.2 Gear teeth in the case of an existing basic solid ......................... I-203
11.6.3 Integrating the KISSsoft Add-in (menu options in CAD) .......... I-205
11.6.4 Add-in functions (calls) .............................................................. I-209
11.6.5 Opening the calculation file for the created gear........................ I-210

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11.7 3D interface to Autodesk Inventor............................................................. I-211

11.7.1 Gear teeth in the case of existing shaft data ............................... I-211
11.7.2 Add-in (menu items in CAD) ..................................................... I-212
11.7.3 Add-in functions (calls) .............................................................. I-215
11.7.4 Opening the calculation file for the created gear........................ I-216
11.8 3D interface to Unigraphics NX ................................................................ I-217
11.8.1 Add-in (menu items in CAD) ..................................................... I-218
11.8.2 Running KISSsoft via an add-in ................................................. I-221
11.8.3 Add-in functions (calls) .............................................................. I-228
11.9 3D interface to Creo Parametric (ProEngineer) ......................................... I-229
11.9.1 Integrating the KISSsoft Add-in................................................. I-232
11.9.2 Modifying the selected 3D model .............................................. I-236
11.9.3 Cutting teeth on an existing shaft ............................................... I-237
11.9.4 Modifying the teeth on an existing shaft .................................... I-239
11.9.5 Changing base settings in the interface ...................................... I-240
11.10

3D interface to CATIA ...................................................................... I-242

11.10.1 Registering the interface ............................................................. I-242

11.11

3D interface to CoCreate.................................................................... I-245

11.12

3D interface to ThinkDesign .............................................................. I-247

11.12.1 Integrating the KISSsoft Add-in................................................. I-249

11.13

3D interface to ASCON Kompas ....................................................... I-250

12 Answers to Frequently Asked Questions ..................................... I-251

12.1 Change the output of angles in reports ...................................................... I-252
12.2 Input materials for gear calculations in the database ................................. I-253
12.3 How can I test the software? ...................................................................... I-254
12.4 What licenses are available? ...................................................................... I-255
12.5 Add your own texts in the results window ................................................ I-256
12.6 Restore previous stages of the calculation ................................................. I-257

II Toothing

II-258

13 Introduction ................................................................................... II-259

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14 Cylindrical gears ........................................................................... II-260

14.1 Basic data .................................................................................................. II-262
14.1.1 Normal module .......................................................................... II-262
14.1.2 Hand of gear for gear teeth ........................................................ II-262
14.1.3 Pressure angle at normal section ............................................... II-263
14.1.4 Helix angle at reference circle ................................................... II-263
14.1.5 Center distance .......................................................................... II-263
14.1.6 Number of teeth ......................................................................... II-264
14.1.7 Facewidth .................................................................................. II-264
14.1.8 Profile shift coefficient .............................................................. II-265
14.1.9 Quality ....................................................................................... II-268
14.1.10 Geometry details ....................................................................... II-271
14.1.11 Material and lubrication ............................................................ II-272
14.2 Load .......................................................................................................... II-279
14.2.1 Calculation methods .................................................................. II-279
14.2.2 Service life................................................................................. II-287
14.2.3 Application factor ...................................................................... II-287
14.2.4 Power, torque and speed............................................................ II-288
14.2.5 Strength details .......................................................................... II-288
14.2.6 Strength details (AGMA) .......................................................... II-303
14.2.7 Define load spectrum................................................................. II-304
14.2.8 Calculate scuffing ...................................................................... II-306
14.2.9 Calculate the internal temperature and the flash temperature ... II-307
14.3 Factors ...................................................................................................... II-308
14.3.1 Transverse coefficient ............................................................... II-308
14.3.2 Dynamic factor .......................................................................... II-308
14.3.3 Load distribution coefficient ..................................................... II-309
14.3.4 Alternating bending factor......................................................... II-310
14.3.5 Face load factor ......................................................................... II-313
14.3.6 Taking into account shaft bending (face load factor and contact
analysis) .................................................................................................. II-333
14.3.7 Z-Y coefficients and the technology factor ............................... II-338

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14.3.8 General calculation procedure for KHbeta as specified in ISO 63361, Appendix E. ........................................................................................ II-341
14.4 Reference profile ...................................................................................... II-342
14.4.1 Configuration ............................................................................ II-342
14.4.2 Preliminary treatment and grinding allowance.......................... II-349
14.4.3 Tip alteration ............................................................................. II-351
14.5 Tolerances ................................................................................................. II-352
14.5.1 Tooth thickness tolerance .......................................................... II-352
14.5.2 Tip diameter allowances ............................................................ II-354
14.5.3 Root diameter allowances ......................................................... II-354
14.5.4 Center distance tolerances ......................................................... II-355
14.5.5 Settings ...................................................................................... II-355
14.6 Modifications ............................................................................................ II-356
14.6.1 Define grinding wheel for gear n dialog window ...................... II-357
14.6.2 Type of modification ................................................................. II-358
14.6.3 Underlying principles of calculation ......................................... II-359
14.6.4 Profile modifications ................................................................. II-361
14.6.5 Tooth trace modifications .......................................................... II-366
14.6.6 Sizing modifications .................................................................. II-372
14.6.7 Notes about profile modification ............................................... II-376
14.7 Tooth form ................................................................................................ II-377
14.7.1 Context menu ............................................................................ II-378
14.7.2 Operations ................................................................................. II-379
14.8 Flank breaking .......................................................................................... II-399
14.9 Contact Analysis ....................................................................................... II-401
14.9.1 Theory of Contact Analysis ....................................................... II-402
14.9.2 Discretized model ...................................................................... II-406
14.9.3 Smoothing the tooth form curvature to calculate Hertzian pressure in
the contact analysis ................................................................................. II-406
14.9.4 Reduced stiffness on the side edges ......................................... II-408
14.9.5 Linking the individual slices ..................................................... II-409
14.9.6 Wear iteration ............................................................................ II-409
14.10

Gear pump ......................................................................................... II-411

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14.11

Operating backlash............................................................................ II-414

14.11.1 Reference temperature............................................................... II-416
14.11.2 Relative water absorption during swelling ................................ II-416
14.11.3 Coefficient of thermal expansion for housing ........................... II-417

14.12

Master gear........................................................................................ II-418

14.13

AGMA 925 ....................................................................................... II-420

14.14

Rough sizing ..................................................................................... II-422

14.15

Fine Sizing ........................................................................................ II-428

14.15.1 Necessary entries in the input window ...................................... II-429
14.15.2 Conditions I ............................................................................... II-429
14.15.3 Conditions II .............................................................................. II-431
14.15.4 Results ....................................................................................... II-436
14.15.5 Graphics .................................................................................... II-438
14.15.6 Geometry-Fine Sizing for 3 gears ............................................. II-439
14.15.7 Additional strength calculation of all variants........................... II-439

14.16

Measurement grid ............................................................................. II-440

14.17

Modifications sizing.......................................................................... II-443

14.17.1 Conditions I/II ........................................................................... II-443
14.17.2 Results ....................................................................................... II-443
14.17.3 Graphics .................................................................................... II-444
14.17.4 Report ........................................................................................ II-444

14.18

Settings.............................................................................................. II-446
14.18.1 General ...................................................................................... II-446
14.18.2 Plastic ........................................................................................ II-448
14.18.3 Planets ....................................................................................... II-451
14.18.4 Sizings ....................................................................................... II-452
14.18.5 Calculations ............................................................................... II-454
14.18.6 Required safeties ....................................................................... II-459
14.18.7 Contact analysis/Face load factor .............................................. II-460
14.18.8 Summary ................................................................................... II-462
14.18.9 Diagrams ................................................................................... II-462
14.18.10

14.19

Generation of 3D model .................................................... II-463

Tooth thickness ................................................................................. II-466

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15 Bevel and Hypoid gears ................................................................. II-467

15.1 Underlying principles of calculation......................................................... II-468
15.1.1 General ...................................................................................... II-468
15.1.2 Overview of the bevel gear manufacturing process and the
terminology used in it ............................................................................. II-468
15.1.3 Calculation according to Klingelnberg, Gleason and Oerlikon . II-469
15.2 Basic data .................................................................................................. II-471
15.2.1 Normal module (middle) ........................................................... II-471
15.2.2 Reference diameter gear 2 ......................................................... II-471
15.2.3 Pressure angle at normal section ............................................... II-472
15.2.4 Pressure angle driving/driven flank: Hypoid gears ................... II-472
15.2.5 Helix angle ................................................................................ II-473
15.2.6 Shaft angle ................................................................................. II-474
15.2.7 Offset (Center dist.) ................................................................... II-475
15.2.8 Number of teeth ......................................................................... II-475
15.2.9 Facewidth .................................................................................. II-476
15.2.10 Profile shift coefficient .............................................................. II-476
15.2.11 Thickness modification coefficient ........................................... II-476
15.2.12 Quality ....................................................................................... II-477
15.2.13 Addendum angle and root angle ................................................ II-478
15.2.14 Angle modifications .................................................................. II-479
15.2.15 Geometry details ....................................................................... II-480
15.2.16 Manufacturing process .............................................................. II-481
15.3 Type .......................................................................................................... II-482
15.3.1 Converting or inputting Gleason toothing data ......................... II-484
15.4 Manufacture .............................................................................................. II-488
15.4.1 Cutter radius .............................................................................. II-488
15.4.2 Number of blade groups, tool .................................................... II-488
15.5 Load .......................................................................................................... II-489
15.5.1 Methods used for strength calculation ....................................... II-489
15.5.2 Required service life.................................................................. II-493
15.5.3 Power, torque and speed............................................................ II-493
15.5.4 Strength details .......................................................................... II-494

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15.5.5 Application factor ...................................................................... II-496

15.6 Reference profile ...................................................................................... II-497
15.6.1 Default values for tip base clearance ......................................... II-497
15.6.2 Default values for addendum coefficients ................................. II-497
15.7 Contact Analysis ....................................................................................... II-498
15.8 Rough sizing ............................................................................................. II-499
15.8.1 Face width ratio ......................................................................... II-499
15.8.2 Module ratio .............................................................................. II-500
15.9 Fine Sizing ................................................................................................ II-501
15.9.1 Necessary entries in the input window ...................................... II-502
15.9.2 Conditions I ............................................................................... II-502
15.9.3 Conditions II .............................................................................. II-503
15.9.4 Conditions III ............................................................................ II-504
15.9.5 Results ....................................................................................... II-509
15.9.6 Graphics .................................................................................... II-510
15.10

Notes on calculations in accordance with the Klingelnberg standard ..... II-

511
15.10.1 Bevel gears with cyclo-palloid gear teeth .............................. II-511
15.10.2 Hypoid gears with cyclo-palloid gear teeth ............................... II-511
15.10.3 Normal module ranges for Klingelnberg machines (cyclo-palloid) II512
15.10.4 Bevel gears with Palloid toothing ............................................. II-513
15.10.5 Definitions and dimensions of standard cutters for palloid toothing
II-514
15.10.6 Minimum safeties ...................................................................... II-515
15.10.7 Surface roughness at tooth root ................................................. II-515
15.10.8 Accuracy grade bevel gears ....................................................... II-515
15.10.9 Characteristic number................................................................ II-515
15.11

Settings.............................................................................................. II-517
15.11.1 Calculations ............................................................................... II-517
15.11.2 Differential gears ....................................................................... II-517
15.11.3 Helpful information about the Generation of 3D model tab ..... II-518
15.11.4 Factors ....................................................................................... II-519

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15.11.5 Contact Analysis ....................................................................... II-521

16 Face gears ...................................................................................... II-522
16.1 Underlying principles of calculation......................................................... II-523
16.2 Basic data .................................................................................................. II-526
16.2.1 Normal module .......................................................................... II-526
16.2.2 Pressure angle at normal section ............................................... II-528
16.2.3 Helix angle at reference circle ................................................... II-528
16.2.4 Axial offset ................................................................................ II-529
16.2.5 Profile shift coefficient (on the pinion) ..................................... II-529
16.2.6 Quality ....................................................................................... II-530
16.2.7 Geometry details ....................................................................... II-531
16.2.8 Material and lubrication ............................................................ II-532
16.3 Load .......................................................................................................... II-533
16.3.1 Methods used for strength calculation ....................................... II-533
16.3.2 Service life................................................................................. II-535
16.3.3 Power, torque and speed............................................................ II-535
16.3.4 Application factor ...................................................................... II-535
16.4 Factors ...................................................................................................... II-537
16.4.1 Face load factor ......................................................................... II-537
16.5 Modifications ............................................................................................ II-538
16.5.1 Addendum reduction ................................................................. II-538
16.5.2 Type of modification ................................................................. II-538
16.6 Settings ..................................................................................................... II-539
16.6.1 General ...................................................................................... II-539
16.6.2 Sizings ....................................................................................... II-540
16.7 Notes on face gear calculation .................................................................. II-541
16.7.1 Dimensioning ............................................................................ II-541
16.7.2 Pinion - Face gear with Z1 > Z2................................................ II-542
17 Worms with envelop ing worm wheels ....................................... II-543
17.1 Underlying principles of calculation......................................................... II-544
17.2 Basic data .................................................................................................. II-546

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17.2.1 Axial/transverse module ............................................................ II-546

17.2.2 Pressure angle at normal section ............................................... II-546
17.2.3 Lead angle at reference circle .................................................... II-546
17.2.4 Center distance .......................................................................... II-547
17.2.5 Number of teeth ......................................................................... II-547
17.2.6 Facewidth .................................................................................. II-548
17.2.7 Profile shift coefficient .............................................................. II-548
17.2.8 Tooth thickness modification factor .......................................... II-549
17.2.9 Quality ....................................................................................... II-549
17.2.10 Geometry details ....................................................................... II-550
17.2.11 Material and lubrication ............................................................ II-551
17.3 Load .......................................................................................................... II-553
17.3.1 Strength calculation methods .................................................... II-553
17.3.2 Service life................................................................................. II-554
17.3.3 Application factor ...................................................................... II-554
17.3.4 Permissible decrease in quality ................................................. II-554
17.3.5 Power, torque and speed............................................................ II-555
17.3.6 Strength details .......................................................................... II-555
17.4 Tolerances ................................................................................................. II-559
17.5 Settings ..................................................................................................... II-560
17.5.1 General ...................................................................................... II-560
17.5.2 Reference gearing ...................................................................... II-561
17.5.3 Calculations ............................................................................... II-562
17.5.4 Required safeties ....................................................................... II-563
18 Crossed helical gears and precision mechanics worms ...... II-565
18.1 Underlying principles of calculation......................................................... II-566
18.2 Basic data .................................................................................................. II-567
18.2.1 Normal module .......................................................................... II-567
18.2.2 Pressure angle at normal section ............................................... II-567
18.2.3 Helix angle reference circle gear 1 ............................................ II-567
18.2.4 Center distance .......................................................................... II-568
18.2.5 Facewidth .................................................................................. II-568

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18.2.6 Profile shift coefficient .............................................................. II-568

18.2.7 Quality ....................................................................................... II-568
18.2.8 Define details of geometry ........................................................ II-569
18.2.9 Material and lubrication ............................................................ II-570
18.3 Load .......................................................................................................... II-571
18.3.1 Methods used for strength calculation ....................................... II-571
18.3.2 Service life................................................................................. II-574
18.3.3 Application factor ...................................................................... II-575
18.3.4 Power, torque and speed............................................................ II-575
18.3.5 Strength details .......................................................................... II-576
18.4 Settings ..................................................................................................... II-582
18.5 Notes ......................................................................................................... II-583
18.5.1 Checking the contact pattern ..................................................... II-583
19 Beveloid gears ............................................................................... II-584
19.1 Underlying principles of calculation......................................................... II-585
19.2 Basic data .................................................................................................. II-586
19.2.1 Normal module .......................................................................... II-586
19.2.2 Pressure angle at normal section ............................................... II-586
19.2.3 Helix angle ................................................................................ II-586
19.2.4 Shaft angle ................................................................................. II-586
19.2.5 Number of teeth ......................................................................... II-587
19.2.6 Width ......................................................................................... II-587
19.2.7 Cone angle ................................................................................. II-587
19.2.8 Profile shift coefficient (center) ................................................ II-587
19.2.9 Quality ....................................................................................... II-587
19.2.10 Material and lubrication ............................................................ II-587
19.3 Reference profile ...................................................................................... II-588
19.4 Modifications ............................................................................................ II-589
19.5 Factors ...................................................................................................... II-590
19.6 Dimensioning............................................................................................ II-591
19.7 Manufacturing Data and Working Data.................................................... II-592

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20 Non circular gears ........................................................................ II-593

20.1 Input data .................................................................................................. II-594
20.1.1 Geometry ................................................................................... II-594
20.1.2 Tolerances ................................................................................. II-597
20.1.3 Reference profile ....................................................................... II-597
20.2 How to use KISSsoft ................................................................................ II-599
20.2.1 Angle error ................................................................................ II-599
20.2.2 Checking the meshing ............................................................... II-599
20.2.3 Improve tooth form ................................................................... II-600
20.2.4 Accuracy of the tooth form ....................................................... II-600
20.2.5 Export individual teeth .............................................................. II-601
20.2.6 Report ........................................................................................ II-602
20.2.7 Temporary files ......................................................................... II-602
21 Report menu ................................................................................... II-604
21.1 Drawing data............................................................................................. II-605
21.2 Manufacturing tolerances ......................................................................... II-606
21.3 Summary ................................................................................................... II-607
21.4 Service life ................................................................................................ II-608
21.5 Sizing of torque......................................................................................... II-609
21.6 Proposal for the hardening depth EHT ..................................................... II-610
22 Graphics menu ................................................................................ II-611
22.1 AGMA 925 ............................................................................................... II-615
22.1.1 Thickness of lubrication film and specific oil film thickness .... II-615
22.2 2D geometry ............................................................................................. II-616
22.2.1 Gear tooth forms ........................................................................ II-616
22.2.2 Gear tool .................................................................................... II-617
22.2.3 Manufacturing a gear................................................................. II-617
22.2.4 Meshing ..................................................................................... II-617
22.2.5 Profile and tooth trace diagram ................................................. II-618
22.2.6 Flank curvature radii ................................................................. II-622
22.2.7 Angle of flank normal ............................................................... II-623

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22.2.8 Drawing ..................................................................................... II-623

22.2.9 Assembly ................................................................................... II-623
22.2.10 Manufacturing drawing ............................................................. II-623
22.3 3D geometry ............................................................................................. II-626
22.3.1 Tooth system ............................................................................. II-627
22.3.2 Tooth form................................................................................. II-627
22.4 Evaluation ................................................................................................. II-628
22.4.1 Specific sliding .......................................................................... II-628
22.4.2 Flash temperature ...................................................................... II-629
22.4.3 Hardening depth ........................................................................ II-630
22.4.4 Woehler line for material .......................................................... II-631
22.4.5 Safety factor curves ................................................................... II-632
22.4.6 Oil viscosity, depending on temperature ................................... II-632
22.4.7 Theoretical contact stiffness ...................................................... II-633
22.4.8 Contact line (face gear) ............................................................. II-634
22.4.9 Stress curve (face gear) ............................................................. II-635
22.4.10 Scuffing and sliding velocity (face gear)................................... II-636
22.5 Contact Analysis ....................................................................................... II-638
22.5.1 Axis alignment .......................................................................... II-638
22.5.2 Transmission error..................................................................... II-638
22.5.3 Transmission error acceleration ................................................ II-639
22.5.4 Amplitude of transmission error................................................ II-640
22.5.5 Contact lines on tooth flank....................................................... II-640
22.5.6 Normal force curve .................................................................... II-640
22.5.7 Normal force distribution .......................................................... II-641
22.5.8 Torque curve ............................................................................. II-641
22.5.9 Single contact stiffness .............................................................. II-641
22.5.10 Stiffness curve ........................................................................... II-641
22.5.11 Amplitude of contact stiffness ................................................... II-642
22.5.12 Bearing force curve and direction of the bearing forces ........... II-642
22.5.13 Kinematics ................................................................................. II-643
22.5.14 Specific sliding .......................................................................... II-643
22.5.15 Power loss ................................................................................. II-643

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22.5.16 Heat development ...................................................................... II-643

22.5.17 Stress curve ............................................................................... II-643
22.5.18 Flash temperature ...................................................................... II-644
22.5.19 Safety against micropitting........................................................ II-644
22.5.20 Wear .......................................................................................... II-646
22.6 Gear pump ................................................................................................ II-649
22.7 3D export .................................................................................................. II-650
22.8 Settings ..................................................................................................... II-651
22.9 Graphics list .............................................................................................. II-652
23 Answers to Frequently Asked Questions ................................... II-653
23.1 Answers concerning geometry calculation ............................................... II-654
23.1.1 Precision mechanics .................................................................. II-654
23.1.2 Deep toothing or cylindrical gears with a high transverse contact
ratio

II-654

23.1.3 Pairing an external gear to an inside gear that has a slightly different
number of teeth ....................................................................................... II-655
23.1.4 Undercut or insufficient effective involute................................ II-655
23.1.5 Tooth thickness at tip ................................................................ II-656
23.1.6 Special toothing ......................................................................... II-656
23.1.7 Calculating cylindrical gears manufactured using tools specified in
DIN 3972 ................................................................................................ II-656
23.1.8 Variations in rolling as defined in DIN 58405 .......................... II-657
23.1.9 Automatic change of reference profiles .................................... II-658
23.1.10 Non-identical (mirrored symmetry) tooth flanks ...................... II-658
23.1.11 Internal teeth - differences in the reference profile if you select
different configurations .......................................................................... II-659
23.1.12 Effect of profile modifications .................................................. II-660
23.1.13 Number of teeth with common multiples .................................. II-661
23.1.14 Allowances for racks ................................................................. II-662
23.2 Answers to questions about strength calculation ...................................... II-663
23.2.1 Differences between different gear calculation programs ......... II-663

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23.2.2 Difference between cylindrical gear calculation following ISO 6336

or DIN 3990 ............................................................................................ II-663
23.2.3 Calculation using Methods B or C (DIN 3990, 3991)............... II-664
23.2.4 Required safeties for cylindrical gears ...................................... II-664
23.2.5 Insufficient scuffing safety ........................................................ II-665
23.2.6 Material pairing factor (strengthening an unhardened gear) ..... II-666
23.2.7 Defining the scoring load level (oil specification) .................... II-666
23.2.8 The influence of the face load factor KH for tooth trace deviation
fma is due to a manufacturing error. ....................................................... II-666
23.2.9 Load spectrum with changing torque ........................................ II-667
23.2.10 Strength calculation with several geometries on one gear ........ II-669
23.2.11 Bevel gears: Determine permitted overloads ......................... II-670
23.2.12 Take shot peening data into account in calculating the strength of
toothed gears ........................................................................................... II-671
23.2.13 Calculation according to AGMA 421.06 (High Speed Gears) .. II-672
23.2.14 Comparison of a FEM calculation with spiral-toothed gear wheel
calculation ............................................................................................... II-673
23.2.15 Estimate the strength of asymmetrical spur gear toothings ....... II-673
23.2.16 Determine the equivalent torque (for load spectra) ................... II-674
23.2.17 Check changes in safeties if the center distance changes .......... II-674
23.2.18 Warning: "Notch parameter qs . outside RANGE (1.0 to 8.0) ..."
II-675
23.3 Abbreviations used in gear calculation ..................................................... II-676

III Shafts and Bearings

III-683

24 Defining Shaf ts ............................................................................. III-684

24.1 Input window ........................................................................................... III-687
24.1.1 Shaft editor ............................................................................... III-687
24.1.2 Elements tree ............................................................................ III-689
24.1.3 Elements list ............................................................................. III-690
24.1.4 Elements editor ......................................................................... III-691
24.2 Element overview .................................................................................... III-692

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24.2.1 The Shaft element..................................................................... III-692

24.2.2 Outer contour............................................................................ III-697
24.2.3 Inner contour ............................................................................ III-704
24.2.4 Forces ....................................................................................... III-704
24.2.5 Bearing ..................................................................................... III-710
24.2.6 Connection elements ................................................................ III-713
24.2.7 Cross sections ........................................................................... III-715
24.3 Basic data ................................................................................................. III-716
24.3.1 Position of shaft axis in space .................................................. III-716
24.3.2 Number of eigenfrequencies .................................................... III-717
24.3.3 Number of buckling cases ........................................................ III-717
24.3.4 Speed ........................................................................................ III-717
24.3.5 Sense of rotation ....................................................................... III-718
24.3.6 Reference temperature.............................................................. III-718
24.3.7 Temperature of housing............................................................ III-719
24.3.8 Lubricant temperature .............................................................. III-720
24.3.9 Load spectra ............................................................................. III-720
24.3.10 Gears......................................................................................... III-721
24.3.11 Rolling bearings ....................................................................... III-721
24.3.12 Tolerance field.......................................................................... III-722
24.3.13 Modified rating life according ISO 281 ................................... III-724
24.3.14 Consider weight........................................................................ III-725
24.3.15 Consider gyroscopic effect ....................................................... III-725
24.3.16 Housing material ...................................................................... III-725
24.3.17 Lubrication ............................................................................... III-725
24.3.18 Impurity .................................................................................... III-725
24.4 Module specific settings .......................................................................... III-727
24.4.1 Non-linear shaft ........................................................................ III-727
24.4.2 Take into account deformation due to shearing and shear correction
coefficient .............................................................................................. III-728
24.4.3 Activate offset of load center point .......................................... III-728
24.4.4 Use 2013 solver ........................................................................ III-729
24.4.5 Standard radius at shoulder ...................................................... III-729

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24.4.6 Node density ............................................................................. III-729

24.4.7 Iterative calculation of load distribution................................... III-730
24.4.8 Input different load cycles for bending and torsion (for finite life
calculations) ........................................................................................... III-730
24.4.9 Axial clearance ......................................................................... III-730
24.4.10 Failure probability .................................................................... III-731
24.4.11 Required service life................................................................. III-731
24.4.12 Maximum service life coefficient............................................. III-731
24.4.13 Display critical bearing ............................................................ III-731
24.4.14 Surface roughness of housing................................................... III-732
24.4.15 Calculation method for friction ................................................ III-732
24.4.16 Oil level .................................................................................... III-732
24.4.17 Type of oil lubrication .............................................................. III-733
24.4.18 Moment of friction, seals.......................................................... III-733
24.4.19 Bearing manufacturer ............................................................... III-733
24.4.20 Show coordinate system ........................................................... III-733
24.4.21 Show automatic dimensioning ................................................. III-733
24.4.22 Equivalent stress for sizings ..................................................... III-734
24.4.23 Maximum deflection for sizings ............................................... III-734
25 Calculating Shafts ....................................................................... III-735
25.1 Deflection and Bearing Forces, Distribution and Force of Torque ......... III-737
25.1.1 Calculating force on bearings with a contact angle .................. III-739
25.2 Eigenfrequency ........................................................................................ III-742
25.2.1 Bending critical speed .............................................................. III-743
25.2.2 Torsion critical speed ............................................................... III-743
25.3 Buckling................................................................................................... III-744
25.4 Strength .................................................................................................... III-745
25.4.1 Calculation method................................................................... III-746
25.4.2 Type of calculation ................................................................... III-751
25.4.3 Service life................................................................................ III-753
25.4.4 Strength parameters in accordance with Hnchen and Decker III-753
25.4.5 Strength parameters in accordance with FKM ......................... III-754

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25.4.6 Strength parameters in accordance with DIN ........................... III-756

25.4.7 Strength parameter according to AGMA ................................. III-757
25.4.8 Stress ........................................................................................ III-759
25.4.9 Stress ratio ................................................................................ III-759
25.4.10 Load factor for static analysis .................................................. III-760
25.4.11 Load factor for endurance calculation ...................................... III-760
25.4.12 Cross sections ........................................................................... III-761
25.4.13 Sizing........................................................................................ III-763
25.4.14 Cross-section types ................................................................... III-763
25.4.15 General entries.......................................................................... III-769
25.5 Tooth trace modification.......................................................................... III-770
25.6 Campbell diagram.................................................................................... III-773
26 Bearing calculation G eneral ....................................................... III-775
26.1 Classification of bearings ........................................................................ III-776
26.1.1 Properties.................................................................................. III-776
27 Roller bearing ................................................................................ III-778
27.1 Selecting the type of roller bearing .......................................................... III-779
27.1.1 Properties of the most important bearing types ........................ III-779
27.1.2 Comparing types ...................................................................... III-781
27.2 Load capacity of roller bearings .............................................................. III-784
27.2.1 Dynamic load capacity ............................................................. III-784
27.2.2 Permissible static stress ............................................................ III-784
27.2.3 Bearing calculation with inner geometry ................................. III-785
27.3 Thermally permissible service speed ....................................................... III-786
27.3.1 Thermal reference speed .......................................................... III-786
27.3.2 Process for calculating thermally permitted operating speed (DIN
732-2) III-788
27.4 Moment of friction................................................................................... III-790
27.4.1 Calculation according to SKF Catalog 2004 ............................ III-790
27.4.2 Calculation in accordance with SKF Catalog 1994 .................. III-792
27.5 Maximum Speeds .................................................................................... III-794

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27.6 Service life ............................................................................................... III-795

27.6.1 Extended service life calculation in accordance with Supplement to
DIN ISO 281 (2007) .............................................................................. III-795
27.6.2 Service life calculation with load spectra ................................. III-796
27.7 Failure probability ................................................................................... III-798
27.8 Bearings with radial and/or axial force ................................................... III-798
27.9 Calculating axial forces on bearings in face-to-face or back-to-back
arrangements .................................................................................................... III-799
27.10

Oil level and Lubrication type ......................................................... III-801

27.11

EHL lubricant film thickness and spin to roll ratio. ......................... III-802

28 Roller Bearing s (Inner Geometry) ............................................. III-803

28.1 Bearing data tab ....................................................................................... III-804
28.1.1 File interface ............................................................................. III-804
28.1.2 Bearing data.............................................................................. III-806
28.2 Load tab ................................................................................................... III-809
28.2.1 Load.......................................................................................... III-809
28.2.2 Enhanced service life calculation in accordance with ISO 281 III-809
28.3 Graphics ................................................................................................... III-811
28.3.1 Load distribution ...................................................................... III-811
28.3.2 Pressure curve .......................................................................... III-811
28.3.3 Stiffness curve .......................................................................... III-813
28.3.4 Pressure curve for each rolling body ........................................ III-814
29 Hydrodynamic plain radial bearing .......................................... III-815
29.1 Calculation methods ................................................................................ III-816
29.2 Module-specific inputs ............................................................................ III-817
29.3 Thermal expansion coefficients ............................................................... III-818
29.4 Average surface pressure ......................................................................... III-819
29.5 Lubrication arrangement ......................................................................... III-819
29.6 Heat transfer surface ............................................................................... III-823
29.7 Heat transfer coefficient ......................................................................... III-823
29.8 Oil temperatures ...................................................................................... III-823

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29.9 Sizing the bearing clearance ................................................................... III-823

29.10

Sommerfeld number ........................................................................ III-824

29.11

Bearing width .................................................................................. III-824

29.12

Permissible thickness of lubrication film ......................................... III-825

30 Hydrodynamic plain thrust bearing .......................................... III-826

30.1 Calculation ............................................................................................... III-829
30.2 Sizings ..................................................................................................... III-830
30.3 Calculation of volume-specific heat ........................................................ III-831
30.4 Limiting values in the calculation ............................................................ III-832
31 Answers to Frequently Asked Questions .................................. III-833
31.1 Intersecting notch effects ......................................................................... III-834
31.2 Notch effects on hollow shafts................................................................. III-835
31.2.1 Notches on the outer contour.................................................... III-835
31.2.2 Notches on the inner contour.................................................... III-835
31.3 Fatigue Limits for New Materials ............................................................ III-836
31.4 Taking double helical gearing into account in the shaft calculation ........ III-837

IV Connections

IV-838

32 Cylindrical interference fit ........................................................ IV-839

32.1 Inputting Tolerances ................................................................................IV-842
32.2 Coefficients of friction .............................................................................IV-843
32.3 Variable hub external diameter ................................................................IV-845
32.4 Convert external pressure with multiple interference fit .........................IV-846
32.5 Materials ..................................................................................................IV-847
32.6 Settings ....................................................................................................IV-848
32.7 Sizings .....................................................................................................IV-850
33 Conical interf erence fit ............................................................... IV-851
33.1 Calculation ...............................................................................................IV-853

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33.2 Application factor ....................................................................................IV-854

33.3 Axial spanning with nut ...........................................................................IV-855
33.4 Variable external diameter of the hub......................................................IV-857
33.5 Conicity ...................................................................................................IV-858
33.6 Materials ..................................................................................................IV-859
33.7 Settings ....................................................................................................IV-860
33.8 Sizings .....................................................................................................IV-861
34 Clamped connections ................................................................. IV-862
34.1 Calculations ............................................................................................IV-863
34.2 Sizings ....................................................................................................IV-864
34.3 Settings ...................................................................................................IV-864
34.4 Materials .................................................................................................IV-865
35 Key................................................................................................... IV-866
35.1 Main screen..............................................................................................IV-868
35.1.1 Additional inputs for DIN 6892 Method B ..............................IV-869
35.2 Application factor ....................................................................................IV-871
35.3 Load factor ...............................................................................................IV-873
35.4 Own inputs ...............................................................................................IV-874
35.5 Permissible pressure ................................................................................IV-875
35.6 Materials ..................................................................................................IV-876
35.7 Settings ....................................................................................................IV-877
35.8 Sizings .....................................................................................................IV-878
36 Spline shaft .................................................................................... IV-879
36.1 Standard profiles ......................................................................................IV-880
36.2 Application factor ....................................................................................IV-881
36.3 Torque curve/Frequency of change of load direction ..............................IV-882
36.4 Occurring flank pressure..........................................................................IV-883
36.5 Length factor ............................................................................................IV-884
36.6 Share factor ..............................................................................................IV-885
36.7 Permissible pressure ................................................................................IV-886

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36.8 Materials ..................................................................................................IV-887

36.9 Settings ....................................................................................................IV-888
36.10

Sizings ..............................................................................................IV-889

37 Spline (strength) .......................................................................... IV-890

37.1 Standard profiles ......................................................................................IV-891
37.2 Application factor ....................................................................................IV-893
37.3 Torque curve/Frequency of change of load direction ..............................IV-894
37.4 Occurring flank pressure..........................................................................IV-895
37.5 Length factor ............................................................................................IV-896
37.6 Share factor ..............................................................................................IV-897
37.7 Permissible pressure ................................................................................IV-898
37.8 Materials ..................................................................................................IV-899
37.9 Settings ....................................................................................................IV-900
37.10

Sizings ..............................................................................................IV-901

38 Spline (geometry and strength) ................................................ IV-902

38.1 Underlying principles of calculation........................................................IV-903
38.1.1 General .....................................................................................IV-903
38.1.2 Calculation of spline connections as described in DIN 5480 with
diameter centering .................................................................................IV-903
38.2 Basic data .................................................................................................IV-905
38.2.1 Geometry standards ..................................................................IV-905
38.2.2 Normal module .........................................................................IV-906
38.2.3 Pressure angle at normal section an .........................................IV-906
38.2.4 Number of teeth ........................................................................IV-907
38.2.5 Profile shift coefficient .............................................................IV-907
38.2.6 Quality ......................................................................................IV-908
38.2.7 Geometry details ......................................................................IV-909
38.2.8 Strength calculation method .....................................................IV-910
38.2.9 Application factor .....................................................................IV-910
38.2.10 Resulting shearing force ...........................................................IV-911
38.2.11 Define details of strength .........................................................IV-912

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38.2.12 Materials ...................................................................................IV-915

38.3 Tolerances ................................................................................................IV-916
38.3.1 Tooth thickness tolerance .........................................................IV-916
38.3.2 Effective/Actual .......................................................................IV-917
38.3.3 Ball/pin diameter shaft/hub ......................................................IV-918
38.4 Templates.................................................................................................IV-919
38.5 Tooth form ...............................................................................................IV-921
39 Polygon ........................................................................................... IV-922
39.1 Standard profiles ......................................................................................IV-923
39.2 Application factor ....................................................................................IV-924
39.3 Torque curve/Frequency of change of load direction ..............................IV-925
39.4 Occurring flank pressure..........................................................................IV-926
39.5 Permissible pressure ................................................................................IV-928
39.6 Materials ..................................................................................................IV-929
39.7 Settings ....................................................................................................IV-930
39.8 Sizings .....................................................................................................IV-931
39.9 Graphics ...................................................................................................IV-932
40 Woodruff Key ................................................................................. IV-933
40.1 Standard profiles ......................................................................................IV-934
40.2 Application factor ....................................................................................IV-936
40.3 Torque curve/Frequency of change of load direction ..............................IV-937
40.4 Occurring flank pressure..........................................................................IV-938
40.5 Length factor ............................................................................................IV-939
40.6 Share factor ..............................................................................................IV-940
40.7 Permissible pressure ................................................................................IV-941
40.8 Materials ..................................................................................................IV-942
40.9 Settings ....................................................................................................IV-943
40.10

Sizings ..............................................................................................IV-944

41 Bolts and pins ............................................................................... IV-945

41.1 Influence factors ......................................................................................IV-947

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41.2 Materials ..................................................................................................IV-948

41.3 Settings ....................................................................................................IV-949
41.4 Permitted values.......................................................................................IV-950
41.5 Sizings .....................................................................................................IV-951
42 Bolts ................................................................................................ IV-952
42.1 Special features in KISSsoft ....................................................................IV-954
42.2 Basic data inputs ......................................................................................IV-955
42.2.1 Operating data ..........................................................................IV-955
42.2.2 Bolt data ...................................................................................IV-966
42.2.3 Type of bolted joint ..................................................................IV-970
42.2.4 Washers ....................................................................................IV-971
42.2.5 Extension sleeves without external forces ................................IV-972
42.2.6 Tightening technique ................................................................IV-972
42.3 Clamped parts inputs ...............................................................................IV-974
42.3.1 Geometry of clamped parts ......................................................IV-974
42.3.2 Distances for eccentric clamping/load .....................................IV-977
42.3.3 Load application .......................................................................IV-977
42.4 Constraints data ......................................................................................IV-978
42.4.1 Technical explanations ............................................................IV-980
42.4.2 Coefficients of friction ............................................................IV-981
42.4.3 Angle of rotation-controlled tightening ...................................IV-982
42.5 Stripping strength ....................................................................................IV-983
42.6 Settings ....................................................................................................IV-984
43 Welded joints ................................................................................ IV-988
43.1 Welded joints ...........................................................................................IV-989
43.2 Seam length .............................................................................................IV-991
43.3 Welded seam equivalent stress ................................................................IV-992
43.4 Weld seam boundary stress .....................................................................IV-993
43.5 Part safety coefficient ..............................................................................IV-994
43.6 Boundary safety coefficient .....................................................................IV-995
43.7 Materials ..................................................................................................IV-996

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44 Glued and soldered joints ........................................................... IV-997

44.1 Basic materials .........................................................................................IV-999
44.2 Settings ..................................................................................................IV-1000
44.3 Sizings ...................................................................................................IV-1001
44.4 Bracket connection ................................................................................IV-1002
44.5 Shaft connections ...................................................................................IV-1003
45 Retaining ring s (self -locking rings, Seeger rings) .............. IV-1004
45.1 Basic data ...............................................................................................IV-1005
45.2 Automatic calculation of load factor q ..................................................IV-1007
45.3 Automatic calculation of the dishing angle ........................................IV-1008
45.4 Module specific settings ........................................................................IV-1009
46 Answers to Frequently Asked Questions ................................. IV-1010
46.1 Adding new bolt types to the database ..................................................IV-1011
46.1.1 Extending an existing bolt series ............................................IV-1011
46.1.2 Creating a new bolt type .........................................................IV-1013

V Springs

V-1014

47 Compression sp ring s .................................................................. V-1015

47.1 Strength values ....................................................................................... V-1016
47.2 Shear stress values ................................................................................. V-1016
47.3 Bearings coefficient ............................................................................... V-1017
47.4 Materials ................................................................................................ V-1017
47.5 Tolerances .............................................................................................. V-1018
47.6 Relaxation ............................................................................................... V-1019
47.7 Drawing data .......................................................................................... V-1020
47.8 Sizings ................................................................................................... V-1020
48 Tension sp ring s ............................................................................. V-1021
48.1 Strength values ....................................................................................... V-1022

Inhalt

48.2 Shear stress values ................................................................................. V-1022

48.3 Manufacturing type ................................................................................ V-1023
48.4 Eyes screen ............................................................................................ V-1023
48.5 Materials ................................................................................................ V-1025
48.6 Settings .................................................................................................. V-1026
48.7 Tolerances .............................................................................................. V-1026
48.8 Relaxation ............................................................................................... V-1027
48.9 Drawing data .......................................................................................... V-1028
48.10

Sizings ............................................................................................. V-1029

49 Leg springs .................................................................................... V-1030

49.1 Strength values ....................................................................................... V-1031
49.2 Bending stress values ............................................................................. V-1032
49.3 Spring design ......................................................................................... V-1032
49.4 Assumptions made for the calculation ................................................... V-1033
49.5 Materials ................................................................................................ V-1033
49.6 Tolerances .............................................................................................. V-1034
49.7 Drawing data .......................................................................................... V-1034
49.8 Sizings .................................................................................................... V-1035
50 Disc spring s .................................................................................. V-1036
50.1 Strength values ....................................................................................... V-1037
50.2 Stress values ........................................................................................... V-1037
50.3 Materials ................................................................................................ V-1038
50.4 Calculate number ................................................................................... V-1039
50.5 Limit dimensions .................................................................................... V-1040
51 Torsion -bar springs ...................................................................... V-1041
51.1 Head forms ............................................................................................. V-1043
51.2 Strength values ....................................................................................... V-1043
51.3 Shear stress ............................................................................................ V-1044
51.4 Limiting values ...................................................................................... V-1044
51.5 Sizings .................................................................................................... V-1045

Inhalt

VI Belts and chain drives

VI-1046

52 V-belt ............................................................................................. VI-1047

52.1 V-belts data ............................................................................................VI-1048
52.2 V-belt standards .....................................................................................VI-1048
52.3 Configuring Tensioning Pulleys ............................................................VI-1049
52.4 Application factor f1 ..............................................................................VI-1049
52.5 Center distance.......................................................................................VI-1049
52.6 Belt length..............................................................................................VI-1050
52.7 Effective number of V-belts ..................................................................VI-1050
52.8 Tensioning pulley diameter ...................................................................VI-1050
52.9 Position of tensioning pulley (x/y).........................................................VI-1051
52.10

Inspecting V-belts ..........................................................................VI-1052

53 Toothed belts .............................................................................. VI-1053

53.1 Technical notes (toothed belts) .............................................................VI-1054
53.2 Toothed belt standard ...........................................................................VI-1055
53.3 Possible Sizings/Suggestions .................................................................VI-1056
53.4 Configuring Tensioning pulleys ............................................................VI-1056
53.5 Application factor and summand for operational behavior ...................VI-1057
53.6 Center distance.......................................................................................VI-1057
53.7 Belt length and number of teeth on belt .................................................VI-1058
53.8 Effective belt width................................................................................VI-1058
53.9 Tensioning pulley tooth number ...........................................................VI-1058
53.10

Position of the tensioning pulley x/y..............................................VI-1060

54 Chain drives ................................................................................. VI-1061

54.1 Sizings ...................................................................................................VI-1061
54.2 Tensioning pulleys .................................................................................VI-1062
54.3 Standard .................................................................................................VI-1062
54.4 Chain type ..............................................................................................VI-1062
54.5 Number of strands..................................................................................VI-1062
54.6 Application factor ..................................................................................VI-1063

Inhalt

54.7 Speed/number of teeth/transmission ratio..............................................VI-1063

54.8 Configuration ........................................................................................VI-1063
54.9 Center distance ......................................................................................VI-1064
54.10

Polygon effect ................................................................................VI-1064

54.11

Number of links .............................................................................VI-1065

54.12

Geometry of chain sprockets..........................................................VI-1066

VII Automotive

VII-1067

55 Synchronization ......................................................................... VII-1067

55.1 Geometry ............................................................................................. VII-1068
55.2 Operating data...................................................................................... VII-1069
56 Friction clutches ...................................................................... VII-1069
56.1 Calculation ........................................................................................... VII-1072
56.2 Definition of spring forces ................................................................... VII-1075
56.3 Definition coefficients of sliding friction and velocities ..................... VII-1076
56.4 Graphics ............................................................................................... VII-1077
56.5 Settings ................................................................................................ VII-1078

VIII Various

VIII-1079

57 Tolerance calculation ............................................................. VIII-1080

58 Strength verification with local stresses .......................... VIII-1081
58.1 General................................................................................................ VIII-1082
58.1.1 Functionality of the software ............................................... VIII-1082
58.1.2 Areas of application for the FKM guideline........................ VIII-1082
58.2 Background ......................................................................................... VIII-1084
58.2.1 The FKM Guideline: Rechnerischer Festigkeitsnachweis fr
Maschinenbauteile ............................................................................ VIII-1084
58.2.2 Usefulness of the service life calculation ............................ VIII-1084

Inhalt

58.3 Implementation in KISSsoft ............................................................... VIII-1088

58.3.1 Main screen ......................................................................... VIII-1088
58.3.2 Load cases ........................................................................... VIII-1090
58.3.3 Woehler line ........................................................................ VIII-1090
58.3.4 Number of load cycles......................................................... VIII-1090
58.3.5 Temperature ........................................................................ VIII-1091
58.3.6 Temperature duration .......................................................... VIII-1091
58.3.7 Protective layer thickness, aluminum, chapter 4.3.4, Figure 4.3.4
VIII-1091
58.3.8 Stress ratios ......................................................................... VIII-1091
58.3.9 Spectra ................................................................................. VIII-1093
58.3.10 Surface factor KV, section 4.3.3, Table 4.3.7 ..................... VIII-1093
58.4 Materials ............................................................................................. VIII-1094
58.4.1 Surface roughness ............................................................... VIII-1094
58.4.2 Settings ................................................................................ VIII-1095
59 Hertzian pressure ..................................................................... VIII-1100
59.1 Settings ............................................................................................... VIII-1102
60 Hardness conversion ............................................................... VIII-1103
61 Linear drive train ..................................................................... VIII-1104
61.1 Calculation .......................................................................................... VIII-1107
61.2 Sizings ................................................................................................ VIII-1112
61.3 Settings .............................................................................................. VIII-1112
61.4 Materials ............................................................................................. VIII-1113

IX KISSsys

IX-1115

62 KISSsys: Calculation S ystems .................................................... IX-1116

62.1 General...................................................................................................IX-1117
62.1.1 Structure of KISSsys ..............................................................IX-1117

Inhalt

62.1.2 Ways in which KISSsys can be used......................................IX-1117

62.2 The user interface ..................................................................................IX-1119
62.2.1 Tree view ................................................................................IX-1119
62.2.2 Diagram view .........................................................................IX-1120
62.2.3 Table view ..............................................................................IX-1120
62.2.4 3D view ..................................................................................IX-1121
62.2.5 Message output .......................................................................IX-1121
62.2.6 Menus, context menus and the Tool Bar ................................IX-1122
62.3 Creating Models in KISSsys ..................................................................IX-1123
62.3.1 Classic method .......................................................................IX-1124
62.3.2 Element Assistant ...................................................................IX-1125
62.3.3 System Assistant ....................................................................IX-1126
62.3.4 Setup with icon .......................................................................IX-1126
62.3.5 Creating and modifying tables ...............................................IX-1127
62.3.6 Adding variables in tables ......................................................IX-1128
62.3.7 Individual names for elements ...............................................IX-1130
62.4 Extended functionality for developers ...................................................IX-1131
62.4.1 Properties dialog .....................................................................IX-1131
62.4.2 Table view ..............................................................................IX-1132
62.5 The existing elements ............................................................................IX-1134
62.5.1 Variables.................................................................................IX-1134
62.5.2 Calculation elements ..............................................................IX-1135
62.5.3 Elements for shafts .................................................................IX-1137
62.5.4 Connection elements ..............................................................IX-1138
62.5.5 Displaying elements in 3D graphics .......................................IX-1139
62.5.6 System settings .......................................................................IX-1140
62.6 Programming in the Interpreter..............................................................IX-1141
62.6.1 Expressions in variables .........................................................IX-1141
62.6.2 Functions ................................................................................IX-1142
62.6.3 Important service functions ....................................................IX-1144
62.6.4 Variable dialogs......................................................................IX-1144
62.6.5 Defining 2D graphics .............................................................IX-1153
62.7 Specific functionalities ..........................................................................IX-1156

Inhalt

62.7.1 Load Spectrum Calculation ....................................................IX-1156

62.7.2 Efficiency Calculation ............................................................IX-1157
62.7.3 Taking into account housing deformation in static KISSsys
calculations ..........................................................................................IX-1158
62.7.4 Modal analysis of shaft systems .............................................IX-1161

X Bibliography and Index

X-1163

63 Bibliography ................................................................................... X-1164

XI Index

XI-1171

I Gener al

Part

General

Chapter 1

I-41

Installing KISSsoft

Insta lli ng KISSso ft

Chapter 1
Installing KISSsoft

Chapter 1

I-42

Installing KISSsoft

1.1

Basic installation

After you have inserted the KISSsoft CD in the appropriate disk drive, the setup
program starts automatically. If it does not, you can run the setup.exe file directly
in the CD root directory by double-clicking on it.
The setup program guides you through the installation process step by step. All you
need to do is select an installation folder and the required language for the installation. If you change the default installation folder, it is advisable to include the version descriptor as part of the directory name of the other installation folder (e.g.
C:/Programs/KISSsoft xx-20xx).
At the end of the installation we recommend that you install the latest Service Pack
(patch). Download the latest patch http://www.kisssoft.ch/patches.php from our
website. You can choose between an installation program (*.exe) and zipped files
(*.zip). The installation program automatically copies the necessary files after you
specify which installation folder it is to use. However, not all companies permit exe
files to be downloaded. In this case, you must unpack the ZIP file and manually
copy the files it contains into your installation folder. Any files that are already
present must be overwritten by the ones contained in the patch.
After you have installed KISSsoft you need to license (see page I-44) it. If
KISSsoft is not licensed, it will only run as a demo version.
NOTE:

If you are installing KISSsoft on a server, we recommend that you perform the installation from a client (workstation computer). Consequently, all necessary directory entries will automatically be added to the KISS.ini (see page I-53) file
correctly. Otherwise, you will have to change these directory entries from the local
drive name (e.g. C:/...) to the appropriate share name in the network, later,
manually, using an editor.

Chapter 1

I-43

Installing KISSsoft

1.2

Downloading a license file

1. Go to our website, www.KISSsoft.ch, and click on the Service/Support page link on the left. There, you will find a link to the "customer zone". Click
on the link. You will see the Customer Zone web page. In that page, on the
top right-hand side, enter your license number in the License Number field,
and click on "Open".
2. A login window will open, in which you enter your license number, and also your download password, again. If you do not have this password, please get in touch with your commercial contact representative or contact directly KISSsoft via email on info@KISSsoft.CH or phone number +41 55
254 20 53.
3. You are now in your personal download area. Save the lizenzxxxx.lic file
in the license directory of your KISSsoft installation.

NOTE:

It may be that your personal download area contains license files for different versions of KISSsoft. Please make sure you select the correct license file for the system version you have just installed.

Chapter 1

I-44

Installing KISSsoft

1.3

Licensing

After you have performed the KISSsoft Installation (see page I-42) you must license the software either by downloading a license file or activating the program's
license. Please read the relevant section for your license type.

1.3.1

Test version

1. If you start KISSsoft from the client (workstation computer), the user account for the test version will become active.
2. Select License tool in the Extras menu and click on the Activate license tab.
3. Activate online: If your computer has Internet access, and you have received an online code from us, enter this code under the Release Test
or Student version option and then click on Activate license.
4. Direct activation: Under the Activate test version by phone
option you see a question code. Call the telephone number you see there
and tell us this code. We will then give you the appropriate answer code.
Input this in the corresponding field and click the Activate license
tab.

1.3.2

Student version

1. Copy your license file (you will usually be given this by your high school)
to your License directory (see page I-54).
2. Select License tool in the Extras menu and click on the Activate license tab.
3. Input your online code (which you will also be given by your high school)
under the Activate test or student version option and click
on Activate license tab.

1.3.3

Single user version with dongle (protection

key)

1. Copy your license file (see page I-43) to your license directory (see page
I-54).
2. Now, simply plug in the dongle supplied with the system.
NOTE

Chapter 1

I-45

Installing KISSsoft

The single user version of KISSsoft can also be installed on a central server. Local
clients (workstation computers) can then run the software directly from this server.
Please note here that the dongle must always be plugged into each particular client.

1.3.4

Single user version with license code

1. Start KISSsoft from the client (workstation computer) for which the software is to be licensed.
2. Select License tool in the Extras menu and click on the Activate license tab.
3. Enter your contact data under the Request license file option and
click on Send to send your computer-specific access data directly to us.
Alternatively, you can first save this access data in a file and then send us
this file by email.
4. You will receive an email as soon as we have created your license file.
5. Download your License file (see page I-43) and copy it to your License directory (see page I-54).

1.3.5

Network version with dongle (protection key)

For the network version with dongle a server program has to be installed in addition to the licensing of the KISSsoft installation.

1.3.5.1
Inst all ation on the se rver
1. Copy the KISSsoft dongle/MxNet installation directory onto a server.

2. Start MxNet32 on the server. You will see a dongle icon in the task bar.
3. Double-click this icon to start the user interface.
4. Now enter Application: KISSsoft and any file with the file extension
*.mx as the server file. The clients must have both read and write access to this file. Now click New Entry to add this entry.
5. Then click the Active Users button to check who is using KISSsoft.
You can also reactivate a license that has already been used.

Chapter 1

I-46

Installing KISSsoft

1.3.5.2
Licensing the KISSsoft syste m.
1. Copy your license file (see page I-43) to your license directory (see page
I-54).

2. Complete the necessary details in the "ServerFile: serverfilepath" line after

the checksum line in the license file. The "serverfilepath" is the path to the
server file that is defined in the server program.
NOTE

The KISSsoft installation will also run if the client is not connected to the network
and if the dongle is inserted in the client instead of in the server. You can also
"check out" the license if you remove the dongle.

1.3.6

Network version with the license code

1. Start KISSsoft from a client (workstation computer).

2. Select License tool in the Extras menu and go to the General tab.
3. Select an access directory on a server. Please note: If you change this, you
will need a new license.
4. Go to the Activate license tab.
5. Enter your contact data under the Request license file option and
click on Send to send your computer-specific access data directly to us.
Alternatively, you can first save this access data in a file and then send us
this file by email.
6. You will receive an email as soon as we have created your license file.
7. Download your License file (see page I-43) and copy it to your License directory (see page I-53).

Chapter 2

I-47

Setting Up KISSsoft

Settin g Up KISSso ft

Chapter 2
Setting Up KISSsoft

Chapter 2

I-48

Setting Up KISSsoft

2.1

Directory structure

If there are several users it is advisable to store shared data (databases, userdefined report templates and standard files) on one server. This ensures that, if
there are changes and upgrades, all users will be able to work with one uniform set
of data. To set this up, move the KDB, EXT and TEMPLATE directories onto a
server that can be accessed by all users, and then tailor the corresponding variables,
KDBDIR, EXTDIR and TEMPLATEDIR, in the KISS.ini (see page I-53) file.
In contrast, the temporary directories should be defined locally on the workstations
for several users. Otherwise, the interim results of individual users might overwrite
each other. For each installation, KISSsoft uses the temporary user directory in
accordance with the operating system. The CADDIR and TEMPDIR variables can,
however, be tailored in the KISS.ini (see page I-53) file.
If you want to open or save a calculation file or a report, KISSsoft offers you your
personal User directory as the first choice storage location. This property saves
you frequent searches in the directories on your system. You can define this user
directory via the USERDIR variable in the KISS.ini (see page I-53) file. The user
directory will be ignored if you have selected an Active working project (see page
I-96). In this case, KISSsoft offers you the project directory as the first choice storage location.

Chapter 2

I-49

Setting Up KISSsoft

2.2

Language settings

KISSsoft is available in seven languages: English, German, French, Italian,

Spanish, Russian and Portuguese. When you select a language, the program
differentiates between the language used for the user interface and the language
used for the reports. It is therefore possible to operate KISSsoft in one language
and to simultaneously display reports in a different language. Messages will be
displayed either in the same language as the user interface or as the reports.
For global language settings, you need to edit the KISS.ini file (see page I-54).
Additionally, you can also quickly toggle between languages in the program by
selecting Extras > Language, and then the required language. The user can
change the language used for reports by selecting Report > Settings.

Chapter 2

I-50

Setting Up KISSsoft

2.3

System of units

KISSsoft recognizes two unit systems: the metric system and the US Customary
Units system. For global language settings, you need to edit the KISS.ini file (see
page I-54). You can also quickly toggle between systems of units in the program
by selecting Extras > System of units. In addition to changing the system of units, it is possible to switch the unit used for a particular value input field
(see page I-89).

Chapter 2

I-51

Setting Up KISSsoft

2.4

Defining your own default files

Anyone who frequently carries out the same, or at least similar, calculations has to
repeatedly enter the same values into selection lists and value input fields. Thanks
to default files, KISSsoft makes your work considerably easier here. For each
calculation module, there is an internal default setting for all values. If, however,
you have defined your own default file, this default file will be used when you
open a calculation module or load a new file.
To define a default file, you open a new file in the corresponding calculation module and enter your default settings. Click File > Save as template to
transfer your values to the template file. All template files will be saved in the directory that has been defined as TEMPLATEDIR (see page I-53).
Default files can also be defined as project-specific. To define special standards for
a project (see page I-93), select this project in the project tree (see page I-75) and
open its properties by selecting Project > Properties. There, select Use
own templates for this project and specify a directory for the default
files. To define the default files you must select this project as the Active working
project (see page I-96).

Chapter 2

I-52

Setting Up KISSsoft

2.5

Rights

You can restrict the rights for selected areas of KISSsoft for some users.
Right

Implementation

Changes to the general settings

Write protect the KISS.ini (see page I-53) file

Changes or additions in the databases

Write protect databases (files of the type *.kdb) as well as

the directories DAT and EXT/DAT (but write rights for
KDBDIR (see page I-53) should be retained)

Changes to the report templates

Write protect RPT, EXT/RPT and EXT/RPU directories

Changes to the template files

Write protect the TEMPLATE directory

Chapter 2

I-53

Setting Up KISSsoft

2.6

Global settings - KISS.ini

Global settings for KISSsoft are defined in the KISS.ini file, which is located
directly in the installation folder. Most of these settings can also be defined directly
in the software and are then saved to the KISS.ini file.

2.6.1

Definitions in [PATH]

Variable name

Explanation

Note

KISSDIR=<INI
DIR>

The KISSsoft installation folder is

generally defined with the INIDIR
variable.

HELPDIR

Directory for user manual and help

figures

DATADIR

Directory for files of the type *.dat

Attention: You should not carry out any

upgrades or make any changes in this directory. Save your own files in the DAT subdirectory in the EXTDIR.

RPTDIR

Directory for report templates (*.rpt)

Attention: You should not carry out any

upgrades or make any changes in this directory. Save your own files in the RPT subdirectory in the EXTDIR (described below).

USERDIR

Default directory for opening and

saving

CADDIR

Default directory for CAD export

Should be located locally on a workstation.

%TEMP% sets the temporary directory to
the operating system default.

TMPDIR

Directory for temporary files

Should be located locally on a workstation.

%TEMP% sets the temporary directory to
the operating system default.

KDBDIR

Directory for KISSsoft's databases

(*.kdb)

If several users are using the system, we

recommend you store the databases on one
server to ensure data uniformity if there are
changes and upgrades.

EXTDIR

Directory for user-defined report

templates and additional DAT files

If there are several users, it is advisable to

store this directory on one server.

TEMPLATEDIR

Directory for template files (STANDARD.*).

If there are several users, it is advisable to

store this directory on one server.

LICDIR

Directory for the license files

You can install this directory on one server

so that all the users can access the new license files.

Table 2.1: Table of variables used in the PATH environment

Chapter 2

I-54

Setting Up KISSsoft

NOTE

You should have write permission for the directories set in these variables:
TMPDIR, CADDIR, USRDIR and KDBDIR.
Depending on the configuration, you do not have write permission in the operating
system directory: C:\ Program Files\ <KISSsoft Directory Name> or C:\
Program Files\ <KISSsoft Name directory>. Any files you create are
then diverted to the operating system's internal directories. Here, please select
directories with write permission.
The TMPDIR, CADDIR, USERDIR and EXTDIR directories can also be defined
in the "Directories" tab, in the "Program settings" dialog (Extras->Settings).
You can also use JAVADIR to define the path to the java.exe here. You need this
file if you want to use Code_Aster (FEM) to calculate the deformation of planet
carriers due to torsion.

2.6.2

Definitions in [SETUP]

Variable name

Explanation

Values

USCUSTOMARYUNITS

Sets the system of units

0: metric, 1: US customary
units

MATERIALSSTANDARD

REPORTLANGUAGE

Specifies the standard in

which the materials are
defined (configuration tool)

0: DIN, 1: BS, 2: AISI, 3:

UNI, 4: AFNOR, 5: JIS, 6:

Sets the language in which

reports are displayed

0: German, 1: English, 2:
French, 3: Italian, 4: Spanish,
5: Russian, 6: Portuguese, 11:

CN

English with US Customary

Units

SHOWCALCTIME

Shows the calculation time

0: No, 1: Yes

SHOWPROGRESSBAR

Shows the progress bar for

time-intensive calculations

0: No, 1: Yes

DISPLAYLANGUAGE

Sets the language in which the

user interface is displayed

0: German, 1: English, 2:
French, 3: Italian, 4: Spanish,
5: Russian, 6: Portuguese.

DISPLAYFONTSIZE

Sets the font size in KISSsoft

(FONT)

0: System size, otherwise the

MESSAGESINREPORTLANGUAG
E

Sets the language in which

messages are displayed

0: as interface, 1: as reports

MESSAGESSHOWSTATE

Defines which messages are

to appear as a message box.

0: all, 1: Information only in

message window, 2: Informa-

direct font size

Chapter 2

I-55

Setting Up KISSsoft

tion and warnings only in message window

EDITOR

Path to the external editor

USEEXTERNALEDITOR

Defines whether the external

editor is to be used.

DATEFORMAT

Date format, e.g.

DD.MM.YYYY

TIMEFORMAT

Time format, e.g. hh.mm.ss

ENABLENETWORKING

Defines whether the network/Internet may be

accessed (for example, to display innovations).

0: No, 1: Yes

CHECKFORUPDATES

Defines whether the system is

to search for updates when the
program starts.

0: No, 1: Yes

USETEMPORARYDATABASE

Defines whether the databases

are to be copied to a
temporary directory when the
program starts

0: No, 1: Yes

RECENTFILESCOUNT

Number of most recently used

files in the File menu

FORCEEXCLUSIVEOPEN

Defines whether the files can

only be opened exclusively.

0: No, 1: Yes

CALCONOPEN

Defines whether calculations

are to be performed
immediately on a file when it
is loaded

0: No, 1: Yes, 2: no if

CALCINTERFACEOUT

Defines whether temporary

reports for manufacturing data
are to be written during the
calculation

0: No, 1: Yes

ENABLEUSERSETTINGS

Defines whether the settings

in kiss.ini can be overwritten
by local settings.

0: No, 1: Yes

USEFILEEXPLORER

Defines whether the Explorer

is to appear in the "View"
menu list. This process will
slow down KISSsoft
considerably.

0: No, 1: Yes

Table 2.2: Table of variables used in the SETUP environment

0: No, 1: Yes

KISSsoft. is started from

KISSsys, otherwise yes

Chapter 2

I-56

Setting Up KISSsoft

2.6.3

Definitions in [REPORT]

Variable name

Explanation

SIZE

Number 09 that specifies the length of the report

INCLUDEWARNINGS

0/1: Warnings are contained in the report

FONTSIZE

Number for the font size in the report

PAPERFORMAT

Paper format: A3, A4, A5, Letter, Legal

PAPERORIENTATION

0/1: Portrait/Landscape

PAPERMARGINLEFT

Distance from the left-hand page margin [mm]

PAPERMARGINRIGHT

Distance from the right-hand page margin [mm]

PAPERMARGINTOP

Distance from the top page margin [mm]

PAPERMARGINBOTTOM

Distance from the bottom page margin [mm]

COMPARE

0/1: Adds date/time to the report in comparison mode

SAVEFORMAT

04: RTF, PDF, DOC, DOCX, TXT

LOGO

Picture file displayed in the header and footer

HEADER

Definition of the header

USEHEADERFORALLPAGES

0/1: header only on first page/on all pages

FOOTER

Definition of the footer

USEFOOTERFORALLPAGES

0/1: footer only on first page/on all pages

Table 2.3: Table of variables used in the REPORT environment

2.6.4

Definitions in [GRAPHICS]

Variable name

Explanation

BACKGROUND

0: black, 15: white (for more information, see Graphics >

Settings)

Table 2.3b: Table of variables used in the GRAPHICS environment

2.6.5

Definitions in [LICENSE]

Variable name

Explanation

LOGGING

Number to activate the logging of license usage

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0: no log file
1: Log in, Log out, No license, Used and Missing rights
2: Log in, Log out, No license
3: Log in, Log out, No license, Missing rights
In network versions the user's uptime is also displayed in minutes when
they log out.

LICENSELOGFILE

*.log file for generating reports of license usage

TIMEOUT

Duration until an unused floating license is activated on the network again

[min]

Table 2.4: Table of variables used in the LICENSE environment

2.6.6

Definitions in [CADEXPORT]

Variable name

Explanation

USEDXFHEADER

0/1: DXF header will be used for DXF export

DXFVERSION

0/1: Version 12/15

INPUTLAYER

Name of the layer for import

OUTPUTLAYER

Name of the layer for export

DXFPOLYLINE

0/1/2: Uses polygonal course, lines or points for the export

Table 2.5: Table of variables used in the CADEXPORT environment

2.6.7

Definitions in [INTERFACES]

Variable name

Description

DEFAULT

Name of the CAD system:

SolidEdge
SolidWorks
Inventor
CATIA
ProEngineer
CoCreate
Think3 interface

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HiCAD

GEAREXPORT3D

Displays the CAD system name in lists (see DEFAULT)

SYMMETRIC

0/1: Full tooth space/half tooth space mirrored (symmetrical) (default = 0)

SAVEFILENAME

0/1: Saves the entire file contents/Saves only the file name and the path
(Default = 1)

Table 2.6: Table of variables used in the INTERFACES environment

2.6.8

Definitions in [SOLIDEDGE]

Variable name

Description

LIBRARY

Interface dll directory (kSoftSolidEdge.dll)

SMARTPATTERN

0/1: Fastpattern/Smartpattern

APPROXIMATION

1/2/3/4: Polygonal course (supported)/ Arcs (supported)/

Quadratic splines (supported) / Cubic splines (default)

Table 2.8: Table of variables used in the SOLIDEDGE environment

2.6.9

Definitions in [SOLIDWORKS]

Variable name

Description

LIBRARY

Interface dll directory (kSoftSolidWorks.dll)

SIMPLIFIEDPRESENTATIONNA
ME

Setting this variable generates a simplified gear with this name

APPROXIMATION

1/2/3/4: Polygonal course (supported)/ Arcs (supported)/

Quadratic splines (supported) / Cubic splines (default)

Table 2.9: Table of variables used in the SOLIDWORKS environment

2.6.10

Definitions in [INVENTOR]

Variable name

Description

LIBRARY

Interface dll directory (kSoftInventor.dll)

APPROXIMATION

1/2/3/4: Polygonal course ( supported)/Arcs (default)/ Quadratic splines

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(not supported)/Cubic splines (not supported)

Table 2.10: Table of variables used in the INVENTOR environment

2.6.11

Definitions in [CATIA]

Variable name

Description

LIBRARY

Interface dll directory (kSoftCatia.dll)

LIBRARYSWMS

Directory of the interface manufacturer's *.dll files

LANGUAGEFILE

Directory of the interface manufacturer's *.ini files

DEBUG

Interface manufacturer's variable

DEBUGPATH

Interface manufacturer's variable

HELPFILE

Interface manufacturer's variable

LASTSETTING_CONSTRUCTION

Interface manufacturer's variable

LASTSETTING_GEARNAME

Interface manufacturer's variable

LASTSETTING_PRODUCTIONINFO

Interface manufacturer's variable

LASTSETTING_CALCINFO

Interface manufacturer's variable

LASTSETTING_FLAGINFO

Interface manufacturer's variable

APPROXIMATION

1/2/3/4: Polygonal course (not supported)/Arcs (not supported)/

Quadratic splines (default)/ Cubic splines (not supported)

Table 2.11: Table of variables used in the CATIA environment

2.6.12

Definitions in [PROENGINEER]

The ProEngineer interface has an individual subsection/menu for each version (for
example, Wildfire 5, 32bit).
However, the definitions in "kiss.ini" are the same in every 3D interface to Creo
Parametric (ProEngineer) chapters.
Variable name

Explanation

LIBRARY

Interface dll directory (kSoftProEngineer.dll)

INTERFACECOMMAND

Directory containing the interface manufacturer's *.exe files

USCUSTOMARYUNITS

0/1: System of units used in the metric or US Customary Units model

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APPROXIMATION

1/2/3/4: Polygonal course (not supported)/arcs of circles (default)/quadratic splines (not supported)/cubic splines (not supported)

Table 2.12: Table of variables used in the PROENGINEER environment

2.6.13

Definition in [COCREATE]

Variable name

Explanation

LIBRARY

Interface dll directory (kSoftCoCreateCreo.dll)

INTERFACECOMMAND

Directory containing the interface manufacturer's *.exe files

APPROXIMATION

1/2/3/4: Polygonal course (not supported)/Arcs (not supported)/ Quadratic splines

(default)/ Cubic splines (not supported)

Table 2.13: Table of variables used in the COCREATE environment

2.6.14

Definitions in [THINK3]

Variable name

Description

LIBRARY

Interface dll directory (kSoftThink3.dll)

INTERFACECOMMAND

Directory of the interface manufacturer's *.exe files

APPROXIMATION

1/2/3/4: Polygonal course (not supported)/Arcs (default)/ Quadratic splines (not

supported)/Cubic splines (not supported)

Table 2.14: Table of variables used in the THINK3 environment

2.6.15

Definitions in [HICAD]

Variable name

Description

LIBRARY

Interface dll directory (kSoftHiCAD.dll)

APPROXIMATION

1/2/3/4: Polygonal course (not supported)/Arcs (default)/ Quadratic splines (not

supported)/Cubic splines (not supported)

Table 2.15: Table of variables used in the HICAD environment

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2.7

User-defined settings

User-defined settings can be reset via Extras > Configuration tool.

2.7.1

Configuration tool

In the General tab, you can select the older version's "kdb" database directory
(Update database option). Click "Run" to transfer the data records you have
defined yourself, in the older version, to the current version, to ensure these records
are available in the current version.
Click Update external data to select the "ext" directory of the older version. This then automatically copies the "dat", "rpt" and "rpu" subdirectories to the
current release.
Click Update settings to transfer your personal settings from the previous
version to the current release.
Select Connect file extensions to link all the KISSsoft files with the
current version so that you can double-click on any particular file to open it in the
current release.

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Figure <Kap3>.1: General tab in the Configuration tool window

In the Materials tab you can specify the standard with which the material
descriptions in the database are to comply.

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Figure <Kap3>.2: Materials tab in the Configuration tool window

In the Settings tab you can delete the user-defined settings (divided into
groups). This reloads the default values.

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Figure <Kap3>.3: Settings tab in the Configuration tool window

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2.8

Rules

Rules are used to ensure that in-house guidelines for the validity ranges of parameters are applied and adhered to. This typically concerns the maximum and minimum limits of input values, calculated values and the relationships between these
values i.e. length-width relationships, length-diameter relationships or even the
relationship between the module and the center distance.
These rules are defined by being stored in a <module>.rls file, where <module>
stands for the in-house labeling of the calculation module, e.g. Z012 for cylindrical
gear pairs.
These rules are subdivided into those that must be fulfilled before the calculation is
performed and those that must be checked afterwards. If a rule is infringed, the
appropriate messages can be displayed. In the case of rules that must be checked
before the calculation, variables can also be set to constant or calculated values.

The following statements are possible in this situation:

precalc: marks the beginning of the rules that must be checked before a calculation
is performed.
postcalc: marks the beginning of the rules that must be checked after a calculation.
assert(<Condition>): The <condition> is ensured. In this case, the <condition>
usually represents a comparison, where both the right-hand and left-hand side of
the comparison can also be calculated.
action msg <Message>: If the <condition> of the previous assert has not been
fulfilled, the <message> is output. Here the <message> can include variables, in
the same way as report templates.
action set <Assignment>: If the <condition> of the previous assert has not been
fulfilled, the <assignment> is performed. The assigned value can be a constant or
be calculated from variables, in the same way as for the report templates.
An assignment is only really useful in the precalc section because changing the
contents of variables after the calculation merely leads to inconsistent results and
has no other effects.

Here is an example file for a helical gear calculation:

precalc
assert (ZR[0].x.nul < 1)

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action msg "Profile shift for Gear 1 too big, is {ZR[0].x.nul}, maximum 1. It has
been reset to 1."
action set ZR[0].x.nul = 1

assert (ZR[1].x.nul < 1)

action msg "Profile shift for Gear 2 too big, is {ZR[1].x.nul}, maximum 1. It has
been reset to 1."
action set ZR[1].x.nul = 1
postcalc
assert ((ZP[0].a/ZS.Geo.mn) < 200)
action msg "Center distance too big for module (a={ZP[0].a}, mn={ZS.Geo.mn},
a/mn={ZP[0].a/ZS.Geo.mn})."

Explanations:
The "precalc" statement open the section of the rules that must be executed before
the calculation.
The first "assert" statement checks whether the nominal profile shift of gear 1 is
less than 1.0.
If this "assert" is not fulfilled, the "action msg" statement outputs the message that
the profile shift is too big, displays the current value and tells the user that the profile shift has been set to 1.0.
The "action set" then sets the profile shift to 1.0.
The second "assert" statement checks the same values for gear 2.

The "postcalc" statement signifies the end of the set of rules to be executed before
the calculation and opens the section of the rules to be checked after the
calculation. The example shows a definition of an "assert" statement. This checks
the ratio from the center distance to the module. If the rule is infringed, the "action
msg" statement triggers a message. However, there is no point in converting one of
these two values after the calculation and this is why the "action set" statement is
not present here.

The "General Results and Reports Report templates Formatting Calculation

variables" section details which operators and functions can be used in the
formulae.

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The file containing the rules is stored in the template directory (TEMPLATEDIR,
usually the "template" subdirectory, see the "Directory structure" section in the
"Setting Up KISSsoft" section). As the template directory can also be projectspecific, you can also define project-specific rules.

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Star tin g KISSs oft

Chapter 3
Starting KISSsoft

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3.1

Initial parameters

KISSsoft can be called up from the input prompt with the following initial parameters:
Parameter

Description

INI=directory

The KISS.ini (see page I-53) file will be loaded from the specified
location. You can transfer a file name including its directory path, or
only a directory name.

START=module

The specified calculation module will be started. The module

descriptor is, for example, M040 for bolt calculation or Z012 for
cylindrical gear pair calculation.

LOAD=file name

The calculation module belonging to the file is started and the file is
loaded. If the supplied file name does not include a path, the system
looks for the file in the User directory (see page I-53).

LANGUAGE=number

KISSsoft starts with the language specified for the interface and reports. (0: German, 1: English, 2: French, 3: Italian, 4: Spanish, 5:
Russian, 6: Portuguese, 11: English with US Customary Units)

DEBUG=filename

A log file containing debug information will be written. It can be very

helpful for error-tracking. It is advisable to define the file name with a
complete path, so that you can find the log file easily later.

File name

The calculation module belonging to the file is started and the file is
loaded. This also provides a way to associate KISSsoft with the
appropriate filename extensions in Windows.

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3.2

Disconnect license from the network

If KISSsoft has not been properly shut down, it may be possible that users remain
registered, in the case of a network version. This may lead to licenses being
blocked even though some users are no longer working with KISSsoft. You can
disconnect a license from the network by selecting the required license (the user
and start time are also specified) under Extras > License tool in the Network tab, which deletes the appropriate cookie file and activates the blocked license on the network again.
Unused licenses will be activated after a certain time, as soon as the next user logs
on. This time-span can be predefined via the TIMEOUT (see page I-56) variable
in the kiss.ini (see page I-53) file.
NOTE

A user who has been disconnected from KISSsoft can no longer carry out
calculations in the current session. The user must restart KISSsoft. However, data
backups can still be carried out.

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Elem en ts o f the KISSso ft Us er Interfac e

Chapter 4
User Interface
KISSsoft is a Windows-compliant software application. Regular Windows users
will recognize the elements of the user interface, such as the menus and context
menus, docking window, dialogs, Tooltips and Status bar, from other applications.
Because the internationally valid Windows Style Guides are applied during development, Windows users will quickly become familiar with how to use KISSsoft.

Figure 4.1: KISSsoft's user interface

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4.1

Menus, context menus and the Tool bar

In the File main menu you can open, store, and send calculation files as email
attachments, restore previous calculation stages, view file properties, and close
KISSsoft. Click File > Save as template to retain user-defined default
values (standard files (see page I-51)).
You can use the KISSsoft Project Management (see page I-93) functionality from
both the Project main menu and the Project (see page I-75) tree. You can open,
close and activate projects, insert files into a project, or delete them, and also view
project properties.
Each individual docking window (see page I-74) in the user interface can be hidden or displayed in the View main menu. If you are in the report or helptext viewer, select View > Input window to return to the calculation module input
dialog.
In the Calculation main menu you can run the current calculation (see page I87), add more calculations to the calculation module as default or special tabs and
call subcalculations as dialogs. Select Calculation > Settings to change
the module-specific settings.
In the Report main menu you will find actions for generating and opening a report. The system always generates a report for the current calculation. Click Report > Drawing data to display Drawing data (on page I-109) for the element currently selected in the Report Viewer (see page I-84). Click Report >
Settings to change the report's font size, page margins and scope. The actions
for saving, sending and printing are only active if a report is open.
You can open and close the Graphics (see page I-77) window of a calculation module in the Graphics main menu.. Select 3D export to access KISSsoft's
CAD interfaces. Select Graphics > Settings to select the CAD system into
which you want to export the selected element.
In the Extras menu you will find the license tool, the configuration tool and the
database tool. In this main menu you can start the Windows calculator and change
the Language (see page I-49) and System of units (see page I-50). In Extras >
Settings you can change general program settings such as the formats for time
and date values.
In accordance with Windows conventions, at the end of the menu bar you will find
the Help icon which you can use to navigate in the KISSsoft manual. In Help >
Info you will find information on the program version and on the support
provided by KISSsoft.
In addition to the main menu, KISSsoft uses context menus in many locations.
Context menus give you access to actions for a particular area or element of the
software. Context menus are normally called up via the right-hand mouse button.

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The Tool bar gives you faster access to actions from the menus that are used
particularly frequently. You should also note the tool tips which display information about the actions in the Tool bar as well as other descriptions in the Status bar
(see page I-86).
NOTE

The Calculation, Report and Graphics main menus are only active if a
calculation module is open. The actions available in these menus may vary
depending on the current calculation module.

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4.2

Docking window

Beside the menu bar, Tool bar and Status bar, the docking windows are important
elements in the KISSsoft user interface. Docking windows are windows that, can
either be moved freely on the desktop, like a dialog, or can be docked onto the pages of the program, in any arrangement that suits you. Several docking windows
can be placed on top of each other and be represented as tabs.
You can unlock a docking window by double-clicking in its title bar. You move a
docking window by clicking with the left-hand mouse button in the title bar and
moving the mouse with the key held down. If you move the mouse close to the edge of the main window, a new position for the docking window will be displayed.
Release the mouse button to position the docking window. Docking windows can
be displayed and hidden via the View (see page I-72) menu.

4.2.1

The module tree

The module tree shows all KISSsoft calculation modules in an easy to understand
and logically structured list. Any calculation modules for which you have not
purchased a license are grayed out. You open a module by double-clicking on it
with the left-hand mouse button. The current calculation module will be shown in
bold.

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Figure 4.2: KISSsoft calculation modules

4.2.2

The project tree

The project tree gives you an overview of the open projects, and the files belonging
to these projects, and highlights the active working project (see page I-96) in bold.
You use the project management (see page I-93) functions via the Project menu or from a context menu (see page I-72).

4.2.3

The Results window

The KISSsoft results window displays the results of the last calculation.

Figure 4.3: The KISSsoft results window

4.2.4

The Messages window

The messages window displays all information messages, warnings and errors. Generally, all additional messages are not only displayed, but also appear in a message box. You can change the way information and warnings are displayed in a message box by selecting Extras > Settings.

4.2.5

The info window

The Info window displays information that is displayed when the user clicks on an
Info (see page I-89) button in the calculation module. You zoom and print the information via a context menu (see page I-72).

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4.2.6

Manual and Search

The manual's Table of Contents and search function are also available as docking
windows. When you select an entry by double-clicking on it, the Helptext viewer
(see page I-85) opens and the relevant section in the manual is displayed.

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4.3

Graphics window

In KISSsoft you can open as many graphics windows as you need at the same time
and arrange them in the same way as the other docking windows (see page I-74).
This means you can see all the graphics and diagrams you require for your
calculations at a glance. To make working with graphics more effective you can
use the Tool bar (see page I-78), the Comment field, the context menu (see page
I-80) and the Properties (see page I-80).

Figure 4.4: Components of the graphics window

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4.3.1

Tool bar and context menu

Use the selection list in the Tool bar to switch from one graphic to another in a
group. You will also see various icons for saving, printing and locking a graphic, as
well as functions for highlighting and graying out its properties.

Save graphics as
This stores the graphics as DXF, IGES or other image or text formats under the
name you enter here.
Saving diagrams in a DXF file usually creates a conflict between the diagram axis
units and the unit used in the DXF file. For this reason, when you save a diagram,
the program opens a dialog in which you can specify the drawing area to which the
diagram is to be projected in the file.

Print
Prints the current section of the graphic. The information underneath the graphics
is defined in the graph?.rpt report templates (see Report templates (on page I113)).

Lock
This is useful for comparing two calculation results. In this way, you can, for
example, generate a Specific sliding graphic for a toothing scenario, lock
this graphic and then, after having changed the gear parameters, open a new graphics window that shows the new calculation results. The locked window will no
longer be updated.

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(a) Locked window

(b) Window with new calculation results

Figure 4.5: Locking graphics windows

When you lock a graphics window, a dialog will open in which you can enter a title
for the window, which will make it easier for you when you are making
comparisons.

Figure 4.6: Dialog window for inputting the window title

Properties
This opens a list with the Properties (see page I-80) of the current graphic in the
same window.

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4.3.2

Comment field

In the Comment information is displayed about the graphic. You can change the
Comment to suit your needs and it is included in the print output.

4.3.3

Context menu

Here, use the left-hand mouse button to select, move, zoom and measure elements
in a graphic. You can permanently select which action is to be performed in the
context menu. You can access this more quickly by using these combinations: Move: Shift, Zoom: Ctrl and Measure: Alt key with the left-hand mouse button.
Other actions in the context menu are: Zoom In (plus), Zoom out (minus) and Fit
window (Pos1 or Home). Use the direction keys to move the current section of the
graphic.

4.3.4

Properties

In Properties you can display or hide elements in a graphic and change its colors
and line styles. You can make different modifications, depending on the graphic:
for diagrams and such like, you can modify the value ranges and units to match the
axes, or for a meshing you can change the center distance.

Figure 4.7: Graphic properties

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If the properties are displayed, you will see three other icons in the Tool bar. You
use them to store curves in a graphic as text, or in the graphic itself.

Save curve as text

Stores the coordinates of the curve selected in Properties in a text file. This makes
it easy to transfer curves to, for example, an Excel file.

Save curve
Stores the curve selected in Properties in the graphic. This function is ideal for
comparing the graphical outputs of a calculation whilst you change its parameters.

Delete memory
Deletes the curve from the memory.

Figure 4.8: Graphics with saved and different curves

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4.3.5

Toothing

If you select Toothing, additional icons are displayed for generating the gear pair
and creating the flanks when you open the Geometry graphics window.

Rotate to the left

Turns the gear pair to the left.
Key combination: Ctrl + left direction key
Rotate to the right
Turns the gear pair to the right.
Key combination: Ctrl + right direction key

Rotate independently to the left

One gear remains static whilst the other is rotated to the left. The profiles overlap.
Key combination: Alt + left direction key

Rotate independently to the right

One gear remains static whilst the other is rotated to the right. The profiles
overlap.
Key combination: Alt + right direction key

Make flank contact left

The gears are rotated until the flanks of both gears touch on the left.

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Make flank contact right

The gears are rotated until the flanks of both gears touch on the right.

NOTE:

Hold down a rotate button to rotate the gears continuously (movie).

NOTE:

Click Properties (see page I-80) to specify the number of rotation steps for the rotation. The number of rotation steps here refers to the pitch.

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4.4

Main input area

The main input area shows a calculation module's input window. In addition, it is
used to display the internal report viewer or the internal help viewer.

4.4.1

Report Viewer

When you generate a report in KISSsoft, the report viewer in the main input area
will open, the entries in the Report menu will be activated and the report viewer
Tool bar will be displayed. The report viewer is a text editor that supports the usual
functions for saving and printing a text file. In KISSsoft, you can save reports in
Rich Text Format (*.RTF), in portable document format (*.PDF), in Microsoft
Word format (*.doc) or as ANSII text (*.txt).
The report viewer's other functions are Undo/Redo, Copy, Cut and Paste, and
Search with the usual shortcuts. You can zoom in on the view and later edit the
report by changing the font size, bold, italics and underlining style. To change the
general appearance of the report, select Report > Settings.

Figure 4.9: The KISSsoft report viewer

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4.4.2

Helptext viewer

The KISSsoft manual is displayed in the Helptext viewer in HTML format. To

open the manual, select something in the Table of Contents or the Search function.
If you press function key F1, the system displays more information on the location
in KISSsoft at which the cursor is currently is located.

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4.5

Tooltips and status bar

Whenever it is useful, tool tips are provided in KISSsoft, to give you additional
information about program elements. Tooltips appear automatically if you slowly
move the mouse over a program element.
If you position the mouse over a particular menu option, the system will display
detailed information on all actions available in that menu, in the left-hand area of
the Status bar. If the mouse is positioned over a selection list, the currently selected
list entry will be displayed in the Status bar. This is especially helpful if the display
is restricted by the width of the selection list.
In the right-hand area of the Status bar the system will display the current status of
the calculation. The flag is set to CONSISTENT if the results are current.
INCONSISTENT shows that a new calculation needs to be carried out.

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KISSs oft Calc ula tio n Mo dul es

Chapter 5
KISSsoft Calculation Modules

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5.1

Standard and special tabs

The input window for most calculation modules is subdivided into different tabs.
This ensures that inputs are separated logically. For more complex calculations
such as for a cylindrical gear pair, the system does not automatically display all
existing tabs. When you open a new calculation, you only see the tabs that contain
the absolutely necessary inputs (e.g., for a cylindrical gear pair this would be the
Basic data, Reference profile and Tolerances tabs). In the Calculation menu
you can add more tabs if needed (e.g., for a cylindrical gear pair you would need
the "Modifications" and "Correction of the gears" tabs).
KISSsoft calculation modules use two types of tabs: Standard tabs and Special
tabs, as shown in Figure 1.1.

Figure 5.1: Standard and special tabs

If a standard tab (e.g. Basic data) is active when the calculation is run, then the
standard calculation will be executed and the results of this standard calculation
will be displayed in the Results window (see page I-75). When a report is
generated, the default report is created.
Special tabs are marked with the
icon. If a special tab is active when the
calculation is run, then a special calculation will be executed in addition to the
standard calculation, (e.g., for a cylindrical gear pair the calculation of the meshing
line under load). The results of this additional calculation will then be displayed in
the Results window, and when you generate reports you will get a report containing
the results the additional calculation.

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5.2

Input elements

All KISSsoft calculation modules use the same input elements for input. These input elements are described in more detail in the sections that follow.

5.2.1

Value input fields

In general, a value input field always includes the label of the variable, a formula
character, the edit field and a unit. If the edit field is grayed out, this variable
cannot be predefined. Instead it will be determined during calculation. One or more
of the following buttons can follow a value input field:
You can retain a value by selecting the Check button.
You can set a radio button to specify which values in a group should be calculated
and which should be retained
Click the Sizing button to calculate the value using calculation methods
Click the Convert button to calculate the value using conversion formulae
Click the Plus button to display additional data for a value
Click the Info button to display information in the Info window (see page I-75)

5.2.2

Formula entry and angle input

In some cases it is advisable to use a small auxiliary calculation to determine a value. Click the right-hand mouse button in the Edit field of a value input field (see
page I-89) to open a formula editor. In it you can enter a formula, which must be
one of the four basic calculation types: +, -, * and /. Additionally, you can use all
the functions that are supported by the report generator ( see Table on page I119). Confirm the formula by pressing Enter. The system will evaluate the formula.
The formula itself will be lost: if you return to the formula entry dialog, the
calculated value will be shown there instead of the formula.
In value input fields (see page I-89) that display an angle, a dialog in which you
can input degrees, minutes and seconds will be displayed instead of the formula
editor.

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KISSsoft Calculation Modules

5.2.3

Unit switch

In KISSsoft, you can switch all the units in the value input fields (see page I-89)
and in the tables (see page I-89). To do so, click on a unit with the right-hand
mouse button. A context menu will open, offering all possible units for the value. If
you select a different unit from the one that is currently in use, KISSsoft converts
the current value in the value input field into the new unit.
To switch between metric and US customary units globally, select Extras
> System of units.

5.2.4

Tables

In some modules data will be displayed or entered in a table. You select a row by
double-clicking, just like when you select a field for input. For tables, additional
information is often displayed in a tooltip (see page I-86). In general, the following
buttons come after tables so that you can input data:
Click the Add button to insert a row into the table
Click the Remove button to delete the selected row from the table
Click the Clear button to delete all entries in the table

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5.3

Calculating and generating a report

Click on Calculation > Click Run to perform the current calculation. In addition, the tool bar and the F5 function key give you quick, convenient access to this
action. Here, please note that a calculation module can have other special
calculations in addition to the standard calculation. These special calculations are
only executed if the appropriate Special tab (see page I-88) is active.
Select Report > Generate to generate a report about the current calculation.
Also note the differentiation here between the default report and the reports about
the special calculations in the Special tabs (see page I-88).
The status of a calculation is consistent if it could be performed without error. As
soon as you change data in the input window, the calculation becomes inconsistent,
which means that the results of the calculation in the Results window and the graphics no longer match with the data in the interface. The current status of the
calculation is displayed in the Status bar (see page I-86).

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5.4

Messages

A calculation sends different types of messages to the input window: information,

warnings and errors. Information and warnings should always be taken note of to
ensure accurate results. If an error has occurred, the calculation is interrupted.
Normally, all the messages are displayed in a message box and in the Messages
window (see page I-75). You can change the way information and warnings are
displayed in a message box by selecting Extras > Settings.

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Project Management

Projec t Ma nage me nt

Chapter 6
Project Management
KISSsoft contains its own project management system to help you organize your
calculation files and your external files. The most important area in the project management system is the KISSsoft project tree (see page I-75). In it you can see
which projects are currently opened or active, and you can see all the information
about the files belonging to the individual projects.

Figure 6.1: The KISSsoft project tree

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Project Management

6.1

Creating, opening and closing projects

Click on Project > New... to create a new project. A dialog opens in which
you enter the name of the project, the project directory, descriptions and comments,
and also the directory for the templates (see page I-51) that are to be used. The
newly created project is inserted into the project tree and defined as the Active
working project (see page I-96).
When you open an existing project (click on Project > Open...) this is also
inserted into the project tree and defined as the Active working project (see page I96).
You close a project by selecting it and then clicking Project > Close. You
will also find this action in the project tree's Context menu (see page I-72). The
project will still be retained, and you can open it again at any time.

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6.2

Adding and deleting files

Files can be added and deleted either via the Project properties (see page I-98) or
the Context menu (see page I-72). Not only can you insert calculation files from
KISSsoft into a project, but also any external files.

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6.3

The active working project

The project tree shows all opened projects, and it is not absolutely necessary to
define an active working project. If you have defined an active working project, it
is highlighted in bold. Click on Project > Set as working project to
enable a project. Alternatively you can do this in the Context menu. If you select
Project > Work without project, this deactivates the active working
project.
The current calculation file does not necessarily have to belong to the active working project.

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Project Management

6.4

Storage locations

Files belonging to a project do not necessarily have to be stored in that project's

directory. Consequently, files can also belong to several projects simultaneously.
However, if you have defined an active working project (see page I-96) KISSsoft
will prompt you with its project directory as the first choice storage location
whenever you want to open or save a calculation file or a report. If you are working
without a project, the system will display your personal user directory (see page I53) as a default storage location, which you can change.

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6.5

Project properties

Click on Project > Properties to display the project properties of the selected project. Alternatively, you can display this in the project tree's context menu
(see page I-72).

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Dynamic user Interface

Dynam ic user Interfac e

Chapter 7
Dynamic user Interface
The KISSsoft interface is defined by its editable text files (descriptive data). The
elements it contains are fixed components of the software. However, any user can
decide how these elements are divided up and arranged. Frequently used entries
can be given priority in the tabs and dialog and less commonly used entries can be
either hidden or write-protected. KISSsoft can therefore easily be adapted to suit
the requirements of individual users.

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7.1

Modified tabs and dialogs supplied with

the system

The description files for the tabs and dialogs supplied with the system are stored in
the kui (kisssoft user interface) directory. These files should never, under any
circumstances, be modified by the user. This is because interface upgrades, which
are supplied with a patch, always overwrite any user modifications. To modify the
interface to suit your own requirements, copy the corresponding description file to
the ext/kui directory and change it there. KISSsoft evaluates the files in this directory first. The description files are assigned to the corresponding calculation module by file name and file extension *.kui. This is why the file name must not be
changed.

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7.2

Adding additional tabs and dialogs

The description files for additional tabs and dialogs are stored in the ext/dui (dynamic user interface) directory. KISSsoft evaluates the files in this directory every
time a module is started. You can give these files any name you want, although the
file extension must always be *.dui.
The <module> tag tells KISSsoft which calculation module the description file
was defined for. This entry is mandatory for tabs. The titles of the tabs or dialogs
are defined by the <title> tab. The tag can contain either an actual text or the ID
(number) of a text from the KISSsoft Glossary (wpoolUi_.txt).
Use the <before> tag to define the position of the additional tabs. If you do not
see the <before> tag, the additional tab is placed after the standard system tabs.
An additional tab can also be used to replace a standard tab. To exclude a tab, set
the <exclude> tag.
Example of an additional tab:
<KISSsoft filetype="userinterface">
<module>Z012</module>
<title>My own title</title>
<before>Tolerances</before>
<exclude>Z012_BasicData.kui</exclude>
<element>a</element>
<element>Q</element>
</KISSsoft>
An additional tab is always displayed. Set the <permanent> tag to define that
the tab can be enabled via the "Calculations" menu.
<permanent>false</permanent>
Additional tabs always work in the same way as the standard tabs supplied with the
system. Insert the <calculation>, <report> and <results> tags to
represent the behavior of a special tab. The <calculation> tag executes a
COM function. All the functions that are available via the COM interface are also
available here. The name of the corresponding template is set for the report and the
results (see Results and Reports (on page I-106) section in the manual).

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Use the <setup> tag to give additional dialogs a COM function. This function is
executed when the dialog starts.
Examples of additional description files can be requested from KISSsoft AG.

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7.3

Formatting

7.3.1

Elements

Set the <element>ElementName</element> tag to add an element. The

elements in the description file appear in the same sequence as they appear in the
interface.
The following element types are available:

Value input fields

For entering whole number values or floating values

Selection lists (drop-down

lists)

For selecting list entries, database entries, materials, lubricants or load spectra

Checkboxes

For enabling/disabling calculation options

Titles and texts

For structuring the interface

The following attributes can be set for an element:

de, en, fr, it, es, pt, ru, all

Overwrites the element's label. Use this option to create company-specific or

regional glossaries. The attribute can contain either an actual text or the ID
(number) of a text from the KISSsoft Glossary (wpoolUi_.txt).

nolnput

Set this attribute to true to write-protect the associated element. Use this option to predefine values (see Defining your own default files in the manual)
and prevent other users from changing them.

unit

The set unit is then used as the default in the interface.

index

Elements with multiple entries are reduced to a fixed index.

<element attribute1="wert" attribute2="wert">Name</element>

Lists of available elements can be requested from KISSsoft AG requested.

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7.3.2

Columns

Set the <column> tag to add a column. The columns in the description file appear
in the same sequence as they appear in the interface. You will not usually need more than two columns.
Example of a two-column layout:
<column>
<element>Element1</element>
<element>Element2</element>
</column>
<column>
<element>Element3</element>
<element>Element4</element>
</column>

7.3.3

Groups

Set the <group> tag to add a group. The groups in the description file appear in
the same sequence as they appear in the interface. Groups can also contain columns. Groups cannot be nested.
Set the <title> tag to define a group's title. The tag can contain either an actual
text or the ID (number) of a text from the KISSsoft Glossary (wpoolUi_.txt).
Example of a Group:

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<group>
<TITLE>145</TITLE>
<element>Element1</element>
<element>Element2</element>
</group>

7.3.4

Tabs

Dialogs can also contain tabs. Set the <tab> tag to add a tab. The tabs in the description file appear in the same sequence as they appear in the dialog. Each tab
includes elements that are arranged in groups or columns. Sub-tabs are not
supported in the tabs in a calculation module.
Set the <title> tag to define the title of a tab. The tag can contain either an
actual text or the ID (number) of a text from the KISSsoft Glossary (wpoolUi_.txt).

7.3.5

Comments

Comments in a description file are a useful way of explaining how the file is structured. Comments start with //.
<title>32</title>

// Basic data

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Resul ts a nd Re ports

Chapter 8
Results and Reports

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8.1

Results of a calculation

KISSsoft displays the results of a calculation in the Results (see page I-75)
window. If no results are displayed, an error has occurred during the calculation. In
this case, you will be alerted to the error by a system message in a message box.
An indicator in the status bar (see page I-86) shows whether the results are
consistent, i.e. whether the results match up with the data in the user interface.

8.1.1

Add your own texts in the results window

To do this, define a new file in the KISSsoft installation folder in "\ext\rpt\".

This file must then be named like this: "Modulname + result.RPT" (e.g. for a
cylindrical gear pair Z012result.RPT).
Then define the new parameters or values that are to be added. These values then
appear at the end of the "Results" window.
The syntax corresponds exactly to the entries for the report templates.

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8.2

Calculation reports

Select Report > Generate to generate reports about your calculations. In addition, the tool bar and the F6 function key give you quick, convenient access to
this action. The report contents depend on which tab (see page I-88) is currently
active. The Length (see page I-114) and Appearance (see page I-114) of standard
reports can be influenced by user-defined report templates (see page I-113).
A calculation module can contain further reports which you can access via the Report menu.
Reports are usually displayed in the KISSsoft Report Viewer (see page I-84).
Important: The report is not saved when you return from the report viewer to the
input window. To make it permanently available, you must save it under a new
name!
NOTE

In general, a report should only be created if the calculation is consistent (see page
I-91). If this is not the case, you can still generate the report, but the status of the
calculation will then be noted in the report.
NOTE

When you generate a report, the system generates an RTF file with the module's
label as its file name. The file is saved in the directory defined as the TEMPDIR
(see page I-53) in the KISS.ini (see page I-53) file.

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8.3

Drawing data

Depending on which calculation module you are using, click Report> Drawing data to create a report that can be used to output drawings.

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8.4

Report settings

Under Report > Settings, you can tailor the automatic generation of reports.
All the settings can also be defined globally in the KISS.ini (see page I-56) file.

8.4.1

General

Here you define the scope of the report (see page I-114) and whether warnings
from the calculation are to be included in it. Further options are the font size and
language, along with the standard format used to save the report.
The report can be viewed in two different modes: "update" or "compare".
If a report is generated and a previous report is still open, the data will be updated.
The cursor in the editor will remain in the same line where it was left. This feature
will help the user to analyze specific values using different inputs.
Change the report mode to "compare" if you need to compare two or more reports
at a time. This mode can only by set if you are using KISSedit as the editor. You
can also synchronize the reports and scroll through them all at the same time.
You can also set these properties directly in the KISS.ini file.

8.4.2

Page layout

Here you can define the paper size and the page margins used to create reports
automatically.

8.4.3

Header and footer

In KISSsoft, reports are usually generated with headers and footers. You can define
your own header and footer lines. There are a number of placeholders available for
this.

Placeholder

Explanation

%logo

Picture file

%date

Dated

%time

Time

%pn

Number of pages

%pc

Number of pages

%t

Tab

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The %logo placeholder uses the selected graphics file to integrate a user-defined
logo (company label). The date and time are output in accordance with the details
specified under Extras > Settings.

8.4.4

Start and end block

Reports in KISSsoft are usually generated with a start and an end block. You can
define these start and end blocks yourself. The start and end blocks are defined in
template files which are stored in the rpt directory in the installation folder.

Language

Start block file

End block file

German

kissd.rpt

kissfd.rpt

English

kisse.rpt

kissfe.rpt

French

kissf.rpt

kissff.rpt

Italian

kissi.rpt

kissfi.rpt

Spanish

kisss.rpt

kissfs.rpt

Russian

kissr.rpt

kissfr.rpt

Portuguese

kissp.rpt

kissfp.rpt

Commands that can be used in these templates and what they mean:

Command

Explanation

DATE

Date (set your own output format under "Extras/Settings")

TIME

Time (set your own output format under "Extras/Settings")

PROJECT

Project name

PROJECTDESCRIPTION

Description of the project

FILENAME/DESCRIPTION

File name

FILENAME.EXT

File name with extension (e.g. "Example1.Z12")

FILEPATH

Path with file name (e.g. "C:\Temp\GearPair.Z12")

DESCRIPTION

Description of the file

COMMENT

Comment for the file

CUSTOMER

Customer name as defined in the project

USER

User name (Windows user name)

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RELEASE

Version number (e.g. "04-2010")

COMPANY

Company name (as defined in the license file)

NLINES

Number of lines in the report

IMPERIALUNITS

Whether US customary units are specified for IF statements

METRICUNITS

Whether metric units are specified for IF statements

PROJECTUSED

Whether projects are used for IF statements

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8.5

Report templates

For each calculation module, KISSsoft provides report templates to define the form
and content of the reports. You can use these supplied templates as the basis for
generating user-defined templates to produce reports that meet your requirements.
However, you must ensure the Formatting (see page I-114) and Storage locations
(see page I-113) remain the same.

8.5.1

Storage locations and descriptions

The report templates supplied by KISSsoft are stored in the directory that has been
set as RPTDIR (see page I-53) in the KISS.ini (see page I-53) file. If RPTDIR
(see page I-53) was not defined in KISS.ini (see page I-53), you will find the
templates in the installation folder under rpt. It is essential that user-defined report
templates are stored in the RPT subdirectory, in the EXTDIR (see page I-53) directory. This is the only way to prevent your templates from being overwritten if a
patch is installed. When the system generates a report, it uses the user-defined
template from the EXTDIR directory, if present. Otherwise it uses the template
from the RPTDIR to create the report.
The descriptions of the report templates have the structure MMMMlsz.rpt, which
consists of the following:
MMMM

Module descriptor

e.g. M040

historical

always = l

Language of the report

s = d, e, f, i, s or a

historical

always = 0

.rpt

File type

EXAMPLES

Bolt calculation:
M040LD0.RPT

Bolt calculation, German printout

M040USER.RPT

Default printout via the interface,

results in the M040USER.OUT file

Cylindrical gear calculation:

Z012LD0.RPT

Cylindrical gear pair, German printout

Z012USER.RPT

Default printout via the interface,

results in the Z012USER.OUT file

Z10GEAR1.RPT

Output via interface, contains only data

for gear 1, results in file Z10GEAR1.OUT

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Results and Reports

Z10GEAR2.RPT

Output via interface, contains only data

for gear 2, results in file Z10GEAR2.OUT

Z011LD0.RPT

Single gear, German printout

Z013LD0.RPT

Rack, German printout

Z014LD0.RPT

Planetary gear, German printout

Z015LD0.RPT

3 gears, German printout

Z016LD0.RPT

4 gears, German printout

Spring calculation
F10SPRING.RPT

Default printout for drawing data results in the F10SPRING.OUT

file

English printout:
M040LE0.RPT

Bolt calculation, English printout

American printout:
M040LA0.RPT

8.5.2

Bolt calculation, American printout

Scope of a report

The scope, or the length of a report can be preset on a scale of 1 to 9 in the Report > Settings menu. 9 will produce a complete report, and 1 will produce
a short report. In the report template, you see a number between 1 and 9 at the
beginning of every row. This number acts together with the setting described above
to determine whether or not the row is to be read.
Example: If you entered 5 (medium) as the report length, all the lines in the report
template that start with 1, 2, 3, 4 or 5 are read. Rows with 6, 7, 8 and 9 will be not
read.

8.5.3

Formatting

Both the report template and the report created from this are text files that are
created with the Microsoft Windows font. You should always edit text in MS Windows, otherwise accented characters such as , , , as well as some special characters, may be represented incorrectly.
The following statements and key words are defined in the report format:
Texts that are to be output
Comments that are not to be output

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Descriptions and formatting of calculation variables

Limited branchings (IF ELSE END)
Repetitions (FOR loops)

8.5.3 .1
Text formatt ing featu re s
In general, reports in KISSsoft are created in RTF format. RTF can handle the
following text formats:
Description

Start

End

Underline

<UL>

</UL>

Cross out

<STRIKE>

</STRIKE>

Grease

<BF>

</BF>

Italic

<IT>

</IT>

Superscript

<SUPER>

</SUPER>

Subscript

<SUB>

</SUB>

Font size

<FONTSIZE=xx>

Enlarge font size

<INCFONTSIZE>

</INCFONTSIZE>

Reduce font size

<DECFONTSIZE>

</DECFONTSIZE>

Page break

<NEWPAGE>

Line break

<BR>

Text color red

<RED>

<BLACK>

Text color green

<GREEN>

<BLACK>

Text color blue

<BLUE>

<BLACK>

Blank space

<SPACE>

Insert figure

<IMAGE=name,WIDTH=xx,HEIGHT=yy>

Insert image

<INCLUDEGRAPHIC=name,WIDTH=xx,HEIGHT=yy>

Adding a report template

<EXECUTE=name.rpt>

8.5.3 .2
Comments
Comment lines begin with //. Comments are ignored when a report is created

EXAMPLE

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// I changed the report template here on 12.13.95, hm

External diameter mm : %10.2f {sheave[0].da}

In this case, only the second line will be output.

8.5.3 .3
Calculation vari ables
You cannot define your own variables (apart from the number variables used for
FOR-loops (see section "FOR loop" on page I-121), which the user specifies, and
which can output a value.

Placeholder
Use placeholders to specify the file type and formatting for a variable:
%i stands for a whole number
%f stands for a floating point number
%1.2f stands for a formatted floating point number with 1 places in total
(including prefix operator and decimal point) and 2 decimal places
%s stands for a left-justified character string (text)
%ns stands for a right-justified character string in an n-character-long field (n
is a whole number).
The data types must match the definition in the program. The value is returned in
exactly the place where the placeholder is positioned. The syntax of the formatting
corresponds to the C/C++ standard.

EXAMPLES

%10.2f returns a right-justified 10-digit floating point number, with 2 decimal

places.
%i returns an unformatted whole number exactly in this location.
%30s stands for a right-justified character string in a field that is 30 characters
long (if the number 30 is omitted, the characters will be left justified).
COUNTER-EXAMPLES

%8.2i is an invalid formatting because a whole number has no decimal places.

%10f2 outputs a right-justified 10-digit floating point number. However, the 2
decimal places are ignored and output as text 2. The default setting is to output
floating point numbers to 6 decimal places.

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Variables
The variable to be displayed must stand after the placeholder in the same row. The
variable is identified by being enclosed in curly brackets. If these brackets are left
out, the variable name will appear as normal text.
Important: It is essential that the number of placeholders exactly matches the number of pairs of brackets {}.

EXAMPLE

%f {sheave[0].d} returns the value of the variable sheave[0].d in the location %f as

a floating point number with 6 decimal places.

Basic calculation types - output of changed variables

You can output changed variables in the report. They can be multiplied or divided
with a coefficient. You can also add or subtract a number. This functionality is also
available in the arguments used in the IF or FORstatements (see below).
Value of the variable multiplied

%3.2f

{Var*2.0}

Value of the variable divided

%3.2f

{Var/2.0}

Value of the variable added

%3.2f

{Var+1.0}

Value of the variable subtracted

%3.2f

{Var-2}

The two Degree and Gear functions are also available for converting variables to
degrees or radians:
Angle %3.2f {grad(angle)}
Variables can also be directly linked with each other, e.g. in the form {sheave[0].dsheave[1].d}. More than two numbers can be linked. Numbers that have prefix
operators must be enclosed in brackets, for example {ZR[0].NL*(1e-6)}.
The available functions are listed in Table 8.2.
Function

Meaning

sin(angle)

sine of angle in the radian measure

cos(angle)

cosine of angle in the radian measure

tan(angle)

tangent of angle in the radian measure

asin(val)

arcsine of val, returns radian measure

acos(val)

arccosine of val, returns radian measure

atan(val)

arctangent of val, returns radian measure

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abs(val)

|val|

exp(val)

eval

log(val)

Return value x in ex = val

log10(val)

Return value x in 10x = val

sqr(val)

Return value val2

sqrt(val)

Return value

int(val)

Whole number of val

pow(x;y)

Return value xy

sgn(val)
Return value
sgn2(val)
Return value
grad(angle)

Converting from the radian measure to degrees

rad(angle)

Converting from degrees to radian measure

mm_in(val)

Return value val/25.4

celsius_f(val)
Return value

val + 32

min(1; ...; 5)

The return value is the minimum of 1,...,5

max(1; ...; 5)

The return value is the maximum of 1,...,5

and(1; 2)

binary and function

or(1; 2)

binary or function

xor(1; 2)

binary exclusive or function

AND(1; ...; 5)

logical and function

OR(1; ...,5)

logical or function

NOT(val)
Return value
LESS(1; 2)
Return value
EQUAL(1; 2)
Return value
GREATER(1; 2)
Return value
ROUND(x;n)

Rounds off x to n places

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strlen(str)

Length of character string

strcmp(str1;str2)

Compare character string

Return value:
-1 str1 <str2
0 if str1 = str2
1 if str > str2

Table 8.2: Functions available for calculations in the report.

8.5.3 .4
Condition query IF ELSE END
The condition query or branching enables you to only output certain values and
texts if a particular condition has been fulfilled. The following conditions are
supported:
Combination of characters

Meaning

==

equal

>=

greater than or equal

<=

less than or equal

!=

unequal

<

smaller

>

larger

This condition is entered as follows:

IF (condition) {Var}
Case 1
ELSE
Case 2
END;

EXAMPLE

IF (%i==0) {Zst.kXmnFlag}
Addendum modified no
ELSE
Addendum modified
yes
END;

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If the Zst.kXmnFlag variable is equal to 0, then output the first text, otherwise output the second text. There can be any number of rows between IF, ELSE and END.
For each branching opened with IF you must use END; to close it again (do not
forget the semicolon after END). The key word ELSE is optional. It reverses the
condition. Branchings can be nested within each other up to a depth of 9.

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EXAMPLE OF A SIMPLE BRANCHING

IF (%i==1) {ZP[0].Fuss.ZFFmeth}
Calculation of tooth form coefficients according to method: B
END;
If the variable ZP[0].Fuss.ZFFmeth is equal to 1, then output the first text,
otherwise it is not output.

EXAMPLE OF ENCAPSULATED BRANCHINGS

IF (%f<=2.7) {z092k.vp}
Lubrication regular by hand

(Text1 )

ELSE
IF (%f<12) {z092k.vp}
Lubrication with drop dispenser (2 to 6 drops per minute)

(Text 2)

ELSE
IF (%f<34) {z092k.vp}
Lubrication with oil bath lubrication

(Text 3)

Lubrication with circulation system

lubrication

(Text4)

ELSE

END;
END;
END;

If variable z092k.vp is smaller than or equal to 2.7, text 1 is output. Otherwise you
are prompted to confirm that z092k.vp is smaller than 12. If yes, text 2 is output.
Otherwise you are prompted to confirm that z092k.vp is smaller than 34. If yes, text
3 is output, otherwise text 4 is output.

8.5.3 .5
FOR loop
In KISSsoft you can also use FOR loops in the report generator. Within a FOR
loop a numerical variable will be incremented (or decremented). You can use
constructs that are nested down to 10 levels.

This loop is specified as follows:

FOR varname=%i TO %i BY %i DO {startwert}{endwert} {schritt}
// access variable with #varname or $varname

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...
END FOR;
Instead of %i or %f you can also use fixed figures (static FOR loop):
FOR varname=0 TO 10 BY 1 DO
...
END FOR;
or a mixture:
FOR varname=5 TO %i BY -1 DO {endwert}
...
END FOR;
Each FOR loop must end with the statement END FOR; (including semicolon).
Each defined numerical variable (varname) within the loop can be addressed
with the statement #varname.
The increment can also be selected as a negative value (for example -1). However, it must never be 0. You must always specify the intervals.
The #varname statement can be used for defining a variable. For example:
Number of teeth: %3.2f {ZR[#varname].z}
The $varname statement can be used for outputting the variable value as a letter. The value 0 corresponds to A, 1 corresponds to B etc. For example:
FOR quer=0 TO 3 BY 1 DO
Cross section $quer-$quer : %8.2f {Qu[#quer].sStatisch}
END FOR;
EXAMPLE OF A SIMPLE LOOP

FOR i=0 TO 10 BY 1 DO
Run number #i $i
END FOR;
Results in the following output:
Run number 0 A
Run number 1 B
Run number 2 C
Run number 3 D
Run number 4 E
Run number 5 F
Run number 6 G

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Run number 7 H
Run number 8 I
Run number 9 j
Run number 10 K
The numerical variable can be used anywhere within the loop, even for arrays.

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Database Tool an d Extern al Ta bles

Chapter 9
Database Tool and External Tables
As calculation inputs you may, in addition to the unique data, also encounter
recurring data, for example the characteristics of a material. KISSsoft will store
these characteristics in databases. You view and change them with the database
tool, whose use will be explained in the following sections. Tables form the elements of the databases and are contained in your program package as editable ASCII files. The External tables (on page I-132) section deals with the setting up and
handling of external tables (also called "look-up tables).
In KISSsoft there are four databases:
KMAT

- Materials

M000

- Shaft-hub Connection and Bolts

W000

- Shafts and Bearings

Z000

- Gears

In Figure 9.3 you can see an example of the M000 database which shows how data
is organized in KISSsoft. As shown there, the F040NORM and M090MAT tables
belong to the group of shaft-hub connections.

KMAT

KMAT

M000
W000

F040NORM
M000

Z000

M090MAT
W000

(a) Databases

Z000
(b) tables

Figure 9.4: How data is organized in KISSsoft

Up to now, the following tables have been created in the databases: Center distance
tolerances, Reference profiles, Bore standard, Thread type bolt, Production process
for hypoid bevel gears, Production process for bevel gears, V-belt standard, Spline
standard, Chain type DIN 8154, Chain type DIN 8187, Chain type DIN 8188, Glue

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materials, Load spectra, Soldering materials, Key standard, Polygon standard,

Woodruff key standard, Lubricants, Bolt Type, Washer standard, Multi-spline
standard, Roller bearing, Materials for glued and soldered joint, Material, Tooth
thickness tolerances, Toothed belt standard.

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9.1

Viewing database entries

Open the database in the Extras Database tool menu item, as shown in
(Figure 9.5, ). A dialog window appears with the question whether you want to
open the database with write authorization ( ). If you press Yes, you can edit the
database entries, otherwise they are write protected. If you choose No, the actual
database tool window ( ) will start in read-only mode. There, you can select a
table from a list that is assigned to a particular database. The row of a table
contains the values that set the parameters for the database entry. The columns
contain the parameters for the database entries, i.e. values for the yield point of different materials. This section (see section "Managing database entries" on page I129) describes how to edit database entries. You can also display table entries by
selecting a row in the database tool window and then confirming this by clicking
Display ( ). The Display entry window opens with a structured display of
the value amount from a table row ( ).

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Figure 9.5: Accessing database entries

NOTE:

With the KISSsoft database tool you can change the databases and expand them
with your own entries. The data stored in the databases are in a sense "sensitive",
so that incorrectly entered values can have consequences that are initially
imperceptible noticeable, yet eventually far-reaching and serious. For this reason,
when you open the database you are asked whether the access should have write
authorization. If you answer this question in the negative, you can view the data in
the tables but not change it.

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If you want to make absolutely sure that the databases remain unchanged, you can
write protect their corresponding files (*. kdb). Any attempt to open a table with
write authorization results in an error message and the table will normally be
opened in write protected mode. To change the write protection attribute of a file,
right-click on the file in Windows Explorer, and then click on Properties.
Click in the Properties dialog field, on the General tab, and then click the
Write Protected selection box. If you want to make changes to a write
protected file, you must first deselect the selection box Write Protected or
else save the file with a different name.

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9.2

Managing database entries

If you want to change one of your own entries in a table in the database, you must
work in write authorization mode. To do this, go to the ( sh. Figure 9.5 on page
I-126) dialog window and click on Yes. In the list that you see next, ( ) select the
required table by double-clicking on the appropriate row or single-click on the
Edit button at the bottom right of the window after you have selected the row.
The database tool window now shows a list of the table entries ( ) and a row of
new buttons appears on the bottom left in the window:
Moves the selected item up one row
Moves the selected item down one row
Moves the selected item(s) to the start of the list
Moves the selected item(s) to the end of the list
Adds a new item to the list
Moves the selected item into the list of hidden data records

With the Filter drop-down menu on the top right of the window you can select
between displaying active data records, hidden data records, or both. Active data
records can be used within the calculation modules, hidden ones cannot.

9.2.1

Generating a database entry

If you click on the

button without having selected a row, the Display entry window ( ) opens and the input fields in it are empty. Only the Name field
contains the entry _NEW, which normally identifies the new table entry. After you
have transferred the necessary data, confirm your entries by clicking on OK and
then Savein the database tool window. The new entry is assigned an identification
number (ID) 20000 and is then transferred into the list of active data records.
Use the Edit button to change entries with an ID of 20000.
If you click on the
button after having selected a row, the Display
entrywindow opens and contains predefined values in the input fields according
to the table entry. The suffix _NEW will automatically be attached to the name, in
order to differentiate it from the original data record. In all remaining steps, you
then proceed as described above.
Example: Generating a database entry
Let's assume you want to add a new spring material to the KMAT.F000 table. In
accordance with the described procedure you would select the F000 table from the
KMAT database, in it press the
button to add a new entry/new row to the table,
and then transfer the new data into the input fields in the Display entry

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window. However, as only few parameters can be freely selected there, the next
question is, where can the other values such as the yield point and Young's
modulus be changed? The reply is: In the base material input fields, i.e. in table
KMAT.KISS. You must always specify a base material before you can introduce a
new spring material. If this is not present, you have to define it in the KMAT.KISS
table first of all and finally complete the missing entries in KMAT.F000.

NOTE

All material-specific tables such as KMAT.F000 or KMAT.Z080 - with the

exception of KMAT.KLUB - have a checkbox
beside the Base material
drop-down menu. If you have marked the checkbox, you have the option to select
an alternative base material in the associated drop-down list-menu. If the checkbox
is empty, access to the menu of the base materials is blocked. This option helps to
protect against unwanted changes during the assignment of the base material.

9.2.2

Deleting a database entry

Data records in KISSsoft will never be deleted. It is only possible to move entries
with an ID 20000 into the table of hidden data records. Select the appropriate
entry with a single mouse click in the window and then click the
button. The
selected row will be copied into the range that contains the hidden data records and
removed from the list of active data records. To access the table of inactive data
records, select the Display only hidden data records option in the
Filterdrop-down list menu in the top right of the database tool window.

9.2.3

Restoring a database entry

In the table of hidden data records you select the appropriate row with a single
mouse click and then click on the
button. The entry will be copied into the table
of active data records and then removed from the range of inactive data records.

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9.3

Import and export data with the database

tool

The data records from every table in the database tool can be exported to a file or
imported from a file. These data records can be imported or exported as a single
data record or imported from a list of data records.
To import a list of data records, you will need to save it in a file, preferably an Excel spreadsheet with the extension "*.csv". The inputs in the spreadsheet columns
should correspond to the database table columns.
Lists saved with the "*.txt" extension can also be interpreted by the software. The
list inputs should be separated by a "comma" or a "semicolon". The settings in your
operating system will show which separator should be used.
Import a data record from a file with the extension "*.kds".
Export the selected data record to a file with the extension "*.kds".
Import a list of data records from a file with the extension "*.csv".
Important notes:
1. Only "user data records" (ID >= 20000) >can be exported or imported.
2. An existing "user data record" can be overwritten if you are processing individual data records.
3. The names of the columns in the "*.kds" files is case sensitive and must
exactly match the names in the database tool. You could export a data record to verify the column names.
4. A new ID is assigned automatically to every data record when an entire list
is imported or exported.

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9.4

External tables

KISSsoft uses external tables, also called look-up tables, to handle larger data volumes. It is the task of external tables to assign one or more output values to one or
more input values (see Figure 9.6).

Figure 9.6: Principle of functionality of external tables

The output data that is assigned to the input data are contained in the table.
The external tables are stored in the /<KISSsoft installation folder>/dat directory.
If a new table name is entered into a database, a file with the same name and the
file extension .dat must also be created manually.
Because tables are located externally, KISSsoft can only determine how many of
them there are during program execution. The user directly benefits from the fact
that they can generate their own files with data tables in a similar way to the files
supplied by KISSsoft. The tables are readable ASCII files and consequently can be
edited and expanded by the user. It would for example be possible to use an internal standard as an alternative to the ISO base tolerances.
Figure 9.7 shows the three table types used by KISSsoft in one diagram:

Figure 9.7: Types of external tables

A table always has the following structure, no matter what type it is:
:TABLE <Type> <variable or ID>
<Table header >
DATA

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<Data>
END
The :TABLE command marks the external table as an external table. You must use
one of the following designations for the <Type> argument:
FUNCTION

Functions tables

RANGE

Range tables

LIST

List tables

NOTE

Blanks in tables can be marked with *, - or blank spaces. Note here that no space
characters may be used if they are followed by more values. KISSsoft interprets
blank space as value separators.
The structure of the table header and the body data, which is dependent on the type,
is described with example applications in the following sections.

9.4.1

Functions tables

Functions tables are tables that expect one or two input values (1D or 2D table) and
which return exactly one corresponding value.

EXAMPLE 1D TABLE

The angle coefficient (factor) is determined on the basis of a specified (angle).

For example: if the input value angle = 45 supplies an output value of factor = 0.35.
-- table type: Functions table; output variable: factor
:TABLE FUNCTION factor
-- INPUT X angle defines the input parameter angle;
-- interim values will be interpolated linearly
INPUT X angle TREAT LINEAR
-- data: 1. row: input values), 2nd line: output values

DATA
0

30

60

90

...

0.1

0.25

.45

.078

...

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END

INPUT is a key word, i.e. a word that is reserved by the Tables Interpreter, and is
followed by an argument X, which assigns a dimension to the angle input parameter. The key word TREAT, with associated LINEAR argument, specifies that
interim values are to be interpolated linearly. The output value factor will
determined using the value of the angle variable. The first row of data in the 1D
table (between DATA and END) corresponds to the input value angle, and the second row corresponds to the output value. The data in a 1D table is therefore
always a (2 n) matrix, i.e. both rows must contain the same number of values.

EXAMPLE OF A 2D TABLE

The nominal power is defined on the basis of the speed and the sheave diameter.
For example: if the input values diameter = 60 and speed = 60 supply
an output value power = 8.6.
-- table type: Functions table; output variable: power
:TABLE FUNCTION power
-- INPUT X diameter defines the input parameter diameter;
-- INPUT Y speed defines the input parameter speed;
-- interim values will be interpolated linearly in both dimensions
INPUT X angle TREAT LINEAR
INPUT Y Speed TREAT LINEAR
-- data: ( sh. Figure (see section "Example: Interference fit calculation" on page I-172))

DATA
50

100

200

300

...

50

12

25

...

75

12

25

30

35

...

...

...

...

...

...

...

END

Here, the variable power is defined with the input variables INPUT X and INPUT Y. Interim values running down the columns (Y) should be interpolated
linearly. The same applies across the rows (X). The first row in the table
corresponds to the values of the INPUT X entry variables. The first column

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corresponds to the values of the INPUT Y entry variables. The values placed at the
points where the entry values intersect are values which correspond to the output
variables (see Figure 9.8).

Figure 9.8: Data schema of 2D tables

Please note that in this way it would be possible to define an inverse table.
Assuming that, in your XY belt catalog, the table that shows the power output
contains the speed in the first row, and the diameter in the first column, then there
is no need for you to turn your table upside down. Instead, simply change the
assignment in the table header (i.e. replace X with Y).

9.4.2

Range tables

Range tables check whether a given value is moving within a defined range.

EXAMPLE

-- table type: range table; Name of the table: 'A'

:TABLE RANGE 'A'r
-- INPUT X drehzahl defines the drehzahl (speed) input parameter;
-- interim values will be interpolated logarithmically.
-- INPUT Y power defines the input parameter power
INPUT X drehzahl TREAT LOG
INPUT Y power
-- data: 1. row: INPUT X, 2nd row: INPUT Y upper limit
-- 3rd row: INPUT Y lower limit

DATA

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200

300

500

1000

4000

LOWER

1.5

2.0

3.0

10

20

UPPER

10

15

20

15

40

END

The two input variables are drehzahl (speed) and leistung (power). The output value represents the decision on whether the power in dependency with the
speed is moving within a defined range and does not have to be declared. Interim
values of the speed will be interpolated logarithmically. The first row of the body
data corresponds to values of the drehzahl (speed) variable. The other rows
correspond to values of the leistung (power) variable with LOWER as the lower,
and UPPER as the upper, limit. The input value of leistung (power) will be
compared with these limits and a report sent to the program stating whether the
leistung is located below, within, or above, the given range A.

9.4.3

List tables

In list tables containing at least one input value, several output values will be
defined. If more than one input value is entered, the sequence of the input values is
important. The reading direction goes from left to right and the first input value
defines the range of the next input value, which in turn defines that of the next one,
etc. up to the last. All input values apart from the last one must correspond with the
entries in the body data (TREAT DIRECT, list of used key words (see page I138).

EXAMPLE 1

The following three input values are assumed:

g.d = 2.0; g.P = 0.8; s.l = 6
In accordance with the code shown below, the output values would then be:
s.l = 7; s.k = 3; s.k = 4.5.
-- table type: List table; output variable s.norm

:TABLE LIST s.norm

-- INPUT g.d defines the input parameter g.d;
-- INPUT g.P defines the input parameter g.P;
INPUT g.d
INPUT g.P
-- IN_OUT s.l defines s.l as phase variable
-- TREAT NEXT_BIGGER specified how interim values are handled

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IN_OUT s.l

TREAT NEXT_BIGGER

-- OUTPUT s.k, s.dk declares s.k and s.dk as output variables

OUTPUT s.k,s.dk
-- data: A (N Nin) matrix

DATA
2.0

0.4

2.0

0.8

4.5

2.0

0.8

4.5 - relevant data row

2.0

0.8

10

4.8

END

In contrast to functions tables, s.norm in the first row of the code specifies the
name of the external table and not the output variable. IN_OUT s.l declares a
variable s.l, which is used both as an input and output variable (phase variable).
TREAT functions again as a key word for processing the interim values:
NEXT_BIGGER shows that input values are to be evaluated it they are not present
in the corresponding column of the body data. In the example, the input value s.l
= 6 lies between the values 5 and 7 and, in accordance with NEXT_BIGGER, will
be promoted to the next bigger value. OUTPUT s.k, s.dk declares not only
s.l. but also the output variables s.k and s.dk. The number of the columns of
the body data must at least correspond to the number of input variables and at most
correspond to the number of input variables + output variables, in this case: 3 < Nin
> 5.

EXAMPLE 2

To determine the diverse measurements of a bolt, two input values will be used: the
bolt type, here represented by the typ variable and the length of the bolt, given by
l.

:TABLE LIST schraube.geometrie

INPUT type
INPUT L

TREAT NEXT_SMALLER

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OUTPUT M, dw, (s), e, bez, vorrat

DATA
...
12x2.5

20

12

14.57

23.78

5.75

ID 1

12x2.5

25

12

15.78

24.88

5.75

ID 2

...
END

This table is called bolts.geometry. The sequence in the table header defines
that within the columns, the first column therefore corresponds to the typ variable,
the second to the l variable, etc. The typ and l variables will be used as inputs,
where the value for the typ variable must be present in the list. If an interim value
is given for the l variable, the row with the next smaller value will be interpreted
as the result. Blanks are not permitted, i.e. in this type table values must always be
present. It may happen that individual variables are shown in brackets in the output
definition. This has the effect that the corresponding column is ignored, i.e. this
variable will not be specified.

NOTE

Commented-out output definitions cannot be changed by the user.

9.4.4

List of key words used

--

Everything in a row coming after this comment

character will be ignored by the Interpreter.

DATA

Below this is located the data matrix.

END

Ends the input area of the external table.

INPUT [<dim>] <var>

Input variable, with definition of the dimension if

required.

IN_OUT <var 1>[, <var 2>,

...]

List tables: Phase variables

LOWER

Range tables: Lower limiting value.

OUTPUT <var 1>[, <var 2>,

...]

Output value(s)

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:TABLE <Type>

Defines the type of the external table.

TREAT DIRECT

Interim values: none permitted. Input values in the

corresponding column/row must match up with
those of the body data.

TREAT NEXT_SMALLER

Interim values: The next smallest value is

assigned.

TREAT NEXT_BIGGER

Interim values: The next highest value is assigned.

TREAT LINEAR

Interim values: Linear interpolation.

TREAT LOG

Interim values: Logarithmic interpolation.

UPPER

Range tables: Upper limiting value.

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9.5

Description of database tables

The individual database tables have very different structures. The next section
describes these database tables and their specific fields.
The Label field appears in every table and is only described once, here. You must
enter a unique name for the data record in this field. This name is then used to select the data records in the program.
Note: Fields in which file names are to be entered have an auto-fill function. To
perform this, the software searches in the ..\dat and ..\ext\dat folders, and also in the
current project directory.

9.5.1

Center distance tolerances

File name: the database entries refer to external tables (see External tables (on
page I-132)). The tables used for center distance tolerances begin with K10???.dat. The center distance tolerances specified in ISO 286 are imported directly from the program code and not from a file.

9.5.2

Machining allowance for cylindrical gear

File name: the database entries refer to external tables (see External tables (on
page I-132)). The tables for the cylindrical gear machining allowance begin
with ZADDT-???.dat.

9.5.3

Reference profiles

You input reference profile data directly in the database. However, each individual
value depends on the other.
Description in accordance with ISO: the standard on which this is based
Comment: Text field for your own use
Data source: Text field for your own use
Definable reference profile data: Dedendum coefficient h*fP, root radius
coefficient *fP, addendum coefficient h*aP, tip radius factor *aP, topping,
protuberance height coefficient h*prP, protuberance angle prP, tip form
height coefficient h*FaP, ramp angle KP

9.5.4

Compression springs standard

You can store data from geometry standards for compression springs.

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File name: the database entries refer to external tables (see External tables (on
page I-132)). The tables for compression spring standards begin with f010??.dat.
Tolerance: tolerance data for the geometry standard

9.5.5

Selection of hobbing cutters

File name: the database entries refer to external tables (see External tables (on
page I-132)). The table for cutter data in accordance with DIN 3972 is called
Z000-BP.dat.

9.5.6

Basic material Glued and Soldered joints

Tensile strength Rm: [N/mm2] Data about the tensile strength of the material is
required to calculate glued and soldered joints.

9.5.7

Manufacturing process for bevel and hypoid

gears

These values are only necessary for calculations using the Klingelnberg method.
They correspond to tables for machine types that use the Klingelnberg in-house
standard.
Values that must be defined: Machine type, Cutter radius cutter tip r0 [mm],
No. of cutter blade groups z0, Maximum machining distance MDmax [mm],
Minimum normal module mn,min [mm], Maximum normal module mn,max
[mm]

9.5.8

V-belt Standard

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for the V-belt standard begin with Z090-???.dat.
Calculation method:

1) Narrow V-belts (Fenner)

2) Narrow V-belts/ Force belts

3) Conti belts

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More definitions: Maximum belt speed vmax [m/s], Elasticity E [N], Weight
per length q [kg/m], Coefficient of friction r

9.5.9

Spline Standard

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for spline standard norms begin with M02C-???.dat.
Calculation method: the appropriate calculation method is selected for each
spline.

9.5.10

Chain profiles ISO606

Values to be defined for this table: Type, Pitch p [mm], Number of strands
ns, Maximum diameter of roller d1 [mm], Maximum bearing pin body
diameter d2 [mm], Minimum width between inner plates b1 [mm], Maximum width over inner link b2 [mm], Total width btot [mm], Maximum inner plates depth h2 [mm], Ratio tH/tS

9.5.11

Adhesives

Comment: Text field for your own use

Definable values: Minimum and maximum shear strength B,min ,B,max
[N/mm2].

9.5.12

Modifications

The different modifications applied to gears are defined as database classes. If a

data record is not displayed in the database it will no longer appear in the
modifications selection list.
Although you can add new data records to the database, these will not be visible in
the calculation module.

9.5.13

Load spectra

All inputs (frequency, power, speed) must be defined in coefficients. The power and speed are given as factors of the nominal power. In the calculations,
the coefficient for torque (load factor/speed factor) is used for forces and torques. You can either import load spectra from a file or enter them directly. If

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you input this data directly, the number of load cases is defined by the number
of rows you enter.
Input: Specify whether the factors are for power or torque. This also applies if
the load spectrum is imported from a file.
Read load spectrum from file: If this flag is set, you can select a file with the
load spectrum. If the flag is not set, you can input the load spectrum directly.
Own input of load spectra: You can input the load spectrum directly or load
it from a file.
File name: Click the
button to select a file from the directories. The file
containing the load spectrum must be a text file (*.dat). You will find a sample
load spectrum file (called "Example_DutyCycle.dat") in the "dat" directory.
You should store load spectra you define yourself in the "EXT/dat" directory to
ensure they are always available even after a version upgrade.

Example of a file used to input a load spectrum

Frequency: H0 ... H19, the total of these frequencies must be 1.

Load factor (torque factor): P0 ... P19, 0 < Pn < .
Speed factor: N0 ... N19, 0 < Nn < .
Load spectrum bins with negative power or speed are interpreted as a change from
driving to driven. This does not affect the root and flank strengths, however it does
change the safety against scuffing and against micropitting.

9.5.14

Solders

Definable values: Minimum and Maximum shear strength B,min , B,max

[N/mm2].

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9.5.15

Surface roughness of shafts and shaft -hub connections

You can also input your own data for shaft-hub connections in the "Own Input"
field. The Rz values for the shafts are taken from the list.
Comment: Text field for your own use
Definable values: Average roughness height Rz [m] and Roughness average value Ra [m].

9.5.16

Key standard

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for key standards begin with M02A-???.dat.

9.5.17

Polygon standard

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for polygon standards begin with M02D-???.dat.

9.5.18

Woodruff Key standard

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for polygon standards begin with M02E-???.dat.

9.5.19

Bolts/pins

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for bolts/pin standards begin with M03A-???.dat.

9.5.20

Lubricants

Comment, description as specified in ISO, data source: Text fields for your
own use
Additive for rolling bearings:

without additives: lubricants without additives, or with those additives

whose effectiveness in roller bearings has not been tested.

with additives: lubricants, whose effectiveness has been tested in roller

bearings

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Oil/ Grease: specify whether the lubricant is an oil or a grease.

Kinematic viscosity at 40C and at 100C 40,100 : [mm2/s]
Lubricant base: Selection options:

Mineral oil

Synthetic oil based on polyglycol

Synthetic oil based on polyether

Synthetic oil based on polyalphaolefin

Synthetic oil based on esters

Polyalphaolefin: similar to mineral oil, easily mixable with mineral oil,
some approved for use with foodstuffs.
Esters: some approved for use with foodstuffs, some biodegradable.
Test procedure scuffing: Selection options:

No information about scuffing

FZG Test A/8.3/90; ISO 14635-1 (normal)

FZG Test A/16.6/90

FZG Test A/16.6/120

FZG Test A/16.6/140

FZG Test A10/16.6R/120; ISO 14635-2

Input of scuffing temperature

Load stage for scuffing FZG test: Input scoring load level as specified in the
FZG test. These values are required for gear calculations.
1= weakest level; 12=best level
Good gear lubricants all have scuffing load level 12.
Scuffing temperature s: You can also input the scuffing temperature for the
scuffing test procedure.
Micropitting process: Selection options

No information available for micropitting load stage

C-GF/8.3/90 (FZG)

Load stage micropitting test: The best achievable load stage is 10.
Density : [kg/dm3]

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Cone penetration at 25C (grease) Pe: [0.1mm] This value is only required to
calculate grease lubricated sliding bearings.
Soap proportion (Grease) cs: [Vol%] This value is only required to calculate
grease lubricated sliding bearings.
k-coefficient, s-coefficient (compression viscosity) k, s: Coefficient used to
calculate compression viscosity (AGMA 925):

If you do not know these values, you can input 0 and then the values are
taken from the standard (AGMA 925-A03, Table 2).
Lower/ Upper limit working temperature min, max : [C]

9.5.21

Bolts: Tightening factor

Calculation method: Select VDI 2230(1990) and VDI 2230(2014)

Minimum tightening factor Amin: Minimum value, can be defined per tightening technique.
Medium tightening factor Amid: Medium value, can be defined per tightening technique.
Maximum tightening factor Amax: Maximum value, can be defined per tightening technique.

9.5.22

Bolts: Bore

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for bores begin with M04-???.dat.
Unit in use: select whether the values in the file are to be given in mm or inches.

9.5.23

Bolts: Strength class

Comment: Text field for your own use

Definable values: Yield point Rp [N/mm2], Tensile strength Rm [N/mm2],
Shearing strength ratio b/Rm[-]

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NOTE:

The yield point and tensile strength for the lower diameter limit for strength classes
8.8 and SAE J429 Grades 2 and 5 are always displayed in the database. If the diameter is greater than the diameter limit, this is corrected in the program.
The shearing strength ratios were taken from the Table 5.5/2 in VDI 2230 (2014)
according to the strength classes. Undefined SAE classes are set to the ratio 0.6.

9.5.24

Bolts: Nuts strength class

Comment: Text field for your own use

Definable values: Vickers hardness for standard thread for diameter d <=
16 mm [HV], Vickers hardness for standard thread for diameter d > 16
mm [HV], Vickers hardness for fine thread for diameter d <= 16 mm
[HV], Vickers hardness for fine thread for diameter d > 16 mm [HV]
NOTE:

The minimum value specified in the DIN EN ISO 898-2:2012 standard is assumed
in the strength grades. However, as this value depends on the diameter, in some
strength grades, both values are defined in the database. In the program, you can
then specify which diameter the value is to be used for. The same applies to
differentiating between fine or standard threads. The program handles the value
that is being used differently, according to the selection in the interface.

9.5.25

Bolts: Coefficients of friction classes

Comment: Text field for your own use

Definable values: Minimum coefficient of friction min [-] and maximum
coefficient of friction max [-]
NOTE:

The minimum and maximum coefficients of friction are always displayed in the
database for the coefficients of friction classes. The values are used to size the
coefficients of friction for bolts.
The predefined values are taken from Table A5 in VDI 2230, Sheet 1 [75].

9.5.26

Bolts: Thread type

Name: Text field for your own use

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for threads begin with M04-???.dat.

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Coefficient used to calculate the flank diameter/core diameter

Flank angle : []

9.5.27

Bolts: Nuts

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for nuts begin with M04-???.dat.
Unit in use: select whether the values in the file are to be given in mm or inches.

9.5.28

Bolts: Type

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for bolt types begin with M04-???.dat.
Name: Text field for your own use
Thread type screw: selection list to show which thread type this bolt belongs
to.
Unit in use: select whether the values in the file are to be given in mm or inches.

9.5.29

Bolts: Washer

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for washers begin with M04-???.dat.
Unit in use: select whether the values in the file are to be given in mm or inches.

9.5.30

Selection of pinion type cutters

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for pinion type cutters begin with Z000-Cutter-?.dat.

9.5.31

Disc spring standard

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for disc springs begin with F040-?.dat.

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9.5.32

Tolerances standard

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for tolerances begin with K10-???.dat.
The tolerances in accordance with DIN EN ISO 286 have been programmed
directly into KISSsoft. For tolerance classes H, h, JS and js, the tolerance has been
extended up to the nominal length 10000 mm (according to the standard up to 3150
mm). The values were determined by extrapolation.

9.5.33

Beam profiles

Drawing file: image displayed on screen when a shaft is calculated.

Values for profiles: Height h [mm], Width b [mm], Cross section A [cm2],
Moments of inertia of plane area on x/z axis Ix/ Iz [cm4], Moment of inertia
of torsion It [cm4], Section modulus relating to x /z axis Wx/ Wz [cm3], Moment of resistance in torsion Wt [cm3]

9.5.34

Multi-Spline standard

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for multi-spline profiles begin with M02b-???.dat.

9.5.35

Materials

The materials consist of a database table Basic data Materials and the particular
table for the modules. The Basic data table lists the general material data. As the
materials can then be transferred to the individual module tables, you therefore
only need to define the basis data once. Module-specific data is then defined in the
module tables.
In module-specific tables, you must always select one Base material.

9.5.35.1

Basic data: Mate rials

Label according to DIN, BS, AISI, UNI, AFNOR, JIS, CN, Old label, Material number, Origin of data, Comment: Text fields for your own use
Young's modulus at 20C E20: [N/mm2]
Poisson's ratio : [-]
Density : [kg/dm3]

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Coefficient of thermal expansion : [10-6/K]

Shearing modulus at 20C G20: [N/mm2]
Type of treatment: In this list you can select the type of treatment.
Material type: In this list you can select the material type.
Hardness value: This value is purely for information purposes and has a
negligible effect on the calculation.
Hardness unit: You can select this in this list.
Core hardness value: this value is used, for example, for the strength calculation according to AGMA 6101-E08/AGMA 6001-E08. However, for other calculations, the value is purely for information purposes and has only a minor influence on the calculation. For case-hardened case hardening steels, the value
for the tensile strength Rm was taken from the DIN EN 10084 standard for a
diameter between 16 and 40 mm, and was then calculated with the hardness
conversion of the Brinell hardness HBW.
Core hardness unit: You can select this in this list. You can select Brinell
hardness or Vickers hardness as input values.
Tensile strength Rm: [N/mm2] A max. of 10 different diameter ranges can be
defined
Yield point Rp: [N/mm2] A max. of 10 different diameter ranges can be defined
Raw diameter d: [mm] A max. of 10 difference diameter ranges can be defined

9.5.35.2
Material Spring calcul ation
This table applies to Compression (F010), Tension (F020) and Leg springs (F030)

Permissible shear stress: the database entries refer to external tables (see External tables (on page I-132)). Tables for springs begin with F01-???.dat. In
this file you can view or define the permissible shear stress, the values for the
Goodman diagram and the values for the relaxation diagram. If the curves of
the relaxation diagram are only defined with 2 points, you must set the values
for tau3 and rel3 to 0 so KISSsoft can recognize them.
Comment: Text field for your own use
Minimum and Maximum wire diameter dmin, dmax [mm]
Shearing modulus depending on temperature G: [1/K]
Use: selection list with the cold and thermo-formed variants

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9.5.35.3

Material o f plain bearings

Comment: Text field for your own use

9.5.35.4
Material o f e nve loping worm wheels
The table applies to worm wheels (Z080)

Comment: Text field for your own use

Material characteristics: Selection list (such as CuSn bronze/ CuAl bronze/
GGG40/ GG25/ PA-12)
Mineral oil coefficient WMLOel: Material/lubrication coefficient for mineral oil
Coefficient for polyglycol (DIN)/ (ISO) WMLGDIN/ WMLGISO: Material/lubrication coefficient for polyglycol
Coefficient for polyalphaolefin WMLA: Material/lubrication coefficient for
polyalphaolefin
Material coefficient YW: (see DIN 3996, Table 5)
Pitting strength HlimT: [N/mm2] (We recommend you use reduced values as
specified in ISO 14521)
Shear fatigue strength FlimT: [N/mm2]
Reduced shear fatigue strength FlimTred: [N/mm2] (If no slight deformation is
permitted, you must include reduced strength values in the calculation.)

9.5.35.5

Material Interfe rence fit

Comment: Text field for your own use

9.5.35.6 Material o f bolts

The table applies to the bolt module (M040)

Comment: Text field for your own use

Permissible pressure pG: [N/mm2] (Data should be entered as specified in
VDI 2230)
Shear strength B: [N/mm2]

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9.5.35.7

Material Welded jo ints

Comment: Text field for your own use

9.5.35.8 Material Di sc spring calculation

The table applies to disc springs (F040):

Comment: Text field for your own use

Goodman diagram: the database entries refer to external tables (see External
tables (on page I-132)). Tables for the Goodman diagram begin with F04???.dat.
Young's modulus depending on temperature E: [1/K]

9.5.35.9

Material o f sh aft - hub connection

Comment: Text field for your own use

9.5.35.10 Material Shaft ca lculat ion

The table applies to shafts (w010):

Values for calculating strength according to Hnchen:

Bending fatigue limit bW: [N/mm2]

Values for strength calculation according to DIN 743:

Reference diameter db [mm], Tensile strength Rm [N/mm2], Yield point

Rp [N/mm2], Bending fatigue limit bW [N/mm2], Tension/Compression
fatigue limit zdW [N/mm2], Torsion fatigue limit tW [N/mm2]

Experimental data: the database entries refer to external tables (see

External tables (on page I-132)). Tables for the experimental Haigh
diagram begin with W01-???.dat.

CrNiMo case hardening steel: When determining the size coefficient K1

for case hardening steel, you need to specify whether the steel is CrNiMo
case hardening steel. The materials 20NiCrMo13-4, 17NiCrMo6-4,
17NiCrMoS6-4, 18NiCr5-4, 17CrNi6-6, 18CrNiMo7-6, 14NiCrMo13-4,
22CrMoS3-5 and 15NiCr13 belong to this group. According to DIN
10084, there is no significant drop in the tensile strength of these materials.
These materials also belong to this group according to Prof. Linke.

Values for strength calculation according to FKM:

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Tensile strength for reference diameter Rm,N [N/mm2], Yield point for
reference diameter Re,N [N/mm2], Effective reference diameter for
deff,N,p deff,N,p [mm], Effective reference diameter for Rm,N deff,N,m
[mm], Constant used to calculate Kd (flow) ad,p, Constant used to
calculate Kd (fracture) ad,m , Tension/compression fatigue limit for reference diameter W,zd,N [N/mm2], Fatigue limit for bending for reference diameter W,b,N [N/mm2], Shear stress fatigue limit for reference
diameter W,s,N [N/mm2], Torsion fatigue limit for reference diameter
W,t,N [N/mm2]

Elongation at break A: [%]

FKM Group: Selection list showing the material group to which the entry
belongs.

9.5.35.11

Material o f gears

Comment: Text field for your own use

File for hardness curve: the database entries refer to external tables (see External tables (on page I-132)). Tables for the hardness curve begin with Z22???.dat. Measured hardness value of the material shown as a graphic in module
Z22. Does not influence the calculation. Here is an example of how to create
this type of hardness curve in an external table.

Figure 9.08: Example of a hardness curve definition (Z22-100.dat)

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Woehler line file: the database entries refer to external tables (see External
tables (on page I-132)). Tables for Woehler lines begin with Z014-10?.dat.
You must input a file name for plastics here. The file contains material data
(Woehler lines, Young's modulus, etc.) used in the calculation.
For metallic materials you can also input a file name here. The file contains
the Woehler lines for resistance to bending and for Hertzian pressure that are
used in the calculation, if the Calculate with own Woehler line
flag is set.

Figure 9.09: Example of a file with Woehler lines for a metallic material

Endurance limit root (ISO, DIN/ AGMA 2101) Flim/sat, Endurance limit
flank (ISO, DIN AGMA 2101) Hlim/sac: [N/mm2] Endurance limit values specified in DIN 3990 or ISO 6336 Part 5.
Endurance limit root (AGMA 2001) sat,Endurance limit flank sac (AGMA
2001): [lbf/in2] Strength calculation based on AGMA 2001.
Mean peak-to-valley roughness root/flank RzF/ RzH: [m]
Thermal contact coefficient BM: [N/mm/s0.5/K] This coefficient is needed to
calculate the flash factor. You will find more information about this in DIN
3990, Part 4, equations 3.11, 4.17, 4.18, 4.19. For the most commonly used
materials it is 13.795.

9.5.36

Roller bearing

Roller bearing tables are sub-divided into 2 different tabs:

Basic data tab

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Internal geometry tab

9.5.36.1

Rolle r bearing basis data

Bearing label: The codes for the bearing series are as specified in DIN 623
Part 1.
Main dimensions of the bearing: Inside diameter d [mm], External diameter
D [mm], Bearing width b [mm], Corner radius rsmin [mm]
Dynamic load number C: [kN]
Static load number C0: [kN]
Factors X1, Y1, X2, Y2, e, e0, X01, Y01, X02, Y02
Defining individual factors:
X1,Y1,e:

Coefficients in formula P = X1*Fr + Y1*Fa for

Fa/Fr <= e

X2,Y2:

Coefficients in formula P = X2*Fr + Y2*Fa for

Fa/Fr > e

X01,Y01,e0:

Coefficients in formula P0 = X01*Fr + Y01*Fa for

Fa/Fr <= e0

X02,Y02:

Coefficients in formula P0 = X02*Fr + Y02*Fa for

Fa/Fr > e0

X1,Y1,X2,Y2,e:

For some bearings, these values are not imported

from the database. Instead they are imported from
the files, depending on the axial force.

Ball bearing: dependent on f0*Fa/C0

at normal bearing clearance: Data is imported from file W05-100.dat

at bearing clearance C3. Data is imported from file W05-101.dat

at bearing clearance C4: Data is imported from file W05-102.dat

Shaft bearing: dependent on f0*Fa/C0/i
for bearings with pressure angle 15

Single bearing: Data is imported from file W05-103.dat

Bearing in O or X arrangement: from file W05-104.dat

Speed limit using grease lubrication nGmax: [1/min]

Speed limit using oil lubrication nOmax: [1/min]
Weight m: [kg]

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Contact angle 0: [] Input the contact angle for high precision angular contact ball bearings, ball bearings etc. for four-point contact bearings:
If you input 0 this is set to 35
for axial spherical roller bearings: If you input 0 this is set to 50.
Permitted axial force F*azul: [-] Input the permitted axial force in % of Fr. The
permitted axial force is not checked if you input 0.
Maximum set angle : [min] If you input 0, the angle adjustability (i.e. a
comparison of the permitted angular deviation of the shaft with the effective
angular deviation in the bearing) is not checked.
Thermal reference speed nr: [1/min]
currently not evaluated in KISSsoft: Availability (0=in stock; 1=not in stock),
price [in local currency]
Addition A-E: You can input additional data for specific types in these fields.
(see table: Use of additions A-E.)
radial and axial spring stiffness cr ,ca: [N/m]
Spring stiffness for bending crot: [Nm/] Input spring stiffness for bending.
Coefficient f0: Required to determine x and y (for example, for deep groove
thrust ball bearings) as these values depend on the coefficient f0*Fa/C0.
Minimum load P/C: Minimum load P/C (P: average dynamic equivalent load:
C: dynamic load rating) is usually:

0.01 for cylindrical roller bearings with a cage

0.02 for roller bearings with a cage

If you input 0 in the database, these values are used automatically in the
calculation.
This entries only apply to radial load. The minimum axial force is
calculated directly in the software.
Fatigue load limit Cu: Coefficient for calculating the extended service life
Type

Addition A

Addition B

Angular contact
bearing (single row)

Displacement a
(mm) (*2)

Shaft bearing (paired)

Displacement a
(mm) (*2)

Axially cylindrical
roller bearing

Coefficient A (*1)

Addition C

Addition D

Max. axial
force (kN)

Addition E

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Tapered roller bearing

(single row)

Width B (mm)

Taper roller bearing

(paired, O)

Dimension T (mm)
(*1)

Dimension C
(mm) (*1)

Tapered roller bearing

(paired, X)

Dimension 2B
(mm)

Dimension
2T (mm)

Barrel-shaped and
spherical roller
bearings

Calculation coefficient
k1 (SKF: CARB,
Internal geometry)

Calculation
coefficient k2
(SKF: CARB,
Internal geometry)

Axially spherical
roller bearing

Dimension d1 (mm)

Dimension T2
(mm)

Displace
ment a
(mm) (*2)

Mass D1
(mm)

Dimension C
(mm)

Dimension
T1 (mm)

Table 9.4: Use of additions A-E

Descriptions given in additional data conform with those in the INA/FAG

catalog 2008.
(*1)

Values are only used for SKF bearings, as specified in the SKF catalog

2005.
(*2)

Values for the mass a for FAG bearings have been provided by the
manufacturer up to the center point. In KISSsoft, half the bearing width was then
added to this value for the database (this may result in values that vary slightly
from those in the bearing catalog). The value at the bearing center was used in this
calculation. This corresponds to the data we received from the manufacturer.

9.5.36.2
Rolle r bearin g Inte rnal geometry
Description of the Inner geometry tab:

Inner geometry data is not yet available for every bearing type.
The Material ID is present in every table in which you must select a material for
the balls. However, this is not yet taken into account.
List of bearings whose inner geometry is taken into account.
You need the details documented below in order to calculate inner geometry.
You can specify a user-defined roller profile definition file (".dat") for roller
bearings. The third column is the custom defined roller profile, given relative to the
roller diameters in non-dimensional form. (Acceptable range of values from 0 to
0.5). The second column is the position on the rollers of the profile defined above,
and is given relative to the roller length in a non-dimensional form. The origin is

Coefficien
t A (*1)

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the roller center, so the acceptable range here is from -0.5 to +0.5. The first column
is the data index, and is not used in the calculation.
Deep groove ball bearing (single row), four-point contact bearing: Number of
balls Z [-], Ball diameter DW [mm], Reference diameter DPW [mm], Inside
diameter of the rim, pressure side DBI [mm], Outside diameter of the rim,
pressure side DBA [mm], Radius of curvature, inside ri [mm], Radius of
curvature, outside ro [mm]

Figure 9.10: Dimension of the deep groove ball bearing

Angular contact ball bearing (single row): Number of balls Z [-], Ball diameter DW [mm], Reference diameter DPW [mm], Inside diameter of the rim,
pressure side DBI [mm], Outside diameter of the rim, pressure side DBA
[mm], Radius of curvature, inside ri [mm], Radius of curvature, outside ro
[mm], Minimum initial tension vmin [m], Maximum initial tension vmax
[m], Minimum pretension force Fvmin [N], Maximum pretension force
Fvmax [N]

Figure 9.11 Dimension of the angular contact ball bearing

Cylindrical roller bearing (single row): Number of rollers Z [-], Diameter of

roller DW [mm], Reference diameter DPW [mm], Inside diameter of the rim,

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pressure side DBI [mm], Outside diameter of the rim, pressure side DBA
[mm], Roller length LWE [mm], Axial displacement possibility non-locating
bearing vl [mm], Axial displacement possibility fixed bearing vf [mm]

Figure 9.12: Dimension of the cylindrical roller bearing

Cylindrical roller bearing (double row): Number of rollers Z [-], Diameter of

roller DW [mm], Reference diameter DPW [mm], Inside diameter of the rim,
pressure side DBI [mm], Outside diameter of the rim, pressure side DBA
[mm], Roller length LWE [mm], Row distance a [mm]

Figure 9.13: Dimension of the double row cylindrical roller bearing

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Taper roller bearing (single row): Number of rollers Z [-], Diameter of roller
DW [mm], Reference diameter DPW [mm], Roller length LWE [mm]

Figure 9.14: Dimension of the taper roller bearing

Double row self-aligning roller bearings Number of rollers Z [-], Diameter of

roller DW [mm], Reference diameter DPW [mm], Inside diameter of the rim,
pressure side DBI [mm], Outside diameter of the rim, pressure side DBA
[mm], Radius of curvature, inside ri [mm], Radius of curvature, outside ro
[mm]

Figure 9.15: Dimension of the double row self-aligning roller bearing

Needle roller bearing, Needle cage: Number of rollers Z [-], Diameter of roller DW [mm], Reference diameter DPW [mm], Roller length LWE [mm], Axial
displacement possibility non-locating bearing vl [mm]

Figure 9.16: Dimension of the needle roller bearing/needle cage

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Deep groove thrust ball bearing Number of balls Z [-], Ball diameter DW
[mm], Reference diameter DPW [mm], Radius of curvature, inside ri [mm],
Radius of curvature, outside ro [mm]

Figure 9.17: Dimension of the deep groove thrust ball bearing

Cylindrical thrust roller bearing Number of rollers Z [-], Diameter of roller

DW [mm], Reference diameter DPW [mm], Roller length LWE [mm]

Figure 9.18: Dimension of the cylindrical thrust roller bearing

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Double row self-aligning thrust ball bearing Number of rollers Z [-], Diameter of roller DW [mm], Reference diameter DPW [mm], Roller length LWE
[mm], Distance LWC [mm], Radius of curvature, inside ri [mm], Radius of
curvature, roller Rp [mm], Radius of curvature, outside ro [mm]

Figure 9.19: Dimension of the Double row self-aligning thrust ball bearing

9.5.37

Roller bearing tolerance

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for roller bearings begin with W05-??-??.dat.

9.5.38

Roller bearing Tolerance classes

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for roller bearing tolerance classes begin with W05???.dat.

9.5.39

Tooth thickness tolerances

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for tooth thickness tolerances begin with Z01-???.dat or
Z9-???.dat.

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Interpret as:

Tooth thickness allowance: the data is interpreted as a tooth thickness

allowance.

Base tangent length allowances: the data is interpreted as the base tangent
length allowances (or normal play).

9.5.40

Toothed belt standard

File name: the database entries refer to external tables (see External tables (on
page I-132)). Tables for the toothed belt standard begin with Z091-???.dat.
Calculation method:

1)"normal" toothed belts (RPP)

2) GT types (PolyChain)

3) AT types (Brecoflex)

4) PG types (PowerGrip)

Differences:

Special calculation for toothed belts with integrated steel rope (Method 3)

Calculating the operating factor: the special factor for the speed increasing
ratio is added (Method 1, 2, 4) or multiplied (Method 3)

Additional performance table for higher performance at greater

conversions (Method 2)

Calculation method for belt pretension:

1) in % of the circumferential force; Slack = 1/50 of the tension length

2) in % of the maximum permitted circumferential force; Slack = 1/50 of

the tension length

3) in % of (operating factor*performance(W)/circumferential speed reference circle (m/s)) (according to DAYCO RPP Panther) Slack = 1/64 of the
tension length

4) in % of the circumferential force ; Slack = 1/64 of the tension length

Nominal range for power table b: [mm] belt width, which corresponds to the
performance data stored in the file (see file name).
Coefficient for belt pre-tension f: 0 ... 1.0 (% factor for calculating the coefficient for belt pre-tension)

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Maximum belt speed vmax: [m/s]

Summand for operation Fs: No influence
Pitch p: [mm] pitch of the toothed belt
Elasticity E: [N] Elasticity = force that doubles the length of a belt (with nominal width). If you do not know this value, enter 0 as the threshold value (in
this case the elasticity is ignored when the bending test is performed).
Strain : [%] Strain along the total length of the belt
Weight per length q: [kg/m/mm] per meter length and millimeter width
File contents:
List of suggested standard tooth numbers for toothed
lock washers

:TABLE LIST z.RadZahne

List of suggested belt standard tooth numbers

:TABLE LIST z.NormZahne

Minimum number of teeth, depending on the speed

(small disc)

:TABLE FUNCTION
z091k.factorINCR

Correction factor for powering up, depending on the

ratio (this is added to the operating factor)

:TABLE FUNCTION
z091k.factorINCR

Transmissible power depending on the number of

teeth (small disc) and speed (small disc)

:TABLE FUNCTION z091k.powerNr

Correction factor for the number of contacting teeth

(small disc)

:TABLE FUNCTION
z091k.factorCorrEZ

Correction factor for belt length

:TABLE FUNCTION
z091k.factorLength

Correction factor for belt width

:TABLE FUNCTION belt.bth

Correction factor for belt width (same values as

shown in the table above)

:TABLE FUNCTION belt.beff

Disc width depending on belt width

:TABLE FUNCTION
z091k.ScheibenBreite

Belt type-layout: minimum transmissible power

(lower limit) depending on the speed (small disc)

:TABLE FUNCTION z091k.kWlower

Belt type-layout: maximum transmissible power

(upper limit) depending on the speed (small disc)

:TABLE FUNCTION z091k.kWupper

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Chapter 10
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10.1

Interfaces between calculation programs

and CAD - Overview

The closest contact point of calculation programs within a CIM concept is the one
with the drawing program (CAD). KISSsoft's public data interface can be freely
formatted, allowing for very powerful communication with third party programs.
All input and output data can be exported in ASCII format. The scope and format
of this data is freely definable. For this, each calculation module contains a special,
editable report file. The MMMMUSER.RPT1 files are used as a template for this
data transfer. The default setting is that these files are empty. If you want to output
data over the interface, you first have to expand the templates. External programs
can, in addition, transfer input data (also in ASCII format) to calculation modules.
This data is read automatically during start-up, and then displayed on the screen.

10.1.1

Efficient interfaces

An automated data transfer between calculation and CAD should only be

established if the benefits are considerably larger than the effort required. For
example, an interface between a bolt calculation program and CAD is only of
secondary importance since the information to be transferred (for example that, due
to the calculation, an M10 bolt has to be selected) is too limited and could be
transferred much faster "by hand". If, however, a standard parts library with bolts is
available, the bidirectional link between the three components (calculation program, standard parts library and CAD) can prove very efficient.
The following efficient interfaces are available (but this list can be extended):
General
It should be possible to start the calculation programs from the CAD environment (for example by pressing a function key). This enables you to carry out a
short calculation while you are drawing, transfer the results and then continue
drawing.
Shafts and bearing calculation

Output of a contour from the CAD (i.e. a shaft from detailed or drawing
with combined elements) and reading it into the calculation program. (Problem: in many CAD programs it is unfortunately rather difficult to define
the contour to be exported.)

The character string MMMM in a file name is a placeholder for the module to which the file refers.
Example: M040USER.RPT

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Output of a shaft that has been optimized in the calculation program

(including roller bearings etc.) and reading it into CAD as drawing information.

Transfer of bending and similar data into the CAD.

Roller bearings and plain bearings are calculated and then the contour is
transferred to the CAD system. (Frequently, the CAD already contains information on roller bearings, so that only the bearing label is of interest.)

Gear calculation

Calculation of fabrication data in the program and transfer of the required

values to the CAD as text. This is a very important function, since the recording of the data is rather error-prone, and the consequences of errors
can be correspondingly serious.
Calculation of the exact tooth form in Print Preview and transfer to the
CAD. (Although this results in very pretty drawings, it usually does
not supply any necessary information, except if the data undergoes further processing, i.e. via transfer onto a wire electro-discharge machine.)

Transfer of the schematic axial section or the Print Preview of the gears to
the CAD system (can, however, be done just as fast "by hand" in CAD).

Machine elements
Transfer the contour of calculated machine elements to the CAD such as bolts,
V-belt sheaves etc. (Frequently, the CAD station already contains appropriate,
preprogrammed information, so that only the parts definition is of interest).
Shaft-hub connection
The sizing or proofing of connections should be implemented directly in a
CAD system, so that known data from the CAD can be transferred into the
calculation and the results of the calculation can in turn be returned to the CAD
system.

10.1.2

Open interfaces concept in KISSsoft

The KISSsoft interfaces concept has a simple, yet very flexible structure.
It should be possible to integrate calculation programs into all kinds of CAD systems as simply as possible, and use them in different environments (operating systems such as MS Windows or UNIX).
The interface mechanism between CAD and KISSsoft is based on a text data record (ASCII file), and an ID is transferred together with the numerical value for all

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transfer data (see Figure in example (see section "Example: Interference fit
calculation" on page I-172)). This data record can be of variable length, while only
the values that are known in the CAD will be transferred. This depends on the
CAD system and the currently active drawing.
The data record transferred by the third party program will be tested for
completeness and consistency by KISSsoft and if it should prove necessary, additional data will be requested in the KISSsoft input system. Subsequently, the
calculation will be carried out and the output data important for the CAD will be
written into a second text data record and returned to the CAD. By using the report
generator you can select any format for the output file, i.e. KISSsoft adapts itself to
the third party program. The CAD can now read the data required by the situation
and selectively process them.
This concept results in simple interface forms, consequently enabling even nonspecialists to write applications quickly.

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10.2

Defining input and output

10.2.1

Preamble

In this description the KISSsoft program is always taken as a reference, i.e. an

input file for KISSsoft becomes an output file for the third party program and
vice versa.
For automatic data exchange with other programs you will require files with
the name MMMMUSER.RPT. You can adapt these files to your own requirements. However, if you have purchased KISSsoft interfaces, you should act
with caution, since these files are also required for these interfaces.
File name

Storage location

Description

MMMMUSER.IN

<CADDIR> *)

Input file for KISSsoft (is written by the third

party program)
User's temporary input file (= will be deleted
when imported into KISSsoft)

MMMMUSER.OUT

<CADDIR>

KISSsoft output file (will be written by

KISSsoft and read by the third party program).
Temporary (= should be deleted by the third
party program)

MMMMUSER.RPT

<KISSDIR>

Defines the output format (similar to report),

can be permanent/optional (= will usually be
created once and is retained)

Z10Gear1.RPT
Z10Gear2.RPT
Z10Gear3.RPT
Z10Gear4.RPT

<KISSDIR>

Defines the output format for the manufacturing

data in the case of cylindrical gears (see below).
Corresponds to MMMMUSER.rpt for this special case.

Z10Gear1.OUT

<KISSDIR>

Output file of the toothing stamp

for cylindrical gears.

Z70Gear1.RPT
Z70Gear2.RPT

<KISSDIR>

Defines the output format for bevel gears.

Z17Gear1.RPT
Z17Gear2.RPT

<KISSDIR>

Defines the output format for crossed helical

gears.

Z80Gear1.RPT
Z80Gear2.RPT

<KISSDIR>

Defines the output format for worm gears.

Z9aGear1.RPT
Z9aGear2.RPT

<KISSDIR>

Defines the output format for spline connections.

Z??Gear1.OUT
Z??Gear2.OUT

<CADDIR>

Toothing stamp, similar to definition files.

*) If you specify the complete file name including the directory, it can also be read
from any location.

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10.2.2

Requirements placed on the third party pr ogram

To successfully operate KISSsoft within a third party program, the following

minimum requirements must be met. The third party program must
1. have a query mechanism (i.e. macro language) in order to provide information, e.g. input data,
2. be able to write and read ASCII files,
3. be able to start a program.

10.2.3

Used files

10.2.3.1
Input fil e
An input file with the name MMMMUSER.IN will be used. It has the same structure and the same function as the saved calculations, except for its temporary status.
The values will be assigned to the KISSsoft variable names with =. A separate row
will be used for each variable.

EXAMPLE

VERSION=2.5;
m02Aw.dWa=30;
m02Aw.lW=20;
m02An.lN=25;
The input file will be read after the default values are predefined (see page I-51),
i.e. the values of the temporary input file will overwrite the values set by the default.
Note: Temporary input files are used for frequently changing variables such as
geometry and/or performance data: data which typically changes from calculation
to calculation. It would also be possible to write this data into the template files,
since they represent normal input variables. This would however mean that the
program generating these files had to interpret the data that has already been
written, i.e. has to accept permanent constraints, in order to be able to completely
define the standard and to reset it again at the end.

10.2.3.2
Output file
To return the data that is relevant for the KISSsoft calling program, the specified
output file MMMMUSER.OUT will be generated immediately after a calculation.

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The scope and the format of the output file will be defined in a report template
called MMMMUSER.RPT.
This means that KISSsoft can fully adapt itself to the syntax of a third party program. The range of commands and the syntax of the report generator are described
in the Reports (see section "Report templates" on page I-113) section. To help you,
example report files are supplied.

10.2.4

Service life of files

The input file MMMMUSER.IN is generated by the third party program and, after
having been read, will be deleted by KISSsoft. The output file MMMMUSER.OUT
will be deleted when KISSsoft starts, and be written again after a calculation.

10.2.5

Explicitly reading (importing) and generating

data

In addition to the automatic definition described above, you can click the File
> Interface > Import data menu to read (import) data specifically via
or click File > Interface > Export data. You are therefore
completely free to choose the point in time and thus use it for many varied tasks,
i.e. the generation of an order form etc.

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10.3

Example: Interference fit calculation

The following example of the Interference fit assembly calculation is used to

illustrate the way that the KISSsoft interfaces concept works, in more detail.
For the Interference fit assembly between the gear rim and the cylindrical gear hub,
the user needs to find the one tolerance pairing that meets the following
constraints:
Permanent torque MD = 88000 NM
The tolerance pairing involves a system of the standard drill hole (H) .
Safety

against sliding > 1.4

against fracture of the wheel or hub > 1.5
against fracture of the gear rim > 1.5
against the yield point of the hub > 1.1
against the yield point of the gear rim > 1.1

Pro c ed ur e :

The necessary information for the geometry will be extracted direct from the drawing, with a suitable CAD routine, and converted into the interfaces format defined
by KISSsoft:
m01allg.df=640
m01n.da=800
m01w.di=242
m01allg.l=200

Content of the M010USER.INI file

Then, the user starts the KISSsoft module. It accepts the geometry data and displays it in the main screen.
In the main screen, the user enters any parameters that are still missing, the torque
and the materials, and then starts the calculation. KISSsoft also allows the user to
size the tolerance pairing. Here, the user is asked to select the suitable tolerance
combinations from a list and the system then carries out the calculation with the
user's final selection.
After the user has concluded the calculation, the results file is automatically
converted to a format that can be read via the CAD macro. The format of this result
file is defined via the templates file M010USER.RPT:
[SHAFT]

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ntol_max = %f{m01w.tol.max}
ntol_min = %f{m01w.tol.max}
ntol_bez = %s{m01w.tol.bez}
[HUB]
ntol_max = %f{m01n.tol.max}
ntol_min = %f{m01n.tol.max}
ntol_bez = %s{m01n.tol.bez}

Content of the M010USER.RPT file

The result has then following appearance:
[SHAFT]
wtol_max = 390.000000
wtol_min = 340.000000
wtol_bez = s6

[HUB]
ntol_max = 50.000000
ntol_min = 0.000000
ntol_bez = H6

Content of the M010USER.OUT file

Via the macro, this data will now be attached directly to the appropriate dimension
in CAD.
Su mm ar y:

The individual tasks are therefore split up: Each side of the interface will perform
only the tasks it is best suited to. The CAD administers the geometry and passes
this information on to the calculation program, which knows how to process the
data, and which, in turn, will return the result to the CAD.
By using the defined interface an efficient combination of CAD and calculation
program can be achieved.

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10.4

Geometry data

KISSsoft contains different interfaces for transmitting geometry data (contours,

drawings):
DXF format (recommended for communication with most CAD systems)
IGES format (with which tooth forms can be exported as splines)
BMP format (Windows bitmap)
JPG/JPEG format (pixel image)
PNG (Portable Network Graphic) format

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10.5

COM Interface

KISSsoft offers the possibility of remote control via a COM interface. It can easily
be accessed from Visual Basic or Excel.

10.5.1

Registering the server

Now register the KISSsoft COM server on your local computer.

There are two different ways of doing this:
Right-click at the Windows prompt and select "As administrator" from the context menu. Then, go to where the ".../bin32" sub-directory is stored and run the
"KISSsoftCOM_Register.bat" file.
To do this, enter these two command lines in a Windows input prompt, in the
KISSsoft installation bin32 directory:
KISSsoftCOM.exe /regserver
regsvr32 KISSsoftCOMPS.dll

You will need administrator rights to register the program.

10.5.2

Server functionality

The server provides a number of functions that you can use to start a calculation
module, read or set values, and perform a calculation.
GetModule([in] BSTR module, [in] VARIANT_BOOL interactive) starts a calculation module from the module descriptor (e.g. Z012
or W010). "interactive" defines whether the calculation module is to be generated with a graphical user interface.
Calculate() performs the main calculation for the active module.
CalculateRetVal([out, retval] VARIANT_BOOL* isOk) runs
the main calculation for the active module, and returns a value to tell you
whether the calculation is OK.
SetVar([in] BSTR name, [in] BSTR value) is a function with
which you can set variables to a required value. This data is transferred as text.
You will find the variable names in the report templates, but there is no guarantee that all these variables will remain the same in the future.

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GetVar([in] BSTR name, [out, retval] BSTR* value) returns a variable from KISSsoft as text.
ShowInterface([in] VARIANT_BOOL wait) displays the graphical
user interface. Use the "wait" parameter to specify whether the function is to
wait until the dialog is closed.
IsActiveInterface([out, retval] VARIANT_BOOL* isActive) shows whether a KISSsoft dialog is active.
IsActive([out, retval] VARIANT_BOOL* isActive) shows
whether a module has been loaded.
ReleaseModule() releases the loaded module again. You must always release a module again, to reduce the load on the server.
LoadFile([in] BSTR filename) loads the specified file.
SaveFile([in] BSTR filename) saves the calculation in the specified
file.
CheckLicense ([in] name BSTR, [out, retval] VARIANT_BOOL* isOk) shows whether the license is valid.
GetININame([OUT, retval] BSTR* name) supplies the name of the
loaded INI file.
GetVersionFromFile([in] BSTR filename, [out, retval]
BSTR* version) supplies the version number of the KISSsoft module in
the calculation file (e.g. 2.6). (The version number depends on which module is
being used)
GetModulFromFile([in] BSTR filename, [out, retval]
BSTR* name) supplies the KISSsoft module name in the calculation file
(e.g. M040).
GetKsoftVersionFromFile([in] BSTR filename, [out,
retval] BSTR* kSoftVersion) supplies the KISSsoft version number
(e.g. 03-2011), given in the calculation file.
GetKsoftVersion([out, retval] BSTR* kSoftVersion)
supplies the KISSsoft version (e.g. 03-2011), that is registered and was started
via the COM interface.
GetDBName([in] BSTR db_name, [in] BSTR table, [in]
SHORT flag, [in] LONG ID, [in] LONG order,
[out,retval] BSTR *name) Use the "flag" parameter to specify
whether the ID (flag = 0) or the result (flag = 1) is to be used as the input. The
output is then either the order and the name of the entry or the ID (in material

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database BEZ_DIN). If there is an error, no message is displayed. A "False" is

returned for the function.
GetDBValue([in] BSTR db_name, [in] BSTR table, [in]
LONG ID, [in] BSTR fieldname, [out,retval] BSTR
*name) supplies the value present in this database field. If there is an error, no
message is displayed. A "False" is returned for the function.
GetKsoftVersionSettings([out, retval] BSTR* kSoftVersionSettings) supplies the KISSsoft version of the temporary settings
folder in which the personal settings are stored (e.g. 03-2014).
SetSilentMode([in] VARIANT_BOOL silent) defines whether
messages are to be hidden or not, so that calculations can be performed without
the user having to confirm system prompts.
Report([in] LONG show) writes the report. You can specify whether
or not this report is to be displayed. The report is created in the Temp directory
in the "KISS_?" sub folder.
ReportWithParameters([in] BSTR infile, [in] BSTR outfile, [in] LONG show, [in] LONG type) creates the report
using the specified report template (infile) in the predefined place with the predefined name (outfile) and supplies the file type. You can enter file names
either with or without the path. When you enter the report template ("infile")
you should also input the file extension (e.g."Z012ld0.rpt"). If you do not enter
a path for this file the program will search the default directory (see also Reports) for the file. You must also enter the file extension for an output file. If
you do not specify the path, the file is saved to the Temp directory with the
name "KISS_?". The file extension should match the specified type. Use the
"show" parameter to define whether the report is to be displayed (or not). Use
the "art" (meaning "type") parameter to define the output format. (art=0 rtf
format with *1 ; art=1 rtf format without *1; art=2 html format with *1 ;
art=10 txt format without *1 ; art=20 txt format in Unicode without *1)

*1 = takes into account the data level

Examples of possible combinations: With default report templates RTF

format: ReportWithParameters("C:\Program Files (x86)\KISSsoft 032014\rpt\Z070ld0.rpt","C:\Temp\Z070ld0.rtf" ,1,0), HTM format: Call
ksoft.ReportWithParameters("Z070ld0.rpt", "C:\Temp\Z070ld0.htm", 1, 2)
; with drawing stamp report template TXT format:
ReportWithParameters("Z10GEAR1d.rpt","C:\Temp\Z010GEAR1d.txt"
,1,10)

Message([out] VARIANT *strings, [out] VARIANT

*types:, [out] LONG *numElem) returns the messages from the last

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calculation in the first parameter, as an array containing strings. The second parameter contains the particular message type (error, warning, info). The number of existing messages is shown in numElem.
CallFunc([in] BSTR name) Use these functions to run special calculations. A more detailed list of the available calculations is available on request.
CallFuncNParam([in] Variant paramArray) Use these functions
to run special calculations. A more detailed list of the available calculations is
available on request.

10.5.3

Example of a call from Excel

The best way to describe the functionality is to use an example. To use KISSsoft
from Excel, you must first activate the KISSsoftCOM type library in the Visual
Basic Editor in Tools>References.
The first example shows how to use a single gear calculation to define the tip and
root circles of a gear:
Public Sub ExampleKISSsoftCOM()
Dim ksoft As CKISSsoft
Dim da As String
Dim df As String

' get KISSsoft instance

set ksoft = New CKISSsoft

' get KISSsoft module for single gear

Call ksoft.GetModule("Z011", False)

' set values

Call ksoft.SetVar("ZR[0].z", "20")
Call ksoft.SetVar("ZS.Geo.mn", "5.0")
Call ksoft.SetVar("ZR[0].x.nul", "0.5")

' Calculate

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Call ksoft.Calculate

' get values

da = ksoft.GetVar("ZR[0].da.nul")
df = ksoft.GetVar("ZR[0].df.nul")

' release module

Call ksoft.ReleaseModule

' release server

Set ksoft = Nothing

End Sub

The second example shows how to display the KISSsoft user interface:
Public Sub ExampleKISSsoftCOM()
Dim ksoft As CKISSsoft
Dim da As String
Dim df As String

' get KISSsoft instance

Set ksoft = New CKISSsoft

' get KISSsoft module for single gear

Call ksoft.GetModule("Z011", True)

' show interface

Call ksoft.ShowInterface(True)

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' get values

da = ksoft.GetVar("ZR[0].da.nul")
df = ksoft.GetVar("ZR[0].df.nul")

Call ksoft.ReleaseModule

Set ksoft = Nothing

End Sub

The same example with "later binding" (the exact property or method is not
determined until runtime, which enables you to compile the Visual Basic client
without having to know the exact function of the call):
Public Sub ExampleKISSsoftCOM()
Dim ksoft As Object
Dim da As String
Dim df As String

' get KISSsoft Object

Set ksoft = CreateObject("KISSsoftCOM.KISSsoft")

' get KISSsoft module for single gear

Call ksoft.GetModule("Z011", True)

' show interface

Call ksoft.ShowInterface(True)

' get values

da = ksoft.GetVar("ZR[0].da.nul")

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df = ksoft.GetVar("ZR[0].df.nul")

Call ksoft.ReleaseModule

Set ksoft = Nothing

End Sub

The fourth example shows a contact analysis that was run using the caControll.dat
control file (you will find an example file in the dat folder) and they way messages
were processed after the calculation:
Public Sub ExampleKISSsoftCOM()
On Error GoTo ExitOnErr
Dim ksoft As CKISSsoft

' get KISSsoft instance

Set ksoft = New CKISSsoft

' get KISSsoft module for gear pair

Call ksoft.GetModule("Z012", True)

' load File change this to fit to a real file on your machine
Call ksoft.LoadFile("C:\yourPathHere\ExCOM3.z12")

' calculate
Call ksoft.Calculate

Dim ioData(3) as String

' Which calculation to start
ioData (0) = "CalculatePathOfContactForPairKS"

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' controlling file

ioData (1) = "C:\ yourPathHere\caControl.dat"
' Path for results
ioData (2) = "C:\ yourPathHere\prot"

' calculate contact analysis

Call ksoft.CallFuncNParam(ioData)

' Check for messages

Dim mess As Variant
Dim types As Variant
Dim numElem As Long
Dim typesElem As Long
Dim typesElemStr As String

Call ksoft.Message(mess, types, numElem)

If (numElem > 0) Then

Dim msg As String
For i = 0 To numElem - 1
msg = CStr(mess(i))
typesElemStr = CStr(types(i))
typesElem = CLng(types(i))
If (typesElem = 0) Then
Call MsgBox(msg, vbInformation)
ElseIf (typesElem = 1) Then
Call MsgBox(msg, vbExclamation)
Else
Call MsgBox(msg, vbCritical)

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End If
Next
End If

' close ksoft

Call ksoft.ReleaseModule

' no problems, so exit

Exit Sub
ExitOnErr:
MsgBox ("error occurred when calling KISSsoft.")

End Sub

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11

3D in terfaces

Chapter 11
3D interfaces

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11.1

Overview of the available CAD interfaces

and their functionality

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11.2

Generation of 3D gears

You must first perform a gear calculation to ensure that the results are consistent.
Select Graphics > Settings to choose the CAD system to which you want
to export the selected element.

Then, in the Graphics > 3D export menu option, you can select which individual gear and the configuration (only possible as individual gears) you want to
generate.

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In the case of Unigraphics NX, generation is only possible if you have started
KISSsoft from the NX add-in menu, then run the gear calculation and pressed the
required generation button. In the case of Creo Parametric (ProEngineer), CATIA
and Think3, the CAD interface must be opened so that the gear generation process
can be started from KISSsoft. If you are working with the SolidWorks, Solid Edge,
Inventor, Kompas or Creo Elements/Direct Modeling (CoCreate) CAD systems,
click on the Generate button to start the CAD program if it has not already been
opened.

The default setting runs the gear generation process with a permitted tooth form
deviation (tolerance band) 1 m. If this tolerance is too large, you can open the
Tooth form tab to change the tolerance. Once this is changed, you must click
Calculate again (Tooth form tab active), to transfer the inputs and recalculate
the tooth form.
Changing the generation type in the Tooth form tab (polylines, circular pitch approximation, arc estimation, splines) only affects the 2D display. In NX,
SolidWorks, Solid Edge and Kompas, the part is generated with splines. In Inventor, Think3, Creo Parametric (ProEngineer), CATIA and Creo Elements/Direct
Modeling (CoCreate) it is created with arcs of circles. SolidWorks and Solid Edge
also support other generation types, which you can change by entering the additional parameter APPROXIMATION=1 in the kiss.ini (see page I-58) file under
the relevant CAD.
In the case of the gears, the transverse section of the tooth space is usually cut out
from a cylinder and then duplicated as a pattern. For worms with a helix angle of >
50o and number of teeth < 4, the tooth space is cut out in the axial section and then
duplicated.

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11.3

Generating 3D shafts

Until now it has only been possible to generate shafts in 3D in the SolidWorks,
Solid Edge, Autodesk Inventor, Kompas and NX CAD systems.
First a shaft analysis must be performed to ensure the results are consistent. Select
Graphics > Settings to choose the CAD system to which you want to export the selected element.

Then click Graphics> 3D Export to select the shaft and configuration (if you
want to generate more than one shaft) that you require. In a configuration, each
shaft is created individually, in sequence, in its own part.

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You can therefore create a 3D shaft in the CAD system at the click of a button,
using the data from a KISSsoft shaft analysis.

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11.4

Viewer with neutral format interface

KISSsoft provides a 3D viewer for displaying individual gears or a gear system.

The viewer is activated from the Graphics > 3D Geometry menu.
In the 3D viewer, you can export the solid model in STEP and Parasolid formats
(text and binary). Supported gears (see page I-185) and for operating the viewer
(see page II-626). You can change the settings by selecting Calculation > > Settings > > Parasolid.

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11.4.1

Parasolid Export of 3D Shafts

The solid model of the shaft can be generated by using Parasolid. Data can be
exported in STEP, Parasolid text (X_T) and binary (X_B) format.
Select File> Export > Shaft>3D Geometry to generate the model. If the
calculation model contains a number of shafts, you can export these by selecting
File> Export > Geometry 3D System.

11.4.2

Face gear - 3D geometry

The 3D model of a face gear is generated by simulating the cutting process, and has
no limitations affecting the helix angle, shaft angle and offset. The reference
coordinates of the model are defined in accordance with Roth [79], and the
corresponding positions of pinion and gear are defined by equations (1) and (2).

(1)

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(2)
Where rtS is the pinion reference radius and xS is the pinion profile shift coefficient.
rtS in the cutting operation is calculated from the pinion cutter.
The shaft angle and radial offset ( and a) are defined in
Geometry>Details..
The face gear model is generated by simulating the cutting process, and the tooth
flank is approximated as a spline surface.
The manufacturing process is based on the Parasolid core, where the quality of the
model depends on the settings made in Parasolid modeling (see Calculation >Settings > Generation of 3D).
NOTE:

The strength calculation is performed with the assumption that the shaft angle is
90 and the radial offset is 0. The shaft angle and radial offset are only used for 3D
model generation, so the strength calculation result may not be valid.

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11.4.3

Bevel gear - generating a 3D model

The 3D geometry model for straight-, helical and spiral bevel gears is defined
according to ISO 23509 and the tooth form is calculated for several sections along
the facewidth. The tooth form is the planar involutes of the virtual spur gear. Then
the tooth flank surface is generated by sweeping the tooth forms of the sections
(Figure 10.1). The tooth forms in the individual sections are transformed by the
angle into the relevant position. The angle of each section is calculated both
for the generating and face milling processes by using the auxiliary angles and .
Therefore, the final tooth form along the facewidth is an extended epicycloid (face
hobbing) or circular (generating) form, as shown in Figure 10.2.

Figure 11.1 Definition of the sections for tooth form calculation

Figure 11.2 Transformation angle of generating (left) and face milling (right) processes

Machine tool manufacturers (such as Klingelnberg and Gleason) also have their
own methods for generating tooth forms, that differ slightly from the procedures
mentioned above. The tooth form is called an octoid and may differ slightly from
our tooth form. However, we have ascertained that the difference between the tooth
forms is much less than the tolerance range and will not give rise to any problems
in practical use.

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11.4.4

Worm wheel - generating a 3D model

The 3D model of the enveloping worm wheel is generated by simulating the actual
cutting process. The tooth forms at several sections along the facewidth are
calculated and the tooth flank is approximated as a spline surface. Theoretically,
the hobbing tool is the worm, in regard to arc of circle, pressure angle, and tooth
form. However, if the tool itself was manufactured to these specifications, it would
no longer be usable after resharpening because it would be smaller than the worm.
The hobs used to manufacture worm wheels are therefore slightly larger than the
worm they are to create so that they can be resharpened several times, as required
[91]. To generate the model using the larger hob, you can set the oversize factor in
the module-specific Settings window.

Figure 11.3 Oversize factor for worm wheel cutter

In this case, the hob will have a larger tooth thickness and therefore generate a
smaller tooth thickness on the gear. The cutting distance between the hob and the
gear will then be changed accordingly, to ensure a consistent result for the root and
tip diameter on the gear.

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11.5

3D interface to Solid Works

Manufacturer: KISSsoft AG
The interface between Solid Edge and KISSsoft creates the direct integration into
the 3D CAD system. Use this to start all KISSsoft calculation modules directly
from within Solid Works. Face or bevel gears calculated in KISSsoft can be
generated directly in Solid Works as a 3D part (see page I-186) with a real tooth
form. Shafts calculated with KISSsoft can be generated as a 3D part comprising
cylinder and cone elements (see page I-188) directly in Solid Works. From within
KISSsoft you can start Solid Works with one click on a button. The system opens a
new part and the appropriate part will be generated. You can create cylindrical
gears with straight or helical teeth, which are outside or inside, racks with straight
or helical teeth, or straight-toothed bevel gears, as defined in DIN 3971, Figure 1,
and shafts.
Furthermore, you have the option of adding toothing to existing shafts (see page I195) at a later point in time. In addition, with the interface in the 2D range, you can
automatically insert gear manufacturing data (see page I-200) as a text field. The
gear manufacturing data is attached to the relevant cutout (tooth space).

11.5.1

Gear teeth in the case of an existing b asic solid

11.5.1.1
Procedure for toothing creation
1. Select the required area in CAD

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2. In KISSsoft, select which gear (e.g. Gear 1) you want to generate on the
cylinder.

Prerequisites:
The diameter of the cylinder must already have the correct external diameter of
the toothing before the generation starts.

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In the case of internal teeth, a hollow cylinder must already be modeled before
the gear teeth can be cut out.

This generation of toothing will be performed for inside and outside cylindrical
gears with spur and helical teeth.

11.5.2

Integrating the KISSsoft Add -in (menu options

in CAD)

The add-in should be registered as part of the installation process. However, if this
did not happen, and you do not see the KISSsoft menu in SolidWorks, you must
register the add-in manually.
This is how to perform manual registration.
Windows Vista/7/8:
As you can only perform the registration if you have administrator rights, you can
only do this here with the command prompt.
1. Start the command prompt as the administrator.
2. Go to where the registration file is to be executed (SolidWorks folder).
Confirm by pressing Enter.

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3. Run the registration file. Confirm by pressing Enter.

If KISSsoft is running on a server drive, you can enter the following command at
the prompt to ensure you can access this drive as an administrator.
Pushd \\SERVER\directory

This command assigns a temporary drive letter to the directory. You can then go to
where the *.bat file is stored and register the interface.
If the KISSsoft add-in has been registered successfully, you see this message.

To remove the registration, double-click on the SolidWorksUnRegister.bat

file in the KISSsoft installation folder. This message is displayed if the process has
been performed successfully.

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If the add-in does not appear directly in SolidWorks, select the Extras > Addins menu option to open this window.

Here, select KISSsoftSWAddin and then click OK to confirm.

This integrates the KISSsoft menu options in SolidWorks. The menu remains
present, even after a restart, and only needs to be linked once.
The KISSsoft add-in menu options are available in seven languages (English,
French, German, Italian, Portuguese, Spanish and Russian). They use the same language as was selected when KISSsoft was being installed. To set the language, go
to the kiss.ini file in the KISSsoft installation folder, click on
DISPLAYLANGUAGE, and set the language you require (0 = german; 1 = english;
2 = french; 3= italian; 4= spanish; 5= russian; 6= portuguese). This language setting now also applies to your KISSsoft system.

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11.5.3

Add-in functions (calls)

11.5.3.1

Running KISSso ft via an add -in

Select the KISSsoft menu item to open all KISSsoft calculation modules
directly. The generation of a new/additional gear will then continue in accordance
with the information given about gear generation earlier (see page I-186).

11.5.3.2
Adding manufacturing data
The Add manufacturing data menu item only works in the Part view. Procedure for adding a gear stamp on a drawing:

1. Open the part and select the cutout of a tooth.

2. Select the Add manufacturing data menu item.
This creates a new draft document into which the gear stamp of the selected cutout
for the gear teeth will be inserted.

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11.5.3.3
Opening the calculatio n file for the cre ated gear
The Open calculation file menu item only works in the Part view. Procedure
for opening a calculation file:

1. Open the part and select the cutout of a tooth.

2. Select the Open calculation file menu item.
This starts KISSsoft in each particular calculation module and opens the
calculation file.

11.5.3.4
Simplified vi ew of the gears
You have the option to draw the gear in two different views. With the simplified
view you can create a section display view of the gear in the drawing extraction in
which only the edge contours and the reference circle of the gear are shown. At the
moment, the simplified view is only available for external teeth. In the default setting, the simplified view will not be carried out.

To obtain a simplified display, open the KISS.ini file in the KISSsoft installation folder and change this entry:
SIMPLIFIEDPRESENTATIONNAME=Name
The name given in the kiss.ini file is also the name of the view.

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11.6

3D interface to Solid Edge

Manufacturer: KISSsoft AG
The interface between Solid Edge and KISSsoft creates the direct integration into
the 3D CAD system. This enables you to start all KISSsoft calculation modules
directly from Solid Edge. Face or bevel gears calculated in KISSsoft can be
generated directly in Solid Edge as a 3D part (see page I-186) with a real tooth
form. Shafts calculated with KISSsoft can be generated as a 3D part comprising
cylinder and cone elements (see page I-188) directly in Solid Edge. From within
KISSsoft, you can start Solid Edge with one click on a button. The system opens a
new part and the appropriate part will be generated. You can create cylindrical
gears with straight or helical teeth, which are outside or inside, racks with straight
or helical teeth, or straight-toothed bevel gears, as defined in DIN 3971, Figure 1,
and shafts.
Furthermore, you have the option of adding toothing to existing shafts (see page I203) at a later point in time. In addition, with the interface in the 2D range, you can
automatically insert gear manufacturing data (see section "Adding manufacturing
data" on page I-209) in the drawing as a text field. The gear manufacturing data is
attached to the relevant cutout (tooth space).

11.6.1

Changes of the parameters for generation

When copying the tooth space (pattern) in Solid Edge, you can switch between two
settings. The possible modes are: SmartPattern and FastPattern. In the case of
SmartPattern, a more precise generation of the tooth form is carried out, but it takes
a long time and the file containing the gear data will be very large. FastPattern uses
a less precise method, but this ensures quick construction and a smaller generation
file. Until now, SmartPattern has always been used for gear generation, since
otherwise the gears cannot be created or represented correctly. In the kiss.ini
(see page I-58) file in the KISSsoft installation folder you can set
SMARTPATTERN=0, which executes the copying of the tooth space in FastPattern
mode.

11.6.2

Gear teeth in the case of an existing b asic solid

11.6.2.1
Procedure for toothing creation
1. In Solid Edge, draw a surface in the required area where the gear teeth
should be cut out.

2. Select the level

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3. In KISSsoft, select which gear (e.g. Gear 1) you want to generate on the
cylinder.

Prerequisites:
The diameter of the cylinder must already have the correct external diameter of
the gear toothing before the generation process starts.

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In the case of internal teeth, a hollow cylinder must already be modeled before
the gear teeth can be cut out.

This generation of toothing will be carried out in the case of inside and outside
cylindrical gears with spur and with helical teeth.

11.6.3

Integrating the KISSsoft Add -in (menu options

in CAD)

The add-in should be registered as part of the installation process. However, if this
did not happen, and you do not see the KISSsoft menu in Solid Edge, you must
register the add-in manually.
This is how to perform manual registration.
Windows Vista/7/8:
As you can only perform the registration if you have administrator rights, you can
only do this here with the command prompt.
1. Start the command prompt as the administrator.
2. Go to where the registration file is to be executed (Solid Edge folder).
Confirm by pressing Enter.

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3. Run the registration file. Confirm by pressing Enter.

If KISSsoft is running on a server drive, you can enter the following command at
the prompt to ensure you can access this drive as an administrator.
Pushd \\SERVER\directory

This command assigns a temporary drive letter to the directory. You can then go to
where the *.bat file is stored and register the interface.
If this message is displayed, the add-in has been successfully registered.

To remove the add-in registration, double-click on the

SolidEdgeUnRegister.bat file in the KISSsoft installation folder. This
message is displayed if the process completes successfully.

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Under Tools/Add-Ins you can select Add-In-Manager where you can activate/deactivate the add-in.

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You will see the KISSsoft add-in in the main menu. This integrates the KISSsoft
menu options in Solid Edge where they remain present, even after a restart.

The KISSsoft add-in menu options are available in seven languages (English,
French, German, Italian, Portuguese, Spanish and Russian). They use the same language as was selected when KISSsoft was being installed. To set the language, go
to the kiss.ini file in the KISSsoft installation folder, click on
DISPLAYLANGUAGE, and set the language you require (0 = german; 1 = english;
2 = french; 3= italian; 4= spanish; 5= russian; 6= portuguese). This language setting now also applies to your KISSsoft system.
NOTE:

If the selected language uses Unicode fonts (e.g. Cyrillic for Russian), the
Localization must be set to this language (a country with this language) in the operating system.

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11.6.4

Add-in functions (calls)

11.6.4.1

Running KISSso ft via an add-in

Select the KISSsoft menu item to open all KISSsoft calculation modules
directly. The generation of a new/additional gear will then continue in accordance
with the information previously given about gear generation (see page I-186).

11.6.4.2
Adding manufacturing data
The Add manufacturing data menu item only works in the Part view. Procedure for adding a gear stamp on a drawing:

1. Open the part and select the Cutout of a tooth.

2. Select the Add manufacturing data menu item.
This creates a new draft document into which the gear stamp of the selected cutout
for the gear teeth will be inserted.

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11.6.5

Opening the calculation file for the created

gear

The Open calculation file menu item only works in the Part view. Procedure
for opening a calculation file:
1. Open the part and select the Cutout of a tooth.
2. Select the Open calculation file menu item.
This starts KISSsoft in each particular calculation module and opens the
calculation file.

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11.7

3D interface to Autodesk Inventor

Manufacturer: KISSsoft AG
The interface between Inventor and KISSsoft is achieved by direct integration in
the 3D CAD system. Use this to start all KISSsoft calculation modules directly
from within Inventor. Face or bevel gears calculated in KISSsoft can be generated
directly in Inventor as a 3D part (see page I-186) with a real tooth form. Shafts
calculated with KISSsoft can be generated as a 3D part comprising cylinder and
cone elements (see page I-188) directly in Inventor. From within KISSsoft, you
can start Inventor with one click on a button. The system opens a new part and the
appropriate part will be generated. You can create cylindrical gears with straight or
helical teeth, which are outside or inside, racks with straight or helical teeth, or
straight-toothed bevel gears, as defined in DIN 3971, Figure 1, and shafts.
Furthermore, you have the option of adding toothing to existing shafts (see page I211) at a later point in time. In addition, with the interface in the 2D range, you can
automatically insert gear manufacturing data (see section "Adding manufacturing
data" on page I-215) as a table on the drawing. The gear manufacturing data is
attached to the relevant cutout (tooth space).

11.7.1

Gear teeth in the case of existing shaft data

11.7.1.1

Procedure for toothing creation

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1. Select the required area

2. In KISSsoft, select which gear (e.g. Gear 1) you want to generate on the
cylinder.
Prerequisites:
The diameter of the cylinder must already have the correct external diameter of
the gear toothing before the generation process starts.
In the case of internal teeth, a hollow cylinder must already be modeled before
the gear teeth can be cut out.

This generation of toothing will be performed for inside and outside cylindrical
gears with spur and helical teeth.

11.7.2

Add-in (menu items in CAD)

11.7.2.1
Integrat ing the KIS Sso ft Add-in
The add-in should be registered as part of the installation process. However, if this
did not happen, and you do not see the KISSsoft menu in Inventor, you must register the add-in manually.

This is how to perform manual registration.

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Windows Vista/7/8:
As you can only perform the registration if you have administrator rights, you can
only do this here with the command prompt.
1. Start the command prompt as the administrator.
2. Go to where the registration file is to be executed (Inventor folder).
Confirm by pressing Enter.
3. Run the registration file. Confirm by pressing Enter.

If KISSsoft is running on a server drive, you can enter the following command at
the prompt to ensure you can access this drive as an administrator.
Pushd \\SERVER\directory

This command assigns a temporary drive letter to the directory. You can then go to
where the *.bat file is stored and register the interface.
If this message is displayed, the add-in has been successfully registered.

If you no longer want the Inventor add-in to be registered, double-click on the

InventorUnRegister.bat file in the KISSsoft installation folder. If the addin has been registered successfully, you see this message.

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The KISSsoft add-in menu options are available in seven languages (English,
French, German, Italian, Portuguese, Spanish and Russian). They use the same language as was selected when KISSsoft was being installed. To set the language, go
to the kiss.ini file in the KISSsoft installation folder, click on
DISPLAYLANGUAGE, and set the language you require (0 = german; 1 = english;
2 = french; 3= italian; 4= spanish; 5= russian; 6= portuguese). This language setting now also applies to your KISSsoft system.

This integrates the KISSsoft menu options in Inventor. The menu remains present,
even after a restart, and does not need to be linked.

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11.7.3

Add-in functions (calls)

11.7.3.1

Running KISSso ft via an add -in

Select the KISSsoft menu item to open all KISSsoft calculation modules
directly. The generation of a new/additional gear will then continue in accordance
with the information previously given about gear generation (see page I-186).

11.7.3.2
Adding manufacturing data
The Add manufacturing data menu item only works in the Part view. Procedure for adding a gear stamp on a drawing:

1. Open the part and select the Cutout of a tooth.

2. Select the Add manufacturing data menu item.
This creates a new draft document into which the gear stamp of the selected cutout
for the gear teeth will be inserted.

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11.7.4

Opening the calculation file for the created

gear

The Open calculation file menu item only works in the Part view. Procedure
for opening a calculation file:
1. Open the part and select the Cutout of a tooth.
2. Select the Open calculation file menu item.
This starts KISSsoft in each particular calculation module and opens the
calculation file.

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11.8

3D interface to Unigraphics NX

Manufacturer: KISSsoft AG

The interface between NX and KISSsoft is achieved by direct integration in the 3D

CAD system. Use this to start all KISSsoft calculation modules directly from
within NX. Face or bevel gears calculated in KISSsoft can then be generated
directly in NX as a 3D part (see page I-186) with a real tooth form. Shafts
calculated with KISSsoft can be generated as a 3D part comprising cylinder and
cone elements (see page I-188) directly in NX. You can create cylindrical gears
with straight or helical teeth, which are outside or inside, worms, or straighttoothed bevel gears, as defined in DIN 3971, Figure 1, and shafts.
If you create a new part, the New dialog opens first. In it you can enter the name of
the file in which the part should be generated. When you use Teamcenter, its dialog
is displayed automatically so you can also generate or save the part in the Teamcenter environment. Furthermore, you have the option of adding toothing to
existing shafts (see section "Gear teeth when existing shaft data is present" on page
I-222) at a later point in time. In addition, with the interface in the 2D range, you
can automatically insert gear manufacturing data as a table on the drawing. The
gear manufacturing data is attached to the relevant cutout (tooth space).

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11.8.1

Add-in (menu items in CAD)

11.8.1.1
Integrat ing the KIS Sso ft Add -in
First, copy the supplied folder, e.g. NX9, with its startup sub-folder, to a location that can be accessed by the user at any time.

The definitions of the KISSsoft add-in menu options are located in the
"kSoftNX_e.men" file. This file has different name endings to indicate which language has been selected. For example, the _e in this file name represents English. Also used: _d: for German; _f: for French; _i: for Italian; _s: for
Spanish; _r: for Russian; _p: for Portuguese; The file in the required
language can be copied to the startup folder to ensure the KISSsoft menu is
displayed in the selected language.
NOTE:

If the selected language uses Unicode fonts (e.g. Cyrillic for Russian), the
Localization must be set to this language (a country with this language) in the operating system.

From NX9 KISSsoft is also available as a ribbon menu. By default, the English
menu with "_e" is integrated in the "startup" sub-folder. If you want to change the
language in which the menu is displayed, delete all the files in the startup subfolder that have "_e" in their name. The "... \\NX9 \\64bit" sub-folder contains a
sub-folder for every available language (e.g. "kSoftNXRibbon_d" for German).
You can copy the entire contents of the folder that has the language you require
into the "startup" sub-folder. The menu will then be displayed in this language.
The kSoftNX9.dll file (for example), which contains the links and commands
for the menu items, is also stored in this folder.

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You must enter the path of the previously copied folder, for example,
NX9/64bit, in the "UGII\menus\custom_dirs.dat" file in the UGS directory, so
that the UGS system can tell where the files it is to use are stored.

The KISSsoftCOM server should be registered as part of the installation process.

However, if this did not happen, and the KISSsoft interface does not work, you
must register KISSsoftCOM manually.
This is how to perform manual registration.
Windows Vista/7/8:
As you can only perform the registration if you have administrator rights, you can
only do this here with the command prompt.
1. Start the command prompt as the administrator.
2. Go to where the registration file is to be executed (the folder, e.g.
NX9/64bit). Confirm by pressing Enter.

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3. Run the registration file. Confirm by pressing Enter.

If KISSsoft is running on a server drive, you can enter the following command at
the prompt to ensure you can access this drive as an administrator.
Pushd \\SERVER\directory

This command assigns a temporary drive letter to the directory. You can then go to
where the *.bat file is stored and register the interface.
The following message is displayed if the KISSsoft add-in has been registered
successfully.

To remove the registration, double-click on the NXUnRegister.bat file in the

KISSsoft installation folder. This message is displayed if the process has been
performed successfully.

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To ensure the KISSsoft icons are displayed next to the menu options, you must also
set a system variable with the path, to tell the program where the KISSsoft icons
can be found.
Set system variable and use it as a value for the path, for example:
KSOFT_ICONS
C:\Program Files(x86)\KISSsoft 03-2014\bin32\icons
The startup folder also contains a kSoftNX.ini file in which a part's layers,
sketches, planes, and drafts, can be changed.

11.8.2

Running KISSsoft via an add -in

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Select the KISSsoft menu item to open all KISSsoft calculation modules
directly. By doing this you can perform NX8 calculations (for example) in
KISSsoft quickly and easily during the design process. The NX8 (etc.) menu items
are inactive whilst KISSsoft is open. In order to reactivate the CAD program, you
must close KISSsoft.

11.8.2.1
Gear teeth when existing shaft dat a is presen t
Prerequisites:

The cylinder diameter must already have the same external diameter as the
gear toothing before the generation process starts.
In the case of internal teeth, a hollow cylinder must already be modeled before
the gear teeth can be cut out.
For example, go to the KISSsoft menu in NX8 and select the cylindrical gear pair
calculation. The procedure for generating the gear (see page I-186) is identical to
the procedure for creating a new one.

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If a part is already opened in NX (whatever version) when you return, the

following list is displayed:

1. A new part opens, and the complete gear is generated.

2. If you select Available part, absolute positioning, only
one side surface needs to be selected, on which the gear teeth are to be cut.
For the generation, fixed levels will be generated, on which the gear teeth
will be positioned.
3. If you select Available part, relative positioning, you
can select a side surface and two levels (which will intersect the side surface). Consequently, the toothing can be positioned at relative planes (DATUM PLANE) and is not dependent on the absolute zero point. This positioning is mainly required in the case of the methodical operational behavior defined in the Master Model concept (Teamcenter).

The generation of toothing on existing cylinders is performed on both inside and

outside cylindrical gears with straight or helical toothing.

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11.8.2.2
Adding manufacturing data on the drawing
You can use the Add manufacturing data menu item to insert a gear stamp
of the current gear in a drawing.

Teamcenter: If you are working in accordance with the Master Model

concept, the features of the master part are displayed automatically in the
non-master drawing when you call up Add manufacturing data.
After you select this menu item, the following screen appears:

In this screen, select the following:

Straight-toothed cylindrical gears: INSTANCE[0](4)TOOTH(4)

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Cylindrical helical gears/worms/bevel spur gears: TOOTH

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If you press OK, a new drawing will open and the following window appears:

With one mouse click you can position the manufacturing data on the drawing. The
mouse click will position the upper left corner of the table.
If you want to insert the data into an already existing drawing sheet, you have to
select the tooth space in the Drawing view if the required drawing sheet is opened.
You will then see the screen in which you can select the tooth space, and are then
prompted to decide if it should be inserted into the current drawing sheet.

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If you click OK you can use the mouse to position the current manufacturing data
on the drawing. Click CANCEL to open a new drawing sheet in which you then can
insert the manufacturing data.

11.8.2.3
Opening the calculatio n file
Select the Calculation file menu item to start KISSsoft and load calculation
file for the toothing whose information is saved directly on the toothing Feature
(tooth space). After you select this menu item, the following screen appears:

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In this screen, select the following:

Straight-toothed cylindrical gears: INSTANCE[0](4)TOOTH(4)
Cylindrical helical gears/worms/bevel spur gears: TOOTH
If you then click OK, KISSsoft opens in the corresponding module with the
toothing's calculation file loaded.

11.8.3

Add-in functions (calls)

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11.9

3D interface to Creo Parametric (ProEngineer)

Manufacturer: Applisoft Europe (Italy)

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The cylindrical gears or bevel gears calculated in KISSsoft can then be generated
directly in Creo Parametric (ProEngineer) as a 3D part (see page I-186) with a real
tooth form. You can create cylindrical gears with straight or helical teeth, which
are external or internal, or straight-toothed bevel gears, as defined in DIN 3971,
Figure 1.

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In addition to the part, the system opens a drawing into which the gear manufacturing data are inserted in a table. Open the CAD system before you start generating
a part in the 3D interface to Creo Parametric (ProEngineer).

In the interface to ProEngineer, you can enter additional variables in the files for
the particular gear (e.g. Z10GEAR1CAD.rpt) in the CAD directory. These additional variables will later be defined as parameters and saved in ProEngineer.
The parameters used for the generating process are already defined in ProEngineer
and can no longer be used. Predefined parameters:
pz, z, b, da, d, df, di, elica, USUnit
If you want to create a model of a part in US customary units (not metric), go to the
kiss.ini (see page I-59) file and set the USCUSTOMARYUNITS
parameter to 1.
You can also change an existing toothing without actually affecting the part (see
Modifying a selected 3D model (see section "Modifying the selected 3D model" on
page I-236)).

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You can also cut a toothing on an existing shaft (see Cut intermeshing on an
existing shaft (see section "Cutting teeth on an existing shaft" on page I-237)).
A new dialog opens as soon as you start the generating process:

here you can select what you require by clicking Generate gear in new
file to generate the gear in a new part file.
If communications cannot be set up with ProEngineer, because the
PRO_COMM_MSG.exe file is blocked, for example by a firewall or anti-virus
program, the following message appears to tell you what to do, so you can still
generate a gear:

NOTE:

You can either set your anti-virus program to permit the pro_comm_msg.exe and
apsfkissvb.exe processes to run, or generate the gear directly in the KISSsoft menu
in ProEngineer.
If you can also specify if you want to prevent the selection menu or message from
being displayed (see Changing base settings in the interface (on page I-240)).

11.9.1

Integrating the KISSsoft Add-in

The KISSsoftCOM server should be registered as part of the installation process.

However, if this did not happen, and the KISSsoft interface does not work, you
must register KISSsoftCOM manually.

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This is how to perform manual registration.

Windows Vista/7/8:
As you can only perform the registration if you have administrator rights, you can
only do this here with the command prompt.
1. Start the command prompt as the administrator.
2. Go to where the registration file is to be executed (ProEngineer folder).
Confirm by pressing Enter.
3. Run the registration file. Confirm by pressing Enter.

If KISSsoft is running on a server drive, you can enter the following command at
the prompt to ensure you can access this drive as an administrator.
Pushd \\SERVER\directory

This command assigns a temporary drive letter to the directory. You can then go to
where the *.bat file is stored and register the interface.
The following message is displayed if the KISSsoftCom server has been registered
successfully.

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To remove the registration, double-click on the ProEUnRegister.bat file in

the KISSsoft installation folder. This message is displayed if the process has been
performed successfully.

Use one of the three following methods to ensure the KISSsoft menu is present
every time you start ProEngineer/Creo:
1. You can copy the Protk_EditGear_Creo1_64bit.dat file (depending on
the version of ProEngineer/Creo) to this Creo sub-directory: .../Common
Files/.../text/ (for ProEngineer, copy it into the .../text/ sub-directory).
Then rename the file to Protk.dat.
Using this method, you can change your ProEngineer start directory to ensure that the KISSsoft menu always starts at the same time.
If a different Protk.dat file is already present, you can add lines from the
Protk_EditGear_Creo1_64bit.dat file to the Protk.dat file.
2. Copy the Protk_EditGear_Creo1_64bit.dat file into the ProEngineer
Start working directory. Rename the file to Protk.dat.

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This method requires you to copy the Protk.dat file to the Start directory
(you will find the path displayed under Properties).
3. Then enter the following line in your config.pro file (in ProEngineer).
(This is where you define your own path):
protkdat C:\Program Files (x86)\KISSsoft 032014\ProEngineer\Protk_EditGear_Creo1_64bit.dat
Select the path to the file that contains the name of your version of ProEngineer.
This method saves you having to copy or rename any files.

Description of the content of the Protk.dat file:

NAME EditGear
EXEC_PATH C:\Program Files (x86)\KISSsoft 032014\ProEngineer\EditGear\bin_nt\EditGear_64bit_Creo1.dll
TEXT_PATH C:\Program Files (x86)\KISSsoft 032014\ProEngineer\EditGear\text.GB
STARTUP DLL
ALLOW_STOP TRUE
UNICODE_ENCODING FALSE

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END

EXEC_PATH and TEXT_PATH must be the absolute path of the installation.

STARTUP DLL and UNICODE_ENCODING FALSE are predefined (do not change them).
ALLOW_STOP TRUE Use this to stop the ProEngineer program (Tools>Auxiliary Application->Stop).

You can delete this line in the Protk.dat file to prevent the user from stopping the
interface.
NAME EditGear and END must be present, although you can change the
EditGear name if required.

11.9.2

Modifying the selected 3D model

Every time you export a tooth form from KISSsoft, the model is generated in a new
part in ProEngineer.
To modify an existing model:
1. Import the model you want to modify into ProEngineer (or use the current
part)
2. Go to the KISSsoft menu and select Edit and then click Yes (to import
the current toothing)

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3. Then select Open calculation file. KISSsoft is then loaded with

the corresponding toothing data.

KISSsoft can then regenerate the modified intermeshing and therefore adapt the
existing toothing.

11.9.3

Cutting teeth on an existing shaft

The following menu is displayed if you activate the KISSsoft 3D export:

To modify an existing model:

1. Select Generate gear on shaft

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2. In ProEngineer, open the shaft on which you want to cut the gear teeth.
3. Set a new system of coordinates to describe the point at which the gear
teeth are to be cut. You can use this coordinate system if you want the gear
teeth to be cut from the point of origin.
4. Select the GearShaft menu item in the KISSsoft menu in ProEngineer.

5. This opens another menu in which you can specify whether the gear teeth
are to be cut across the entire width or only across part of the shaft.

6. After you select the option you require, you can then select the coordinate
system into which the toothing is to be inserted. (the co-ordinate system
you select must have a Z-axis that is equal to the shaft axis).
7. The gear teeth are then cut on the shaft.

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11.9.4

Modifying the teeth on an existing shaft

Follow these steps to modify the teeth of a gear on an existing shaft in a model that
has already been generated (gear generated using the KISSsoft interface):
1. Import the model you want to modify into Creo Parametric (ProEngineer),
or use the current part.
2. Select the Edit Gear on Shaft menu item to select the toothing you
want to modify. The system then opens KISSsoft directly with the data that
was saved for the toothing element when it was generated.

3. You can then modify or recalculate the toothing in KISSsoft, and restart
the 3D export for corresponding toothing.
Then, click on the cross at the top right to close the KISSsoft window.

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You then see this prompt to save or not save the temporary calculation file.
Yes: the model is modified
No: the model is not changed.

4. The system now modifies the model if you confirm the prompt.

11.9.5

Changing base settings in the interface

You can set up your interface in a number of different ways. For example, you can
tailor it by setting environment variables:
KISS_PROE_INTERFACE_NO_MENU = YES
This is designed for users who do not have a connection to Creo Parametric (ProEngineer) (via PRO_COMM_MSG.exe).
If you set this environment variable to "Yes", the interface will no longer attempt to
use this process to manage the connection. You will also no longer see a warning
that this connection is not possible.
KISS_PROE_INTERFACE_NO_MENU = NO
If you set this environment variable to "No", a warning is displayed if no direct
connection to ProEngineer can be created.
The warning message describes what you must do to generate the gear even though
the connection to ProEngineer is not present.
KISS_PROE_INTERFACE_CLASSIC = YES
The extra dialog in which you can select either "Generate gear in a new file" or
"Generate gear on shaft" is not now displayed.
KISS_PROE_INTERFACE__CLASSIC = NO

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A dialog is displayed in which you can select either "Generate gear in a new file"
or "Generate gear on shaft".

If no environment variables are set, both these values are set to NO.

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11.10

3D interface to CATIA

Manufacturer: SWMS (DE)

Cylindrical or bevel gears calculated in KISSsoft can be generated directly in CATIA as a 3D part (see page I-186) with a real tooth form. You can create
cylindrical gears with straight or helical teeth, which are outside or inside, or
straight-toothed bevel gears, as defined in DIN 3971, Figure 1.
Furthermore, you have the option of adding toothing to existing shafts at a later
point in time.
You will find a more detailed description of the interface in a *.pdf file in the CATIA folder in the KISSsoft installation folder.

11.10.1

Registering the interface

The CATIA interface should be registered as part of the installation process. If this
did not happen, you must register the interface manually.
This is how to perform manual registration.
Windows Vista/7/8:
As you can only perform the registration if you have administrator rights, you can
only do this here with the command prompt.

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1. Start the command prompt as the administrator.

2. Go to where the registration file is to be executed (Catia folder). Confirm
by pressing Enter.
3. Run the registration file. Confirm by pressing Enter.

If KISSsoft is running on a server drive, you can enter the following command at
the prompt to ensure you can access this drive as an administrator.
Pushd \\SERVER\directory

This command assigns a temporary drive letter to the directory. You can then go to
where the *.bat file is stored and register the interface.
The following message is displayed if the registration was successful.

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To remove the registration, double-click on the CatiaUnRegister.bat file in

the KISSsoft installation folder. This message is displayed if the process has been
performed successfully.

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11.11

3D interface to CoCreate

Manufacturer: Studio Tecnico Turci (Italy)

Chapter
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Cylindrical or bevel gears calculated in KISSsoft can be generated directly in the

3D interface to Creo Elements/Direct Modeling (CoCreate) as a 3D part (see page
I-186) with a real tooth form. Simply click on the appropriate button to start Creo
Elements/Direct Modeling (CoCreate interface) from KISSsoft. This opens a new
part and generates the corresponding part. You can create cylindrical gears with
straight or helical teeth, which are external or internal, or straight-toothed bevel
gears, as defined in DIN 3971, Figure 1.

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11.12

3D interface to ThinkDesign

Manufacturer: Studio Tecnico Turci (Italy)

Chapter
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Cylindrical or bevel gears calculated in KISSsoft can then be generated directly in

ThinkDesign as a 3D part (see page I-186) with a real tooth form. You can create
cylindrical gears with straight or helical teeth, which are external or internal, or
straight-toothed bevel gears, as defined in DIN 3971, Figure 1.
You must open the CAD system before you can generate a part in ThinkDesign.

The gear data for the drawing is stored both in the model and as file settings.

The information can be inserted in the drawing as symbolic text.

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11.12.1

Integrating the KISSsoft Add-in

If the KISSsoft menu does not automatically appear in the CAD system, you can
copy the two files (KISSsoft.msg, KISSsoft.prc) from the Think3 folder to the
KISSsoft installation folder in the ThinkDesign installation
.../thinkdesign/autoload.

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11.13

3D interface to ASCON Kompas

Manufacturer: KISSsoft AG
Cylindrical or bevel gears calculated in KISSsoft can then be generated directly in
Kompas as a 3D part (see page I-186) with a real tooth form. Shafts calculated
with KISSsoft can be generated directly in Kompas as a 3D part comprising
cylinder and cone elements (see page I-188). From within KISSsoft, you can start
Kompas with one click on a button. The system opens a new part and the
appropriate part will be generated. You can create cylindrical gears with straight or
helical teeth, which are outside or inside, racks with straight or helical teeth, or
straight-toothed bevel gears, as defined in DIN 3971, Figure 1, and shafts.

Chapter
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12

12

Answers to Fr eque ntly Aske d Ques tio ns

Chapter 12
Answers to Frequently Asked
Questions

Chapter
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12.1

Change the output of angles in reports

Can you output angles (in calculations) in the KISSsoft angle report as degree values as well as decimal numbers?
Current form:

##.####

Required form:

## ## ##

To do this, modify the report template (*.rpt) accordingly. Refer to the notes in the
Report templates (see page I-113) manual. The calculation is then performed in the
report.
A helix angle is used to show this method:
Current form as a decimal:
Helix angle (grd)

%11.4f {Grad(ZS.Geo.beta)}=>

Afterwards, the required form:

Helix angle (grd)
%i %i' %i"
{Grad(ZS.Geo.beta)}
{(Grad(ZS.Geo.beta)-int(Grad(ZS.Geo.beta)))*60} {((Grad(ZS.Geo.beta)int(Grad(ZS.Geo.beta)))*60-int((Grad(ZS.Geo.beta)int(Grad(ZS.Geo.beta)))*60))*60}

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12.2

Input materials for gear calculations in

the database

When comparing the materials used for toothings in a particular company, it

became evident that not all the required materials were present in the database
provided by KISSsoft.
In particular, the following key values necessary for gear calculation are missing.
These include Flim/Sat, Hlim/Sac, RzF, RzH, BM.
When you redefine materials and their properties, you must compare them with
similar materials in our materials database.
First of all, define the basic data for a material in the database. Then define the
gear-specific data for this base material.
Then calculate the values of Flim/Sat, Hlim/Sac depending on the hardness values, as
described in ISO 6336-5.
To do this, you can use either the relevant material diagram, the conversion function for Own input for materials (see page II-272) or formulae from ISO. The Sat,
Sac values are converted on the basis of Flim, Hlim.
If you do not know the thermal contact coefficient BM, simply leave this entry
blank so that the default values are used in the calculation.
For medium total heights, specify average values with RzF 10m and RzH 3m. You
will find more detailed information in ISO 6336-2.
You will find more information about the influence of medium total heights in our
article under point 2 http://www.kisssoft.ch / deutsch / downloads / doku_artikelISO6336Neuheiten.pdf.

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12.3

How can I test the software?

A demo version (see page I-42) of the software is available. Although the demo
version does not have an expiration date, its functionality is limited so that, for
example, you cannot change and store material data. The demo version is designed
to give you an initial impression of the software. For a detailed trial, request a Test
version (see page I-44). The test version runs for 30 days, is free of charge and is
the same as the full version (without third party programs).

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12.4

What licenses are available?

Individual user licenses and floating licenses are available for both KISSsoft and
KISSsys. A floating license allows the software to be used at more than one
workplace.
However, floating licenses are not available for some of the third party products,
for example, some CAD interfaces.

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12.5

Add your own texts in the r esults window

To do this, define a new file in the KISSsoft installation folder in "\ext\rpt\".

This file must then be named: "Modulname + result.RPT" (e.g. for a cylindrical
gear pair Z012result.RPT).
Then define the new parameters or values that are to be added. These values then
appear at the end of the "Results" window.

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12.6

Restore previous stages of the calculation

(Select File > Restore... (acts like the Undo function) to retrieve an earlier state of
the current calculation file. For this reason, every calculation run stores the current
state as a point at which it can be restored. The list of restoration points is deleted
when you open a different file.

II Tooth ing

Part

II

General

Chapter
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Introduction

13

13

Intr oduc tio n

Chapter 13
Introduction
KISSsoft provides calculation modules for different toothing types, ranging from
cylindrical gears in different configurations to bevel gears and face gears to worm
wheels. The input windows for the different gear calculations are very similar.
There are also calculation options for multiple modules. The table below shows
you all the input windows in the individual calculation modules.
Input window

Secti
on

Basic data

14.2

Rating

14.3

Factors

14.4

Reference profile

14.5

Tolerances

14.6

Modifications

14.7

Tooth form

14.8

Flank breaking

14.9

Contact Analysis

14.10

Operating backlash

14.12

Master gear

14.13

AGMA 925

14.14

is supported by all calculation modules

Table 13.1

- Single gear, - Cylindrical gear pair, - Pinion with rack, - Planetary

gear, - Three gears, - Four gears, - Bevel and Hypoid gears, - Face gears,
- Worms with double enveloping worm wheels, - Crossed helical gears and
precision mechanics worms, - Splines (Geometry and Strength)

Chapter
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14

14

Cylin drical g ears

Chapter 14
Cylindrical gears
You can use KISSsoft cylindrical gear calculation software to calculate a range of
different configurations.
The single gear calculation has been developed to calculate the geometry and
test dimensions of individual gears
The cylindrical gear pair is the most important configuration for geometry and
strength. You can also use it for additional calculations and several individual
calculations at the same time.
The planetary gear software checks the practical aspects of the configuration
and monitors both pairs of gears whilst they are being sized. The Fine Sizing
function enables you to optimize the center distance quickly and efficiently.
You can usually input your own values here. However, you must take into consideration that, as torque cannot be applied to the planet, it is not possible to
perform a strength analysis on a Wolfrom drive or on a Ravigneaux gear set.
The configurations for three and four gears enable you to calculate a gear
wheel chain, in which torque is applied only to the first and last gear.
The calculation used for a rack and pinion only includes one rack in the geometry calculation and one cylindrical gear with a large number of teeth for the
strength calculation.
As the input screens for the different configurations are very similar, they are
described together in the sections below.

Chapter
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Cylindrical gears

Chapter
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Cylindrical gears

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14.1

Basic data

Figure 14.1: Basic data input window for cylindrical gear pair

The Basic data input window is one of the standard tabs (see page I-88) and is
subdivided into the two groups Geometry, Material and Lubrication.

14.1.1

Normal module

Enter the normal module. The normal module defines the size of the teeth. A standard series is for example defined in DIN 780 or ISO 54. However, if you know the
pitch, the transverse module or the diametral pitch instead of the normal module,
click the
button to open a dialog window in which the conversion will be
performed. If you want to transfer the diametral pitch instead of the normal module, you can select Input normal diametral pitch instead of normal module by
selecting Calculation > Settings > General.

14.1.2

Hand of gear for gear teeth

Hand of gear for gear teeth (see Figure on page II-263) defines the direction of
the axial forces. A gear with helical teeth usually produces less noise than a gear
with straight teeth, but it generates an additional bending moment and an axial force. A gear with continuous double helical teeth consists of two halves of a helical
gear with a different hand of gear. Although it does not generate any axial forces, it
must be possible to adjust the gear along its axis and it is more difficult to
manufacture. In a herringbone gear (with continuous double helical teeth), click the
button to set the gap width bn.

Chapter
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Cylindrical gears

14

14.1.3

Pressure angle at normal section

The normal pressure angle at the reference circle is also the flank angle of the reference profile. For standard toothings the pressure angle is n = 20o. Smaller
pressure angles can be used for larger numbers of teeth to achieve higher contact
ratios and insensitivity to changes in center distance. Larger pressure angles
increase the strength and allow a smaller number of teeth to be used without
undercut. In this situation, the contact ratio decreases and the radial forces increase.

14.1.4

Helix angle at reference circle

Enter the helix angle in [o]. Click the

button in the Convert helix angle
window to calculate this angle from other values such as, for example, the overlap
ratio and axial force.

Figure 14.2: Helix angle at reference circle.

14.1.5

Center distance

As stated in ISO 21771, the center distance for external and internal teeth is positive for two external gears and negative for an external gear paired with an internal
gear. For internal teeth, the number of teeth on the internal gear and the axis center
distance are always negative.

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14

If you select the checkbox to the right of the axis center distance unit, the value
used in the calculation will remain constant. Otherwise, the axle center distance
will be calculated from the profile shift total.
Click the

button to select one of the following sizing options:

Fixed sum of profile shift coefficients. The axle center distance is calculated on
the basis of a predefined profile shift sum. Click the
button to display a
suggested value for the profile shift sum (as defined in DIN 3992). The sum of
profile shift influences the profile shift coefficients of both gears as well as the
operating pitch circle and the operating pressure angle.
Fixed profile shift coefficient Gear 1 (or 2), balance specific sliding. Optimize
axis center distance with respect to balanced sliding: For a specified profile
shift of a (selectable) gear, this option calculates the axis center distance in
such a way as to balance gear pair specific sliding (for cylindrical gears). If the
Own input menu option is not selected from the Own input drop-down list
in the Reference Profile input window, this calculation is performed
with automatic tip alteration as specified in DIN 3960. You can also enter your
own tip alteration value in the Basic data input window by clicking the
Details... button. In the Define geometry details window select the checkbox next to the Tip alteration input field.

14.1.6

Number of teeth

The number of teeth is, by default, a whole number. You can also enter the number
of teeth as an amount with values after the decimal place (see section "Input of
number of teeth with decimal places" on page II-447). For internal toothed gears,
you must enter the number of teeth as a negative value as stated in ISO 21771. For
a pinion-ring internal gear gear pair, the center distance must also be entered as a
negative value (e.g. z1 = 20, z2 = -35, a = -7.5, mn = 1).
The minimum number of teeth is limited by geometric errors such as undercut or
tooth thickness at the tip. For spur gears without profile shift there is for example
undercut if there are fewer than 17 teeth.

14.1.7

Facewidth

Normally the facewidth shouldn't be greater than 10 to 20 times the normal module, or also not greater than the reference circle of the pinion. The contact pattern
deteriorates if the facewidth is too great. Click the
button to the right of the
facewidth input field to enter the axial offset bv (see also Figure 14.3). The axial
offset reduces the effective width for the strength calculation. The common width

Chapter
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14

is used to calculate the pressure. A certain amount of overhang is taken into

account for the Tooth root strength. The selected pinion width is often somewhat
greater than the gear width.

Figure 14.3: Axial offset bv

In double helical gears2 you must specify the total width of the gear teeth (i.e. the
width of both halves together with the gap). To enter the width of the gap bn, click
the
button on the right of the hand of gear drop-down list for the toothing.

14.1.8

Profile shift coefficient

Preliminary note: If the profile shift sum has not yet been specified, click the
Sizing button ( ), to the right of the center distance (see page II-263) input field,
to display a suggested value for the distance in the Sizing center distance window. The suggested value is based on DIN 3992 recommendations for well
balanced toothing (Area P4/P5). You will find more information about this in DIN
3992 or in Niemann [64], Figure 22.1/6.
The tool can be adjusted for manufacture. The distance between the production
pitch circle and the tool reference line is called the profile shift. To create a positive
profile shift, the tool is pulled further out of the material, creating a tooth that is
thicker at the root and narrower at the tip. To create a negative profile shift the tool
is pushed further into the material, with the result that the tooth is narrower and

Double helical gears are gears that consist of two gear halves; the first half has a left hand helix and
the second half a right hand helix.

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undercutting may occur sooner. In addition to the effect on tooth thickness, the
sliding velocities will also be affected by the profile shift coefficient.
The distribution of the total profile shift affects the tooth thickness, sliding
movements and strength values. It can be performed in accordance with a range of
different criteria. To achieve this, use the various sizing options provided by
clicking the
window.

button in the Sizing of profile shift coefficient

For optimum specific sliding

The value suggested here shows the profile shift for a cylindrical gear pair that
has been balanced for a specific sliding between the pinion and the gear. When
more than two gears are involved, the profile shift coefficient is set to the smallest value that corresponds to the specific sliding movement at the root.
For minimum sliding velocity
The minimum sliding velocity at the tip of the two gears is often used for speed
increasing ratios. In a cylindrical gear pair, this means both gears have the same sliding velocity and that the access and recess length of the path of contact
are also the same.
For maximum root safety
The profile shift coefficient is defined iteratively for the range x*
*
min, x max.
For maximum flank safety
The profile shift coefficient is defined iteratively for the range x*min, x*max.
For maximum scuffing safety
The profile shift coefficient is defined iteratively for the range x*min, x*max.
For gear 1 without undercut and point at tip (min)
The minimum value of the profile shift coefficient for gear 1 is calculated from
the undercut boundary of gear 1 and the minimum topland of gear 2.
For gear 1 without undercut and point at tip (max).
The maximum value of the profile shift coefficient for gear 1 is calculated from
the minimum topland of gear 1 and the undercut boundaries of gear 2.
For undercut boundary per gear.
The proposed value only refers to the selected gear. No check is performed to
see whether the resulting profile shift is also permitted for the other gear in the
pair. For more information, please refer to the explanations above.
For minimum topland per gear.
The proposed value only refers to the selected gear. No check is performed to
see whether the resulting profile shift is also permitted for the other gear in the
pair. You can specify the minimum thickness of the topland in Calculation

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> Settings > General > Coefficient for minimum tooth

thickness at the tip. For more information, please refer to the explanations above.
Click the
button and KISSsoft will determine whether the profile shift
coefficient is to be taken from measured data or from values given in drawings.
The following options are available here:
Base tangent length
Here you must enter the base tangent length (span) and the number of teeth
spanned. This option cannot be used for (internal) helical gear teeth because
their base tangent length cannot be measured.
Measurement over two balls
To do this, enter this dimension and the diameter of the ball. In a gear with helical gear teeth and an odd number of teeth, the measurement over balls is not
the same as the measurement over two pins, see Measurement over pins.
Measurement over 2 pins
To do this, enter this dimension and the diameter of the pin. For helical gear
teeth and gears with an odd number of teeth, you must also enter a minimum
span. This measurement cannot be calculated in internal helix gears.
Measurements over 3 pins
Here, enter the measurement over pins and the pin diameter. For helical gear
teeth and gears with an odd number of teeth, this is equivalent to the measurement over 2 pins. You cannot use this option for internal and helical gear teeth
or gears with an even number of teeth.
Tip circle
This is a rather imprecise calculation because the tip diameter does not always
depend solely on the profile shift.
Tooth thickness at reference circle
Here, you specify the tooth thickness. You can also enter the arc length or
chordal length, and whether the value is in transverse or normal section.
NOTE

If one of the two profile shift values appears in gray, this means it will be
calculated by . This is what happens when you activate the checkbox for entering
the center distance. If you overwrite a gray field, it will become active and
KISSsoft will calculate the value for one of the other gears .

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14.1.9

Quality

In this input field, you specify the accuracy grade in accordance with the standard
shown in brackets. To change the standard used for this calculation, select
Calculation > Settings > General > Input of quality. The
accuracy grade specified in ISO 1328 is approximately the same as the quality
given in DIN 3961 or BS 436/2.
The qualities that can be achieved are displayed in the Quality values (see Table
"Quality" on page IV-908) table.
Manufacturing process

Quality according to DIN/ISO

Grinding

...

Shaving

...

Hobbing

(5)6

...

Milling

(5)6

...

Shaping

(5)6

...

Punching, Sintering

...

12

Table 14.1: Quality values for different manufacturing processes

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Conversion of qualities in accordance with AGMA:

When converting qualities as defined in AGMA 2015-1-A01, Annex B.2 the total
of the quality figures in version 2015 (comparable with ISO) and version 2000
equals 17.

Quality as specified in ISO 1328

and AGMA: 2015

Q. according to AGMA 2000

16

15

14

13

12

11

10

10

11

Table 14.2: Quality values in different standards

If you want to define different tolerances, click Calculation>Settings>General and set the Varying qualities flag.
This activates the Plus button next to Quality in the main screen. Click the Plus
button to open a new window in which you can enter the tolerances you require.

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You can input the tolerances in standard-specific tabs. The changes in the window
are then applied to all the gears in the calculation module.

Table 14.3: Input window for different tolerances

This is the table in which you input any deviation from the base quality (specified
in the "Basic data" tab). Example: The base quality of gear 1 is 6. If you then input
+2 for the runout tolerance, the runout tolerance will be calculated with a quality of
8.
In every case, only those tabs (standards) are displayed that are possible for the
calculation module.
The user entries remain in this window as long as you continue using the same
calculation module. You can therefore import a different file, and set the flag.
The same entries will still appear in the window next to the Plus button. You only
need to input the data again if you change calculation module.

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14.1.10

Geometry details

To open the Define geometry details window, click the Details...

button in the upper right-hand part of the Geometry area. Here you can change the
values for:
Drawing number
Rim thickness coefficient SR*
Inside diameter di
Inside diameter of rim dbi
Web thickness coefficient bs/b*
Web thickness bs
The drawing number is only used for documentation purposes. You can enter any
text here.
The inside diameter is needed to calculate the mass moment of inertia. For solid
wheels, enter 0, for external wheels with a web, enter the corresponding diameter di
as shown in Figure 14.4. For internal wheels, enter the external diameter of the
gear rim.
In accordance with ISO or AGMA, the gear rim thickness sr, defined by the inside
diameter of rim dbi, affects the strength. If no gear rim thickness is present, you can
enter a value of 0 for dbi. In this case the gear rim thickness sr will be determined

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from the diameter di. Where thin gear rims are used, this factor can greatly
influence the calculation of safety factors. For thin gear rims, this value can also be
calculated in accordance with VDI 2737 (see page II-458).
Web thickness coefficient: If the inside diameter di > 0, the value input for the web
thickness (bs or bs/b) is taken into account. If bs/b = 1.0, this means no web is
present. In this case, the gear body coefficient CR is 1.0. The ratio b/bs can vary
between 0.2 and 1.2. In this case, CR is then < 1 (if b/bs < 1) or > 1 (if b/bs > 1).
The coefficient CR is then used to calculate the tooth contact stiffness (c).

Figure 14.4: Measuring the diameter.

14.1.11

Material and lubrication

14.1.11.1
Material s
The materials displayed in the drop-down lists are taken from the materials database. If you cannot find the material you require in this list, you can either select Own
Input from the list or enter the material in the database (see section "External

tables" on page I-132) first. Click the

button to the right of the materials dropdown list to open the Define material, Gear 1(2) window in which you
can select the material you require from the database list of available materials.
Select the Own Input option to enter specific material characteristics. This option corresponds to the Create a new entry window in the database tool.

Str e n gt h ca lc ula ti o n w it h u n us ua l m at er ial s:

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The cylindrical gear strength calculation formulae defined in ISO 6336, DIN 3990
or AGMA 2001 only involve specific (most commonly used) materials and treatment methods. These are:
Heat treatable steel
Case hardening steel
Nitriding steel
Structural steel
Gray cast iron with spheroidal graphite
Cast iron with flake graphite

Ma t eri als n o t i n cl ud e d i n t h e s tr e ng t h cal c ula ti o n s ta n da rd s:

Stainless steel
Free cutting steel
Aluminum and bronze alloys
KISSsoft handles these materials in the same way as heat treatable steels. This
affects some of the less important values that are used to calculate the permitted
tooth root and flank resistance (e.g. the support value). The maximum possible error is minimal.
Plas ti cs

The strength of plastic gears is calculated in accordance with Niemann or VDI

2545. The permitted demands and Young's modulus used for plastics are largely
dependent on the temperature and lubrication type. As a consequence, calculating
the characteristics of plastics requires a great deal of time and effort. At present,
there are only a few reliable values that can be applied solely to the following materials:
POM, PA12, PA66
Laminated fabric
Plywood
You can add additional materials quite easily because the specific data is already
present in files (the file name is present in the materials database). As yet no really
reliable data is available for the new generation of plastics (such as fiber-reinforced
and other plastics), even from the manufacturers.

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It takes a significant amount of time and effort to determine all the data for
calculating the strength of plastics. For this reason, you can also enter plastics with
a limited amount of data in the database.

For this reason, the comment you input for gear strength data for all plastics can
state which data is present and therefore which type of calculations can be
performed.

The entry has this format:

[SBFoFgFdWoWgWd]
Abbreviations:
S

data for the static root strength calculation is present

Woehler lines for calculating the root endurance limit (VDI) are present

F
Woehler lines for all lubrication types for flank endurance calculation
(VDI) are present
Fo
Woehler lines for oil lubrication for flank endurance calculation (VDI) are
present
Fg
Woehler lines for the grease lubrication for flank endurance calculation
(VDI) are present
Fd
Woehler lines for the dry run for the flank endurance calculation (VDI) are
present
Fgd

means: Woehler lines for grease and dry run for the flank are present, etc.

Wear coefficients for all lubrication types are present for wear calculation

Wo

Wear coefficients for oil lubrication are present for wear calculation

Wg

Wear coefficients for grease lubrication are present for wear calculation

Wd

Wear coefficients for dry runs are present for wear calculation

NOTE:

When you select a calculation method either in accordance with VDI or Niemann,
the root, tooth flank and wear values are calculated automatically, if the relevant
data is available for them. However, if data is not present for one or more of these
methods, only those calculations for which data is available are performed.

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Co n v er ti n g har d n es s t o e nd u ra nc e l imi t val u e s Hl im, Flim

When you enter data for your own material, the hardness can be taken for
conversion into the endurance limit values Hlim, Flim. To open the conversion
dialog, click the appropriate conversion button next to the input fields for the
endurance limit values Hlim, Flim. The data is converted in accordance with the
ISO 6336-5:2003 formula described in section 5.
(The data for forged steels is used for heat treatable steels "not alloyed/through
hardened" and "alloyed/through hardened".)
Hlim, Flim=A*x+B
x: Hardness value in the unit used in the table (depending on the HV or HBW material type)
A,B: Factors for the particular material type and processing. (from Table 1, ISO
6336-5)

Figure 14.13: Convert endurance limit values dialog window

Values for Hlim and Flim that are required for the conversion specified in ISO
6336-5 are displayed directly in the material screen under "Own Input" if these values are possible with the specified hardness and material type.
In the next conversion dialog, click on another conversion button next to the
hardness input field to start converting the hardness value. In the case of materials
that are not alloys you can calculate the hardness from the tensile strength value or
other hardness values.

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14.1.11.2
Calculation o f the wear coefficient kw fo r ste e l
According to Niemann [65], Table 21.6/5, and Plewe's dissertation (Plewe, H-J:
"Untersuchung ber den Abriebverschleiss von geschmierten, langsam laufenden
Zahnrdern" (Abrasive wear and endurance calculation for lubricated, low-speed
gears), Technical University of Munich, 1980) which calculates an approximate
guide value for coefficient of wear kw. kw depends on the size of the lubricant gap
in the operating pitch circle hc. The function defined by Plewe, kw = f(hmin), is
valid for standard mineral oil without high pressure additives.

Figure 14: Input window for Proposed value for wear coefficient

You should take care when using this guide value because the existing information
is far from complete. In particular, very little is known about the influence of
surface roughness and the influence of lubricant additives. You should take careful
measurements to check the wear coefficient to ensure reliable results from the
calculations.
Influence coefficient of lubricant: As stated in [65], adding suitable additives to a
lubricant can significantly reduce the amount of wear. The influence coefficient of
the lubricant can therefore lie in a range between 0.01 and 1,000.
Influence coefficient of material: Plewe took measurements from various different
material pairings: Gear made of heat treatable steel paired with a hard or soft counter gear, gear pairs made of case hardening steel, and gear pairs made of nitriding
steel. The kw as defined by Plewe was then determined for these combinations.

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The influence coefficient (if known) can be used for other combinations. For more
information see [65].

14.1.11.3

Lubricat ion

Select the lubricant from a list. If you select Own Input, click the
specify your own lubricant.

button to

If you see the note (with kw info) after the lubricant description, this means an
influence coefficient kwlub is present for this lubricant. This coefficient can then be
used to determine the wear factor kw more accurately.
You can select oil bath or oil spray lubrication, or grease lubrication, or none at all
(dry run). You can select dry run only when using a calculation method for plastics.
Click the
button to the right of the lubrication type drop-down list to open the
Define temperatures window (see Figure 14.13)

Figure 14.13: Define temperatures for dry run dialog window

Here you can either specify your own lubricant temperature or enter the root and
flank temperatures for a dry run in case of plastics. Usually, these temperatures will
be calculated for plastics. However, you can also switch off the calculation and
define your own temperatures.
12. C al cu l a ti ng t h e r e qu ire d a m o u nt o f l ub ric ati ng o il

When the spray lubrication method is used, the required amount of lubricating oil
is calculated as specified by Schlecht [97]. This assumes a difference of 10C
between the temperature of the oil at the inlet and exit. The specific heat capacity
cp (Ws/(KG*K)] and the specific weight at operating temperature is defined as
specified by Niemann [64].

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14.2

Load

Figure 14.14: Load input window for cylindrical gear pair

The Load input window is one of the standard (see page I-88) tabs and is
subdivided into 2 areas: Strength and Load spectrum.

14.2.1

Calculation methods

In the drop-down list, you can select the following calculation methods:
1. Geometry calculation only. If the Rating module is not selected in the
Calculation menu, only the geometry is calculated.
2. Static calculation. Unlike DIN 743 which, for example, has a specific method for static shaft calculations, ISO 6336 does not have its own
calculation method for static calculation. In a static calculation, the nominal stress is usually compared with the permitted material parameters
(yield point and/or tensile strength). This runs a static calculation of
cylindrical gears in KISSsoft where the nominal stress in the tooth root
(calculated by tooth form factor YF ) is compared with the yield point and
tensile strength. See Static calculation (on page II-283).
3. ISO 6336:2006 Method B (Calculation of load capacity of spur and
helical gears). Method B is used for this calculation.
4.

DIN 3990, Method B (Calculation of load capacity of cylindrical gears).

This calculation is also performed using Method B. However, either Me-

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thod B or Method C can be used to calculate the tooth form factor (We
recommend Method C for internal meshings. Otherwise, use Method B).
5. DIN 3990, Method B (YF Method C).
(See DIN 3990, Method B)
6.

DIN 3990, Part 41 (Vehicle Transmission), Method B (Load capacity

calculation for vehicle transmissions). Method B is used for this
calculation. You must enter two application factors (see page II-287) to
represent load spectra accurately.

7. AGMA 2001-B88. (See AGMA 2001-C95)

8. AGMA 2001-C95. This edition of the AGMA 2001-C95 American national standard replaces AGMA 2001-B88. The previous version of the
AGMA standard has been retained because many companies still use old
versions of the guidelines. In fact, there are very few differences between
the old edition, B88, and the new edition, C95. However, the new edition
does include the service factor calculation.
The standard is implemented in its entirety, and the dynamic factor and the
face load factor are calculated according to AGMA recommendations. The
geometry factors (for tooth root and flank) are calculated entirely
according to ANSI/AGMA 908-B89.
The following values are also output in addition to all the relevant intermediate results:
Pitting Resistance Power Rating, Contact Load Factor, Bending Strength
Power Rating, Unit Load for Bending Strength, Service Factor.
This calculation can also be used for every other cylindrical gear configuration (including planetary stages). However, it is remarkable that AGMA
standard does not allow tooth root strength to be calculated directly in
internal gear pairs. In this case the calculation must be performed using the
graphical (see page II-303) method.
9. AGMA 2001-D04.
Most recent version of AGMA 2001. Differs only slightly from the
previous version, C95.
10. AGMA 2101-D04. (Metric Edition)
Equivalent to AGMA 2001-D04, but all values in SI units.
11. Special AGMA standards: 6004-F88, AGMA 6014-A06, AGMA 6011I03
Special standards used in the USA to calculate the strength of open gear
rims. These calculation methods are based on the AGMA 2001 or 2101 ba-

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sic standards. However, some factors have been specifically defined for
special applications.
AGMA 6014 replaces the old AGMA 6004, but both methods are still
available because AGMA 6004 is still requested separately.
12. AGMA 6011-I03: For turbo drives (High Speed Helical Gear Units)
and API 613
The AGMA 6011 standard is a special edition for high speed drives and is
less complex than AGMA 2001 (or the metric AGMA 2101) base standards. In this case, less complex means that some data is already
predefined. For example, AGMA 2001 has the options "Open gearing",
"Commercial gear unit" and "Precision gear unit" for defining the face load
factor, whereas AGMA 6011 has "Precision gear unit" as a predefined
requirement. AGMA 6011 also provides information to help you select the
application factor KA for specific turbo-driven applications and other
useful notes about this type of gear (lubrication arrangement etc.). It is
therefore always possible to perform the calculation according to AGMA
6011 using AGMA 2001 or 2101 without causing any problems. To input
data correctly for AGMA 2001, as implemented in KISSsoft, that is also
correct for AGMA 6011 you must be aware of the constraints and take
them into consideration when entering the parameters. Select the AGMA
6011 method to save the user having to do this. In this situation, the program checks whether all the constraints are set and, if not, queries the user
to see if they want to make any modifications.
Calculation according to API613 (Special Purpose Gear Units for Petroleum, Chemical and Gas Industry Services, 2003). API613 states that the
calculation must be performed according to AGMA 6011. However, this
also involves a number of special features. To perform the calculation
correctly, you must use our information sheet which describes the
necessary checks and inputs: kisssoft-anl-078-E-CylindricalGears
API613.docx. The values required by API613, such as flank load K or the
permitted value Ka, bending load S and the permitted value Sa, as
specified in Appendix J of API613, are documented.
13. GOST-21354-87
Calculation according to the Russian guideline (latest edition, 1987). Take
the following notes into account, see GOST-21354-87 (on page II-283).
14. Plastic as defined in Niemann
Please refer to [65] and Table 13.3 to see the differences.
15. Plastic as defined in VDI 2545 (YF, Method B) (thermoplastic materials
used in gears). This method has been withdrawn, and replaced by the new
method, according to VDI 2736. This regulation defines how calculations
are performed on gears made of plastic or combinations of plastic and

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steel. See Plastic as defined in VDI 2545 (YF, Method B) (see section
"Plastic according to VDI 2545 (YF Method B)" on page II-285).
16. Plastic as defined in VDI 2545 (YF, method C).
In this calculation method, the tooth form factor Y F is calculated according
to Method C.
17. Plastic as defined in VDI 2545 modified (YF, Method B).
This method was recommended for use by KISSsoft before VDI 2736 was
published. VDI 2736 contains all the modifications recommended
according to Tables 13.3 and 13.4. This method is recommended for plastics with normal toothing. Transverse contact ratio < 1.9. See table in
14.4 for the differences between VDI and VDI modified.
18. Plastic according to VDI 2545 modified (YF, Method C).
This method is recommended for plastics with deep toothing. Transverse
contact ratio > 1.9. See table in 14.4 for the differences between VDI
and VDI modified. See table in 14.4 for the differences between VDI and
VDI modified. In this calculation method, the tooth form factor Y F is
calculated according to Method C.
19. Plastic according to VDI 2736.
We recommend you use this calculation method, VDI 2736, which was
published for the first time in 2014/15. It includes all methods described in
sheet 2 of VDI 2736 (empirical calculation, tooth root, tooth flank, deformation, wear).
20. As in FVA program (DIN 3990). Supplies the same results as the FVA
(Forschungsverein Antriebstechnik: German Research Society for Transmission Techniques) Reference Program. Based on DIN 3990 Method B
with minor differences.
21. BV/Rina FREMM 3.1 Naval Ships and Rina 2010 (ISO 6336)
Calculation guidelines for ships' engines.
22. DNV 41.2, Calculation guideline for ships' engines
The Det Norske Veritas calculation guideline [93] for ships' engines
corresponds in principle to ISO 6336 (root, flank) and ISO 13989
(scuffing). However, it does have some significant differences, especially
where Woehler lines are concerned. These differences are detailed in our
kisssoft-anl-076-DE-Application_of_DNV 41.2.pdf information sheet,
which is available on request.
23. Lloyd's register, classification for ships
Calculation guideline for ships' gears
24. ISO 13691, High-Speed Special Purpose Gear Units
Calculation guideline for high-speed gear units

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14.2.1.1
Static calculation
Each coefficient (application factor, face load factor, transverse coefficient,
dynamic factor) is set to 1.0. The load at the tooth root is calculated with
the tooth form factor according to ISO 6336 Method B and the helix angle
(without the stress correction factor).

(12.1)

(12.2)

It also calculates the local tooth root stress multiplied by the stress
correction factor YS. This stress is approximately the same as the normal
stress calculated in an FEM model. This stress is then also output in the report:

(12.3)

14.2.1.2
GOST -21354-87
Quality according to GOST 21354-87
GOST only takes into account one quality, which is why the poorer quality of the
two gears is used during the calculation.
Q = max (Q1, Q2)

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Endurance limit values for root and flank

The endurance limit values Flim and Hlim are saved in the database, in
KISSsoft, or you can enter them, if you select "Own Input".

Endurance limit for tooth root

The endurance limit sFlim is calculated as follows, according to GOST:
Flim = Flim0 * Yz * Yg * Yd * YA * YT
Flim0 nominal endurance limit in the case of a limit load cycle (GOST 2135487, Tables 14 to 17).
Yz - blank coefficient (GOST 21354-87 Table 13, Formula 10.3).
Yd Takes into account the hardening of the root transition zone (GOST 2135487, Tables 14-17).
Yg takes into account the grinding of the root transition zone (GOST 21354-87,
Tables 14 to 17).
YT technology factor (GOST 21354-87, Table 13, Formula 10.2). The default
technology factor setting is 1.0, but you can change it in KISSsoft. Select Factors
Z Y factors.
YA alternating bending factor (GOST 21354-87 Table 13, formula 10.6). The
alternating bending factor setting is 1.0, but you can change it to your own entry in
KISSsoft. Select Factors Alternating bending factor.
The Yd, Yg and Yz coefficients cannot be entered in KISSsoft and must be
included directly when the endurance limit is entered.
In addition to the coefficients mentioned above, the endurance limit defined in
GOST must be divided by 2.0 before being entered in KISSsoft. In the calculation,
sFlim is then multiplied by the stress correction factor YST = 2, in a similar way to
in ISO or DIN.
Consequently, the correct entry for sFlim in KISSsoft, for calculations according to
GOST, is:
Flim (KISSsoft entry) = sFlim0 (according to GOST) * Yd * Yg * Yz / 2.0

Required minimum safeties

GOST has the special property that the minimum safety set for tooth root fracture
and the flank depends on the material type and the surface hardening. For this reason, you can enter minimum safeties for every gear individually, for GOST, under
"Settings" > "Required safeties".

Information about root rounding

In various GOST formulae, a distinction is made between whether the root
rounding is ground or not. To make this distinction, you must enter a suitable value
under "Load" > "Details" > "Gear".

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Face load factor flank calculation KHb

The face load factor (flank) is calculated according to GOST 21354-87, Table 6,
Formula 7. The considerations described in GOST 21354-87, Appendix 6, are
ignored.

Face load factor root KFb

The face load factor (root) is calculated according to GOST 21354-87 Table 13,
Formula 4.

Dynamic factor KV
The dynamic factor is calculated according to GOST 21354-87 Table 6, Formula 6.
If conditions (34) and (35) specified in Formula 6 are not fulfilled, KISSsoft
calculates the dynamic factor according to GOST 21354-87 Appendix 5.

Load spectra
Calculations with load spectra are performed using the rules defined by PalmgrenMiner, according to ISO 6336-6.

Safety of the hardened layer

The safety of the hardened layer is calculated according to DNV 41-2.

14.2.1.3
Plastic according to VDI 2545 (YF Method B)
The calculation methods used for plastics take special account of the fact that these
materials are very sensitive to extremes of temperature. The types of lubrication
used here include oil, grease or none at all (dry run). The acceptable load for each
material is calculated from figures in data tables whilst taking into consideration
the local temperatures at the tooth flank and root as well as the number of load
cycles. The local temperature can be calculated when grease is used as the lubricant
or during a dry run. However, when oil is used as the lubricant, the oil temperature
is used as the local temperature. The calculation is performed for combinations of
plastic/plastic and also steel/plastic. The acceptable deformation is also checked.
KISSsoft supplies data for the following materials:

Plywood
Laminated fabric
Polyamide (PA12, PA66)

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14

Polyoxymethylene (POM)
All the specific properties of each material are stored in text tables to permit integration of own materials (see page I-124). The strength of plastics can be calculated
either as defined by Niemann [66] or VDI 2545 (1981)3 (tooth form factor as
defined in Method B or C). You can also use the modified calculation method as
detailed in VDI 2545. This calculates the stress using the tooth root stress
correction factor Ys. The major differences between the two methods are:
Root

Niemann

VDI 2545

VDI 2545-mod.

YF

B or C

B or C

YS

DIN 3990

1.0

DIN 3990

8)

7) 9)

1/ 7) 9)

1.0

1.0

DIN 3990 10)

DIN 3990 10)

FE

2 *Flim

Flim

2 *Flim

1/

Table 14.3: Differences between the various calculation methods used for plastics and tooth root

Flank

Niemann

VDI 2545

VDI 2545-mod.

1.0

DIN 3990

DIN 3990

ZV

DIN 3990 5) 10)

1.0

1.0

ZR

6) 10)

1.0

1.0

DIN 3990

Table 14.4: Differences between the various calculation methods used for plastics and tooth
flank

Tooth deformation: Very different calculation methods!

5)
For plywood only, otherwise 1.0
6)
For steel/plastic combinations only, otherwise 1.0
7)
For tooth form factor YF as defined in Method B: 1.0
8)
The method sets the face contact ratio for the tooth root stress to the value 1.0.
According to Niemann, this is because the material data is not always precise. The
formulae used in VDI 2545 correspond to those used in ISO 6336:1996.
9)
For crossed helical gears = 0.25 + 0.75/
10)
For crossed helical gears = 1.0

Calculation method VDI 2545 has been withdrawn because it has not been revised as required. A new
calculation guideline, VDI 2736, is currently being developed. We recommend the "VDI 2545-mod."
method is used until the new standard is launched. Its announced publication date is 2014. We are
unaware of a better version.

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14.2.2

Service life

Enter the required service life directly in the input field.

Click the
button to size this value. Based upon the minimum safety value for
the tooth root and flank strength, this process calculates the service life (in hours)
for every gear and for every load you specify. The service life is calculated in
accordance with ISO 6336-6:2006 using the Palmgren-Miner Rule. The system
service life and the minimum service life of all the gears used in the configuration
is displayed. You can size the service life using the
button either with or
without defining a load spectrum (see section "Define load spectrum" on page II304).

14.2.3

Application factor

The application factor compensates for any uncertainties in loads and impacts,
whereby KA 1.0. Table 14.5. illustrates the values that can be used for this factor.
You will find more detailed comments in ISO 6336, DIN 3990 and DIN 3991.
When deciding which application factor should be selected, you must take into
account the required safety values, assumed loads and application factor in one
context.
Operational behavior
of the driving machine

Operational behavior of the driven machine

uniform

moderate
shocks

medium
shocks

heavy
shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

Table 14.5: Assignment of operational behavior to application factor

DIN 3990, Part 41 (car gearboxes), distinguishes between application factors for
flank strength KAH and for tooth root strength KAF . Except for flank strength
calculations, all other calculations (e.g. resistance to scoring) use application factor
KAF .
However, according to DIN 3990 Part 41, the application factor can also be less
than 1.0. This is intended to avoid the need to perform a calculation involving a
load spectrum. For example, DIN 3990, Part 41, Appendix A, suggests the
following values for a 4-speed car gearbox:

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Gear

1
5

1.5 * 10

3
7

NL

10

KAH

0.65

0.65

0.65

0.65

KAF

0.70

0.70

0.80

0.80

14.2.4

2 * 10

2
6

3 * 10

4
7

2 * 108

Power, torque and speed

Click the
button next to the power input field (for the torque) to calculate the
power (torque) so that a predefined safety minimum (see page II-459) can be
maintained.

14.2.5

Strength details

Click on the Details... button to open the Define details of

strength window which is divided into the System data and Pair/Gear
data tabs. Note that a different window layout is used for calculations according
to AGMA (see page II-303).

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14.2.5.1

System data

Pro fil e m odi fic a ti o n

You can modify the theoretical involute in high load capacity gears by
grinding/polishing the toothing. You will find suggestions for sensible
modifications (for cylindrical gears) in KISSsoft Module Z15 (see section
"Modifications" on page II-356). The type of profile modification has an effect on
how scuffing safety is calculated. The load sharing factor X is calculated
differently according to the type of profile modification used. The main difference
is whether the profile has been modified or not. However, the differences between
for high load capacity and for smooth meshing are relatively
small. The strength calculation standard presumes that the tip relief Ca is properly
dimensioned but does not provide any concrete guidelines. The resulting load sharing factor X in accordance with DIN 3990, depends on the type of profile
modification:

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(a) no profile modification

(b) high performance gears; pinion

drives

(c) high performance gears; gear drives

(d) balanced meshing

Figure 14.9: Load sharing factor X for different profile modifications

L if eti m e f ac t or s a s d e fi n ed i n IS O 63 36

The fatigue limit factor ZNT reduces the permitted material stress in accordance
with ISO 6336-2:2006:

(12.14)
(12.15)

As stated in ISO 6336, this value is important for cylindrical gear calculations and
is the reason for the lower safety values in the range of endurance limit when
compared with DIN 3990.
1. normal (reduction to 0.85 at 1010 cycles): The permitted material stress in
the range of endurance limit (root and flank) is reduced again. Fatigue
strength factors Y NT and ZNT are set to 0.85 for 1010 load cycles.
2. increased with better quality (reduction to 0.92): Y NT and ZNT at 1010
load cycles are set to 0.92 (in accordance with the data in ISO 9085).
3. with optimum quality and experience (always 1.0): This removes the reduction and therefore corresponds to DIN 3990. However, this assumes the
optimum treatment and monitoring of the materials.
M o difi ca ti o n of S -N c ur v e ( W o e hl er li n e) i n t h e r an g e of e n d ura nc e lim it

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In a standard Woehler diagram, the range of endurance limit is reached at a

particular number of load cycles. From this point onwards, the dynamic strength no
longer changes even when the number of load cycles increases. This behavior is
called "according to Miner".
However, more recent investigations have revealed that there is actually no such
thing as an endurance limit and that the S-N curve (Woehler line) should be
modified in the endurance limit range.
In the range of endurance limit, you can therefore select the following modified
forms:
Miner (corresponds to DIN 3990, Parts 2, 3 and 6)
According to Corten/Dolan
According to Haibach
Figure 14.73 shows the relevant characteristics. Experience has shown that
performing a service life calculation with load spectra using the Miner method returns results that are far too optimistic. We recommend you use the Haibach method of approach.

Figure 14.73: Endurance limit models

Note concerning calculations according to ISO or DIN:

The slope of the S-N curve (Woehler line) for bending in the time-dependent domain (between N0 and N00) is defined using the YNT, YdrelT, YRrelT and YX
coefficients for the static and endurance cases, but in the endurance domain (NL >
N00), only the YNT coefficient is used for the static and endurance cases. The same applies to pitting with the ZNT, ZL, ZV, ZR and ZW factors. This corresponds
to the method used in ISO 6336 for the endurance domain. However, this does

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mean that buckling occurs on the S-N curve (Woehler line) at N00, according to
the Corten/Dolan rule.
As an example: for case-carburized steel the slope of the S-N curve (Woehler line)
in the endurance domain is 13.2, but in the time-dependent domain it is
approximately 10, depending on the precise values for YdrelT, etc.
If all the factors, YdrelT, etc., are set to 1.0 using "Own input" then there will be no
buckling of the S-N curve (Woehler line) at N00.
T o ot h f orm fa c to rs

The tooth form factor YF takes into account how the tooth form affects the nominal
tooth root stress F0. The stress correction factor YS takes into account the effect of
the notch on the tooth root. These two factors can be calculated in three different
ways:
1. In accordance with the formulae in the standard (normal)
As defined in ISO 6336 or DIN 3990, the tooth form and the stress correction factors are calculated at the tooth root at the point at which the tangent
and the tooth center line form an angle of 30o. However, it is generally
acknowledged that this method is rather imprecise, for deep meshings in
particular.
2. Using graphical method
According to Obsieger [68], there is a more precise approach in which the
product of the tooth form factor YF and the stress correction factor YS is
calculated and the maximum value is determined. This method is based on
the production procedure used for a specific tooth form and is applied to all
points in the whole root area. This maximum value is then used in calculating the strength. Factors YF and Y S are calculated in accordance with the
formulae in ISO 6336 or DIN 3990.
This is the recommended method, particularly for unusual tooth forms and
internal teeth. If required, this calculation procedure can also be applied in
strength calculations as defined in ISO 6336 and DIN 3990, as well as in
fine sizing.
Note:
If you use the graphical method here, KISSsoft will calculate the tooth
form before it calculates the strength, each time. It takes its parameters
either from the cutter data you entered previously in the Tooth form
(see section "Gear tooth forms" on page II-616) input window or
from the default settings in the Reference profile input window.
The maximum value of the product of the tooth form and stress modification factor is calculated at the same time and included in the strength calcu-

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lation.

Figure 14.15: Tooth form factors using graphical method

3. for internal toothing, in accordance with VDI Proposal 2737
When calculating strength according to ISO 6336 or DIN 3990, selecting
this option allows you to use the tooth form factor as defined in VDI 2737,
which is more precise for internal teeth, because it evaluates the stress at
the point of the 60 tangent and derives the tooth form from the manufacturing process with the pinion type cutter.
The tooth root stress calculation specified in ISO 6336 is more accurate
than the one implemented in DIN 3990. However, the calculation applied
to the root rounding in the critical point (for a 60 tangent) is still incorrect.
The method defined in VDI 2737, Annex B is much more accurate, which
is why we recommend you use this method. If you select this option, only
the root rounding F and the root thickness sFn in the critical cross section
is calculated according to the formulae in 2737. All other sizes are calculated according to ISO 6336.
The table (below) uses 4 examples to show the large variations that still
arise in root rounding between the result defined in ISO 6336 and the effective values measured on the tooth form. However, the calculation method stated in VDI 2737 is very suitable.

Gear
x=

Pinion
Cutter
x0=

F in ISO
6336-3 2006
and 2007-02

F in ISO
6336-3 2007-04

F measured
on the tooth
flank

F with
VDI 2737

-0.75

0.1

0,201

0,426

0,233

0,233

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-0.75

0.0

0,175

0,403

0,220

0,220

0.0

0.1

0,298

0,364

0,284

0,286

0.0

0.0

0,274

0,343

0,265

0,264

Table14.10: Comparison of root roundings

Note about calculating YF:

The theoretical profile shift is used for the calculation of the allowance is As <
0.05*mn (according to ISO 6336-3). Otherwise the larger manufacturing profile shift xE.e is used. This corresponds to the procedure used in the STplus program (from Munich, Germany). An exact definition is not provided in the ISO
standard. However, if this is specified in Settings Strength calculation using mean position in tolerance field (of tooth
form), the calculation will always be performed with the average manufacturing allowance xE.m.
According to the ISO standard, the reference profile for the entire toothing is to
be used for the calculation. For this reason, if you input the reference profile
for pre-machining with protuberance, and a manufactured profile with remaining protuberance is left after deduction of the grinding allowance, the reference profile for final treatment is used for the calculation. In the case of the reference profile for preliminary treatment without a protuberance (or a protuberance that is too small), a grinding notch is produced. To ensure that this situation can be correctly taken into consideration the pre-machining reference profile (with preliminary treatment manufacturing profile shift) is used to calculate
YF. Furthermore, the final treatment reference profile is used to calculate the
grinding notch and therefore define YSg (section 7.3 in ISO 6336-3).

T o ot h c o n tac t st iff n e ss

Tooth contact stiffness is required to calculate the dynamic factor and the face load
factor. You can use one of these calculation options:
1. In accordance with the formulae in the standard (normal)
In the standard calculation, the tooth contact stiffness cg is calculated using
empirical formulae (in ISO 6336, DIN 3990, etc.).
2. Using the tooth form
In this option, the tooth form stiffness c' is calculated in accordance with
Weber/Banaschek's dissertation [69]. This takes into consideration tooth
bending, basic solid deformation, and Hertzian pressure. The last condition
determines the load dependency of c'. The contact stiffness is determined

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using the effective tooth form (see Meshing stiffness (Z24)). The mean value of the stiffness curve that is calculated using this method is then included in the calculation. If required, this calculation procedure can also be
applied in strength calculations as defined in ISO 6336 and DIN 3990, as
well as in fine sizing (Z04). The single spring stiffness c' is calculated from
the cg, by extrapolating c' from the formula for cg (ISO or DIN).
3. constant (20 N/mm/m)
In this option, the tooth contact stiffness constant is replaced by

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Sma ll n o. o f pi t ti n gs p er mis si bl e

In specific cases, the appearance of a small number of pittings on the flank may be
permissible. In a range of materials this results in higher flank safeties in fatigue
strength range due to the changed S-N curve (Woehler line), as can be seen in
either ISO 6336-2, Figure 6, curve 1 or DIN 3990-2, Figure 8.1.
L u bric at i on c o ef fi ci e nt

The lubricant coefficient is needed to calculate the friction factor, loss, micropitting
and scuffing.
These values are specified in ISO 15144:
1.0 for mineral oils
0.6 for water-soluble polyglycols
0.7 for non-water-soluble polyglycols
0.8 for polyalphaolefins
1.3 for phosphate esters
1.5 for traction fluids

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14.2.5.2

Pai r/gear dat a

Rel at iv e w el di n g f ac t or (s cu ffi n g)

The relative welding factor takes into account differences in materials and heat
treatment at scoring temperature. However, the standards do not provide any details about how to proceed when different types of material have been combined in
pairs. You must input this coefficient yourself because it is not set automatically by
KISSsoft.
Relative welding factor as defined in DIN 3990, Part 4:
Heat-treated steels

1.00

Phosphated steel

1.25

Coppered steel

1.50

Nitrided steel

1.50

Case-hardened steels

1.15 (with low austenite content)

Case-hardened steels

1.00 (with normal austenite content)

Case-hardened steels

0.85 (with high austenite content)

Stainless steels

0.45

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The standard does not provide any details about how to proceed when the pinion
and gear are made of different material types. In this case it is safer to take the
lower value for the pair.
Nu m be r of l o ad cy cl e s

KISSsoft calculates the number of load cycles from the speed and the required service life. If you want to influence the value, you can define it in the Number of
load cycles for gear n window. Click the
button to access this. In
this window you can select one of five different options for calculating the number
of load cycles.
1. Automatically The number of load cycles is calculated automatically from
the service life, speed, and number of idler gears.
2. Number of load cycles Here you enter the number of load cycles in millions. You must select this option for all the gears involved in the calculation
to ensure this value is taken into account.
3. Load cycles per revolution Here you enter the number of load cycles per
revolution. For a planetary gear unit with three planets, enter 3 for the sun
and 1 for the planets in the input field.
Note:
If the Automatically selection button in the calculation module is selected, KISSsoft will determine the number of load cycles in the Planetary stage calculation module, while taking into account the
number of planets.
4. Load cycles per minute Here you enter the number of load cycles per minute. This may be useful, for example, for racks or gear stages where the
direction of rotation changes frequently, but for which no permanent speed
has been defined.
5. Effective length of rack The rack length entered here is used to calculate
the number of load cycles for the rack. The rack length must be greater
than the gear's perimeter. Otherwise, the calculation must take into account
that not every gear tooth will mesh with another. You must enter a value
here for rack and pinion pairs. Otherwise the values NL(rack) =
NL(pinion)/100 are set.
NOTE

This calculation method is used for transmissions with a slight rotation angle.

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This scenario assumes that a reduction is present

and a pivoting angle w in [o] from gear 2, where gear 2 constantly performs forwards and backwards movements by the angle value w. The effective endurance is
given as the service life. The two coefficients N1 and N2, which reduce the absolute
number of load cycles, NL, are now calculated. To do this:
a) Set the alternating bending factor of the pinion and gear to 0.7, or calculate
it as defined in ISO 6336-3:2006. In this case, a complete forwards/backwards movement is counted as a load cycle.
b) For the pinion, coefficient N1 is determined as follows:

c) The number of load cycles of teeth in contact in gear 2 is smaller by a

coefficient of N2 when compared with the number of load cycles during
continuous turning.

The coefficient 0.5 takes into account both the forwards and backwards
movements.
d) Enter coefficients N1 and N2 in the Load cycles per revolution
input field.

The correct number of load cycles can now be calculated on the basis of the data
entered in steps a to d.
Gri ndi n g n ot c h

As defined in DIN 3990 or ISO 6336, the effect of the grinding notch can be taken
into account by the coefficient YSg. Here, you input the ratio tg to the radius of
grinding notch g in accordance with the figure in DIN3990-3, Section 4.4 or ISO
6336-3, Figure 5. KISSsoft then calculates the coefficient Y g = YSg/Y S (a factor,
which was multiplied with YS).

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The distance between the 30o tangents for the initial and final contour is used as the
grinding notch depth tg. If a pre-machining allowance has been entered in KISSsoft
(see Figure 14.11), you can no longer enter the ratio tg/g. It is calculated by the
software instead. A grinding notch occurs when a grinding depth (see section
"Modifications" on page II-356) was entered and no protuberances remain, either
because no protuberance tool was used, or the selected allowance was too small.
The fillet radius g is then calculated by generating the grinding wheel at the 30o
tangent (or, for internal teeth, at the 60o tangent).

Figure 12.11: Grinding notch

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Pre t e ns i on

The influence of a press fit or other processing methods that influence tooth root
stress can be taken into account with the pretension P. This value influences the
calculated tooth root stress as well as the safety according to the following
formulae:
For static strength:

F F P
'

SS
'

SB
'

RP

F
'

Rm

F
'

For fatigue strength:

'
FG FG 1 P
Rm

FG
'

SF
'

The pretension P merely generates additional results in the reports. The results in
the results window remain unchanged. You define this under "Strength" -> "Details".
NOTE 1

This rule is not documented in the ISO standard. For this reason, we recommend
extreme caution if the preload effect is to be taken into account. The formulas
are proposed by Alstom Ecotecnia. KISSsoft only shows this effect in the report.

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NOTE 2

If the main calculation (single load or load spectra) requires the use of this rule, the
value Flim must be changed as follows, according to the equation for FG:

Flim must be used instead of Flim in the material values. The main calculation
will then be performed using this rule for pretension.
Op ti mal ti p r eli e f

To calculate safety against micropitting as specified by Method B in ISO 15144,

you must specify whether or not the profile modification is to be assumed to be
optimal. The same applies to calculating the safety against scuffing. The software
checks whether the effective tip relief (Ca) roughly corresponds to the optimum tip
relief (Ceff). If this check reveals large discrepancies, i.e. Ca < 0.333*Ceff or Ca >
2.5*Ceff, a warning is displayed. In this case, the value you input is ignored and
documented accordingly in the report.
Ro o t r o u nd in g, gr o u nd

The setting specifying whether the root rounding is ground or not is only used in
calculations according to GOST.
Har d e ni ng d ep t h, k n ow n by it s a bb r evi a ti o n " EH T "

You can input the intended hardening depth (for hardness HV400, for nitrided
steels, or HV550 for all other steels). You can also input the hardness HV300. This
value is then used to display the hardening curve as a graphic. The input applies to
the depth measured during final machining (after grinding).
When you input this data, the safety of the hardened surface layer is calculated
automatically according to DNV 41.2 [93]. Here a minimum value of t400 (nitrided
steel) or t550 (all other steels) is used. If only the value for HV300 is known, this
value is then used. However, the calculation should then only be seen as an
indication. The calculation is performed as described in the section in [93]
"Subsurface fatigue". The values required to define the EHT coefficient YC as
specified in DNV 41.2 are also needed. The calculation is performed using different solutions than the calculation of the proposal for the recommended hardening
depth, but still returns similar results (proposal for hardening depth). To obtain a
proposal for a sensible hardening depth, we recommend you call the calculation in
Report->Proposals for hardening depth. A maximum value for the
hardening depth is only used to check the hardening depth at the tooth tip. It is
mainly used for documentation purposes.

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14.2.6

Strength details (AGMA)

Figure 14.12: Define details of strength input window for calculating

strength as defined in AGMA

NOTE

Only values in the input window that differ from those defined in ISO are
described here.

14.2.6.1
Li fetime factors
The endurance limit factors determine which material values can be entered in the
field for limited time and strength. In standard applications, endurance strength
values up to 1010 load cycles are reduced from 100% to 90% for the root and to
85% for the flank. As stated in AGMA, the reduction in strength also extends
beyond 1010 load cycles. In critical application areas, where a gear breakdown must
be prevented at all cost, the material values are further reduced in comparison to
those used in standard application areas.

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14.2.6.2
Form facto rs
For cylindrical spur gears, or spur gears with low helix angles, you can specify that
the load is to be applied either at the tip or at a single meshing point (the more
precise option). For cylindrical gears with a large helix angle ( 1) in
accordance with AGMA the force is always applied to a single meshing point
(HPSTC).

Calculating with the HPSTC results in a lower load at tooth root because the load is
divided between the two teeth. However, if large single pitch deviations occur, this
load distribution does not take place and therefore the force should be assumed to
be placed at the tooth tip.
As stated in AGMA, the contact point between the tooth form and the Lewis
parabola is selected as the critical root cross section. The stresses are determined
here. AGMA does not provide a formula for calculating internal teeth. Instead, it
recommends you use the graphical method to calculate the tooth form. The
required data is to be taken from measurements. If you click the checkbox to select
the graphical method of calculating the tooth form factor, the software
automatically calculates the tooth form at the point where the Kf or I factor is greatest. In contrast to the method defined by Lewis, where the calculation is only
performed at the contact point of the parabola, the calculation using the cross
section with the greatest stresses gives more precise results and is therefore the method we recommend for external gears too.

14.2.6.3
Transmi ssion accuracy level numbe r
AV (or QV for AGMA 2001-C95 or earlier) is calculated in accordance with the
formulae defined in AGMA 2001 or 2101 and is extremely dependent on the
accuracy grade. However, the AV may be one level higher or less than the accuracy
grade and is needed to calculate the dynamic factor. You can overwrite this value if
required.

14.2.7

Define load spectrum

Figure 14.72: Load spectrum group

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14

In this group, you can also access load spectra that have been stored in the database. You can also define the load spectra directly.
If you select Read, you can import a file (in either *.txt or *.dat format) with a
load spectrum.
The "Example_DutyCycle.dat" file in the dat sub-folder in the KISSsoft installation directory is an example of a file that shows how a load spectrum can be
defined.
If you want the calculation with load spectra to include separate factors (K H, K,
etc.) for each load spectrum element, you must make the appropriate settings in the
Factors tab for the load distribution coefficient (on page II-309) K, the
alternating bending factor (on page II-310) YM and the face load factor (on page
II-313) KH. You will find an example file that shows how a load spectrum with
factors (KH, K, etc.) can be defined in the "Example_DutyCycleWithFactors.dat"
file in the dat sub-folder in the KISSsoft installation folder.

14.2.7.1
Type of load spectrum
The calculation of service life for load spectra is performed as specified in ISO
6336, Part 6, and is based on the Palmgren-Miner rule.

Three load spectra are predefined here, as shown in DIN 15020 (Lifting
Appliances), along with many other standard spectra. You can enter your own load
spectra.
A load spectrum consists of several elements (up to 50 in the database or an
unlimited number if imported from a file). Each element consists of the frequency,
speed, and power or torque. The data always refers to the reference gear you selected when you input the nominal power (Performance-Torque-Speed screen). The
program stores these values as coefficients so that they are modified automatically
when the nominal power changes.
If two speeds that are not equal to zero have been predefined for planetary stages,
you can select two load spectra. In this case, only the speed factor is important for
the second load spectrum.

NOTE

The load dependency of the K coefficients are included in the calculation (K

coefficients: dynamic, face load and transverse coefficients). If you want to
examine the result in greater detail, you will find the most interesting interim
results in the Z18-H1.TMP text file (in the TMP directory).

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14.2.7.2
Load spectra with negative element s
Load spectra with negative load bins (T < 0 and/or n < 0) can also be calculated as
follows (this is only applied to bins whose alternating bending factor is YM=1.0).

IMPORTANT:
A load bin is considered to be negative if the mating flank is placed under load.
The same definition is used for the speed and torque (or power) prefix as in
KISSsys.
Consequently, the following bins are evaluated as negative:
Factor for torque or
power

Factor for
speed

Flank under load

Actual load bin

Working flank (*)

Evaluated as positive

Working flank (*)

Evaluated as positive

Mating flank

Evaluated as negative

Mating flank

Evaluated as negative

(*) Working flank as entered in the Strength tab

Under "Details" in the "Strength" section of the "Load" tab, you can select the
following:
For calculating pitting safety

Evaluate all negative load bins as positive (as up to now)

Consider only positive load bins

Consider only negative load bins

For calculating the tooth root safety

Evaluate all load bins (as up to now)

For negative load bins, increase root stress by 1/0.7

Increase bending stress for positive load bins by 1/0.7

14.2.8

Calculate scuffing

The following selection options are available here:

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Corresponding to the strength calculation method

Here, if the DIN strength calculation method is used, scuffing is calculated
as defined in DIN 3990-4, for all other calculation methods, scuffing is calculated
as specified in ISO TR 13989.
Always in accordance with ISO TR 13989
Scuffing is always calculated as specified in ISO TR 13989.
Always in accordance with DIN 3990-4
Scuffing is always calculated as specified in DIN 3990-4.
Depending on which option is selected, the integral temperature and flash
temperature are calculated in accordance with the corresponding standard.

14.2.9

Calculate the internal temperature and the

flash temperature

The calculation is performed for cylindrical gears and bevel gears. Here you can
specify whether the scuffing is calculated in accordance with DIN or as specified in
the selected strength calculation method as defined in ISO.

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14.3

Factors

Figure 14.15: Factors input window for a cylindrical gear pair

The Factors input window is one of the standard (see page I-88) tabs.

14.3.1

Transverse coefficient

The transverse coefficient KH is calculated in accordance with the calculation method you selected. The transverse coefficient takes into account irregular contact
characteristics across a number of teeth. When the contact ratio increases, the
transverse coefficient also becomes larger depending on the predefined accuracy
grade. A high contact ratio will result in a reduction of the root stresses. Large
single pitch deviations, the transverse coefficient will compensate this effect.
In unusual cases, the transverse coefficient will be unrealistically high. If you want
to reduce the transverse coefficient in this situation, simply click the checkbox to
the right of the input field. You can then change this value.

14.3.2

Dynamic factor

The dynamic factor takes into account additional forces caused by natural
frequencies (resonance) in the tooth meshing. It is usually calculated using the
calculation method you selected, however you can also input the value if it has
already been derived from more precise measurements. To change the value, click
the checkbox next to the input field.

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14.3.3

Load distribution coefficient

The load distribution coefficient takes into consideration the uneven load distribution across multiple planets or idler gears. In this case the load is multiplied by this
coefficient. Dimensioning suggestion according to AGMA 6123-B06:
Number of planets
Application

Level

Quality

Flexible

ISO 1328

Mountin
g

AGMA
2015
1

1.16

1.23

1.32

1.35

1.38

1.47

1.60

without

1.00

1.00

1.25

1.35

1.44

1.47

1.60

1.61

56

without

1.00

1.00

1.15

1.19

1.23

1.27

1.30

1.33

without

1.00

1.00

1.08

1.12

1.16

1.20

1.23

1.26

with

Table 14.9: Load distribution coefficient K defined by the number of planets

Level of application

Explanation

Typical of large, slow-turning planetary gear units

Average quality, typical of industrial gears

High quality gears, e.g. for gas turbines

Table 14.10: Meaning of the level of application

NOTE

Level 2, or higher, requires at least one floating element.

Level 3, or higher, requires a flexible gear rim.
In a flexible assembly, the planets must be mounted on flexible pins/shafts or on
bearings with couplings.
The calculated according to AGMA 6123 method is used to calculate
the load distribution coefficient K for application level 1 3 depending on the
accuracy grade and the number of planets.
If a different load distribution coefficient is input for each element when load
spectra are in use, you should select the Own input, per load stage method.

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14.3.4

Alternating bending factor

The tooth root strength calculation is dedicated for the pulsating load on the tooth
root. However, in some cases, the tooth root is subject to alternating bending loads
(e.g. a planet gear in planetary gear units). In this scenario you can change the
alternating bending coefficient of individual gears by selecting either the Own
input or Own input, per load spectrum element methods. As an
alternative to transferring these values directly, select the Calculate in
accordance with ISO 6336-3 Annex B method to calculate the
coefficient. To do this, you must then open the Rating tab, go to the Load
spectrum section, and input the flow and fhigh parameters for each gear. fhigh must
always have the fixed default value of 100%.
ISO 6336-5:2003, Section 5.3.3 and DIN 3990-5, Section 4.3 have 0.7 as the value
YM for pure cyclic load. In ISO 6336-3:2006, Annex B, the stress ratio R for idler
and planetary gears is taken into account by using this formula:

(12.16)

(12.17)

fhigh

Load on the flank side that is subject to the higher load (must always have
the fixed default value of 100%)

flow

Load on the flank side that is subject to the lower load

Dimensionless number depending

on the type of treatment and load type
(see Table B.1 in ISO 6336:2006-3, Appendix B)

Stress ratio

YM

Alternating bending factor

Treatment

Steels

Endurance strength

Coefficient for
static proof

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case-hardened

0.8 0.15 YS

0.7

case-hardened and shot

peened

0.4

0.6

nitrided

0.3

0.3

heat/induction-hardened

0.4

0.6

not surface-hardened steel 0.3

0.5

cast steel

0.6

0.4

Table 14.11: Mean stress ratio M as specified in Table B.1 - Mean Stress Ratio - in ISO
6336:2006-3

According to Linke [58] the alternating bending factor (described there as Y A) is

determined as shown in Figure 14.10. For plastics, Niemann recommends 0.8 for
laminated fabric and 0.667 for PA (polyamide) and POM (polyoxymethylene).

Figure 14.10: Alternating bending factor in accordance with Linke [58]

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14.3.4.1
Load spectrum with changing torque
Load bins can also be entered with negative torques.

The problem:
until now, no calculation guidelines have been drawn up to describe how to
calculate gears with changing load spectra.
The only unambiguous case is when a change in torque takes place, during every
cycle (and in each element of the collective). At this point, the load change
corresponds exactly to a double-load with +torque and then with torque. This instance can be calculated correctly by entering the load spectrum of the +moments
and the alternating bending factor YM for the tooth root. The flank is also
calculated correctly, because the +moments always apply to the same flank.
If, in contrast, the drive runs forwards for a specific period of time and then runs
backwards, the experts agree that the tooth root is not subjected purely to an
alternating load (and possibly this is the only point at which an alternating load
change takes place). However, discussions are still raging as to how this case can
be evaluated mathematically. It is even more difficult to define how mixed load
spectra with unequal + moments and moments for the tooth root are to be
handled. For this type of case, only the +moments are considered for the flank
(with the prerequisite that the +moments are equal to, or greater than, the
moments).
Note about handling load spectra with reversing torque:
A load progression as represented in Figure 13.10 below, where the tooth is
subjected to a load a few times on the left flank, and then a few times on the right
flank, can be converted into a load spectrum as shown below. This is represented in
an example here.
Load progression (example):
13 loads with 100% of the nominal load (100 Nm) on the left flank, then
9 loads with 80% of the nominal load (80 Nm) on the right flank, etc.
This results in the following process:
11 load cycles with 100% load, positive torque, pulsating; then
1 load cycle with 100% load on the left and 80% load on the right; then
7 load cycles with 80% load, negative torque, pulsating; then
1 load cycle with 80% load on the right and 100% load on the left;
then repeated again from the start.
This can be represented as a load spectrum as follows:

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Frequency

Torque

Load left flank

Load right flank

11/20 = 0.55

100 Nm

100%

0%

7/20 = 0.35

80 Nm

0%

100%

2/20 = 0.10

100 Nm

100%

80%

14.3.5

Face load factor

The face load factors KHKFKB take into consideration the influence of an
uneven load distribution over the facewidth on the flank surface pressure, the
scoring, and the tooth root stresses. You can specify that the face load factor is
either to be set as a constant value or calculated from other values. If you already
know the face load factor KH, select the Own input method and input this value.
During a calculation according to DIN/ISO, click the
button to open the
Define face load factor window, in which you can use a number of
parameters to calculate the value you require.

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The usual setting here is "Calculation according to calculation method". The face
load factor is then calculated according to the formulae used in the strength
calculation standard (ISO, AGMA or DIN). You will need to input some values for
this. These values are displayed on the right of the window (tooth trace
modification, etc.) and are described in the sections that follow. You can input
other values by clicking the
button in the "Define face load factor" window.
The formulae proposed in the standards for defining face load factor KHb enable
you to determine KHb very quickly (but only empirically, and therefore not very
accurately). The KHb coefficient calculated using these formulae is usually higher
than it actually is, so the calculated value is therefore on the conservative side. If
you think the coefficient is too high ( > 1.5), it is a good idea to perform a more
accurate calculation. You can use the "Calculation according to ISO 6336 Annex
E" method to do this.
Although the "Calculation according to ISO 6336 Annex E" method is very
accurate, it requires quite a lot of time and effort. As described in [44], it calculates
any gaping in the meshing, and therefore defines the load distribution over the
entire facewidth. To perform this calculation, you will need to know the exact dimensions of the shafts and support. Click the "Define axis alignment" button to
input the shaft values stored in the shaft calculation program for the relevant shafts.
The "Calculation with manufacturing allowance according to ISO 6336 Annex E"
method is the most accurate. However, if you use this method, you must also enter
the toothing tolerance fHb (tooth trace deviation over the carrying facewidth) and
the axis alignment tolerance fma (angular deviation of the axis alignment in the
plane of action). In this case, the load distribution over the facewidth is calculated 5
times (according to [44]): First without allowance, then sequentially using (+fHb,+
fma), (+fHb,- fma), (-fHb,+ fma) and (-fHb,- fma). The greatest face load factor
KHb determined here is then taken as the end result.
NOTE

See Module specific settings -> Face load factor for the settings involved in the calculation according to ISO 6336 Annex E.
If you want to calculate the face load factor by applying load spectra for each element, select either the Own input, per load stage, Calculation
according calculation method or Calculation with/without
manufacturing allowance according to ISO 6336-1 Annex
E, per load stage method.
In the cylindrical gear pairs, three- and four-gear chains, and planetary systems,
calculation module, shaft calculation files can be used to calculate the relative
displacement between the gear flanks more accurately, based on the corresponding
shaft bending lines (see page II-333). The torque, power, and force, for all the load

Chapter
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14

elements involved in the shaft calculation are then modified according to the partial
load coefficient wt .
This means you can include any torsion that occurs in the gear. Here the
calculation assumes a solid cylinder or hollow cylinder (external diameter = root
circle + 0.4*normal module or operating pitch circle, depending on what has been
predefined under "Settings", bore = inside diameter) is involved. In other words,
the inside diameter is taken into account and the torque on one side is zero. The
torque is distributed in a linear fashion along the facewidth (parabolic course of
deformation by torsion). You can select which side is to be subjected to torsion
moment. In this case, I and II refer to the same side, as is also the case when you
enter the toothing corrections. The increase in torque for a sun in planetary stages
is taken into account by using multiple contacts (several planets). Multiple contact
is not taken into consideration in any other configuration (e.g. for pairs of gears). In
such situations, the correct torque curve can be used if the deformation is taken
from the shaft calculation.
The facewidth is divided into slices, to help you calculate the face load factor as
defined in ISO 6336, Appendix E:
You can set the accuracy of the face load factor calculation according to Appendix
E in the "Define number of slices" dialog. Click the plus button next to the
calculation method to open this dialog.

14.3.5.1
Tooth trace modificat ion
You can achieve balanced contact characteristics if you perform targeted tooth
trace modifications. Figure 1.5 shows the two most frequently used modifications.

Figure 14.5: End relief and crowning

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14.3.5.2
Cylind rical gear pairs
The calculation, as specified in ISO 6336, is based on an approximate estimate of
the pinion deformation. In many cases, this is extremely inaccurate and usually
results in face load factors that are much too high.

The face load factor is the ratio between the maximum and average line load. The
basic equation used for the face load factor corresponds to equation (41) in the
standard4:

(14.4)

The effective tooth trace deviation Fy, see equation (52) in the standard, is defined
with the inclusion of a linearized, specific deformation component fsh. The multiplier 1.33 in the equation stands for the conversion of the linearized specific deformation progression into the real parabolic progression - see equation. (14.5).

(14.5)

The manufacturer component of the tooth trace deviation fma is derived from
tolerances specified by the manufacturer. If a usual procedure for checking the
accuracy grade is used, you can apply this formula (equation (64) in the standard):

(14.6)

If you have used KISSsoft's shaft calculation software to calculate the exact tooth
trace deviation due to deformation (torsion and bending) in the plane of action, you
can correct the approximate value fsh extrapolated from the standard and therefore
calculate the face load factors much more precisely! The formula as specified in
ISO 6336 only applies to solid shafts or hollow shafts that have an inside diameter
that is less than half of the external diameter.

The equation numbers used in this section refer to ISO 6336:2006

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In Method C2, the face load factor is calculated using these equations:
Size

Drop-down list

Selection

Equation

KH

(8.04)/
(8.06)

(8.08)

position of the
contact pattern

not verified or inappropriate

(8.26)

favorable

(8.27)

optimal

(8.28)

fsh
fsh0

(8.39)
None

0,023

(8.31)

Crowning

0,012

(8.34)

End relief

0,016

(8.35)

a)

Slight crowning

0,023

b)

Helix angle modification

0.0023

b)

Crowning + helix angle

correction

0.0023

b)

Tooth trace
modification

Solid

fma

Gearing

straight/angled

(8.32)

helical

(8.33)

None

1.0 fH

(8.51)

Crowning

0.5 fH

(8.53)

End relief

0.7 fH

(8.52)

Total tooth trace modification

0.5 fH

a)

Slight crowning

0.5 fH

b)

Helix angle modification

1.0 fH

b)

Crowning + helix angle

correction

0.5 fH

b)

Tooth trace
modification

Table 14.6: Overview of equations used according to DIN 3990:1987

a)
b)

No.

same as DIN 3990, Equation (6.20)

same as ISO 9085, Table 4

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Size

Drop-down list

Selection

Value

No.

KH

(39)/
(41)

(43)

position of the
contact pattern

not verified or inappropriate

(52)

favorable

(53)

optimal

(56)

fsh

(57)/
(58)

fma

(64)

B1/B2

None

1 /

Crowning

0.5 /

0.5

End relief

0.7 /

0.7

Tooth trace

Full

0 /

0.5

modification

Slight crowning

1 /

0.5

Helix angle modification

0.1 /

1.0

Crowning + helix angle

correction

0.1 /

0.5

Table 8

(56)

Table 8

Table 14.7: Overview of equations used according to ISO 6336:2006

Type of pinion shaft

Load as defined in ISO 6336:2006, Figure 13 (DIN 3990/1, Figure 6.8) or the
bearing positioning is shown in Figure 14.6.

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Figure 14.6: Load as defined in ISO 6336:2006, Figure 13.

Load in accordance with AGMA 2001

Definition of s and s1 according to AGMA 2001, Figure 13-3. Figure 14.7 shows
the bearing positioning as described in AGMA 2001.

Figure 14.7: Load as defined in AGMA 2001, Figure 13-3

Chapter
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14.3.5.3
Planet ary st ages
The face load factor for planetary stages is calculated in a different way than for
cylindrical gears. The deformation component fsh is derived from the deformation
of the mating gears on the shaft due to torsion and bending. In order to simplify the
situation for a pinion-gear pair, only the pinion deformation (which is much
greater) is taken into account.

Planetary stages are subject to the following sizable deformations: Since the sun
has several tooth meshings, all radial forces are canceled out No bending takes place because deformation is caused solely by torsion. However, the multiple meshing
which corresponds to the number of planets means this is greater than for normal
pinion shafts. - A planet gear has two meshings with opposed torques, which
prevents deformation due to torsion. Bending may be calculated in the same way as
for pinion shafts; however, the circumferential force must be doubled because of
the sun/planet and planet/internal gear. - In most cases, rim deformation can be
ignored. As a result, the torsion at the pinion and the bending at the planet bolt
must be taken into consideration for sun/planet meshing whereas, for planet/internal gear, only the bending at the planet bolt is important. For most support
arrangements for planets, bending can be determined analytically using a procedure
similar to that specified in ISO 6336. Figure <12>.8 shows the four most common
cases.

Figure 14.8: Support arrangement for planets

a) Planets mounted with fixed clamped bolts on both sides

b) Planets are on bolts, which have flexible bearings in planet carrier
c) Planets mounted with gently tightened bolts (flexible bearings) on both sides

Chapter
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14

d) Planets mounted with fixed clamped bolts on one side

Configuration

ISO 6336

DIN 3990

AGMA 2001

Part 1,

Formulae

Chapter 15, (37)

Annex D

6.20/6.21/6.24/6.25/

Part 1,

Formulae

Annex D

6.24A/6.24B/6.25A/6.25B

Part 1,

Formulae as defined in Part 1,

Annex D

Appendix C, see [49]

c and d

Chapter 15, (37)

Chapter 15, (37)

Table 14.8: Configuration of planetary stages as defined in ISO, DIN and AGMA

For ISO 6336 see also the explanation in [49].

Equations (14.7a - 14.7d) show the bending components in relationship to the distance x from the planet's face width. As we are only interested in bending variation
across the facewidth, the constant term was left out of the equations so that fb(x =
0) is zero. Similar formulae can be found in other technical documentation [38].
For cases a to d as illustrated in Figure 1.8 the following equations apply.
(14.7a)

(14.7b)

(14.7c)

(14.7d)

The sun's deformation due to torsion, as described in equation (14.8), can be

calculated from Annex D (fT in accordance with formula D.1).

Chapter
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(14.8)

In order to stay as close as possible to the methods used in ISO 6336 (and be able
to apply formula 2), the average deformation components fbmpla (bending at the planet) and ftmso (torsion at the sun) will be determined.

(14.9)

(14.10a)

(14.10b)

(14.10c)

(14.10d)

(14.11)

According to ISO 6336:2006, equation D.8, the linearized deformation components

of the tooth trace deviation fsh (in mm) will be:

(14.12)

Chapter
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(14.13)

This can then be used with equations (14.4) and (14.5) to calculate face load factors
for the sun/planet and planet/internal gear.
formula symbol

Unit

Meaning

mm

Meshing face width

N/(mm m)

Meshing stiffness

dpla

mm

Planet reference circle

dsh

mm

Planet shaft diameter

dso

mm

Sun reference circle

Ep

N/mm2

Young's modulus planet bolt/shaft

Eso

N/mm2

Young's modulus sun

fbpla

mm

Planet shaft deflection

fH

Helix slope deviation according to ISO

1328

f m

Tooth trace deviation

manufacture error

fsh

(Linearized) deformation components of

the
tooth trace deviation

ftso

mm

Sun torsion deviation

Fm/b

N/mm

Average line load

(Fm/b)max

N/mm

Maximum local line load

Fy

Actual tooth trace deviation

KH

[-]

Face load factor

mm

Planet bolt/shaft length

mm

Number of planets

mm

Distance to the left side of the facewidth

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[-]

Run-in factor

14.3.5.4
Calc ulation o f KH with manufactu ring errors
According to ISO 6336-1(E), the lead variation (fHb) and shaft misalignment (fma)
errors are applied in the plane of action in such a way that they increase the
meshing gap. In such a case, their combined effect is taken into account for the
flank gap in three cases:

Case 1: fma = fHb = 0, i.e. no error

Case 2: fma = |fma|, fHb = |fHb|, so positive values for both errors
Case 3: fma = -|fma|, fHb = -|fHb|, so negative values for both errors
The face load factor KH is calculated for all three cases, and the maximum value is
selected as the face load factor of the gear pair.
The positive direction always lies in the direction of the pinion's material, seen
from a common point of contact.

Figure 14.9: Definition of the positive direction

In all three cases, the manufacturing error is documented in the report and in the
gaping and load distribution graphics.

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14.3.5.5

Define misalignment fo r individual e lements

Figure 1: Define axis alignment tab

The following elements are assumed in a planet system:

Sun wheel
Planet carrier
N planetary gears with the corresponding n pins
Internal gear
You can specify the position of these elements in the gear unit and the
corresponding misalignment in the "Define axis alignment" dialog. To open this
dialog, click on the "Axis alignment" button in the "Factors" or "Contact analysis"
tab.
The alignment of the system elements is defined as follows in the "Axis alignment"
tab:
Tilting of the sun to the gear axis (see Figure 2). If no shaft file is used, the sun
can be handled as a "floating sun".
Tilting of the planet carrier to the gear axis (see Figure 3)

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Tilting of the planet pin to the planet carrier in circumferential direction dt and
in radial direction dr (see Figure 4). To model a carrier deformation due to torsion, you must first define a value for dt.
The tilting of the planet gear is relative to the planet pin axis. The positive misalignment (in circumferential direction dt and radial dr) is defined according
to the convention in Figure 4.
The tilting of the internal gear relative to the gear axis (see Figure 2). The conical extension of the internal gear can also be taken into consideration.
The deformation of the planet pin is caused by the twisting of the planet carrier. If the direction of torque has been input in the "Torsion" tab, the software
checks the values and issues a warning message if the prefix for dt has not been
entered correctly.
If the direction of torque has been input in the "Torsion" tab, the software assumes that dt represents the twisting of the carrier due to torque. For this reason, the prefix operator of dt is changed when is calculated for load
spectrum elements with a negative load factor

Figure 2: Tilting of the sun and internal gear to the gear axis

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Figure 3: Tilting of the planet carrier to the gear axis

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14

Figure 4: Tilting of the planet pin to the planet carrier

Figure 5: Tilting of the planet to the planet pin

You can also use shaft files to define the alignment of all the shafts, except the planet pin. The shaft files undergo the same checks as a gear pair. For example, the
value input for gear torque in the shaft calculation files must match the value
entered for the gears in the calculation module. The carrier shaft is characterized by
its two couplings: one coupling transfers the torque to the sun wheel and the other
transfers the torque to the internal gear. The "effective diameter" for both couplings
must be the same as the sun-planet center distance. The "length of load application"
must also be appropriate for the facewidth of the planet gear. If a shaft file is used
for the sun, planet or internal gear, click the additional Plus button to select which
meshing is to be taken into consideration.
The angle to the first planet defines where the first planet gear must be located
for a particular system definition. Every one of the subsequent planetary gears must
have an angular offset of 2 / N to the previous gear. The load distribution on the
planet for the specified planet carrier misalignment is dependent on the position of
the planets. If changes, KHb can also change. For this reason, the entry makes it
possible to determine the "worst case".
In the "Torsion" tab, you define the side from which torque is introduced to the
system or the side from which it is produced (depending on whether the element is
a driving element or a driven element). You can select one of the following 3 options for inputting the direction of torque:

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Not taken into account

Torque is applied/produced on side I
Torque is applied/produced on side II
Each configuration is also displayed as a graphic so that the user can check their
entries.
If a shaft file is used to define the shaft deformation, the torque is calculated
automatically from the results of the shaft calculation.
The planet carrier is usually more complicated than is specified in the shaft
calculation. For this reason, the carrier torsion is often greater than determined in
the shaft calculation. Consequently, you can either take the torsion deformation
value from the shaft calculation or enter it under dt for "planet pin" (or use an FEM
calculation to determine it).
Cal cu la ti ng pla n e t carri er d ef or ma ti o n w i t h F E M

The deformation of the planet carrier causes the planet pin to become misaligned
(the pin tilts at dt and dr relative to the planet carrier axis). Use the Finite Elements
Method (FEM) to calculate the exact planet carrier deformation. A range of different options are available here:

The calculated FEM results can be input directly as point coordinates and point
deformations (one node for each of side I and side II on a two-sided planet carrier; two nodes on one side for a single-sided planet carrier, (see Figure)

Figure 14: Planet carrier tab

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Import the file with the FEM results for the planet carrier deformation. The
deformations in both nodes are then extracted from this file. The node coordinates do not need to be specified exactly, the deformation data of the adjacent
node is transferred.

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14

Input some of the planet carrier's fundamental dimensions. KISSsoft then generates the carrier in 3D and uses the relative torque to define the planet carrier's
deformation.
Input this data:
Single or two-sided planet carrier
Partial load for calculation (used to define the reference torque which is then
used to perform the FEM calculation)
Pin diameter (d)
Coefficient for the external diameter of the planet carrier (fwa)
Coefficient for the internal diameter of the planet carrier (fwi)
Coefficient for the wall thickness of the planet carrier (fsw)
Width coefficient of the planet carrier (fbpc)
Coefficient for planet carrier's connector (fdcon)
Coefficient for the planet carrier's internal connector (fdicon)
External flange diameter on side I (dfaI)
Flange length on side I (LFI)
Flange wall thickness on side I (SwfI)
External flange diameter on side II (dfaII)
Flange length on side II (LfII)
Flange wall thickness on side II (SwfII)

Input these coefficients under "Details".

You can also click on the "Dimension planet carrier" and "Dimension flange"
buttons to display standard entries for this data.
The coefficients and dimensions are shown in greater detail in the next Figure.
Depending on how the direction of torsion is entered, side I or side II may not
be required for a single-sided planet carrier.

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The FEM solver called by KISSsoft in the background is the Code_Aster open
source solver, which you can obtain from the website at www.code-aster.org/. The
preprocessor used to build the FE model is also an open source program, called
Salome, located at www.salome-platform.org. To ensure you have the correct versions, install both programs from the KISSsoft DVD, or download them from the
KISSsoft website. The only precondition for using this method is that Java is
installed. (You can download it from www.java.com). Also ensure that the bin
path, where java.exe is located, is set correctly in KISSsoft, in 'Extras->Settings>Directories' JAVADIR. Both the solver and the preprocessor are distributed under
the GPL license, similar to the versions that can be found at the websites
mentioned above (more details about this license can be found in these programs'
installation folders in KISSsoft and on their websites).

II.14.3.5.5..1 Model and results viewer

To view the FEM model or the FEM results, start the Salome program. To do this,
double-click on the "run_salome.bat" file, which is stored in the KISSsoft
"bin32/FEPreProcessor" folder. Do this before you close the KISSsoft FEM

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calculation program. Then the user can open the correct KISSsoft temp folder (as
defined in Extras->Settings->Directories TMPDIR) and either open the
"PlanCarr.unv" file to see the FEM network model, or open the "PlanCarr.0.med"
file to see the FEM results. To view the mesh in Salome, select the Mesh module
from the drop-down list in the Salome toolbar and then select "File->>Import>>UNV file". To view the results, select the ParaViS module in Salome and then
open the "med" file mentioned above. More information about how to work with
meshes and the results files in Salome is provided in a special instruction file
"kisssoft-anl-100-E-FEM-Planetencarrier.docx". You can request this
documentation from the Hotline.

14.3.6

Taking into account shaft bending (face load

factor and contact analysis)

Shaft bending can be taken into account using the "Define axis alignment" dialog.
You can access this dialog either from the "Factors" tab (provided that either the
"Calculation according to ISO 6336 Annex E" or "Calculation with manufacturing
allowance according to ISO 6336 Annex E" option is selected, in the "Face load
factor" field) or the "Contact analysis" tab.

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14.3.6.1
Main sett ings
Instead of directly specifying the deviation and inclination of the axes (linear deformation model), you can use shaft calculation files to define the influence of
bending and torsion on the shafts on which the gears are to be mounted more
precisely.

The "Define axis alignment" dialog is described below. This is where you
determine the axis alignment by using the shaft calculation files. In the "File Shaft
Gear 1/Gear 2" fields, enter the file name for the shafts to which the pinion (1) or
the gear (2) belong. You must input the file name with its entire path (for example
C:\MyCalculations\ContactAnalysis\pinion_shaft.W10). However, if the shaft files
are stored in the same folder as the gear calculation file Z12, you only need to input
the name of the shaft calculation file (as shown in the figure).

Figure 14.53.5: Define axis alignment (planets and gear pair)

If a shaft file is used, click the additional Plus button to select the meshing to be
taken into consideration.
In the case of planetary stages, each meshing has a different load distribution, and
consequently a different KHb value. If you select "KHb for strength calculation" in
the "Define axis alignment" dialog, you can specify which KHb value is to be used
in the strength calculation according to the required standard (ISO, AGMA or
DIN). The standard provides no information on this point. It seems reasonable to
use the mean value of the KHb values of all sun-planet pairings, and all the planetinternal gear pairings.
Conical expansion can be taken into account for hollow gears.

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14.3.6.2
Conditions for using shaft calculation file s
If you are working with shaft files, the sizing parameters in the gears module must
match those in the selected W010 files. More specifically:

1. The pinion geometry must match the geometry defined for the pinion in
shaft file 1. The selection is based on the operating pitch circle (with an error tolerance of 10%), the direction (driving/driven) and the contact flank.
The same applies to the gear shaft.
2. The gear pair performance must match the gear performance defined in the
shaft files (with an error tolerance of 5%).
3. The sense of rotation for both the pinion and the gear (according to shaft files W10) must be consistent. For example, if the pinion rotates in a clockwise direction, the gear must rotate counterclockwise. However, if the gear
is an internal gear, both the pinion and gear must rotate clockwise in this
example.
From these conditions you can also easily see whether the shaft files can be used
for the contact analysis. If one of these conditions is not met, no calculation can be
performed.
In addition to the conditions listed above, a number of other conditions (warnings)
concerning the helix angle, the facewidth, and the gear's working transverse
pressure angle, are also checked.

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14.3.6.3
Effect of to rsio n on the body of the gear
You can take the effect of torsion on the body of the gear into account either by
applying the results of the shaft calculation or by inputting your own data (the same
applies to side I and II). Obviously, the results of the shaft calculation can only be
referenced if shaft files have been used to define the axis alignment.

If you defined the gear's torsion in "Own Input", then the torsion moment of resistance is calculated from the root circle df and the inner diameter.

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14.3.6.4
Effect of partial load
You can use the partial load coefficient wt (Contact analysis tab) to modify the performance of all the force elements defined in the shaft calculation files, as shown in
the following setting. The diagram of bending are always modified by this setting.
However, the effect of torsion can only be identified if the setting for torsion
(previous section) has been made using the shaft calculation file.

For example, if all the force/power elements in a shaft file are 100N/100W, and the
partial load coefficient is 85%, the force elements are calculated as 85N and the
power elements as 85W.

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14.3.6.5

Handling bending and torsion using the resu lt s fo r the

shaft
If a gear pair has been found and the shaft calculations performed successfully, the
bending and the effect of torsion are determined from the results for the shaft.

The results for bending in each shaft file are all transferred to a single coordinate
framework, where pinion contact occurs at 0 and gear contact occurs at 180. The
torsional angle of each gear is assumed to be 0 on the side that is furthest to the
left (side I, i.e. the side with the smallest Y-coordinate in the shaft file) and every
torsional angle for this particular gear then refers to this side.

14.3.7

Z-Y coefficients and the technology factor

If necessary, you can modify any of the coefficients that affect the permitted material values (root and flank) as specified in ISO or DIN in the "Z-Y coefficients"
window.
Coefficients ZL, ZV, ZR, ZW and ZX affect the safety against pitting limit sigHG.
Coefficients YT, YdrelT, YRrelT and YX influence the root safety limit sigFG.
You can predefine any of these coefficients in the range 0.5 to 2.0. However, if you
input a value that lies outside this range, it will be set automatically to 1.0.
The technology factor takes into account the change in tooth root strength caused
by manufacturing. In this situation, the material's permissible stress is multiplied by

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YT 1.0. This coefficient is not specified in the DIN or AGMA standards and is
therefore set to 1.0.
Treatment of tooth root area

Technology factor YT

Shot peening
Case-hardened/carbonitrided toothing

1.2

Not ground in the reinforced areas

Rollers
Flame- and induction-hardened toothing

1.3

Not ground in the reinforced areas

Grinding
For case-hardened

0.7 (general)

or carbonitrided toothing

1.0 (CBN grinding discs)

Cutting machining
Not for profile ground teeth!

1.0

Table 14.12: Technology factor according to Linke

According to Bureau Veritas/RINA [70], the technology factors in Table 14.13

shall be applied.
Treatment of tooth root area

Technology factor Y T

Shot peening,

Case hardening steel

1.2

Shot peening,

Heat treatable steel

1.1

Shot peening,

Nitriding steel

1.0

Table 14.13: Technology factors as defined by Bureau Veritas/RINA Directives

Table 14.14 shows the technology factors as defined in ISO 6336-5:2003, Section
6.7. These only apply to tooth root bending stresses and shot peened case
hardening steel.
Material class

Technology factor Y T

ML

1.0

MQ

1.1

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ME

1.05

Table 14.14: Technology factor according to ISO 6336-5:2003, Section 6.7

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14.3.8

General calculation procedure for KHbeta as

specified in ISO 6336-1, Appendix E.

1. Import the shaft files and select the correct gears, perform the initialization
2. Calculate the shafts and determine the diagram of bending and torsion in
the point of contact (if uniform load distribution is present, determine these
values along the facewidth of the gear)
3. Take into account flank modifications from Z012 (not W010)
4. Calculate the gaps in the tooth contact, then the load distribution with tooth
contact stiffness and finally calculate KH
5. Use the calculated load distribution to correct the load distribution on the
original gears
6. Divide the gears into "sections" whose load values are defined in the previous step
7. Use the flank contact ratio (as a vector) from the previous iteration gk-1 and
the current flank contact ratio gk to calculate the root of the sum of the
square error

i
i

g g
100 k i k 1

g k 1

If >0.1%, go back to step 2 and perform further iterations. Otherwise finish.

This procedure exactly follows the method described in ISO 6336-1, Appendix E,
but uses a stricter iteration criterion.

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14.4

Reference profile

Figure 14.16: Reference profile input window

In contrast to traditional mechanical engineering, where a predefined standard reference profile is most commonly used, in precision mechanics the reference profile
is often modified. Input the toothing reference profile or the appropriate tool in the
Reference profile input window. You can input this data either as
coefficients, as lengths or as the diameter.

14.4.1

Configuration

The reference profile of the gear toothing is usually predefined. However, you can
also define your own hobbing cutter or pinion type cutter. The pinion type cutter
parameters are also used in the strength calculation to calculate the tooth form factor. You can also select the Constructed involute for precision engineering. In this case, the involute is defined directly together with a root radius.

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14.4.1.1

Cutter/Tool: Hobbing cutter

Select the hobbing cutter you require from the selection list and then click the
button, (see Figure 14.17.)

Figure 14.17: Select hobbing cutter window

If you select a standardized profile (e.g. DIN 3972III), the list displays the tools
that are present in the database. The name of the cutter file list is entered in the database. Click on the Restrict selection using module and
Pressure angle checkbox to limit the display to tools whose modules and
pressure angles match those defined in the gear geometry. Therefore, only tools
that match the selected module and pressure angle are displayed.

Figure 14.18: Reference profile for the Tool: configuration Hobbing cutter

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Select Own Input to directly define your own cutter:

The cutter addendum coefficient h*aP0 defines the cutter addendum which defines the gear root circle. A usual value is 1.25.
The cutter tip radius factor *aP0 defines the cutter tip radius which then defines
the gear root radius. The tip fillet radius is limited by the maximum, geometrically possible radius, depending upon the profile addendum and the pressure
angle. This value usually lies in the range 0.2 to 0.38.
The dedendum coefficient h*fP0 defines the dedendum that, with a topping tool,
determines the tip circle. A usual value for this is 1. In a non topping tool, there
has to be a certain amount of clearance between the tool and the gear tip circle,
which the software checks. 1.2 is a usual value for an addendum of the reference profile of 1.
The root radius coefficient *fP0 defines the cutter root fillet radius. In a topping
tool, the root radius cuts a tip rounding on the gear in most cases. Depending
on the geometric conditions, a chamfer or corner may occur on the tip.
The protuberance height coefficient h*prP0 defines the protuberance length measured from the addendum. The protuberance is used as an artificial undercut to
avoid the creation of a grinding notch. The protuberance height can be calculated from the protuberance size and angle.
The protuberance angle **prP0 is usually smaller than the pressure angle, however, in some special cutters it may also be larger. In this case no undercut is
present, but the tooth thickness at the root of the gear is larger. The protuberance angle can be calculated from the protuberance height and size. If you enter
the value "0", no protuberance will be present.
When calculating the contact ratio, protuberance is not taken into account until
it reaches a certain value because a contact under load is assumed in the profile
modification. You can specify the threshold used to take into account the protuberance and buckling root flank for diameters in the Calculation ->
Settings (see page II-454) menu item.
The root form height coefficient hFfP0* defines the end of the straight flank part
of the tool with pressure angle n. The height is measured from the tool reference line.
The ramp angle aKP0* defines a ramp or a profile modification that is present in
the cutter. The length is determined by the root form height coefficient. The
angle must be greater than the pressure angle n. If you enter the value "0", this
part will be ignored.

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The threshold value used for protuberance is also taken into consideration here
when calculating the diameter and the contact ratio ( more information (see
page II-454)).
The tooth thickness factor of the reference line s*P0 for the usual tools s*P0 =
2. The value can be overwritten for special tools.
The addendum coefficient of the gear reference profile h*aP for a non topping
cutter/tool is defined with the usual value of h* aP = 1 of the gear reference profile or by the gear's tip circle. The value can be converted from the tip circle.

14.4.1.2

Cutter/Tool: Pinio n typ e cutter

Click the
button next to the pinion type cutter designation to select a pinion
type cutter for inside and outside gears from a list. Pinion type cutters as specified
in DIN 1825, 1826 and 1827 are listed here. You use this window in the same way
as the Define milling cutter window in Figure 14.19. The default setting
is for the list to display only those tools that match the selected module, meshing
and helix angle.

Figure 14.19: Reference profile for the Tool: configuration Pinion type cutter

Select Own Input to directly define your own pinion type cutter:
KISSsoft can prompt the number of teeth z0 for the cutter. If the number of
teeth is too small, it may not be possible to manufacture the tip form circle
and/or the root form diameter of the cylindrical gear. If the number of teeth is
too great, it may cause collisions during manufacture.

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The pinion type cutter profile shift coefficient x0 is often unknown. However, it
does influence the root circle of the resulting gear. This value is set automatically, together with the number of teeth.
A pinion type cutter tip often takes the form of a radius or a chamfer. Click the
button to define the corresponding numerical value.
The pinion type cutter addendum coefficient h*aP0 defines the pinion type cutter
addendum that determines the pinion type cutter tip circle and the gear root
circle. A usual value is 1.25.
The pinion type cutter dedendum coefficient h*fP0 defines the pinion type cutter
dedendum height that determines the tip circle for a topping tool. A usual value
for this is 1. In a non topping tool, there has to be a certain amount of clearance
between the tool and the gear tip circle, which the software checks. 1.2 is a
usual value for an addendum of the reference profile of 1.
The root radius coefficient of the pinion type cutter *fP0 defines the radius at
the cutter root. In a topping tool, the root radius cuts a tip rounding on the gear
in most cases. The input value is only displayed for a topping tool.
The protuberance height coefficient h*prP0 defines the protuberance length measured from the addendum. The protuberance is used as an artificial undercut to
avoid the creation of a grinding notch.
The protuberance angle *prP0 is usually smaller than the pressure angle. If 0 is
input, no protuberance is present.
When calculating the contact ratio, protuberance is not taken into account until
it reaches a certain value because a contact under load is assumed in the profile
modification. You can specify the threshold used to take into account the protuberance and buckling root flank for diameters in the Calculation ->
Settings (see page II-454) menu item.
The root form height coefficient hFfP0* defines the end of the tool involute with
the pressure angle n. The height is measured from the tool reference line.
The ramp angle KP0* defines a ramp flank or a profile modification that is present in the cutter. The length is determined by the root form height coefficient.
The angle must be greater than the pressure angle n. If you enter the value
"0", this part will be ignored.
The threshold value used for protuberance is also taken into consideration here
when calculating the diameter and the contact ratio ( more information (see
page II-454)).
The addendum coefficient of the gear reference profile haP * with the usual value of haP * = 1 defines the tip circle of the gear for a non topping tool. The value can be calculated from the tip circle.

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14.4.1.3
Refe rence pro file
The reference profiles displayed here are taken from the database. If you can't find
a suitable reference profile here, you must first enter it in the database (see page I124) (Z000.ZPROF). Alternatively, select Own Input from the drop-down list,
to open a dialog in which you can edit all the input fields, and so change all the
reference profile parameters. The Label input field is displayed under the Reference profile drop-down list. This is where you enter the name of your own
profile, which will then appear in the calculation report.

NOTE

You do not create a new entry in the database when you define your own profile in
the Own Input field.
The reference profile details are according to ISO 53, DIN 867 or DIN 58400. This
is the reference profile data for the gear. You can calculate the corresponding values in [mm] by multiplying it with the normal module. Please note the following
points:
If the reference profile is set to Own Input, the tip alteration (see section
"Modifications" on page II-356) is set to zero. For this reason the addendum
may change when you toggle from one window to another.
If you are using the BS4582-1:1970 Rack 2 reference profile to determine the correct tip and root diameter, you must input an appropriate tooth
thickness tolerance of

. The tip and root diameter will then match the values defined in BS4582-1(8)).
The ramp flank is usually used to generate a tip chamfer5. Alternatively, you
can also use a small buckling root flank to generate a profile modification.
However, profile modifications are usually defined in the Modifications
(on page II-356) window.
If the angle of the ramp flanks is only slightly different from the pressure angle, it is not taken into account in the contact ratio because the assumption for
profile modifications is that the contact ratio will not decrease under load. In
contrast, the contact ratio should be reduced accordingly for a chamfer. In
Settings (see page II-454), you can specify the difference in angle that is to
be used as the threshold in profile modifications and chamfers.

also called semi-topping.

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If a premachining tool is used, the additional measure for the preliminary

treatment must be entered separately. You must input the gear's reference profile for the preliminary treatment. This data, and the grinding wheel data, is
used to calculate the reference profile used during the final treatment and documented in the report (Processing (see page II-349)).
For profile modifications, where the angle difference < threshold value (see
above), the tip form height coefficient h FaP* does not change between preliminary and final treatment. For a buckling root flank with a large angle difference
(tip chamfer) the height coefficient h FaP* is changed by final treatment ( see
Figure on page II-349). Figure 14.20 shows a reference profile gear to illustrate this point more clearly.

Figure 14.20: Reference profile for configuration: Reference profile gear

Click the
button next to the Reference profile drop-down list to open a dialog which contains proposals for reference profiles according to the following
criteria:

High toothing, according to the theoretical profile contact ratio defined in

the Sizing tab, in the "Module-specific settings" (Calculation >
Settings).

Both gears at minimum topland (do not change x)

Both gears at minimum topland (x is optimized to suit sliding velocity)

Both gears with (dNf-dFf) minimum

haP* always applies as the normal gear reference profile. The tooth thickness on
the reference line is
(12.19)

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14.4.1.4
Constructed invo lute
When you select Constructed involute, you do not need to enter as many
parameters as you do when you select Reference profile. The essential
difference is that no simulation of manufacture is performed, and the involute is
generated directly.

In the gear root, the involute is closed by a radius that is defined by the root radius
coefficient fP. In theoretical involutes, the root radius coefficient is usually greater
than the coefficient for a reference profile, because the manufacturing process does
not involve a meshing movement.

Figure 14.13: Reference profile for configuration: Constructed involute

14.4.2

Preliminary treatment and grinding a llowance

Often gears are premachined with grinding allowance. They are then hardened and
then ground. It is usually the tooth flank that is machined in the grinding process,
not the tooth root. See Figure 14.21.

Figure 14.21: Gear reference profiles during preliminary treatment; grinding wheel; reference
profile during final treatment

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Note: If a cutter, pinion type cutter or constructed involute is selected as the

preliminary treatment tool, the gear reference profile for preliminary treatment is
calculated internally from the tool data.

In this case, the root circle is created by the premachining cutter and the flank by
the grinding process. To complete this process correctly, select either
Preliminary treatment (with own input, or with reference profile for
grinding allowance III or IV as specified in DIN 3972) and then select final
treatment. If you decide to use preliminary treatment, the Grinding
allowance field appears. You can also add your own tolerances to the database.
Enter the profile of the premachining tool (except: haP *) as the reference profile. As
the tooth thickness deviations (tolerances) you have to enter the tooth thickness
allowance of the finished gear teeth (As). In KISSsoft the grinding allowance is
then calculated for the finished gear teeth. The preliminary treatment is then
performed using the total tooth thickness allowance:

(12.20)

For special requirements, click the

button in the "Define grinding allowance
tolerance" window to increase the tolerance. If you input data for qmax-qmin, the
program applies qmax = q+(qmax-qmin)/2 and qmin = q-(qmax-qmin)/2 to
calculate the allowances during preliminary treatment.
In the Modifications (on page II-356) input window you can enter the infeed
and the radius of a grinding wheel.
KISSsoft then determines the reference profile that corresponds to the finished
tooth form. It does this by calculating factors Y F and Y S for the tooth root
strength. The tooth form is then defined automatically by overlaying the
preliminary treatment contour with the subsequent grinding process. The root diameters are derived from the reference profile for preliminary treatment. The control
data (e.g. base tangent length) is calculated and printed out for both the
premachined and the finished gear teeth.

IMPORTANT EXCEPTION

The addendum coefficient h aP* is the theoretical addendum coefficient that is used
to calculate the theoretical tip diameter coefficient. The appropriate minimum root
height of the hobbing cutter h*fP0, which is required to create the tooth form without
topping, is printed in the report. h aP* always applies as the final treatment reference
profile for the gears. The tooth thickness on the reference line is 2 *mn.

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14.4.3

Tip alteration

The tip alteration k*mn is usually calculated from the profile shift total to ensure
that the tip clearance does not change. However, if the reference profile is set to
Own Input, the tip alteration will not be calculated. In an external gear pair, a
reduction in the tip alteration in a negative value for the tip circle reduction. In
contrast, in internal teeth, the result is a positive value for both gears, and therefore
also an increase in the tooth depth. In KISSsoft, the tooth depth of internal teeth is
not increased and therefore the tip alteration is limited to 0.
Alternatively, you can specify your own tip alteration, however, this only has an
effect on non-topping tools. Otherwise the value is set to 0 when it is calculated.
Click a Sizing button
to calculate the proposed value for a constant tip
clearance.
Click the Recalculate button
to input the tip diameter (either da, daE or dai) to
calculate the tip alteration using the current reference profile.

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14.5

Tolerances

Figure 14.22: Tolerances input window

The toothing geometry is calculated for a backlash-free state. A slightly smaller

tooth thickness is manufactured, to prevent the gears jamming in practice. This
reduction in tooth thickness (in contrast to the backlash-free state) is known as the
"tooth thickness allowance". The upper tooth thickness allowance is the upper limit
of the tooth thickness. The lower tooth thickness allowance is the lower limit of the
tooth thickness.

EXAMPLE

Tooth thickness in a backlash-free state:

4.560 mm

Upper deviation of tooth thickness (top limit):

-0.050 mm

Lower tooth thickness allowance:

-0.060 mm

This results in the actual tooth thickness:

4.500 to 4.510 mm

14.5.1

Tooth thickness tolerance

This drop-down list contains the tolerances listed below. You can also include your
own tolerance tables. You will find more detailed information about this in the
section about the KISSsoft Database tool (see section "External tables" on page I132).

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14.5.1.1
DIN 3967
Selection a tolerance as specified n DIN 3967 (for gearbox a module greater than
0.5 mm). Suggestions as defined by Niemann [65 (see section "Gear teeth when
existing shaft data is present" on page I-222)](page 84):

Cast ring gears

a29, a30

Ring gears (normal clearance)

a28

Ring gears (narrow clearance)

bc26

Turbo gears (high temperatures)

ab25

Plastic machines

c25, cd25

Locomotive gears

cd25

General mechanical engineering,

Heavy machines, non-reversing

b26

General mechanical engineering,

Heavy machines, reversing

c25,c24,cd25,cd24,d25,d24,e25,e24

Vehicles

d26

Agricultural vehicles

e27, e28

Machine tools

f24, f25

Printing presses

f24, g24

Measuring gear units

g22

14.5.1.2
ISO 1328
The current edition of ISO 1328 no longer includes tolerance classes for tooth
thickness allowances. For this reason, many companies have continued to use the
tolerance classes specified in the old 1975 edition.

14.5.1.3
DIN 58405
Proposals as specified in DIN 58405, Part 2: Allowances for precision mechanics;
usual gear modifications as defined in DIN 58405 Sheet 2
Material

Processing

Center distance
tolerance

Base tangent
length

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tolerance
Hardened steel

Ground

5J

5f

Heat treatable steel

finely milled

6J

6f

Light metal

finely milled

7J

7f

Light metal

finely milled

8J

8f

Steel/laminate

finely milled

6J

6e

Steel/laminate

finely milled

7J

7d/7c

Light metal

finely milled

8J

8d/8c

Plastic

milled

9J

9e/9d

Plastic

injection molded 10J

10e

14.5.1.4
Own Input
Select this option to input your own data. However, you should note that the values
for tooth thickness allowance, the normal or circumferential backlash (per gear)
and the base tangent length allowance all depend on each other. The (negative) base tangent length allowance corresponds to the normal backlash.

14.5.2

Tip diameter allowances

You can specify the tip diameter allowances if a non-topping tool was defined. In
contrast, the tip diameter allowances for a topping tool are defined from the tooth
thickness allowances. These allowances influence the effective contact ratio due to
the effective tip circle.
Click the
button to specify a tolerance field in accordance with ISO 286. The
tolerances prefix is changed in internal teeth because the tip circle is used as a negative value in the calculation.
Click the
button to specify the minimum and maximum tip diameter from
which the allowances are to be calculated.

14.5.3

Root diameter allowances

Root diameter allowances are usually calculated from the tooth thickness
allowances. In the gear cutting process, the backlash is produced by reducing the
manufacturing distance of the tool. This is why the root diameter allowances
depend on the tooth thickness allowances.

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In special cases, a different manufacturing process is used e.g. for sintered gears or
extruded plastic gears. The user can then input their own root diameter allowances.
Click the
button to specify the minimum and maximum root diameter from
which the allowances are to be calculated.

14.5.4

Center distance tolerances

The center distance tolerances are defined either by a standard tolerance taken from
the database or the value you enter in the Own Input field. They influence the
intermeshing allowance and the contact ratio.

14.5.5

Settings

The base tangent length and the mass across balls and rollers for the most suitable
number of teeth over which the measurement is to be taken or the roller diameters
is specified in the report. If you want to use a different number of teeth spanned or
a different diameter of ball/pin in an existing drawing, this is where you can
overwrite the values selected by the software.
However, no results are output if you enter values for which a measurement cannot
be performed. If the Do not cancel when geometry errors occur
(see page II-447) option is selected, test masses are also output for cases
in which they could not be measured, for example, for points of contact above the
tip circle.

NOTE

The proposed ball/pin diameters are taken from the Z0ROLLEN.dat file. In the
case of splines as defined in ANSI 92.1 these values are taken from the
Z0ROLLENANSI.dat file. This file corresponds to the recommended diameters
specified in DIN 3977. You can then use an Editor to modify the existing ball/pin.
You will find more detailed information about how to handle external data records
in the External tables (on page I-132) section.

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14.6

Modifications

The Modifications input window is where you define the profile and tooth
trace modifications, and a tip chamfer or a tip rounding, and specify the depth of
immersion of the grinding wheel.

Figure 14.23: Modifications input window

Figure 14.24: Definition of modifications to the tooth end

a) tip chamfer
b) chamfer at tooth end
c) tip end chamfer
NOTE:

The tip end chamfer is not specified for gear calculations because it does not affect
the strength. However, if an unusually large chamfer is involved, hk' and bk' can be
simulated by inputting e.g. hk=0.3*hk'. The standards do not offer any guidance for
this.

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14.6.1

Define grinding wheel for gear n di alog window

For gears which have an entry for the grinding process (see section "Preliminary
treatment and grinding allowance" on page II-349) you can click the
button on
the right of the Start modification at root input field to trigger the
grinding process. The most important predefined value in this window is the radius
of the tip of the grinding wheel (see Figure 14.24). You can input the remaining
data either as coefficients, as lengths or as the diameter.

Figure 14.24: Define grinding wheel for gear n dialog window

NOTE

Recommendation for "Generate" or "Form grinding" settings:

If you input finished teeth without a preliminary treatment tool, we recommend
you select the "Form grinding" process. However, if a preliminary treatment tool is
involved, you should select "Generate".

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14.6.2

Type of modification

To create a new entry in the list of corrections to be performed, click the

button. Double-click on a cell in the Type of modification column to open a
drop-down list if you want to change the value in that cell. Figure 14.25 shows an
extract of the range of possible tooth corrections.

Figure 14.25: Type of modification drop-down list

The next two sections, 14.7.3 (see section "Profile modifications" on page II-361)
and 14.7.4 (see section "Tooth trace modifications" on page II-366), provide
descriptions of the corrections defined in ISO 21771.
Input different corrections for right or left flank: to do this, go to Settings >
General and set the Unsymmetrical Profile modifications flag.
Defining the right-hand/left-hand tooth flank (in accordance with ISO 21771):

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Figure 14.26: Tooth flank definition

14.6.3

Underlying principles of calculation

The geometry of straight or helical cylindrical gears is calculated in accordance

with ISO 21771 or DIN 3960. Many manuals and standards use very similar
methods to calculate this geometry. In addition to calculating the geometry, it is
very useful to have information about how to check for defects (undercut,
insufficient active profile, etc.). Technical documentation provided by tooling
manufacturers or machine tool manufacturers may also contain information about
this.
Measurements for tooth thickness and backlash can be selected in accordance with
different standards, such as ISO1328 (1970 edition) or DIN 3967. Manufacturing
tolerances can also be defined using standards such as ISO 1328, AGMA: 2000,
AGMA: 2015, DIN 3961 or DIN 58405 to suit the particular situation.
Strength is calculated in accordance with, for example, ISO 6336 or DIN 3990, by
verifying common defects (tooth root fracture, pitting, scuffing, micropitting). These standards include the most comprehensive and detailed calculation methods
currently available. There are two methods that can be used to calculate safety
against scuffing. The integral temperature method of calculating scoring resistance
is mainly used in the automobile industry whereas the flash temperature method is

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used in turbo gearbox manufacturing. It has not yet been established which of these
two methods is the more reliable.
Micropitting is calculated in accordance with ISO 15144, Method B. This method
is very reliable for gears without profile modifications. However, in the case of
gears with profile modification, it has been specified that the tip relief Ca must
correspond to the optimum tip relief Ceff (as proposed in the standard). If not, the
verification must be performed without taking the modification into account. This
is a significant disadvantage because corrections have a considerable effect on
micropitting. In this case, you should use Method A (Safety against micropitting
using method A).
In the USA, the AGMA 2001 standard must be applied when calculating resistance. This calculation method differs so much from the method specified in DIN
3990 that the results cannot be compared. In addition, numerous different methods
are used to calculate the resistance of plastic gears.
One of the problems with applying DIN 3990 is the wide range of different
calculation methods it contains. There are around 10 different calculation methods
that can be applied between Method A (exact calculation involving measurements)
and method D (the simplest, rough calculation). It is therefore no surprise that very
different results can be obtained from applying calculations in accordance with
DIN 3990 or ISO 6336 to the exact same gear wheel. Whenever possible,
KISSsoft uses the most detailed formulae for dimensioning and analyses during
this calculation procedure. This procedure corresponds to Method B. However,
calculations performed using different programs may also give very different
results. It also takes a lot of time and effort to investigate the precise reasons for
this. It is therefore much more effective and efficient to use a reference program to
perform the comparison. One such program is the ST+ cylindrical gear program
package developed by the FVA (Forschungsverein Antriebstechnik, (Research Society for Transmission Techniques, Germany)), at the Technical University in
Munich. For this reason, KISSsoft provides the As in the FVA program
(DIN 3990) option, which supplies the same results as the calculation with the
FVA code (see section "Calculation methods" on page II-279). The differences
between results obtained by KISSsoft and the FVA are negligible. They are due to
the minor differences between the FVA program and the regular version of DIN
3990. If requested, we can provide you with a number of different documents to
help you compare these methods.
Other interesting results are taken from Niemann's book [65]:
Gear power loss with gear loss grade HV in accordance with equation (21.11/4)
Average friction factor m in accordance with equation (21.11/6) with 1 vt
50m/s

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Cylindrical gears

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Gear power loss PVZ in accordance with equation (21.11/3)

14.6.4

Profile modifications

profile modifications are actually variations of the involute and are known as
height corrections. The following sections describe which profile modifications are
included in the KISSsoft system.
Note: before you can define height corrections, you must first input the length factor LCa* . The length factor is the pitch length Ly (from the tip or root form diameter) divided by the normal module: LCa* = Ly/mn. The pitch length Ly is calculated
in accordance with ISO21771, Equation 17, or DIN 3960, Equation 3.3.07.

14.6.4.1
Line ar tip and root relief
Figure 14.26 illustrates tip relief. The constantly increasing amount of material removed in the transverse section, starting at dCa, up to the tip circle, refers to
the theoretical involute. The same applies to the root relief.

Figure 14.26: Linear tip and root relief

where
dNa

Active tip diameter

dNf

Active root diameter

dCa

Modification end diameter (tip)

dCf

Modification end diameter (root)

LCa

Resulting tip relief length

LCf

Resulting root relief length

Ca

Tip relief

Cf

Root relief

Tip neighboring point

Root neighboring point

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LAE
1)

Resulting tooth height length1)

Corresponds to the meshing length g

The KISSsoft input the size value Ca in the Value input field, for tip relief.
The Coefficient 1 input field defines the quotient from the calculated tip relief length LCa and normal module mn. Similarly, to represent root reliefs, input the
values for Cf and the quotient from LCf and mn.
NOTE

In the "Modifications" tab you can specify that the modification starts at the root.
The figure shows the situation when the modification starts at the active root diameter dNf.

14.6.4.2
Arc-l ike pro fil e modif i cation
The method used here is similar to the one used for a linear profile modification.
The difference is that this method involves approximating an arc of circle which
starts at the point where diameter dCa intersects with the unchanged tooth profile.
The tangents of the arc of circle are identical to the tangent of the unchanged tooth
profile at this point. The benefit of this modification is that the tangents do not
change abruptly in the unchanged tooth form - circular pitch approximation transition point.

Figure 14.27: Arc-like profile modification

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LCa

Resulting tip relief length

LCf

Resulting root relief length

Ca

Tip relief

Cf

Root relief

14.6.4.3
Progre ssive p rofile mo dificatio n
The procedure used here is similar to the one used for a linear profile modification.
The progressive profile modification is also detailed in the description of tooth
form options (see Progressive profile modification (see page II-385))

Figure 14.28: Progressive profile modification

LCa

Resulting tip relief length

LCf

Resulting root relief length

Ca

Tip relief

Cf

Root relief

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14.6.4.4
Line ar tip and root relief with transition radii
Figure 14.29 illustrates tip relief. The constantly increasing amount of material removed in the transverse section, starting at dCa up to the tip circle, refers to
the theoretical involute. The same applies for the root relief.

Figure 14.29: Linear tip and root relief with transition radii

LCa

Resulting tip relief length

LCf

Resulting root relief length

Ca

Tip relief

Cf

Root relief

This is why the KISSsoft in the KISSsoft system, input the value Ca in the Value
input field, in the case of tip relief. The Coefficient 1 input field defines
the quotient from the calculated tip relief length LCa and normal module mn.
Similarly, to represent root reliefs, input the values for Cf and the quotient from
LCf and mn.

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14.6.4.5
Pro file crown ing (barr eling)
Profile crowning (barreling)is where a constantly increasing amount
of material is removed in the transverse section in the direction of the tip and root
circle, starting at the middle of the calculated tooth flank length. Points A, E and
the value Ca define the arc-like progression.

Figure 14.27: Profile crowning (barreling)

where
dNa

Active tip diameter

dNf

Active root diameter

Profile crowning (barreling)

LAE

Resulting tooth height length1)

Tip neighboring point

Root neighboring point

1)

Corresponds to the meshing length g

This is why the KISSsoft enter the value Ca in the input field.

14.6.4.6
Eccentric profile crow ning
In the "Modifications" tab you can add eccentric profile crowning to the tooth profile.

The definition of eccentric profile crowning corresponds to the definition of

eccentric crowning, where coefficient 1 is determined from the difference between
the starting diameter of the modification at the tip. Here, you should note that the
modification is defined by the diameter, not by the length of path of contact.
Therefore, if you input a value of 0.5 for coefficient 1, this does not correspond to
the profile crowning, because this should run symmetrically to the center point of
the path of contact (dSm).

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14.6.4.7
Pre ssu re angle modif ication
You define the pressure angle modification in a similar way to tip/root
relief (see section "Linear tip and root relief" on page II-361). However, the
difference here is that the value CH applies over theentire tooth depth (see Figure
14.28).

Figure 14.28: Pressure angle modification

where
dNa

Active tip diameter

Tip neighboring point

LAE

Resulting tooth height length

CH

Pressure angle modification

Root neighboring point

1)

In KISSsoft enter the value CH in the Value input field.

14.6.5

Tooth trace modifications

Tooth trace modifications are variations across the facewidth. The following
sections describe which tooth trace modifications are implemented in the KISSsoft
system.

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14.6.5.1
Line ar end re lie f I and II
A linear end relief is the constantly increasing removal of material from
the tooth trace, starting from particular points, in the direction of the front and rear
face surface. In this case, the numbers for I and II relate to both face surfaces (see
Figure 14.29).

Figure 14.29: Linear end relief I and II

where
Face I

Face II

LCI

End relief length

LCII

End relief length

CI

End relief

CII

End relief

This is why the KISSsoft system, go to the Value input field and enter the value
CI(II), in the Coefficient 1 input field, enter the quotient LCI(II) / bF where bF is
the facewidth minus chamfer.

14.6.5.2
Arc-l ike end rel ief I an d II
An arc-like end relief is the constantly increasing removal of material
from the tooth trace, starting from particular points, in the direction of the front and
rear face surface. In this case, the numbers for I and II relate to both face surfaces
(see Figure 14.30).

Figure 14.30: Arc-like end relief I and II

Chapter
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Cylindrical gears

14

where
Face I

Face II

LCI

End relief length

LCII

End relief length

CI

End relief

CII

End relief

This is why the KISSsoft system, go to the Value input field and enter the value
CI(II), in the Coefficient 1 input field, enter the quotient LCI(II) / bF where bF is
the facewidth minus chamfer.

14.6.5.3
Helix angle modificatio n
You define the helix angle correction in a similar way as end relief (see
section "Linear end relief I and II" on page II-367). However, the difference here
is that the mass LCI applies over the entire facewidth (see Figure 14.30).

Figure 14.31: Helix angle modification

where
b

Facewidth

CH

Helix angle modification

bF

Usable facewidth

This is why the KISSsoft enter the value CH in the Value input field.

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14.6.5.4
Crowning
Crowning is where material is removed constantly and symmetrically in the
direction of the face surfaces, starting from a common point and where the tooth
trace remains constant. The material is removed in an arc-like progression with the
maximum at the pointF /2.

NOTE

Offset crowning, with its maximum to the right of the point bF /2, is often used in
practice. You can define this modification by inputting centrical crowning with an
additional helix angle modification (on page II-368).

Figure 14.32:Crowning

where
b

Facewidth

Crowning

bF

Usable facewidth

In KISSsoft, go to the Value input field and enter the value C.

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14.6.5.5
Eccentric crowning
In the "Modifications" tab you can add eccentric crowning to the facewidth.

For eccentric crowning, the Value defines the amount of modification and the Factor 1 defines the modification position from the side I divided by the facewidth.
The modification is defined as a part of arc that the center is located along the
vertical line defined by the Factor 1. The radii are shown in the Information field
according to your input. If you define the Factor 1 as 0.5, the modification is
equivalent with general Crowning.

14.6.5.6
Triangul ar end relie f I and II
The corners are broken.

Figure 14.33: Triangular end relief I (left) and II (right)

where
CEa

Tip relief

dEa

Modification end diameter

LEa

Resulting triangular end relief length

bEa

Triangular end relief length

dEf

Modification end diameter

bF

Usable facewidth

This is why the KISSsoft enter the value CEa in the input field. Then go to the
Coefficient 1 input field and enter the quotient of LEa / mn. Then go to the
Coefficient 2 input field and enter the quotient of bEa and facewidth b.

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14.6.5.7
Twist
Twist is the torsion of the transverse section profile along a helix. Usually, the
angle increases in a linear progression from the start of the effective flank to its
end. A positive directional torsion moves clockwise away from the observer. See
also Figure 14.34. Modification C can be input as either a positive or negative value.

Figure 14.34: Twist

where
C

Relief on dNa at I

dNa

Active tip diameter

dNf

Active root diameter

The notation used here is also shown in sections 14.8.4.2 (see section "Helix angle
modification" on page II-368) and 14.8.3.4 (see section "Pressure angle
modification" on page II-366).

14.6.5.8
Topological modification
The Topological modification option allows you to define any type of
modification. The actual modification is described in the file that is to be imported.
You will find an example of this type of entry in the "topological_template.dat" in

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14

the dat directory. The file is self-explanatory. You can define coefficients in any
slice and for any rolling depth. When the file is imported, these coefficients are
multiplied by the value entered under Ca. You can display and check the
modification by clicking Graphics > 3D Geometry > Modifications.

14.6.6

Sizing modifications

Click the
button, as shown in Figure 14.23 on page II-356, to open the
Sizing modifications dialog. The next two sections describe the basic method for performing profile and tooth trace modifications.

14.6.6.1
Pro file modi fication
a) Tip relief on the driven gear reduces the entry impact, whereas tip relief on
the driving gear reduces the exit impact. Tip relief is therefore usually applied to both gears. It is only applied to the driven gear alone in exceptional
circumstances.

b) When calculating the profile modification, you must always specify the tip
chamfer. If not, the active involute will not be included in the calculation.
c) Tooth contact stiffness is always calculated in accordance with the selected
calculation method. Alternatively, you can derive the contact stiffness from
the tooth form (see page II-294).
d) The points along the length of path of contact are labeled in accordance with
ISO 21771. In a situation involving a driving pinion, a tip correction must

Chapter
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14

be applied on the pinion from H -DE to E (or D to E) and on a gear, from

A to H -AB (or from A to AB). For a driven pinion, the descriptions are
swapped in accordance with ISO 21771 (A becomes E, E becomes A).
e) KISSsoft calculates the tip relief value for a nominal torque that was
changed by a modification value. In the case of gears that do not always
have the same operating torque, the modification value is assumed as
approximately 50-75% of the maximum moment, evenly distributed across
the pinion and the gear. The default value for tip relief C is defined using
the mean value of the data as defined by Niemann. A (somewhat greater)
value is set as the meshing start (C.I) at the tip of the driven gear. The value (C.II) is set as the value for the meshing end at the tip of the driving
gear. When you select profile modification For smooth meshing, the
value C.I is also set at the meshing end.
For deep toothing, where > 2, the load-dependent portion of tip relief is
reduced, depending on accuracy grade, to 12.5% (for quality level 8 and
poorer) and up to 50% (for quality level 5 and better).

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f) KISSsoft also calculates the modification length. The "long modification",

as it is known, goes from point A to point B of the length of path of contact, but the "short modification" only goes to point H-AB (the midpoint
between A and B). Usually the short modification is selected. However, the
modification length (from A to AB) should not be too short. A minimum
length (related to the tooth depth) of 0.2mn should always be present. This
value is checked during sizing. If the length from A to AB is too short, the
program prompts you to use a minimum height of 0.2mn. However, the
result of this is that the contact ratio in the unmodified part will be less than
1.0 (< 2.0 for deep toothing where > 2). The program then displays an
appropriate message.

Chapter
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Figure 14.34: Length of path of contact for a cylindrical gear

Figure 14.35: Short (left) and long profile modification

g) The type of Profile modification has an effect on how scuffing

safety (see section "Relative welding factor (scuffing)" on page II-297) is
calculated.
If you selectFor high load capacity in accordance with the suggestion stated in Niemann, the profile modification at the end of the contact
(point E on the path of contact) is somewhat less than that at the beginning
of the contact.
If you select For smooth meshing, the profile modification at the end
of contact is set to the same values as that for the beginning of contact.

14.6.6.2
Tooth trace modificat ion
The procedure you use to size a width modification, for example, an end relief (see
section "Linear end relief I and II" on page II-367) or crowning (on page II-369),
is performed as specified in ISO 6336, Part 1, Annex B.

If you are working with planet systems, the proposed tooth trace modification can
be used to compensate for a misalignment of the planet and the sun. It can also take
into account the effect of torsion on a particular gear. You will find more detailed
information about the direction of torque and the axis alignment in the "Defining
the misalignment of individual parts" section.
However, be aware that this sizing suggestion only applies to planets with a
symmetrical misalignment because of the torsion that influences the beam.

Chapter
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The proposed modifications (KH = 1) are only then correct if the system has a
single planet. If several planets are present, the program searches for the best
compromise so that the proposed modification minimizes the maximum KH for
all the planet contacts.

14.6.7

Notes about profile modification

If you select a short profile modification , the length of the

modification at the tooth tip (or at the tooth root) for both gears is defined such that
the contact ratio of the part of the tooth flank that has not been changed by the
modification is still exactly 1.0 (for deep toothing with > 2 is still exactly 2.0).
This type of profile modification is the one most frequently used because it always
ensures a sufficiently large transverse contact ratio (no matter what load is
involved).
This short profile modification runs from point A of the path of contact up to the
point H-AB (the midpoint between point A and point B), or from E to H-DE.
However, the result of this is that the contact ratio in the unmodified part is 1.0.
However, if you want to design a gear unit that runs as quietly as possible, it is
usually better to select the long profile modification because the transmission error
is usually much lower in this case. To properly evaluate the effect of a profile
modification, we recommend you calculate the meshing under load (see section
"Contact Analysis" on page II-401).

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14.7

Tooth form

Figure 14.36: Tooth form input window

In addition to the actual calculation, the tooth form calculation offers a number of
other options because it simulates the manufacturing process with a precisely
defined cutter. These options include:
tooth form modifications with profile modifications and root contour optimization
taking into account several steps in the manufacturing with different tools
calculating the cutter (pinion type cutter or hobbing cutter) required to manufacture the toothing (for example, for tooth forms that have been imported from
a CAD program or for modified tooth forms)
tooth form modifications for injection molds or for use in manufacturing pinion
type cutters
NOTE

Special tutorials that specifically deal with tooth form modifications have been
designed and provided for use. You can download these tutorials from our website,
http://www.kisssoft.ch.
The Tooth form calculation module input window consists of two columns. The
left-hand column shows which operations are to be performed on the gears. The
right-hand column consists of the Tolerance field for calculation

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and Approximation for export groups and the corresponding operations

group.

14.7.1

Context menu

Click the right-hand mouse button in the operation directory structure group to
open a context menu. This menu refers to the active element (shown with a blue
background) in the directory.

Figure 14.37: Context menu in the tooth form calculation

The context menu gives you these selection options:

Add operation Select this menu item to open a sub-menu that lists the operations (see page II-379) that can be performed on a particular gear.
Choose as result This result is usually displayed in the graphic and used in the
strength calculations. The default setting is for the results of the last operation
to be displayed here, unless the modification involves mold making, wire erosion, or a pinion type cutter.
Activate/Deactivate Use this option to remove an operation that has been assigned to a gear from the list without deleting it. The icon is then marked with
a red cross. The Activate menu item returns a deactivated operation to the
list of active operations. The red cross then disappears.

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Rename Changes the name of an operation. Note that if you change the name
of an operation this does not change the area name in the right-hand subwindow.
Delete Permanently removes an operation entry along with all its associated
parameters.

14.7.2

Operations

You can calculate the tooth form by using a combination of various different operations. You can apply one processing step after another, for example, using a
hobbing cutter or a pinion type cutter and applying modifications such as rounding
or profile modifications. You can label each operation to make it easy to identify at
a later point in time.

14.7.2.1
Automaticall y
The default operation for the tooth form calculation is Automatically. The
tooth form (with its pre-machining and final machining functions) is then generated
using the data entered in the Standard tabs (see page I-88). If you have defined
modifications, these are taken into account when generating the tooth form. You
can also disable this part of the operation in the context menu. The same applies to
any tip chamfer or rounding you specify. If you select ZA as the flank shape, a ZA
worm will be generated. Otherwise a ZI worm is created.

NOTE

If the Automatically operation has been disabled, none of the data input in the
Reference profile or Modifications input windows will be taken into
consideration.

14.7.2.2
Generate cyl indrical gear with hobbing cutte r
To generate a cylindrical gear with a hobbing cutter, input the gear reference profile. When you add this operation, the window is filled automatically using the values you defined in the Reference profile input window. If the tool is a nontopping tool, the addendum of the reference profile is determined automatically
from the tip circle and not transferred from the values you input. For special applications (manufacturing a gear with a cutter with a different module) you can modify the module mn and the pressure angle n. You can then use the sizing buttons.

The sizing buttons ( ) calculate the correct value in each case for the specified
base circle. Click the Cutter... button to open the Define cutter (see pa-

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ge II-343) window which displays a list of tools. To define the tolerance field, you
can either enter the generating profile shift coefficients directly (Own inputs) or
use the pre-machining or final machining tolerances.
The milling cutter data can also be input as factors or as absolute lengths (mm or
inch). These selection options make your job much easier if the milling cutter data
are the lengths (in mm or inches) given in a drawing.
When sizing haP0*, the system calculates the value which is then used to generate
the involute up to the active root diameter. The proposed value shown here is the
exactly calculated value, to which 0.05 is added (to obtain a small distance between
the root diameter and the active root diameter).
If you use the sizing button to define the grinding wheel, the radius aP0 should be
small (e.g. 0.1*mn), otherwise the grinding process may reach the root radius.

Figure 14.38: Operation: generate cylindrical gear with hobbing

cutter

NOTE

The hobbing cutter information entered here is independent of the data specified in
the reference profile input window. In other words, the tooth form
calculation is based exclusively on the values defined in the Tooth form input
window.

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14

14.7.2.3

Generate a cyl indrical gear with an impo rted hobbing cu tter

You can import the cutter contour from the CAD system in either dxf or vda
format. To do this, define 1/2 tooth from the tip at A to the root at E:

Figure 14.39: Tool profile

You can either specify the layer that includes the contour or select ALL for all the
data. You can then decide whether to import the tool in transverse section or in
normal section, and also change the module. The profile shift coefficient you enter
here determines the tooth thickness.
Click on the "Cutter for displaced generation" option to select a normal module for
the tool that differs from the cylindrical gear generated by the program.
Click on the "Input data as a reference" option to modify the module in the drawing. The cutter is then scaled to the normal module specified in the basic data.

14.7.2.4
Generate a cyl in drical gear with a pinio n type cutter
You must define the geometry of the pinion type cutter if you want to calculate the
tooth form of gears manufactured using a shaping process.

Required input data:

Reference profile of the pinion type cutter
In the reference profile of the pinion type cutter, swap the values of the tip and
root used in the reference profile of the work gear at x0 + xE = 0. In other cases,
you need to input a displacement at x0.
Z0 Number of teeth on the pinion type cutter

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14

x0 Profile shift for the pinion type cutter

(if x0 is not known, you can use the cylindrical gear calculation to define the
profile shift from the tip diameter or the base tangent length further info (see
section "Profile shift coefficient" on page II-265))
or determine the length of the chamfer on the pinion tooth tip s or the radius of
the rounding r on the pinion tooth tip (see Figure 14.40)

Figure 14.40: Tool profile

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14

14.7.2.5

Generate a cyl indrical gear with an impo rted pinion type

cutter
You can import a pinion type cutter as a *.dxf or *.vda file. In this situation,
the system imports a half tooth from the specified layer (select ALL for all layers),
as shown below:

Figure 14.41: Pinion type cutter coordinates

Mid tooth tip: Start of contour

Middle tooth space: End of contour

Center point (xm, ym is a required entry)

Number of teeth

Click on the "Input data as a reference" option to modify the module in the drawing. The cutter is then scaled to the normal module specified in the basic data.
NOTE

The file (dxf or vda) must only contain contours A to E in the layer you can
specify for reading (importing). In this case, you must specify the number of teeth
on the pinion type cutter and the manufacturing center distance.

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14

14.7.2.6
Reading (i mporting) a cylindrical gear
You can import a cylindrical gear directly as a *.dxf or *.vda file. To do this,
define a half tooth in the selected layer:

Figure 14.42: Coordinate system for the import

Mid tooth tip: Start of contour

Middle tooth space: End of contour

Center point (xm, ym is a required entry)

Number of teeth

Click on the "Input data as a reference" option to modify the module in the drawing. The cutter is then scaled to the normal module specified in the basic data.
NOTE

The file (dxf or vda) must only have contours A to E in the layer you can
specify for reading (importing).

14.7.2.7
Adding tip rounding
You can add tip rounding as a tooth form modification. The rounding can be added
either in the transverse or axial section.

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14

14.7.2.8
Adding tip chamfer
You can add a tip chamfer as a tooth form modification. The chamfer can be added
either in the transverse or axial section and is defined by the starting diameter and
an angle.

14.7.2.9
Line ar pro fi le modificat ion
In a linear profile modification, the tooth thickness is reduced in a linear progression from the starting diameter to the tip (relief Ca on each flank as a tooth thickness
modification).

Figure 14.43: Linear profile modification

14.7.2.10 Progre ssive p rofile mo dificatio n

In a progressive profile modification, the tooth thickness is reduced from a starting
diameter to the tip (relief Ca on each flank as a tooth thickness modification) in
accordance with

(14.21)

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14

. The coefficient controls the course of the relief. A coefficient of 5 represents a

linear relief. For more information, see also Figure 14.44. If a coefficient greater
than 5 is used, the progressive profile modification moves tangentially into the
unmodified tooth flank. This is the preferred option if larger reliefs are to be
achieved. We do not recommend you use a coefficient of less than 5 (some of these
lower values are simply ignored by the program). Coefficients greater than 20 are
also ignored. In this case, a coefficient of 20 is used.

Figure 14.44: Progressive profile modification

14.7.2.11
Entry curve as spec ifie d by Hirn
An entry curve that passes into the involute tangentially is applied to the tooth tip
starting from the specific diameter dbegin. This entry curve consists of three arcs of
circle. The bend in the curve increases from arc to arc so that the final curve is tangential to the tip circle. This modified tooth form (also called a hybrid tooth) has
significant benefits, because it permits extremely quiet running despite relatively
imprecise production methods. For this reason the modification is applied for
plastic products, for preference. See Figure 14.45.

Figure 14.45: Profile modification as specified by Hirn

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14

An entry curve is usually only applied to deep toothing with transverse contact
ratios of greater than 2.1. In addition, KISSsoft can use its sizing function to
suggest a suitable starting point (diameter) for the entry curve and the tip relief value. To do this, it uses the profile modification (see section "Modifications" on page II-356) calculation.
The start of the entry curve is defined as follows:
For a transverse contact ratio of 2.0: The active involute is reduced until the
transverse contact ratio is exactly 2.0.
For a transverse contact ratio of less than 2.0: The diameter is calculated so that
a medium tip relief is created, i.e. a transverse contact ratio of above 1.0 is reduced by approximately 50%.
For example, from 1.8 to 1.8 - 0.5 . 0.8 = 1.4.
The exact definition is shown here:
For a transverse contact ratio > 2.0 : dstart = minimum (dPunktD, dPointE0.2)
For a transverse contact ratio < 2.0 : dstart = minimum (dPunktE, dPunktE0.2)
The relief Ca at the tip is defined as shown here:
For normal crest widths less than 0.21 .mn: 0.5 . Tooth thickness - 0.01 .mn
For normal crest widths greater than 0.21 .mn: 0.10 .mn to 0.12 .mn

14.7.2.12 Elliptical ro ot modific ation

The root fillet is replaced by an ellipse-shaped contour, which progresses
tangentially in the flank and root circle. The aim is to achieve the greatest possible
radius of curvature. The course of the contour can be influenced by the coefficient
in the range 1 20. Click the sizing button for the diameter to select an active root
diameter as the starting point of the modification. The definable length on the root
circle is then set to > 0 if you want an area of the tooth form to run on to the root
circle. For example, this is a good idea if the root circle is to be measured with
measuring pins.

The greater tooth thickness in the root area means that the generation process with
the other gear in the pair must be checked.

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14

14.7.2.13 Root rad ius

The root contour is replaced by an exact arc of circle with a specifically definable
radius. After you make this modification, check the generation process using the
other gear in the pair.

14.7.2.14 Theoretical i nv olute/fo rm grinding

The tooth form is construed mathematically. The involute is defined using the module and pressure angle along with the tip and root diameter. The tooth thickness is
defined by the profile shift coefficients. You can also define a root radius (in the
transverse section). This option is suitable for involute gears that cannot be
manufactured by a gear generation process (e.g. internal gears with 4 teeth) or for a
processing step involving form grinding.

14.7.2.15 Cycloid
You can select a cycloid as a special tooth form. The cycloid is defined with two
rolling circles and the tip and root diameters. In the main calculation, the tooth
thickness is defined by the allowances. Rolling circle 1 rolls on the inside on the
reference circle and therefore cuts the dedendum flank. Rolling circle 2 rolls on the
outside and generates the tip. Rolling circle 1 of the first gear should correspond to
rolling circle 2 of the second gear. Sizing a cycloid toothing is made easier if you
calculate the other gear in the pair using the data of the first gear during the
optimization process.

Use the Stress curve and Kinematics analyses modules to analyze the strength and
geometry properties of cycloid toothings.

14.7.2.16 Circular pitched teeth

The circular pitched teeth special toothing type can be defined using the tooth flank
radius and the tooth thickness at the reference circle. An arc of circle is created in
the root area.

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A classic arrangement of circular pitched teeth, for example, as specified in NIHS

20-25 [67] consists of an arc of a circle with radius r starting from the reference
circle, a straight line that progresses in the direction of the center of the gear below
the reference circle, and a full root rounding.

Figure 14.46: Arcs of circle on the tooth

14.7.2.17
Straight line fl ank
You can select a straight line flank as a special tooth form. The straight line flank is
defined by the tooth thickness at the reference circle (theoretical toothing), the space width angle in transverse section, the tip and root diameter as well as the manufacturing profile shift coefficient (dependent on the tolerance). You can also
predefine radii for tip and root rounding.

Figure 14.46b: Straight line flank

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14

14.7.2.18 Generate with the othe r gear in the pair

You can use the other gear in the pair to calculate the tooth form on all the gears,
except on gear 1 (gear number - 1). In this case, you can overwrite the manufacturing center distance and the tip circle. The clearance between the gears can be
generated either by reducing the manufacturing center distance or by inputting the
circumferential backlash. The tip clearance is achieved by increasing the tip circle
of the tool.

14.7.2.19 Calculating the r efe ren ce profile

You can calculate the reference profile of an existing tooth form. A hobbing cutter
can then be used to manufacture it. The manufacturing center distance can be
changed in this calculation. This has a significant effect on the practicability of
creating a tooth form using the generation process. In contrast, the value you input
for the profile shift has no effect on the profile. Instead this influences the null
point.

The calculated reference profile is then used as a cutter to calculate the cylindrical
gear again. By comparing the two tooth forms you can then evaluate the extent to
which the tooth form can be manufactured using the generation process. Click
Cutter/Tool to display the reference profile in the graphic.

14.7.2.20 Calculating a pinion type cutter

You can calculate a pinion type cutter for an existing tooth form. To do this, enter
the number of teeth on the pinion type cutter and the manufacturing center distance. The center distance has a significant effect on the practicability of creating a
tooth form using the generation process. Try out a number of different values to
find the best one.

The calculated pinion type cutter is then used as a cutter to calculate the cylindrical
gear again. By comparing the two tooth forms you can then evaluate the extent to
which the tooth form can be manufactured using the generation process. Click
Cutter/Tool to display the pinion type cutter.

14.7.2.21 Generating a face gear with a pinion type cutt er

This operation is not yet available. To generate a face gear select the automatic
option. Define the pinion type cutter in the Reference profile input
window.

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14

14.7.2.22 Generate a rack with a hobbing cutter

Once again, enter the rack's reference profile, as you do when generating a
cylindrical gear using a milling cutter. In this case, the addendum is only relevant if
you are using a topping tool. The profile shift is measured, starting from a reference line, which is defined by the rack height minus the reference profile addendum
in the main screen.

The profile shift coefficients can be either input directly or defined by the premachining and final machining tolerances.

14.7.2.23 Generate a rack with imported hobbing cutter data

You can define a hobbing cutter as a *.dxf or *.vda file. In this case, the
contour must be output as follows so that the KISSsoft system can read the data
correctly:

Figure 14.47: Tool profile

NOTE

The file (dxf or vda) may only have contours A to E in the layer you can specify
for reading (importing).
In addition to the contour, you must also define the manufacturing center distance.
In this case, the reference line for the center distance is defined using the rack
height.

14.7.2.24 Generate rack with a pinion type cutter

Once again, enter the reference profile of the pinion type cutter, as you do when
generating a cylindrical gear using a pinion type cutter. The profile shift is

Chapter
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Cylindrical gears

14

measured, starting from a reference line, which is defined by the rack height minus
the reference profile addendum in the main screen.
The profile shift coefficients can be either input directly or defined by the premachining and final machining tolerances.

Figure 14.48: Cutter tooth geometry

14.7.2.25 Generate rack with imported pinion type cutte r

You can generate a rack with an imported pinion type cutter. In this case, you must
specify the number of teeth on the pinion type cutter and manufacturing center distance in addition to the pinion type cutter contour in *.dxf or *.vda format.

Figure 14.49: Coordinate system for the import

Chapter
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Cylindrical gears

14

Mid tooth tip: Start of contour

Middle tooth space: End of contour

Center point (xm, ym this is a required

entry)

Number of teeth

NOTE

The file (dxf or vda) may only have contours A to E in the layer you can specify
for the import.

14.7.2.26 Reading ( importing) the rack

You can import a rack gear directly as a *.dxf or *.vda file in the following
format:

Figure 14.50: Tool profile

NOTE

The file (dxf or vda) may only have contours A to E in the layer you can specify
for reading (importing).

14.7.2.27 Generate a SA wo rm
This function is currently only available as the automatic option.

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14

14.7.2.28 Reading (importing) a worm into the axial section

You can also import a worm in its axial section. In this case the contour is basically
the same as the contour of the hobbing cutter, apart from the null point which
forms the axis of the worm.

Figure 14.51: Tool profile

NOTE

The file (dxf or vda) may only have contours A to E in the layer you can specify
for the import.

Chapter
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14

14.7.2.29 Modificat ion fo r mold making

When plastic gears are manufactured using the injection molding process, the material shrinks as it cools. To counter this effect, and manufacture precise tooth
forms, the size of the cutter must be increased by the shrinkage amount. Depending
on what type of material is involved, shrinkage may occur either radially or
tangentially. If you enter the same values in the radial and tangential directions, the
strain will be uniform in all directions

If the gear is injection molded around an inlay body, you must also input the
external diameter of this body. The radial strains will then calculated using the
"outside diameter of inlay body".
The modifications only affect the transverse section of the tooth form. No strain in
the axial direction is present when a 3D volume model is generated. If you want to
create an expanded 3D model of a helical toothed gear (if the strain is to be the same in all three axes), you can achieve this by scaling the module (mn), the center
distance and the facewidth.

EXAMPLE

In the main screen, increase the module, center distance and facewidths by the
required strain coefficient.
Coefficient 1.02

Then, do not input a value for strain in the tooth form calculation.
This modification also increases the lead pz by the same coefficient. However the
angle of rotation of the spirals across the facewidth remains the same.
Usual values are:
Radial shrinkage approx. 2%
Tangential shrinkage approx. 2%

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14.7.2.30 Modificat ion fo r wire e rosion

In the erosion process, the electrodes must maintain a specific distance from the
required shape, because additional material is removed due to the spark gap. This is
usually taken into account by the machines involved in the wire erosion process.

When sink eroding an injection mold the eroding wire must therefore be thinner
than the required shape by the amount of the spark gap. If a gear shaped electrode
is used, the tooth will be correspondingly thinner. To achieve this, enter a negative
value for the spark gap. Usual values for the spark gap are 0.03 to 0.07 mm.
After this modification you can also calculate the reference profile in the next step
to determine the shape of a hobbing cutter for the electrodes.
NOTE

You can also use the wire erosion modification to check the practicability of using
the wire erosion method. If the aim is to erode external teeth, enter one
modification with a positive wire radius and then the second with a negative radius.
If the aim is to erode an injection mold for external teeth, first input a negative radius and then run a modification with a positive radius. By comparing the tooth
forms you can then see whether the form can be manufactured, or whether a
practical form can be created using these two steps.

14.7.2.31 Modificat ion fo r pinion type cutter

The effective cutting angle and the draft angle of the pinion type cutter cause a
tooth form deformation in the projection of the pinion type cutter in the horizontal
plane.
The conversion performed here deforms the tooth form in the horizontal plane so
that the projection once again shows the exact tooth form once the pinion type cutter has been manufactured.

By grinding with angle (effective cutting angle) Q moves to P (see Figure 14.52).
If the projection P' is to agree (exact contour in the horizontal plane), P must = Q
must in the H plane.
(12.22)

(12.23)
(12.24)

Chapter
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14

where

Effective cutting angle

Tip draft angle in axial section

Pinion type cutter axis

ra

Pinion type cutter tip circle radius

rp

Coordinate of the point P

Conversion of the tooth form:

Given:

Exact tooth form in polar coordinates P = r (Angle)

Searched
for:

Tooth form in H-plane P' = r' (Angle)

Solution:

r' = r + tan() . tan()(ra-r)

Figure 14.52: Pinion type cutter profile

14.7.2.32 Elliptical defo rmat ion

Applicable on the external gear (Gear1) of an internal-external cylindrical gear
pair. This allows you to display the elliptical deformation of the race in a special
gear box in 2D. Typically z1+z2 = -2 applies here;

Chapter
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14

The contour of the race is stretched vertically by the lengthening factor and
compressed horizontally so that the root circumference of the ellipse matches the
root circle circumference of the undeformed gear. In a 2 D display, it is important
you check:
- that the gear can be generated without collision over a pitch.
- that opposing sides mesh correctly.
If you need to make a correction, select a different lengthening factor or a different
number of teeth (if the total number of teeth is an even number). Values between 0
and 5 % can be used as the lengthening factor.
Note: You cannot create a 3D output for this variant.

Chapter
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14

14.8

Flank breaking

Figure 14.44: "Flank breaking" input window

Flank breaking appears in the area of the active tooth flank instead of in the area of
the highest bending stress at the 30 tangent.
This calculation tab is designed to calculate the safety against flank breaking in
accordance with Dr. R. Annast [89]. The original calculation procedure from Dr. R.
Annast requires detailed measurements of the gear hardness as a function of depth
from the flank surface, to enable the depth of transition layer and the core hardness
to be calculated.
There are three calculation options:
Using a hardness file for the gear material, if this file already exists in the database
Selecting an independent file with the hardness information, or
Direct input of core hardness and transition depth
If a file is used (case one and two) and only one pair of data is found, then it is
assumed (in accordance with case three) that these values are the core hardness and
the transition depth.

Chapter
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Cylindrical gears

14

Figure 14.45: Structure of the Hardness file

When a file containing hardness data is used (case one and two), the original data
are fed to the Annast algorithm. If the algorithm fails due to invalid data, the data is
determined in accordance with the following regression formula (non-linear regres b y
c
sion) HV a e

. If the calculation with this data is also unsuccessful, a last attempt is performed
(linearized regression) with the equation ln( HV ) ln( a ) ln( b ) ( y )
(as above, but without taking the constants into account).

Chapter
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14

14.9

Contact Analysis

Figure 14.53: Contact analysis input window

The load is taken into account when calculating the path of contact. This also
calculates the face load factor KH using the more precise method defined in ISO
6336-1, Annex E. In this case, the meshing stiffness can be calculated either
according to Weber/Banaschek [69], ISO 6336-1 or "Own Input". The calculation
of meshing stiffness according to Weber/Banaschek is based on the effective tooth
form in normal section. You can either enter the "Partial load for calculation Wt"
coefficient for the load, or modify it on the basis of the application factor Ka and
the dynamic factor, by clicking the Sizing button. You can also predefine a
meshing error. The proposed value for the pitch error is then

calculated. You can specify a value for the pitch error with both a positive and a
negative prefix. The results are then displayed if the distance is too great or too
small.
The coefficient of friction between the flanks is assumed to be a constant in the
meshing. Click the sizing button to accept the coefficient of friction as defined in
ISO TR 15144.
For helical gear teeth, non-parallel axes, or tooth trace modifications, the
calculation is performed in several slices of spur gear teeth (discretized toothing
model) that are linked by a coupling with stiffness. This therefore takes profile and
tooth trace modifications into account.
The number of sections is set automatically according to the gear geometry and the
"Accuracy of calculation" option. The number of automatically determined slices
increases correspondingly if a greater overlap ratio and accuracy of calculation is
selected. You can also enter the number of sections, slices and pitches manually by
setting the accuracy of calculation to "Own Input" and clicking the Plus button next
to it. If more than one pitch is calculated, the number of steps is distributed equally
across all the pitches.

Chapter
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14

You can then view the calculation results in the report or in the Graphics > Contact
analysis menu.
The contact analysis can calculate either the transmission error as a length on the
path of contact in m or the angle of rotation error as an angle on the driven gear in
.
The effect of manufacturing errors (fma, f) is taken into account by selecting an
appropriate value from the "Manufacturing allowances" drop-down list in the
"Contact analysis" tab. The manufacturing error increases the flank gap in the normal flank direction, see Figure. 1. A linear error distribution is assumed here, so
that the manufacturing error on side I is 0, and is at its maximum on side II, and
increases in a linear progression along the facewidth. Manufacturing errors are
taken into consideration in pairs, as either positive or negative values, (up to a total
of 5 combinations, but if there is only one combination, the manufacturing error is
ignored).

Figure 1: Definition of the positive direction of manufacturing errors fma and fH

NOTE:
Numerical problems may arise if the selected pitch error is too large relative to the
partial load. In this situation, we recommend you select either a smaller pitch error
or a larger partial load.

14.9.1

Theory of Contact Analysis

As stated in Weber/Banaschek [69], the deformation of the meshing of gear pairs

can be divided into three components:
Gear body deformation
Bending
Hertzian flattening

Chapter
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Cylindrical gears

14

Bending:

Fbti
b

cos Fy
2

1
E

yp
y p y p y 2
2 .4
dy
2
dy
tan Fy
12

3
1
0 2 x '
0 2 x '

Chapter
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Cylindrical gears

14

Gear body deformation:

RK

Fbti
b

cos Fy
2

1
E

18 y 2p
2 1 2

2
s f 20
1

yp
s f 20

4 .8
1
2
tan Fy
1

2 .4

Chapter
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Cylindrical gears

14

Hertzian flattening:

H 1, 2

2
b H2
Fbti 1 1

ln 2

b g E 1
4 t1

1 1 1 1 22 b H2

ln 2

E
E
1
2

4t2

2 1 2

E2

Total deformation has the effect that the contact point is displaced along the path of
contact and the theoretical length of path of contact is increased, in comparison to
the actual length of path of contact. The transverse contact ratio under load is
therefore greater than in the load-free state.
The spring equation F=d*C can be applied to calculate the components of the single contact stiffness from the individual deformation components and the normal
force.

Chapter
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14

14.9.2

Discretized model

A discretized toothing model has been generated so that the deformation theory of
meshing in gear pairs developed by Weber/Banaschek can be applied to three dimensional cylindrical gears with helical gear teeth.

14.9.3

Smoothing the tooth form curvature to calcul ate Hertzian pressure in the contact an alysis

The large variations in curvature that occur during contact cause local, high peak
values in Hertzian pressure and are a well-known problem. These values mean that
any calculations, such as micropitting in accordance with Method A, which involve
Hertzian pressure, will be incorrect. To avoid this, the peak values are filtered out
after the calculation so that results that match the actual situation can be achieved.
This problem usually occurs on the tooth tip (where the curvature radius is 0).
Therefore we implement the following smoothing strategy to counter the curvature
of the tooth form.

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14

If the curvature radius y is less than 1.01 * mn*, then smoothing will be applied to
y. (* current setting in the code)
SmoothFactor = 0.8 (=0: no smoothing, = 1: full smoothing)
y+d and y-d are calculated.
d = 0.3 * mn : the corresponding diameters are then applied to the diameter,
i.e. d+d and d-d.
If (y+d > y-d) then corr = y+d, otherwise corr = y-d,
As this process has been designed for the critical tip area, the smoothing outside the tip area is reduced with the DiaFactor factor.

This results in the "smoothed" y : yNew = SmoothFactor * DiaFactor * corr +

(1 - SmoothFactor * DiaFactor) * yOld

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14.9.4

Reduced stiffness on the side edges

The bending stiffness of the tooth in helical gears is reduced at the edges.

Figure 14.53.3: Illustration of two cuts for a helical gear

Cpet_border = Cpet*(sred/sn)^0.5
Exponent 0.5 was evaluated in comparative analyses with FEM and LVR. The
reciprocal value of this exponent (border weakening factor (buttressing) can be
changed by the user. It has a significant effect on the buttressing effect that occurs
in helical gear teeth.

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14.9.5

Linking the individual slices

The teeth are distributed in slices across the width and are coupled together by
torsional stiffness.

Figure 14.53.2: Linking the slices

Cpet = CZ + CRK = root stiffness as defined by Weber/Banaschek [69]

(CZ = bending stiffness and shear strength as defined by Weber/Banaschek)
(CRK = deformation stiffness due to rotation in the tooth blank)
CH = stiffness from Hertzian pressure as defined by Weber/Banaschek
CC = coupling with stiffness

CC = 0.04*(Asec)^2*Cpet
Asec: Number of slices
All C are in N//mm.

0.04: Empirical factor, confirmed by comparative calculations with FEM. The user
can change this factor (slice coupling factor) in the module-specific settings.
(Asec)^2 is used because different numbers of slices must return the same result
over the total width.

14.9.6

Wear iteration

You can use the wear iteration function to define wear along the tooth flank in more detail, because it performs several steps of the contact analysis with the worn

Chapter
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14

tooth flank. However, this does significantly increase the time it takes this
calculation to run. Click the "Calculate wear iteratively" checkbox to select this
option.
You can input a coefficient for the maximum permitted wear per step. This
coefficient is then multiplied by the normal module. In the contact analysis shown
below, the service life after one iteration was reduced by only applying the maximum permissible wear. The next contact analysis was then calculated with the
worn tooth flank. This process was repeated until the total service life was reached.
By clicking on the sizing button, you can set the maximum permissible wear to half
the wear calculated for plastic [delWn] for the entire service life. This should be
used to perform roughly ten iterations.

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14

14.10

Gear pump

Figure 14.54: Path of contact input window for Gear pump

If you ignore the return volume, you can calculate the transport volume when you
perform the normal calculation. You will find the parameter for this in the Basic
data input window. (see section "Basic data" on page II-262) In this
case, click the Calculation of the displacement volume of gear
wheel pumps checkbox in the Calculations tab in the Settings window,
which you open by clicking the Calculation menu.
In the lower part of the Path of contact input window you can then perform
a detailed calculation for a gear pump.
The system calculates and displays the changes to the critical parameters of a pump
that occur during meshing. These include geometric parameters such as the pinched
volume (between two meshed tooth pairs, return volume), the volume with a critical inflow area (if possible, the flow of oil should be kept constant), the narrowest
point (minimum distance between the first tooth pair without contact), inflow
speed, oil inflow at the entry point (with Fourier analysis to evaluate the noise levels), volume under pressure at input. Other important information is the progression of torque on the two gears, the progression of the Hertzian pressure H, the
sliding velocity vg and the wear coefficient H .vg. Hertzian flattening can be
included when calculating forces because this effect has a significant influence.
The pinched volume depends on how the pump construction functions under
pressure at input or output. This is defined by the appropriate input value and has a
considerable effect on the torque curve. When the pinched volume is reduced, you
see a significant momentary increase in compression in this volume. This produces
strong pulsing forces on the support and therefore generates noise. A pressure release groove must be installed to avoid this increase in pressure. For this reason, it
is very useful to calculate and display the pressure flow in the pinched volume.
This calculation allows you to analyze any type of cylindrical gear with involute
and non-involute teeth forms. At present, the only fundamental restriction is that
this procedure is limited to spur gears.

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14

Op ti mi za ti o n s tr at e gi es fo r g ea r p u mp s

The most important and critical problems regarding gear pumps are
Noise
Efficiency
Size
Wear
Here is some information that may help define the criteria according to which
pumps can be evaluated.
Noise:

Variations in flow through the pump generate noise in the pipes. For this
reason, the flow (Q) should be as continuous as possible.

The enclosed volume (V1) should not be reduced during the generation
process. A reduction in this volume would create a massive increase in
compression in V1 and generate dynamic forces on both the bearing and
the shafts. This effect can be reduced by the precise sizing of relief grooves.

The inlet speed of the oil through the narrowest point should be kept as low
as possible

Efficiency:

Return volume should be kept as low as possible

Size:

The KISSsoft Fine Sizing functions provide a very efficient method of

achieving the highest possible displacement volume for a specified size.

Wear:

You must monitor the course of the wear values (sliding velocity and
Hertzian pressure between the tooth flanks)

NOTE:

You will find more detailed information about gear pump analyses in KISSsoftanl-035-E-GearPumpInstructions.doc [77] (available on request).
The "Gear pump" report shows the input torque on gear 1 [T1] and the torque
transferred from gear 1 to gear 2 [T1Contact].

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14

You should use the torque at the point of contact in the strength calculation and
the contact analysis (calculated from Pout and Pin). Enter this data in the "Basic
data" tab.
You should use the torque at the point of contact in the strength calculation and
the contact analysis (calculated from Pout and Pin). Enter this data in the "Basic
data" tab. The total power [P] and the torque [T1] at the pump inlet are only
documented in the "Gear pump" report and are not otherwise used. All the graphics shown under "Graphics" "> Gear pump" are based on compression. The
torque curve used in the graphic is the input torque [T1].

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14.11

Operating backlash

Figure 14.55: Operating backlash input window

In addition to calculating the theoretical backlash, the backlash after mounting can
also be calculated as defined in DIN 3967 (this includes toothing deviations, deviation error of axis according to ISO 10064 or DIN 3964 (see also Table 14.15). The
operating backlash (including the temperature differences between the gears and
the housing) is also calculated. To calculate them, the required input is a
temperature range for the gears and the housing, and the maximum and minimum
difference in temperature between them. Two cases are calculated simultaneously,
one that produces the maximum operating backlash (with the given temperature
inputs), and one that produces the minimum operating backlash.
If the module is < 1, the statistically evaluated circumferential backlash is also
calculated according to DIN 58405.
The reduction of the backlash due to individual teeth deviations is then calculated
with tolerances Fb, Ff and fp according to DIN 3961. These values as specified in
DIN 3961 are not defined for module < 1. In this case, tolerances for module 1 are
defined according to DIN 3961 and then reduced in proportion to the module.
According to formula: fp(mn) = fp(mn=1.0) * mn.
The reduction in clearance due to deviations in individual teeth is not taken into
account for worm gears.
The effect of the runout error can also be taken into consideration. In this case the
roller runout tolerance (determined using the approximation formula Fr = Fi'' - fi'')
is used instead of the runout error Fr for module < 1.

Bearing center

Axis alignment accuracy class

distance
LG (nominal

10

11

12

Chapter
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Cylindrical gears

14

length)
in mm
bis 50

10

12

16

20

25

32

40

50

63

over 50 up to 125

10

11
2

16

20

25

32

40

50

63

80

over 125 up to 280

10

12

16

20

25

32

40

50

63

80

100

over 280 up to 560

10

12

16

20

25

32

40

50

63

80

100

125

over 560 up to 1000

12

16

20

25

32

40

50

63

80

100

125

160

over 1000 up to 1600

16

20

25

32

40

50

63

80

100

125

160

200

over 1600 up to 2500

20

25

32

40

50

63

80

10
0

125

160

200

250

over 2500 up to 3150

25

32

40

50

63

80

10
0

12
5

160

200

250

320

Table 14.15: Deviation error of axis according to DIN 3964, values in [mm]

As shown in Table 14.15, the values in the Axis position accuracy and Distance
between bearings input fields are used to calculate the axis deviation error
according to DIN 3964.
Backlashes are calculated as specified in DIN 3967.
Circumferential backlash calculation:
The circumferential backlash is calculated according to DIN 3967 with the
following formula on the reference circle:

jt ( As / cos ) 2 Aa tan t
In KISSsoft, the operating backslash is calculated using the more precise formula
in the operating pitch diameter:

jt ( As / cos

cos t
cos wt

) 2 Aa tan wt

Planetary gears are another special feature of the operating backslash calculation
Here, there are 2 operating pitch diameters for the planets (sun/planet and planet/internal gear). The change in operating pitch diameter due to thermal expansion
is defined here for the operating pitch circle determined in this process.

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In addition, the change in tip clearance due to thermal expansion (and water absorption for plastics) is also calculated.

Any elongations that occur in the body of the gear also change its pitch. A single
pitch deviation occurs as soon as both gears show unequal expansion. The increase
or decrease in pitch caused by thermal expansion is defined as follows:

pt

pitch

coefficient of thermal expansion

temperatures

fpt

single pitch deviation

Plastics also undergo expansion due to water absorption.

14.11.1

Reference temperature

The Reference temperatureT is the ambient temperature specified for manufacturing. The tooth thickness input here apply to this temperature.
The Mass temperature for the individual gears defines the thermal expansion of the individual gears, The Gear mass temperature of the scuffing calculation
can be used as here as a starting point.
Taken together with the coefficient of thermal expansion, the Temperature of
housing then defines the amount of thermal expansion that occurs for the
housing.

14.11.2

Relative water absorption during swelling

You must input this value as a [%] of the volume. To calculate clearance, DIN
3967 specifies that: For plastics, the linear expansion due to water absorption
detailed in DIN 3967 is approximately 1/3 of the amount of water absorbed.
However, for fiber-reinforced plastics it is only around 1/12 of the volume of water

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14

absorbed. If you click this checkbox, this phenomenon is taken into consideration
when calculating the change in volume.

14.11.3

Coefficient of thermal expansion for ho using

If you select a material from the database, this field merely provides information
about the coefficient of expansion of the selected housing material. In this case,
you cannot change the value. However, if you have set the Housing material
drop-down list to Own Input, you can enter your own value.

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14.12

Master gear

Figure 14.56: Master gear input window

This KISSsoft calculation module has been designed to enable you to size and
check master gears.
To perform a test for double flank composite transmission, you require one master
gear which is then rotated on a test device together with the gear you want to test.
In the test run, the test gear and the master gear are pressed lightly together so that
no backlash is generated. The deviation in center distances is then measured
carefully. The difference between the minimum and maximum value calculated
here is the tooth-to-tooth composite error. In order to achieve an accurate statement
about the how the test gear behaves when running after it has been installed in the
gear, the active involute of the test gear should be processed as completely as
possible in the test run. However, it is essential that you prevent the master gear
from meshing too deeply in the root area: If the value for the root form diameter of
the test gear is not achieved, this will cause meshing interference which will in turn
generate measurement results that are massively incorrect. You can call the master
gear sizing function for each gear in a particular calculation. When you open the
sizing window, the default values for a suitable standard master gear taken from
DIN 3970 are displayed. The analysis functions check the maximum and minimum
tolerance fields of the tooth thickness of the test gear whose involute is being
processed. The report then show which area of the active involute has been tested,
or not tested. If the value for the root form diameter is not achieved, the program
issues a warning to prompt you to reduce the tip circle diameter of the master gear.
This calculation is also available for cylindrical gears with a minimum number of

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14

teeth greater than 4. Click the Save button to save the master gear data and the
master gear-test gear pair as KISSsoft files.
Take into account total radial composite deviation (in accordance with AGMA
2002): When calculating the smallest test center distance [aMin], the theoretical
center distance stated in AGMA2002 (equation 8.5) is further reduced by the total
radial composite deviation (Vcq specified in AGMA 2000). If the manufacturing
tolerances specified in ISO or DIN are being applied, Fi" is used for that purpose.
If the tolerances specified in AGMA are applied, Vcq is used here:

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14.13

AGMA 925

As specified in AGMA925, you can use this input window to define the probability
of scuffing and wear as well as susceptibility to micropitting

Figure 14.57: AGMA 925 input window

AGMA 925-A03 Effect of Lubrication on Gear Surface Distress calculates the

conditions in the lubrication gap across the gear meshing. AGMA925 defines how
to calculate the lubrication gap height whilst taking into account the flank deformation, lubricant properties, sliding velocity and the local Hertzian stress. The standard then uses this base data to calculate the probability of wear. The wear is
caused by the metal surfaces contacting each other if the lubrication gap is too
narrow. The probability of wear calculated by the standard is greater than the values that occur in practice.
The standard does not give any indications about safety against micropitting.
However, data provided by the relevant technical literature and the results of research reveal that there is a direct correlation between the minimum lubrication
gap-to-surface roughness ratio and the occurrence of micropitting. You can
therefore use this calculation method to optimize gear toothing for micropitting.
AGMA 925 also includes a definition of the probability of scuffing. This analysis
uses the same base data (Blok's equations) as the calculation of scuffing according
to the flash temperature criteria given in DIN3990, Part 4. However, defining the
permitted scuffing temperature in accordance with AGMA925 presents more of a
problem because of the lack of comprehensive or generally applicable information.
In particular, there is no reference to a scuffing load capacity specification as given

Chapter
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14

in the FZG test. There is therefore a tendency to under evaluate oils that have
effective EP additives.
Values for the compression viscosity coefficient of typical gear oils vary between
0.00725mm2/N and 0.029mm2/N and are defined as follows in AGMA 925-A03:

(14.25)

where

Compression viscosity coefficient

mm2/N

see Table 2 in AGMA 925-A03

Dynamic viscosity for tooth temperature M

mPa . s

In practice, calculating wear in accordance with Wellauer results in risk of wear

values that are too high. For this reason, the analysis is performed as stated by
Dowson (as in Annex E of AGMA 925). The report shows the results for both
methods.

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14

14.14

Rough sizing

Rough sizing suggests possible toothing configurations based on the data entered
for the ratio and the load. To use this function, go to the Calculation menu and
select Rough sizing or click the corresponding icon

in the tool bar.

Figure 14.58: Dialog window: Rough sizing

At present you can apply this to inside and outside toothed cylindrical gear pairs
and planetary gears. The target ratio is the most important input parameter. For an
internal gear pair, the ratio must be entered as a negative value in the Geometry
area. In planetary stages, the nominal ratio must be > 2.0.
The operating data (power, speed, etc.) is taken from the KISSsoft main window
(and can be changed there if required). You can also specify a helix angle or a
required overlap ratio (e.g. = 1.0.).
Some important design parameters for gear stages can be preset (the ratios b/mn,
b/d1, b/a). Because these parameters may limit each other, you can click the
appropriate button to specify which parameter is preferred.

Chapter
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14

Click on the Calculate button to open a list of suggestions that you can use to
set the parameters for your gears. Click the right-hand mouse button on any entry
in this list to open a context menu that displays a list of possible sizes (see Figure
14.59).

Figure 14.59: Section of possible parameters in the Context menu

The values that have a tick in their checkbox are displayed in a list. The other values are not displayed. Click a value to set/deselect a checkbox. You will find a
legend describing the parameters used here at the end this section.
Rough sizing automatically defines the most important tooth parameters (center
distance, module, number of teeth, width) from the power that is to be used and the
required ratio together with strength calculation according to the selected
calculation standard. Dimensioning is performed according to minimum safeties
(Required safeties (see page II-459)).
You can specify the intervals for the relationships b/mn-, b/a-, b/d in the
Calculation menu under Settings > Sizings. (Sizings (see page II452))
The program displays a number of different solutions which you can select. You
can then use them to perform optimizing in fine sizing. The window remains open,
to allow you to select more solutions. You will find more detailed information
about fine sizing in section 14.15.
The most important result of this sizing process is that it enables you to define the
achievable center distance ranges and module ranges, as well as the facewidth. You
can then decide how much space is required for the machinery itself.

Chapter
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14

Solutions with a number between 1 and 5 show solutions with any random modules. Solutions from 6 onwards show solutions with default modules according to
DIN 780 (module series for gears).
Number 1: Solution with the most exact ratio
Number 2: Solution with the greatest center distance
Number 3: Solution with the smallest center distance
Number 4: Solution with the largest module
Number 5: Solution with the smallest module
You can predefine the center distance for special cases. However, in these cases,
you must remember that the program's sizing options are not comprehensive, and
fine sizing represents a better alternative.
Sizi n g of s tr e ng t h f or a pla n e tar y g e ar

When performing rough sizing for planetary stages, it is assumed that the rim is
static. If the rim rotates, you must change the speeds after sizing.
Different constraints for rough sizing
The system prompt suggests the number of teeth as defined by Niemann
Table of standard number of pinion teeth according to Niemann [65], Table
22.1/8.
Ratio u

counter-through hardened to
230 HB

32 to 60

29 to 55

25 to 50

22 to 45

Over 300 HB

30 to 50

27 to 45

23 to 40

20 to 35

Cast iron

26 to 45

23 to 40

21 to 35

18 to 30

nitrided

24 to 40

21 to 35

19 to 31

16 to 26

Case-hardened

21 to 32

19 to 29

16 to 25

14 to 22

Through hardened or hardened

Click the Sizing button to transfer these values to fine sizing automatically.
Module ratio b/mn, reference diameter ratio b/d1, center distance ratio b/a (see
page II-452)

Parameter

Meaning

Chapter
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Cylindrical gears

14

No.

Sequential numbering

Center distance

b1(2)

Facewidth

mn

Normal module

Pnd

Normal diametral pitch

Pressure angle

Helix angle

z1(2)
x*1

Number of teeth
x*2

Total profile shift coefficients

x*1(2)

Profile shift coefficient

h*aP1(2)

Addendum coefficient

h*af1(2)

Dedendum coefficient

Tool

ID number of the hobbing cutter1)

Reference profile gear 1(2) Reference profile database ID

da1(2)

Tip diameter

df1(2)

Root diameter

Transverse contact ratio

Overlap ratio

Total contact ratio

max(min)

Specific sliding

AC/AE

Ratio of contact length2)

Transmission ratio

ie[%]

Deviation from nominal ratio

Hunting

z1 and z2 have no common denominator, apart from

1

dw1(2)

Operating pitch diameter

wt

Working transverse pressure angle

wn

Normal pressure angle

Helix angle at reference circle

b/d1

Facewidth to reference diameter ratio

Chapter
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Cylindrical gears

14

b/mn

Facewidth to normal module ratio

b/a

Facewidth to center distance ratio

SF1(2)

Root safety

SFmin

Minimum root safety

SH1(2)

Flank safety

SHmin

Minimum flank safety

SB

Safety against scuffing for flash temperature

SInt

Safety against scuffing for integral temperature

Tmax

Maximum torque

Pmax

Maximum power

Cg

Tooth contact stiffness

cg

Change in tooth contact stiffness

Sliding velocity

Power loss

Total gear weight

Moment of inertia

Dynamic factor

Face load factor

Summary

see Fine Sizing Results (see page II-436)

Hmin, bending

Minimum service life, only include root

Hmin, flank

Minimum service life, only include tooth flank

Hmin

Minimum service life

V5

Displacement volume: as gear pump

Note: To enable this calculation, set the flag for
calculating the displacement volume under
Calculation > Settings
>Calculations.

1)

according to the List of cutters for reference profile drop down list. Only for Fine Sizing (see page II-431).

2)

Results (see page II-436), Point 5

Chapter
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Cylindrical gears

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14

14.15

Fine Sizing

Figure 14.60: Conditions I tab in the Fine Sizing window

To start the Fine Sizing process, click the Calculation menu and select
the Fine Sizing option or click the

icon in the tool bar.

If you input a nominal ratio, a center distance and intervals for the module and helix angle as well as the pressure angle, the system calculates and displays all the
possible suggestions for the number of teeth, module, helix angle and profile shift.
It also shows the deviation from the nominal ratio, the specific sliding and the contact ratio. This module can also be used to size planetary stages and cylindrical
gear stages with change gears.
All the variants found by this process can be evaluated by a wide range of different
criteria (accuracy of ratio, weight, strength, tooth contact stiffness deviation etc.)
Depending on your requirements, limits can also be set on the most important
parameters (tip circle, root circle, minimum number of teeth, tolerated undercut
etc.). In addition to creating text reports detailing the solutions and the summary,
the summary can also be displayed as a graphic.

Chapter
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14

For planetary gear units or cylindrical gears that have an idler gear, you can:
perform the calculation either with the predefined center distance or with a
predefined internal gear V circle d+2*x*mn (normal case).
In the case of cylindrical gear pairs, the center distance can either be fixed (normal
case) or predefined in an interval. To do this, click the checkbox to the right of the
Center distance input field.
The facewidth appears in the input screen, where you can modify it if required.

NOTE

You should check the center distance interval after you change the reference circle
or select a variable center distance. You may then need to repeat the sizing process.

14.15.1

Necessary entries in the input window

Before you start the fine sizing process, you must enter the following data correctly
in the Basic data or Geometry and Strength standard tabs to ensure the
calculation returns the results you require.
Geometry:
Reference profile
Number of idler gears/planets (in a 3 gear configuration)
Strength:
Materials
Power/Speed
Application factor
Service life
Lubrication

14.15.2

Conditions I

14.15.2.1 Limiting the tip diamet er

Solutions whose tip circle exceeds the specified value are rejected. If you do not
want to limit the tip value, you can input either 0 or 1010.

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14

However, the following problem prevents this option being used sensibly in practice: If a gear is to be installed in an existing housing, it is critical that it does not
touch the walls of the housing.

14.15.2.2 Limiting the root diame ter

Solutions whose root circle falls below the specified value are rejected. If you do
not want to limit the root diameter, you can input 0.

However, the following problem prevents this option being used sensibly in practice: If a gear is mounted on roller bearings in a speed change gear unit, you must
guarantee a minimum thickness of material between the bore and the root circle.

14.15.2.3 Maximal no of s o lution s

Proposal: 50 to 250

If the program finds more than the specified number of solutions, you see a
warning message and an appropriate note is entered in the report.

NOTE

You should only perform a final evaluation after all the possible solutions have
been displayed. Otherwise you run the risk of missing the optimum solution.

14.15.2.4 Limiting the number o f teeth

You should not normally need to use this option, which is why the default setting is
for it to be disabled. However, by clicking the individual checkboxes, you can still
fix this parameter. A useful application for this option is when for sizing a planetary gear which has already been modified to fit inside a predefined internal gear. In
this case, the module and the number of teeth for gear 3 are predefined.

Chapter
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14

14.15.3

Conditions II

Figure 14.61: Conditions II tab in the Fine Sizing window

You can specify other essential functions in the Conditions II tab.

1. Show values of KISSsoft Basic Tab as additional variant with number
0
The toothing data in the KISSsoft Basic tab can also be displayed as a variant with the number 0 (table and graphic). However, the data at the start
of the fine sizing process must be consistent before this can happen.
This option can either be enabled or disabled. When you enable this option,
you must restart the fine sizing process so the variant can also be
displayed.
2. Calculate geometry only
If you select this method, no strength calculation is performed.
3. Strength calculation with load spectrum
Before you can perform calculations with a load spectrum, you must
specify a load spectrum in the KISSsoft main window before you start the
fine sizing process and run the calculation (to ensure the data is consistent).
In this case, when you start the fine sizing process, you are prompted to
confirm that you want to perform the calculation with a load spectrum. The

Chapter
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14

flag in the window merely shows whether the calculation includes a load
spectrum. You cannot reset this flag.
4. Permit undercut
If this option is selected, solutions with undercut are not rejected.
5. Reject results with specific sliding higher than 3
Usually specific sliding should not be greater than 3.
6. Consider minimum tooth thickness
If this option is selected, solutions with a tooth tip thickness that is less
than the predefined minimum tooth thickness (see Calculation >
Settings > General) will be rejected.
7. Allow small geometry errors
Minor meshing interference and similar geometry errors will now be
tolerated when the system calculates variants! You can make separate settings to take into account the undercut and the minimum tooth thickness at
the tip (see points 2 and 4).
You must set this option if the program has to find solutions where the
number of teeth is less than 7, or in other exceptional situations. We do not
recommend you set this option in any other situation!
Note:
In these situations, you must also change the minimum number of teeth
accordingly (see point 11).
8. Suppress integer ratios
If this option is selected, results with whole number gear ratios will be
rejected.
9. List of cutters for reference profile
Instead of using the predefined reference profile, you can use a list of
hobbing cutters for fine sizing. In this case, the calculation is performed for
every cutter in the given module and pressure angle range and the tool is
displayed in the results list.
The same hobbing cutter is used for each gear. Internal teeth are not
affected by this setting.
10. Sizing of deep tooth forms
Special reference profiles with larger addendums and dedendums are used
for deep toothing. This sizing function calculates the necessary reference
profile on the basis of the required transverse contact ratio. If this function
is active in fine sizing, the reference profile for every solution is calculated
so that the exact required transverse contact ratio is achieved. As a result,

Chapter
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14

only those solutions that have, at least, the required transverse contact ratio
are displayed.
11. Transmission error
If the "Calculation of transmission error" option is selected, the contact
analysis is performed for every variant. If the "Calculation of transmission
error and profile correction" option is selected, the length and value of the
profile modification (correction) is determined automatically, according to
the settings made for the correction method. Click the
the profile modification settings window.

button to open

The correction method takes into account the objective (for high load

Chapter
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14

capacity or smooth meshing), tip and/or root relief, length (short or long),
and the types (linear, arc, progressive, and linear with transition radius). It
is important to note that the transmission error can only be minimized for
one load, and the partial load for sizing should be set correctly according to
the applied load level.
When contact analysis is performed for transmission error, the default settings are used to prevent the calculation returning unusual results, apart
from the coefficient of friction and accuracy of calculation. Input the settings in the main program, in the "Contact analysis" tab. You can also
specify the accuracy of the calculation, however, we strongly recommend
you use "low" or "medium" to reduce the processing time. Therefore, the
transmission error in fine sizing may not be exactly the same as the one
from the contact analysis, according to the settings.
The default settings are:
Calculation for: right flank
- Torque for gear A: not considered
- Torque for gear B: not considered
- Partial load for calculation: 100 %
- Center distance: Average center distance allowance
- Single pitch deviation: 0 mm
- Deviation error of axis: 0 mm
- Inclination error of axis: 0 mm
The results list shows:
- Transmission error (PPTE)
- Average wear on the tooth flank (delwn1, delwn2
- Maximum flash temperature (theflamax)
- Variation in bearing force (VarL)
The calculation time increases significantly if the transmission error
calculation option is used. We therefore recommend you limit the number
of results before starting the calculation.

12. Suspend results which do not meet required safety factors

Variants which do not meet the predefined minimum safety levels (see
Calculation > Settings > Required safeties) will be
rejected.
Note:
Variants with insufficient safety against scuffing will not be rejected.

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13. Sizing of profile shift coefficient x1

Fine sizing usually generates 3 or 4 variants in which only the profile shift
differs. In this case, the profile shift x1 is changed in increments of 0.1.
Here you can specify the criterion used to determine the largest profile
shift used, x1.
14. Minimum number of teeth zmin
Practical values range for the minimum number of teeth:
For helical gear teeth: 7 to 9
For spur gear teeth: 10 to 12
Click the
of teeth.

button to display a suggested value for the minimum number

Note:
If you want to find solutions where the number of teeth is less than 7, you
must first select the Allow small geometry errors option.
15. Minimum distance between root form diameter and active root diameter dNf - dFf
Meshing interference occurs if the active root diameter is less than the root
form diameter. Here you can specify a minimum value for the distance
between the active root diameter and the root form diameter, i.e. between
active and manufactured involutes. The input value is the minimum
difference between the two diameters.
16. Minimum distance between root form diameter and base circle dFf - db
If the start of the manufactured involute is closer to the base circle, this will
cause greater wear on a tool during the manufacturing process. Here you
can specify a minimum value for the distance between the root form diameter and the base circle. The input value is the minimum difference
between the two diameters.

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14.15.4

Results

Figure 14.62: Results tab in the Fine Sizing window

Click the Report button to open the editor and display a list of the best results. A
brief description of the criteria used to evaluate the best variants is given here.
Please note that these criteria are not relevant to every case, and only need to be
queried in particular applications!
1. Summarize variants for accuracy of gear ratio:
The difference between the actual gear ratio and the required gear ratio is
evaluated here.
2. Weight: this is an indicator for the manufacturing price
3. Specific sliding: maximum value
4. Sliding velocity: maximum value
5. Relationship AC/AE
AC: length of path of contact from meshing point to pitch point
AE: total length of path of contact
"Pushing" sliding occurs in the AC area of contact (sliding velocity of the
driving gear is greater than that of the driven gear). As this area is critical
for unlubricated plastic gears, the AC/AE ratio should be as small as possible in this case.

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6. Summarize variants for vibrations:

The variation in the total contact stiffness is evaluated here (the lower the
variation the better).
The calculation is based on empirical formulae, unless the "Calculate mesh
stiffness" option is set in "Conditions II.
7. Summarize variants for strength:
This summarizes root and flank safety with reference to the required safety. Although safeties of less than the required safety are given a very negative evaluation, large safety margins above the required safety have very
little influence.
8. Transmission error (PPTE)
Transmission error is displayed if the corresponding option is set in "Conditions II".
9. Summary evaluation:
The Summary evaluation weights each component to form a total evaluation coefficient. Set the weighting of individual components in Calculation > Settings > Summary. This weighting depends to a great
extent on which solution you require, for example, whether you want a solution that is optimized for noise reduction or strength.

NOTE

The Rough sizing (on page II-422) section includes a complete list of all the
available parameters. You will find information about noise optimization in [56].

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14.15.5

Graphics

Figure 14.63: Graphics tab in the Fine Sizing window

The Graphics tab in the Fine Sizing window gives you a quick overview of the
number of solutions. It can display three parameters simultaneously. You can
change them in the selection lists. In addition to the two axes, the third parameter is
displayed as a color.

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14.15.6

Geometry-Fine Sizing for 3 gears

Definition of center distances:

14.15.7

Additional strength calculation of all v ariants

The KISSsoft system also calculates the strength (tooth root, flank and scuffing) of
each variant of geometry and displays the data as a list. This option can be used for
cylindrical gear pairs, planetary stages and cylindrical gear stages that have an idler
gear. If you click on the Calculate geometry only checkbox in the
Conditions II tab, the calculation does not include tooth safeties.

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14.16

Measurement grid

A measurement grid report is available for cylindrical and bevel gears

(Calculations > Measurement grid). This report is not available for face gears and
globoid worm gears.

Figure 14.61: Calculating the measurement grid

Setting

Description

Gear

Setting the gear for calculating the measurement grid.

If you select the "All" setting, the measurement grid will be calculated for
every gear.

Measurement
array

Setting the measurement array for the calculation.

0: Tooth flank
1: Root radius

Measurement
machine

Setting the report format using a particular measurement machine

0: Klingelnberg

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1: Gleason
Number of columns

Setting the number of columns across the facewidth (>=3)

Number of columns (number of sections 2) for Parasolid settings, because
the sections
should not include both ends of a tooth.

Number of rows

Setting the number of rows across the tooth profile (>=3)

Distance from
Distance from root form diameter. Default value 0.1* mean normal module.
root form diameter
Distance from
tooth tip

Distance from tooth tip. Default value 0.1* mean normal module.

Distance from
side I/toe

Distance from side I for cylindrical gears, distance from toe for bevel gears.

Distance from
side II/heel

Distance from side II for cylindrical gears, distance from heel for bevel
gears.

Default value is (facewidth)/(number of columns + 1).

Default value is (facewidth)/(number of columns + 1).

The report includes the coordinates and the normal vector of the grid points in the
format [XP YP ZP XN YN ZN]. The reference point and the tooth thickness angle
are displayed in the report header.
The reference coordinates of the data may differ according to which type of
measuring machine is used. For example, the following convention applies to
Klingelnberg machines.

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Figure 14.62: Measurement grid for cylindrical gears and bevel gears for Klingelnberg machines

The sequence of index numbers for points and sections is defined according to
ISO/TR 10064-6. In other words, the index for lines runs from bottom to top, and
the index for columns runs from side II (heel) to side I (toe).

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14.17

Modifications sizing

To call the modification sizing function, click the

icon (tool bar) in the
"Calculation" menu, and then click "Modification sizing".
If you call the optimization process without first opening the "Contact analysis"
tab, the default setting for this tab will be applied.

14.17.1

Conditions I/II

Conditions I
The Conditions I tab is where you define basic modifications that will not be
changed and which are valid for every solution. To automatically adopt
modifications already present in this tab, click the "Import modifications" button.
Select the "Cross-vary value and coefficient 1/2" option to run an additional variation of the coefficients with the modification value.
If the "Without contact analysis, only service life calculation with KHbeta
according to ISO 6336-1, Annex E" option is enabled, the solution range is only
performed using the service life and the calculation of KHbeta.
Every modification can be calculated for a larger partial load area. This can be
specified under "Partial load area for the calculation".
Conditions II
The Conditions II tab is where you define the modifications you want to vary. You
can enter 20 modifications for each gear, each one with a minimum value and a
maximum value. By entering the number of steps per modification you can define
the number of steps between the minimum value and the maximum value. If the
"Synchronize with no." column contains a different value than the line number of
it's own, the modification is synchronized with the modification you selected, and
all the variants are executed with the same number of steps.

14.17.2

Results

All the solutions are displayed as graphics in the "Results" tab. You can then select
the solution that best suits your requirements. Click on Accept or double-click on
the solution to transfer its data to the "Modifications" tab.
In the results overview, you see the following results for all the iteration steps:

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ID: solution ID. You can use this ID to search for more details about the results
in the reports.
Wt: Partial load of the calculated solution in % (depending on the number of
iteration steps specified in the "Number of steps for partial load" field), e.g.
50% partial load with reference to the nominal load defined in the "Basic data"
tab.
Hmin: The minimum service life achieved by the gear pair in hours
PPTE: Amplitude of the transmission error of the driven gear along the path of
contact in [m] or angle of rotation error [] of the driven gear.
rel. PPTE: Relative amplitude of the transmission error/angle of rotation error
in relation to the uncorrected toothing.
a: Transverse contact ratio under load
KHb: Face load factor (if the calculation is performed with load spectra, only
the face load factor of the last load bin is ever displayed)
Hmax: Maximum Hertzian pressure that occurs in the toothing
Slam: Safety against micropitting as specified in ISO TR 15144
: Efficiency
WnA/B: Wear on gear A/B
T: Torque amplitude of the driven gear
Modifications: You can display all the modifications via the Context menu
(click the right-hand mouse button in the Results window).

14.17.3

Graphics

All the solutions are displayed as graphics in the "Graphics" tab. You can display a
maximum of up to 10 graphics at the same time. Each graphic can process its own
data record.
Select the required partial load from the partial load selection list (red is the largest
partial load, blue is the smallest partial load).

14.17.4

Report

The results are documented in three different, detailed reports. We suggest you begin by looking at the summary report which gives a broad overview. The other two
types of report are considerably longer, and also document intermediate results.

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The main calculation performs a series of contact analysis calculations. Each one
has a different combination of modifications with all the intermediate steps, and for
each wt% load level. A contact analysis without modifications is also performed
for each load level to provide a basis for comparison.
A frequently asked question:
How can I use the "Optimize modifications" function to vary the length of the
modification and the relief Ca independently of each other to find out which
combination of length/value gives the best result?
Reply: For example, if you want to vary the tip relief Ca between 100 and 220 mm,
and vary the length factor between 0.78 and 1.56, to determine all the possible
combinations of value - length.

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14.18

Settings

You access the Module specific settings window by opening the

Calculation menu and then clicking on Settings. A huge number of these
settings are available for cylindrical gear calculations. You can therefore enable the
widest variety of possible special functions. Normally there is no need to change
the settings.

14.18.1

General

Figure 14.64: General tab in Module specific settings

14.18.1.1
Input qualit y
The manufacturing allowances that are output in the report and used for particular
factors in the strength calculation procedure are defined either in the DIN 3961,
ISO 1328 or AGMA 2015 standards. You can specify which standard is to be used.
If you click the Calculation method for strength option, the system
applies the standard that is best suited to the strength calculation method (for
example ISO 1328 is used if you are using the ISO 6336 calculation method).

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14.18.1.2 Varying qualit ies

If you select this option, the plus button next to the Quality field in the main screen
appears. You can then use this to input specific tolerances manually.

You will find a more detailed description of this in Qualities (see page II-268).

14.18.1.3 Fp-Tolerance as specified in tables in DIN3962

The total cumulative pitch deviation Fp given in the tables in DIN3962 is, in some
parts, very different from the Fp calculated in accordance with the formulae in
DIN3961.

14.18.1.4 Input normal diametral pitch instead of no rmal module

If you select this option, the Normal module input field in the Basic data or
Geometry input windows is replaced by the Diametral Pitch input field.

14.18.1.5 Input of number o f teeth with decimal places

In KISSsoft, you can perform a calculation with a fractional number for the number
of teeth. We recommend you use this option for arcs of circles or for
nonsymmetrical teeth.

14.18.1.6 Allow l arge profile shift

Use this option to significantly increase the range of profile shifts that can be
performed (- 1.2 x* +1.5). This is very useful for special cases. We recommend
you use it for: cylindrical gears, bevel gears, worms, spiral-toothed gear wheels.

14.18.1.7
Do not cancel if geome try e rro rs occur
If you select this option, the program will continue the calculation even if severe
geometry errors, such as pointed teeth, meshing interference etc. occur. This options enables you to continue the calculation in critical cases, however, you should
then use its results with extreme caution!

14.18.1.8 Retain tip ci rcle when modifying profile shift

In the KISSsoft system, the reference profile is usually retained and the tip circle
and root circle are modified to suit. If you select this option, the tip circle is

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14

retained and the reference profile is modified to match it when the profile shift is
changed. The tip circle value is retained as long as the number of teeth and the
transverse module stay the same.

14.18.1.9 Maintain root ci rcle when changing profile shift

In the KISSsoft system, the reference profile is usually maintained and the tip and
root circle are modified to suit. If you select this option, the root circle is retained
and the reference profile is modified to match it when the profile shift is changed.
The root circle value is retained as long as the number of teeth and the transverse
module stay the same.

14.18.1.10 Use alte rn ative algorit hms fo r the tooth fo rm calc ulation
The tooth form calculation uses a very reliable algorithm for determining the points
on a tooth form. However, in a few special cases this algorithm does not provide a
good solution. In such situations, using an alternative algorithm may help.

14.18.1.11 Coefficie nt fo r minimu m tooth thickness at tip

For manufacturing reasons, a specific minimum tooth thickness at the tooth tip
must always be achieved. The minimum tooth thickness is: Module . Coefficient.
As defined in DIN 3960, the coefficient is usually 0.2.

14.18.1.12 Coefficie nt fo r minimu m tip clearance

The tip clearance is the distance between one gear's tip circle and the root circle of
the other gear in the pair. You can specify a minimum tip clearance. If this
clearance (taking into account the tip circle and root circle allowances) is not
reached, the system displays a warning message.

14.18.2

Plastic

Figure 14.65: Plastic tab in Module-specific settings

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14.18.2.1

Allow simpli fied calculation in accordance with DIN

3990/ISO 6336
If you select this option, you can use the calculation methods for steel gears to
calculate plastic gears. This calculation is performed in accordance with the
endurance limit values listed in the materials database. The values for the plastics
given in this database apply for oil lubrication, a temperature of 70o and a number
of load cycles of 108. In contrast to the calculation in accordance with VDI 2545,
the strength values do not depend on the temperature and lubrication type.

The calculation is performed in the same way as for heat treatable steel, with the
corresponding Woehler line as defined in ISO 6336.

14.18.2.2 Calculation o f flank safety

Flank safety for plastic gears is calculated as specified in VDI 2545 (in a similar
way to the calculation for steel gears). In other words, flank safety is defined using
Hertzian pressure with the permitted material value for pressure Hlim. However,
measurements taken from plastic gears have often shown that their tooth flanks
wear in a similar way to the tooth flanks in worm gears. The KISSsoft system also
provides the calculation of safety against wear as an alternative. Flank safety is
calculated using Hlim if the material database (or the material file with extended
data in that database) includes data for Hlim.
Safety against wear is calculated if wear data is present in the material database. If
data for both calculations is present, the system performs both calculations. If only
data for one calculation is present, the corresponding safety is displayed
automatically.

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14.18.2.3 Permi ssib le maximum wear o f tooth thickness

When you calculate wear safety (see page II-449) you must specify a permitted
wear threshold value. A usual value for plastic is 15% (tooth thickness wear in the
reference circle). If no, or only very little, wear can be tolerated, we recommend
you input a value between 5 and 10%.

Figure 14: Calculations tab in Module-specific settings

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14.18.3

Planets

Figure 14.66: Planets tab in Module specific settings

14.18.3.1 Check if mounting of planets is possible

Planets are usually arranged with a constant pitch on the planet carrier (if 3 planets
are involved, they will each be at 120 degrees etc.). In these situations, the number
of teeth must fulfill certain conditions to ensure the planets can be mounted
correctly. The KISSsoft performs these calculations when you click this checkbox.

14.18.3.2 Minimum d istance bet ween 2 planets

You can specify a minimum distance between the tip circles of two planets in this
input field. If this minimum distance is not reached, the system displays a warning
message.

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14.18.4

Sizings

Figure 14.67: Sizings tab in Module specific settings

14.18.4.1 Required tran sve rse co ntact ratio

You can specify the required transverse contact ratio for sizing deep tooth forms
(see page II-654).

14.18.4.2 Ratio facewidth to normal m odule

The facewidth to normal module ratio is a characteristic value used to achieve
reasonable dimensions for gear stages. If very narrow gears are involved, the axial
stiffness of the teeth cannot be guaranteed, for this reason, b/mn should be greater
than 6 (see Niemann, Table 22.1/7 [65]).

If the gears are too wide, it is essential that the load is spread evenly across the
entire facewidth, depending on the gear type and accuracy grade, b/mn should
therefore be less than 15..40 (see Niemann, Table 22.1/10 [65]).

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14.18.4.3 Ratio facewidth to re fe rence circle, gear 1

The facewidth to normal module ratio is a characteristic value used to achieve
reasonable dimensions for gear stages. Depending on what type of heat treatment is
involved, this ratio should be less than 0.8 to 1.6 (see Niemann, Table 22.1/5 [65]).

14.18.4.4 Ratio facewidth to center dist ance

The facewidth to center distance ratio is a characteristic value used to design standard gear units of modular construction. Depending on the stiffness of the housing,
this value should be smaller than 0.3 to 0.5 (see Niemann, Table 22.1/6 [65]).

14.18.4.5 Sizing of gear geometry

The coefficients for tip clearance and active diameter/form diameter difference (also known as "shape interference") are settings that are needed for the functions
used to size the reference profile, in the "Reference profile" tab and in fine sizing.
For example, you may need to adjust the reference profile there to achieve an exact
shape interference and to ensure that the minimum tip clearance is also exceeded.

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14.18.5

Calculations

Figure 14.68: Calculations tab in Module-specific settings

14.18.5.1 Calculate fo rm diamet er from tooth fo rm

The tooth form calculation simulates the manufacturing process. In doing so it
calculates the effective undercut in the tooth root. Use the Calculate form
diameter from tooth form option to calculate the tooth form in every
calculation run, define any undercut that is present and include it in the calculation.
This is then used to calculate the transverse contact ratio and the root and tip form
circles (generated diameters). If this option is not set, the root and active tip diameter are defined with the usual method for involutes without taking undercut into
account. See, for example, DIN 3960. The warning that undercut may occur is also
only derived from DIN 3960 formulae.

You can select whether the root form diameter, the tip form circle, or both these
values, are to be deduced from the tooth form. Up to now, the form diameter for
racks is not taken from the tooth form.

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14

NOTE:

If this option is selected, and profile modifications have been predefined, the
calculated form diameter will be at the beginning of the modification. This often
results in very small transverse contact ratios .i and .e. This is correct because,
at the start of the modification, the tooth form no longer exactly matches the
involute. However, the message that appears to inform the user that the transverse
contact ratio is too low is rather confusing. If the profile modification has been
sized correctly so that meshing under load involves a whole tooth depth, this message can be ignored. This is because the transverse contact ratio under load
corresponds to the theoretical transverse contact ratio . Generally speaking, we
recommend you do NOT use this option for profile modifications.

14.18.5.2 Calculation u sing you r own Woehler line

The Woehler line of metallic materials is usually defined by the endurance limit
values sigFlim, sigHlim, entered in the database, and the finite life calculation values YNT (root) and ZNT (flank) in accordance with ISO, AGMA or DIN. If this option is active and you input your own Woehler lines for material, the strength
calculation is performed using your Woehler line.

If you use your own Woehler lines to calculate plastics, the Calculation
with own Woehler line flag has no effect.

Notes about calculation methods using your own Woehler lines:

Here you can use the calculation methods specified in ISO and DIN for metallic materials
The Woehler curves are stored in a file (see under: Database). The sustainable
stress (sigFadm for root and/or sigHadm for flank) of the material is defined in
accordance with the number of cycles NL.
The endurance limit values sigFlim and sigHlim, that are input directly in the
database, are also required for documentation purposes and should be detailed
in an appropriate interrelationship with the Woehler line data. We recommend
you use the value of sigFadm/sigHadm if NL=10^7 for sigFlim/sigHlim.
The service life factor, factor YNT and ZNT is defined and reported as follows:
YNT = sigFadm / sigFlim, ZNT = sigHadm / sigHlim
The other factors which influence the permitted material value, such as Ydrel,
YRreIT, YX, ZL, ZV, ZR and ZW, are calculated and used in accordance with
the selected calculation method (ISO or DIN). For this reason, the selected

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14

permitted material value sigFG or sigHG is not exactly equal to the value sigFadm/sigHadm from the Woehler line.

14.18.5.3

Calculation wit h operating center distance an d profile

shi ft according to man ufacture
Cylindrical gear geometry in accordance with DIN 3960 is based on the calculation
of the toothing (which is theoretically without clearance). This allows the total profile shifts for the individual gears over the center distance to be specified.

Using this option you can enter the profile shifts independently of the center distance. This is very useful as it provides a way to check the limits of a toothing
(clearance, contact ratio etc.) if there are major variations in the center distance
(e.g. in the case of center distance tolerance zones).

14.18.5.4 Calculate moment of in ertia from tooth fo rm

The toothing moment of inertia is calculated exactly from the tooth form in the tip
to root diameter range. To achieve this, the KISSsoft tooth form calculation is run
automatically for each calculation and defines the effective tooth form by the
numerical integration of the moment of inertia. The result is output in the
calculation report. The calculation is also performed in fine sizing and the results
documented.

14.18.5.5 Calculating the displac ement volume of gear pumps

This option calculates the transport volume without taking the return volume into
consideration. If you activate this option, the tooth spaces are integrated
numerically to calculate the transport volume and the result is output in the report.
In Fine sizing, the transport volume of each variant is also calculated and output.
This enables you to identify, for example, the variant with the largest displacement
volume.

14.18.5.6 Calculating the displac ement volume of gear pumps

According to ISO 6336 (or DIN 3990), the Hertzian pressure at the single contact
point B is only monitored for the driving gear, and in D the pressure is only
monitored for the driven gear. This option can be used to check both gears at points
B or D, depending on which one is subject to the greater Hertzian pressure.

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14.18.5.7 Take into account user specific addition s

If KISSsoft AG has added customer specific upgrades to the software, you can select them and view them here.

14.18.5.8 Calculate lub rication factor with oil temperat ure

Unlike in ISO 6336 and DIN 3990, where the calculation is always performed with
an oil viscosity of J= 40oC, when you click this checkbox the lubrication
coefficient is calculated with oil viscosity at operating temperature. If this option is
selected, the material pairing factor ZW is also calculated with the viscosity present
at operating temperature.

14.18.5.9

Strength calculation u sing mean posit ion in t olerance

field (of tooth fo rm)
By default, values for the theoretical toothing (without allowances) are referenced
for calculation. When you enable this checkbox, KISSsoft performs the calculation
with the average allowances for the center distance, root circle and tooth thickness.
This option is suitable for use where large tolerances are present.

This option has no influence on calculations performed in accordance with AGMA.

14.18.5.10 Take protuberance into account

If the angle difference (protuberance, or buckling root flank) to the pressure angle
is greater than the maximum difference defined here, its influence on the tip and
root form diameters as well as the transverse contact ratio are taken into account.
The contact ratio then reduces accordingly.

14.18.5.11 Power-on time

The system also takes into account the power-on time when calculating the number
of load cycles (multiplied by the service life).

The power-on time is also taken into account for plastic toothed gears when
calculating the flank and root temperature. For worm gear units this time is also
included when calculating the thermal safety.

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14.18.5.12 Safety factor fo r the calculation o f the she ar stress at EHT

The safety factor is multiplied by the shear stress which is then used to calculate
the hardness. The hardening depth is then defined using this value.

14.18.5.13 VDI 2737: Calculat io n of gear rim

The strength calculation of internal teeth is not very accurate. A significant
improvement is needed. Gear rims are often subject to stresses that can affect their
load capacity. At present, VDI 2737 is the only guideline that includes gear rim
stress and the influences associated with this. The calculation is performed in two
steps

1. Tooth root fracture safety (static and endurance) without taking the gear
rim influence into account.
2. Tooth root fracture safety with gear rim influence. In this case, the maximum shear stress in the tooth root outside the meshing can in some conditions be greater than the actual bending stress in the tooth that is under load.
The notch factor Y S, as in ISO 6336:2006, is defined as the place at which the
tangents on the flank and the tooth center line form an angle of 60o.
The results of the calculation specified in VDI 2737 are detailed in their own
section in the normal report.
Coefficient for maximum load (VDI 2737)
To calculate static safety in accordance with VDI 2737, input a maximum load factor that is then multiplied with the nominal torque. To calculate the endurance limit, the nominal torque is, as usual, multiplied with the application factor KA.

14.18.5.14 Calculation o f siz e coefficients for small gears

Calculation of size coefficients for small gears similar to that stated in FVA report
410:

If mn < 1, the size coefficients (according to DIN or ISO) are ZX and YX > 1.
NOTE

If you use this method, you may need to adjust the required safeties that have been
used up to now. This is because much higher computational safeties are produced.

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14.18.6

Required safeties

Figure 14.69: Required Safeties tab in the Module-specific Settings

window

Required safeties must be predefined not only for every service life calculation but
also for rough and fine sizing.
Safeties are not depending on size
Experience has shown that much lower minimum safeties can be used for smaller
modules. Although the standards do not provide any information about this, this
knowledge is based on experience with many different applications. However, if
you do not require size-dependent safeties, you can still select the "Safeties are not
depending on size" variant.
Minimum safety for calculation in accordance with AGMA
In the tooth strength calculation in accordance with AGMA 2001, the permitted
tooth bending stress sat is a factor of 2 smaller than that in ISO 6336. Although its
meaning is similar, the corresponding sat value in the ISO guideline must be
multiplied by a coefficient of 2, the reference gear's stress correction factor Yst.
Therefore, if the tooth strength is calculated in accordance with AGMA 2001, the
resulting safety is approximately 50% smaller than that in the calculation using ISO

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6336. As a consequence, the safety required for the calculation according to

AGMA 2001 is smaller.
Service coefficient
Some applications of the AGMA calculation method require a predefined service
coefficient. In actual fact this is merely a minimum safety. For this reason, if
required, you can input Service coefficient CSF for flank strength and KSF for tooth
bending strength.

14.18.7

Contact analysis/Face load factor

14.18.7.1
Contact Anal ysis
Unit of transmission error: Here you can select either the length on the length of
path of contact (transmission error) or the angle on the gear (angle of rotation error).

Calculation method contact stiffness: Here you can select either the calculation
method defined by Weber/Banaschek [69] (dynamic stiffness analysis: default setting), the method defined in ISO 6336-1 Method B and Own Input.
Single contact stiffness: If "Own Entry" has been selected as the contact stiffness
calculation method you can enter your own value for the single intervention
stiffness.
Slices Linking factor: Linking factor used to link the individual slices of the
discretized toothing model.
Border weakening factor: Border weakening factor for a weakening of stiffness
on the edge of helical gear teeth.
Stiffness correction factor (according to Winter): Correction factor for Hertzian
flattening as described in the experiments performed by Winter/Podlesnik [95].
Draw data for path of contact: If this option is enabled, the results of contact analysis are displayed quadratically in the 3D diagrams. This makes the data suitable
for export as a matrix.

14.18.7.2 Face load facto r

Iterating the load distribution of the meshings: Only affects planetary stages: If
shaft data is used to define the axis alignment, a constant load distribution over the
facewidth is initially assumed in the shaft calculation, when the bending is
calculated. This is a satisfactory approximation if the load distribution is fairly well

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14

distributed, and the face load factor is therefore not greater than 1.3 (maximum
1.5). If the load distribution is less satisfactory, the load distribution value should
be transferred into the shaft calculation, from the gear calculation, and the next
calculation of bending should be performed with the modified (not linear) load distribution. This produces a more accurate, modified load distribution. This iterative
determination of the load distribution across all the meshings is then performed
until the load distribution stops changing in all the meshings. Be aware that this
option only shows an effect if at least one of the deformation components is linked
with the shaft calculation.
Tooth contact stiffness: This defines whether the tooth contact stiffness is
calculated according to ISO 6226 (C) (default) or whether, as specified in AGMA
927-01, it is constant with Cm = 11 N/mm/m.
Axis alignment if load spectrum is applied: Here you can set the inclination and
deviation errors of the axis (f, f) as a proportion of the partial load wt of the
current load bin, or set them as a constant.
Note: The calculation of KH does not include triangular end relief and twist.
Calculating the torsion moment of resistance: If the calculation of torsion due to
deformation in the "Define axis alignment" dialog is set to "Own Input" the diameter specified here is used in the calculation.

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14

14.18.8

Summary

Figure 14.70: Summary tab in the Module specific settings window

Weighting the individual component to evaluate the Summary coefficients in Fine

Sizing. (see section "Results" on page II-436)

14.18.9

Diagrams

14.18.9.1 Value s on the x -axis o f diagram s

You can select different values for the x-axis from a drop-down list.

Here you can select the rolling angle, the length (path of contact), the diameter of
gear A and the angle of rotation.
You can also decide whether the X-axis (path of contact) and Y-axis (facewidth)
are to appear as scales in the 3D diagrams or not at all.
NOTE

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If you select the angle of rotation for the x-axis the gear axis is 0.

14.18.9.2 Helix angle mod i ficatio n, parallel

The entry concerns the display in the tooth trace diagram. If you select
"Manufacture with modified helix angle eff", the helix angle modification is
included in helix angle , and the base tangent length and measurement over pins
are defined with the modified angle eff.

14.18.10 Generation of 3D model

This is where you modify the parameters used to generate 3D models.
Under "Model", specify the type of model to be generated (volume model,
skin model, cutting model). The volume model can be used for other purposes
such as machining by CNC or finite element analysis. The skin model is most
suitable for contact analysis. The cutting model is only suitable for the gear
models that use cutting simulation, such as face gear and enveloping worm
gear, and is used to view the actual cutting simulation.

The Number of cutting steps sets the number of cuts per half pitch for the
cutting process. The minimum value is 1, and the default value is 20. The quality of the final model can be increased by increasing the number of steps, but
this also increases the probability of manufacturing errors. The "Scale factor" is
used for solving the failure problem. If the operation fails, we recommend that
you use a lower number of generation steps with a larger scale factor.
The Number of sections along facewidth defines the number of sections
along the facewidth for approximating the tooth flank form. The minimum value is 2, and the default value is 11. Normally, the quality of the final model
can be improved by increasing this value, but we do not recommend that you
set a number that is excessively high, compared with the facewidth. The factor
is used for the gear models using cutting simulation and gear models using

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multiple section curves such as spiral bevel gear and cylindrical gear with lead
modification.
The Scaling factor for the cutting model is used to zoom the model during
the cutting simulation process. The minimum value is 1, and the default value
is 10. Sometimes the cutting simulation can fail due to an internal operation error in the Parasolid kernel, especially when the model has a very small module
and/or a large number of generation steps. In order to prevent this type of operating error, use the model zoomed by the scale factor in the cutting process.
Consequently the cutting model can have different dimensions than the actual
design. However, the volume and skin models are automatically zoomed back
after the operation and therefore have the same dimensions as the entered gear.
The Modeling operation sets the tolerance for the internal operations of the
Parasolid kernel, such as the chordal approximation and clash detection in Boolean operations. The default value is 1 m.
The Rendering quality sets the resolution of the resulting graphics in the 3D
geometry viewer. This is used only to improve the viewer display (usability)
and does not affect the quality of the generated model. If the rotation operation
in the viewer is slow, you can increase the quality value to speed up the operation. The default value is 5 m.
Click on "Constant root radius along the facewidth" to specify the method
used to generate the root radius of a bevel gear. The root radius of the bevel
gear changes by the factor of the normal module along the facewidth. If you
activate this flag, we use the constant root radius defined by the normal module
in the middle section. (Available for bevel gear)
Click on "Constant protuberance along the facewidth" to define the protuberance of the bevel gear's reference profile. The protuberance of the reference
profile of the bevel gear changes by the factor of the normal module along the
facewidth. If you activate this flag, we use constant protuberance defined by
the normal module in the middle section. (Available for bevel gear)
If "Display 2D geometry for outside and inside" is selected, the tooth forms
on the internal and external sides are represented as a 2D graphic. (Available
for bevel gear)
If "Generate tooth system model in the saved position" is selected, the system model is generated at the position you saved. This position is saved in the
calculation file, and you will be able to restore the checking position of the
contact pattern in future. (Available for bevel gear)
Click on "Number of points on the edge of cut for spline approximation" to
specify the number of modeling (intermediate) points on each edge that are
used to approximate the spline curves for the root area or the tooth flank. The

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figure shows a diagram in which the points that are to be used are scanned. The
end points (nodes) are removed since they are giving extreme waviness on the
curve. We use only the intermediate points on the cutting edge supposing the
parametric distance between the points is the same. We usually recommend
that more points are used in the root area. However, this model will help the
user determine the optimum value. (Available for enveloping worm gear)
Click on "Oversize factor for worm wheel cutter" to define the coefficient
used to increase the worm wheel cutter. There are different methods of implementing the oversize hob. Those methods include the axial pitch method, the
base pitch method, the extra thread method, and the normal pitch design method. KISSsoft is using the normal pitch method since the method is practically
regarded as the industry standard. These methods are based on the principle,
that the worm wheel cutter uses the same normal pitch and the same normal
pressure angle in the normal section as the worm. The cutting distance between
the hob and the gear will then be changed accordingly, to ensure a consistent
result for the root and tip diameters on the gear. If you are using the oversize
factor, the generated surface will not be conjugate with the worm surface and
will not give the best contact pattern. Thus, especially if you are not using conventional cutting method but want to use theoretical surface geometry, you
should not use the oversize factor. In practical case, the tooth thickness of the
cutter will be increased to consider the tooth thickness tolerance of the worm
wheel. In that case, its recommended to use small oversize factor compensating the tolerance to get the best contact. (Available for enveloping worm gear)
Click on "Cutter shaft angle change" to modify the shaft angle of the worm
wheel cutter during the simulated milling run. The angle can be both positive
and negative, and the positive angle is defined as shown below. (Available for
enveloping worm gear)
Click on "Change in pressure angle of the worm wheel cutter in normal
section" to set the worm wheel cutter to a different pressure angle than the
worm. (Available for enveloping worm gear)
Click on "Flank shape of worm wheel cutter" to set a different tooth form for
the worm wheel cutter than for the worm. There are many research works justifying the different combinations of the tooth form to get better contact pattern
in worm gearing. This setting is used for this purpose. If this option is not selected, the same tooth form is used for both the worm wheel cutter and the
worm. (Available for enveloping worm gear)

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14.19

Tooth thickness

Figure 14.71: Chordal tooth thicknesses dialog window

Click the Calculation > Tooth thickness menu item to calculate the
normal tooth thickness and the normal space width for any diameter.
The tooth thickness is output as an arc length and as a chordal length. To help
measure the tooth thickness, the chordal height is output along with the tooth
thickness allowances.

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15

Bevel and Hypoid ge ars

Chapter 15
Bevel and Hypoid gears
Calculation of the geometry and strength of straight, helical and spiral toothed
bevel gears (gear axes intersect, offset (center distance) is 0) and hypoid gears
(crossed gear axes, offset (center distance) not 0). Geometry as specified in
ISO10300, ISO23509 and DIN3971, tolerances in accordance with ISO17485 and
DIN 3975, strength calculation as specified in ISO10300 (replacement cylindrical
gear toothing method), AGMA 2003, DIN 3991, or Klingelnberg in-house standard
KN3030. The calculation only includes the geometry of bevel gears insofar as is
necessary for the Strength calculation (see section "Methods used for strength
calculation" on page II-489), no matter which manufacturing process is used.

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15.1

Underlying principles of calculation

15.1.1

General

The geometry of bevel gears is calculated in accordance with ISO10300, ISO23509

or DIN 3971. The strength calculation is performed in two steps. A virtual
cylindrical gear toothing is defined first. This is then used for the strength
calculation in a similar way to cylindrical gears. The process is described in [24],
[45] and [66].
Bevel gear machine tool manufacturers (such as Klingelnberg in Germany) also
have their own methods that differ slightly from the processes mentioned above.
Hypoid bevel gears and bevel gears with offset (center distance) are primarily used
in vehicle axle drives. Strength is calculated by defining a virtual cylindrical gear
toothing. The tooth root, flank and scuffing safeties, which are important for
hypoid gears, are calculated as specified in the Klingelnberg in-house standard
KN3030.

15.1.2

Overview of the bevel gear manufacturing pr ocess and the terminology used in it

Various manufacturing processes are used to create bevel gears. Unlike cylindrical
gears, the tooth length forms and tooth depth forms differ according to which manufacturing process is used. In particular, the process used to manufacture spiral
teeth bevel gears uses a multitude of terms, the most important of which are
described below.
The most important differences are shown in the tooth length form, which can be
manufactured as arc of circle (face milling process), epicycloid or involute
toothings (face hobbing process). Arc of circle teeth were developed by the company Gleason and are the result of the face milling principle. Here, every gap is
milled separately and then the gear is rotated further by the width of that tooth space. Epicycloid toothing is used by Oerlikon and Klingelnberg. In this process the
gear rotates constantly during the milling process. Only the palloid manufacturing
process is used to create the involute tooth length form. Although nowadays,
Klingelnberg and Gleason, the market leaders in machine manufacturing, can
produce toothing using both the face milling and face hobbing processes, these
companies are still associated with their traditional processes in the technical
literature You will find more details in section 15.1.3 and 15.2.1.
Although alternative processes for spur gears are available, they are not listed here.

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15.1.3

Calculation according to Klingelnberg, Gleason

and Oerlikon

The strength calculation defined in ISO 10300 DIN 3991 only includes the
relationships (module, helix angle) in the middle of the facewidth in the
replacement cylindrical gear toothing method calculation. The shape of the bevel
and the process used to manufacture it are ignored. As a result, the KISSsoft
strength calculation method can be applied no matter which process is being used,
especially for Klingelnberg and Gleason This also reflects the experience that the
capacity of spiral bevel gears is only slightly affected by the manufacturing process.
The geometry calculation procedure in KISSsoft defines the dimensions, such as
diameter and tooth thickness, in the middle of the facewidth. It also calculates the
diameter at the outside and inside end of the facewidth. These dimensions depend
on the shape of the bevel. However, the results may differ from the actual
conditions because the processes are not described in sufficient detail. This is
particularly true for the Gleason procedure.
Klingelnberg procedure:
The Bevel gear (KN3028 and KN3030) and Hypoid gears
(KN3029 and KN3030) calculation methods enable to you calculate geometry and strength and check the manufacturing process in accordance with the
Klingelnberg in-house standard. However, these methods do not calculate the
machine settings for the selected Klingelnberg machine. When you input formula data from a Klingelnberg program, you must remember that the toothing
data, such as module and helix angle, always applies to the middle of the facewidth (unless otherwise specified).
Gleason process:
Bevel gears are often designed by the Gleason company. Depending on which
calculation program Gleason uses, toothing data such as the module and helix
angle, is either predefined for the outside end of the facewidth or for the middle
of the facewidth.
The Conversion from GLEASON data sheets dialog window allows
you to convert Gleason data from the outside end of the facewidth into data for
the middle of the facewidth (see page II-482). Once this data has been converted, you can perform the strength calculation. Although the bevel dimensions
(tip and root diameter) do not always exactly match the actual geometry they
are close enough to enable you to check the assembly conditions (in a drive).
This procedure does not check to see whether the part can be manufactured on
Gleason machines.
Oerlikon process:
The Oerlikon process is broadly similar to the Klingelnberg process (select
Klingelnberg bevel type).

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15.2

Basic data

Figure 15.1: Basic data input window

15.2.1

Normal module (middle)

The reference circle of the external end of the bevel of Gear 2 (de2) is usually
specified for bevel and hypoid gears. In the basic "Oerlikon" type the reference
circle of Gear 2 is predefined in the middle (dm2). Alternatively, you can specify
the normal module in the middle of the facewidth. However, if you know the pitch,
the transverse module, or the diametral pitch, instead of the normal module, click
the
button to open a dialog window in which the conversion will be performed.
If you want to transfer the diametral pitch instead of the normal module, you can
select Input normal diametral pitch instead of normal module under Calculation > Settings > General.

15.2.2

Reference diameter gear 2

If there are changes to the sizes of the set of bevel gears, click the button to enter
the new outer reference diameter of Gear 2. This is useful for designers since, very
often, the amount of space available for installing the larger gear is predefined. The
module is then recalculated (not optional).

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15.2.3

Pressure angle at normal section

For standard toothings the pressure angle is n = 20o. You can use smaller pressure
angles for a larger number of teeth to achieve higher contact ratios. Greater
pressure angles increase the strength and allow a smaller number of teeth to be
used without undercut. In this situation, the contact ratio decreases.
For hypoid gears, click the
button to input the pressure angle for the driving
flank and the driven flank independently of each other. The driving flank is the
concave flank of the pinion and the convex flank of the gear. The driven flank is
the convex flank of the pinion and the concave flank of the gear.

15.2.4

Pressure angle driving/driven flank: Hypoid

gears

Bevel gears are usually better able to withstand stress when driven by the concave
pinion flank, i.e. when the spiral on the pinion and its sense of rotation run in the
same direction.
The concave flank of the pinion is usually called the driving flank (index D for
"Drive"), and the convex flank is known as the driven flank (index C for "Coast").
In the gear, the concave flank is the driven flank (index C) and the convex flank is
the driving flank (index D). Since the effective nominal pressure angle on the
driving flank is greater by the amount of the edge pressure angle, and on the driven
flank it is smaller than the pressure angle in a normal section, by the amount of the
edge pressure angle, the nominal pressure angle driving flank and driven flank can
be entered independently.
For hypoid gears, as specified in ISO 23509, you should input the nominal design
pressure angle as dD, dC. This is used to calculate the generated pressure angle
("effective pressure angle") nD, nC and the effective pressure angle eD, eC
respectively for the driving (index D for "Drive") and driven side (index C for
"Coast").

The equations specified in ISO23509 are:

nD = dD + flim * lim
eD = nD - lim
If, as a result nD has been specified, dD can be calculated as follows:
dD = nD - flim * lim
dC = nC + flim * lim

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or if eD has been specified, dD can be calculated like this:

dD = eD + lim * (1- flim)
dC = eC - lim * (1- flim)
The boundary pressure angle lim is calculated by KISSsoft and output in the report.

The influencing factor of the boundary pressure angle flim has been introduced so
that you do not always need to take the total value of the boundary pressure angle
into consideration when calculating the flank angle on the tool. For forming tools
(Klingelnberg process), flim = 0 is set. If you use the procedure with a constant
slot width (Gleason) flim = 0.5 is set, otherwise flim = 1.0 is often used.
However, if precise data is not available, you can use the pressure angle in the
normal section in the calculation (with dD = dC = n and flim = 1.0).
NOTE

These input fields are only available if you are calculating the strength of hypoid
bevel gears (see section "Methods used for strength calculation" on page II-489).

15.2.5

Helix angle

The helix angle is transferred in the middle of the facewidth. In the case of helical
bevel gears, the angle remains constant across the facewidth. However, in spiral
bevel gears the spiral angle changes across the facewidth. As the same input screen
is used for both straight flank and spiral toothed bevel gears the term "helix angle"
can be selected for both types selected.
In hypoid gears, the spiral angle is specified in the middle of the facewidth for Gear
2. This value is then used to calculate the value for Gear 1 (pinion).
You can select any value as the helix angle in the middle of the facewidth.
However, we recommend you use a larger angle of between 30 and 45 to ensure
optimum running performance. You should only select a value that is less than this
guide value if the bearing load has to be reduced.

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Figure 15.4: Helix angle

Click the
button to the right of the helix angle input field to open the Additional data for spiral teeth window where you can input the internal
and external helix angle for spiral bevel gears. Click the with spiral teeth
checkbox to enable the input fields.

NOTE

In most cases, however, the internal and external spiral angle is calculated by the
selected process, either arc of circle or continual toothing, and the cutter tip size
[ISO 23509].
If no data has been input for the cutter tip you can usually input an external helix
angle that is approximately 5 larger and an internal helix angle that is
approximately 5 smaller than the helix angle in the middle for Gleason bevel
gears.

15.2.6

Shaft angle

The shaft angle for bevel gears is usually 90. However, you can perform the
calculation for any shaft angle.

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15.2.7

Offset (Center dist.)

In the case of bevel gears without offset (center distance) the axes of the bevel
gears intersect at one point. In the case of bevel gears with offset (center distance)
the axes do not intersect. This application allows you to achieve a higher contact
ratio and greater strength at the tooth root. It is primarily used in the vehicle
construction industry. This pairing is known as a hypoid bevel gear and is
illustrated in Figure 15.5.
NOTE

A positive offset (center distance) is almost always applied to hypoid bevel gears,
because this is the only way of achieving the improvements to the characteristics
described above.

Figure 15.5: Hypoid bevel gear configurations. Positive offset (center distance) (a > 0): Gear 1
left-hand spiral, Gear 2 right-hand spiral. Negative offset (center distance) (a < 0): Gear 1 righthand spiral, Gear 2 left-hand spiral

15.2.8

Number of teeth

You will find reference values for bevel gears with a shaft angle of 90 degrees in
Table 15.1.

1.25

2.5

z1

18 to
40

17 to
36

15 to
30

13 to
26

12 to
23

10 to
18

8 to 14 7 to 11

Table 15.1: Recommended pairing transmission ratio u - number of teeth, pinion z1 in accordance with Niemann [66]

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15.2.9

Facewidth

The facewidth should not usually be larger than the one given in the
recommendations (ratio to cone length, module ratio (see page II-500)). The contact pattern deteriorates if the facewidth is too great.

15.2.10

Profile shift coefficient

You will find reference values for the profile shift coefficient for bevel gears with a
shaft angle of 90 degrees in Table 15.2.

1.12

1.25

1.6

2.5

x*

0.00

0.10

0.19

0.27

0.33

0.38

0.40

0.43

0.44

0.45

Table 15.2: In accordance with Niemann, 24/4 [66], recommended pairings for transmission
ratio u- profile shift coefficient x*

Click on the
button to the right of the profile shift coefficient input field to display the minimum profile shift coefficient for the pinion required to prevent
undercut as well as the recommended value according to Niemann [66].

NOTE

The ISO 23509 standard defines two different data types that can be used to
describe tooth height factors and profile shift. The formulae used to convert data
between these two data types are listed in ISO 23509, chapter 7. The Gleason
calculation sheets also give partial descriptions of factors K and C1. Although these are very similar to data type II, there are slight differences. Click the
to convert data type II data.

15.2.11

button

Thickness modification coefficient

You will find reference values for bevel gears with a shaft angle of 90 degrees in
Table 15.3.

U 1

1.12

1.25

1.6

2.5

xs 0.00

0,010

0,018

0,024

0,030

0,039

0,048

0,065

0,082

0,100

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Table 15.3: Recommended pairing transmission ratio u - tooth thickness modification factor xs
in accordance with Niemann [66]
NOTE

If you are using standard cutters, such as those used for a Klingelnberg palloid or
cyclo-palloid gear, you must use the thickness modification coefficient specified
in the standard.

15.2.12

Quality

In this input field, you specify the accuracy grade in accordance with the standard
shown in brackets. To change the standard used for this calculation, select
Calculation> Settings > General > Input of quality. The
accuracy grade defined in ISO17485 is very similar to that specified in DIN 3965.
You will find notes about the toothing quality in the Manufacturing process (see
page II-481).

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15.2.13

Addendum angle and root angle

All the necessary data required to create the bevel gear drawing can be calculated
from the addendum angle and dedendum angle. These are the tip and active root
diameter on the outside and inside bevel, and the tooth thickness on the outside and
inside cone diameter (see Figure 15.6). The values shown here are output in the
main report. In the case of bevel gears with spiral teeth, the addendum angle and
dedendum angle are calculated using the selected method [ISO 23509, DIN3971].
In the case of bevel gear type 2 (Gleason), you can input the addendum angle. The
root cone of the counter gear is then calculated from this value.

Figure 15.6: Dimensioning a bevel gear

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Figure 15.7: Dimensioning a bevel gear in accordance with Klingelnberg

15.2.14

Angle modifications

In some less than ideal situations it may happen that the cutter tip cuts into any
shaft pins that are located immediately next to the toothing. If this cannot be
prevented by modifying either the design or the toothing data, the cutter tip level at
the calculation point at dm of the gear and pinion can be tilted by a slight angle c
from its intended position o1,2 towards the reference cone angle E1,2. See Figure
15.7.

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15.2.15

Geometry details

Figure 15.8: Define details of geometry dialog window

Click the Details... button in the upper right-hand part of the Geometry group
to open the Define details of geometry dialog window. You can enter
these parameters here.
The following parameters are not described here:
- Inside diameter (see page II-271)

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15.2.15.1

Refe rence cone apexes on the outside/inside of the u nworked part

The reference cone apex on the inside of the blank part is the distance in axial
direction of the reference cone apex to the front face of the blank part.

The reference cone apex on the outside of the blank part is the distance in axial
direction of the reference cone apex to the rear face of the blank part.

15.2.16

Manufacturing process

Tab. 15.10 shows the interrelationship between the manufacturing process and the
achievable accuracy grade.
Process

Achievable accuracy grade

(ISO 17485, DIN 3965)

Milling only

Lapping

Skiving

Grinding

Table 15.10: Interrelationship between manufacturing process and achievable accuracy grade

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15.3

Type

You will find a drop-down list for the type on the top left of the screen in the
Geometry tab.
As you can see in Figure 15.2 the following bevel gear types are available for selection:

Figure 15.2: Basic types of bevel gears

Standard, Figure 1 (tip, reference and root cone apex in one point)
The geometry is calculated in accordance with ISO 23509. No offset (center
distance) is taken into account. If you click the sizing button, the cone angle is
calculated so that the crossing point of the gear axes meet each other (similar to
the standard specified in ISO 23509, Annex C.5.2). In this case, the tip clearance is not constant. Typical applications include form-forged, injection molded,
or sintered, bevel gears, such as differential bevel gears.
Standard, Figure 4 (reference and root apex in one point)
The geometry is calculated in accordance with ISO 23509. No offset (center
distance) is taken into account. If you click the sizing button, the cone angle is

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15

calculated as specified in the standard (ISO23509, Annex C.5.2). The tip clearance is constant.
Standard, Figure 2 (tip, reference and root cone apex NOT in one point)
The geometry is calculated in accordance with ISO 23509. No offset (center
distance) is taken into account. If you click the sizing button, the cone angle is
calculated as specified in the standard (ISO 23509, Annex C.5.2). However
you can also input values for the addendum angle and the dedendum angle manually. The cone angle of the counter gear is calculated by taking a constant tip
clearance into account.
Constant slot width, Figure 2 (Gleason)
The geometry is calculated in accordance with ISO 23509. You can perform
this calculation either with offset (method 1, hypoid gears) or without offset
(method 0, spiral bevel gears). If you click the sizing button, the cone angle is
calculated with a "constant slot width" (ISO 23509, Annex C.5.2). The tip clearance is constant. Gap 2 in Figure 5 does not change. A typical application of
this is a ground bevel gear toothing in the Completing process (duplex), where
the pinion and the bevel gear are each ground in one work step. This process
requires machines that have an additional helical motion.
Modified slot width, Figure 2 (Gleason)
The geometry is calculated in accordance with ISO 23509. You can perform
this calculation either with offset (method 1, hypoid gears) or without offset
(method 0, spiral bevel gears). If you click the sizing button, the cone angle is
calculated with a "modified slot width" (ISO 23509, Annex C.5.2). Gap 2 in
Figure 5 changes. A typical application is the 5-section process, where the pinion is manufactured with 2 different machine settings and consequently a modified slot width is created. The bevel shape is often also referred to as a TRL
(Tilted Root Line). The toothing can be either ground or lapped.
Constant tooth depth, Figure 3 (Klingelnberg)
The geometry is calculated in accordance with ISO 23509. You can perform
this calculation either with offset (method 3, hypoid gears) or KN3028 and
KN3029, or without offset (method 0, spiral bevel gears). The tip and root cone
are parallel. Applications are the cyclo-palloid process and the palloid process. After quench hardening, the cyclo-palloid toothing can be either hardcut (HPG, HPG-S) or lapped. Palloid toothing is characterized by an evolvent
tooth length form with a constant normal module over the facewidth. After
quench hardening, the toothing is usually lapped.
Constant tooth depth, Figure 3 (Oerlikon)
The geometry is calculated in accordance with ISO 23509. You can perform
this calculation either with offset (method 2, hypoid gears) or without offset
(method 0, spiral bevel gears). The tip and root cone are parallel. Applications

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15

are Oerlikon processes such as Spiroflex and Spirac. After quench hardening,
the toothing is usually lapped.

15.3.1

Converting or inputting Gleason toothing data

The "System Data" group in the "Geometry" tab has a selection list (drop-down
list) in its top left-hand corner. If the Gleason variant with "constant slot width" or
"modified slot width" is selected here, the conversion and plus buttons are active.
These two buttons allow you to input data in accordance with the Gleason definition.
Select the conversion button if a Gleason data sheet is present. You can then
input the data in the window as shown in Figure 14.3 and then click Calculate.
Once the calculation is complete, the Report and Accept buttons become active. Click on the Report button to generate a short report. If a complete report is
needed the user must click the

button in the main window. Click the Ac-

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15

cept button to transfer the data to the main window.

Figure 15.3: Conversion from Gleason data sheets

If you click the Plus button, the dialog window shown in Figure 15.4 appears.
You can input bevel gear data directly here using the Gleason method
Although the geometry results will not match the Gleason data sheet exactly,
they are good enough for calculating strength in accordance with ISO 10300

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15

(or AGMA or DIN).

Figure 15.4: Inputting Gleason data

In the drop-down list on the right of gear type the user can choose between different types of Gleason design (by default straight gears are selected):
1. Constant helix angle (straight or helical)
A constant helix angle represents a bevel gear with a constant helix angle.
If necessary, you can modify the helix angle to compare the geometry data
with the Zerol geometry data. If you click the Accept button to close the
dialog, the calculation is usually performed with the selection "Default, Figure 4 (part and root apex in one point)".
2. Duplex (constant slot width)
The term "duplex" refers to bevel and hypoid gears that are manufactured
with a constant slot width across the entire tooth length of both gears. These gear types usually have a spiral angle of 35 in the middle of the facewidth with a continuously changing spiral angle across its width. If you selected Duplex (constant slot width) and then clicked the Accept button to

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15

close the dialog, the calculation is usually performed with a "Constant slot
width".
3. Spiral toothing, default (modified slot width)
These gear types usually have a spiral angle of 35 in the middle of the facewidth with a continuously changing spiral angle in the axial direction.
This gear type is described as having a "modified slot width". If you select
this gear type and then click on Accept, the calculation is usually performed with a "non-constant root gap". In this case the root gap of the gear
pair is constant over the entire tooth length and any gap modifications are
performed on the pinion.
4. Zerol "Duplex taper"
This is a Zerol design (see Zerol), but a root angle variation is performed to
achieve duplex dimensions. If you select Zerol duplex and then close the
dialog by clicking the Accept button, the calculation is usually performed
with the "Constant slot width" selection.
5. Zerol "standard"
The Zerol standard is a gear pair with a spiral angle of less than 10 in the
middle of the facewidth, with a continuously changing spiral angle in the
axial direction. The inner spiral angle is usually negative. To ensure the
program can take into account the change across the tooth length, a value
of b=0.001 is assumed for the case b=0. If you close the dialog by clicking
the Accept button, the calculation is usually performed with a "Modified
slot width".

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15.4

Manufacture

Figure 15.2: Manufacture input window

The process used to manufacture spiral teeth bevel gears is closely linked to this
process. There are two basic processes used here. The arc of circle toothing process
(traditionally known as the Gleason process) and the continuous face hobbing
(traditionally referred to as the Klingelnberg and Oerlikon process). For more details see under Calculation process.

15.4.1

Cutter radius

In the case of spiral teeth bevel gears, the size of the cutter radius rc0 influences the
beveling of the flanks and therefore also the properties of the pair of bevel gears.
This effect applies both to the position of the contact pattern and the strength, and
must be taken into account when calculating the transverse coefficient KFa in
accordance with ISO 10300.
NOTE

This parameter is not present if you use the Klingelnberg method to calculate
strength. In that case you select the cutter radius together with the machine type.

15.4.2

Number of blade groups, tool

The number of blade groups describes the number of cutter blade groups on the
cutter head used to manufacture bevel gears with spiral teeth and, when face
hobbing is in use, it, together with the cutter radius, influences the bevel of the
tooth length. You must enter the number of blade groups as defined in ISO 23509,
Annex E or as specified in the manufacturers' instructions.

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15.5

Load

Figure 15.9: Load input window

15.5.1

Methods used for strength calculation

You can select the following methods:

1. Bevel gears, only geometry calculation
Does not calculate strength. This method only calculates the geometric values, such as the path of contact.
2. Bevel gears, static calculation
The strength calculation for cylindrical gears (see section "Calculation
methods" on page II-279) is implemented here.
3. Differential gear, static calculation
The static calculation method is used for differential gears. The calculation
is performed with the greatest circumferential force F1 or F2, see Figure
15.10

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15

Figure 15.10: Bevel gears in differential gears

Chapter
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15

4. Bevel gears, ISO 10300, Method B (C)

ISO 10300, Parts 1, 2, 3: Load capacity calculation for bevel gears.
5. Bevel gears as specified in ISO/CD 10300 (2011)
Draft version of the next edition of ISO 10300.
6. Bevel gears as specified in AGMA 2003-B97 or AGMA 2003-C10
ANSI/AGMA 2003-B97 or AGMA 2003-C10: Rating the Pitting Resistance and Bending Strength of Generated Straight Bevel, Zerol Bevel and Spiral Bevel Gear Teeth
7. Bevel gears
as specified in DIN 3991, Parts 1, 2, 3, 4: Load capacity calculation for
bevel gears.
This calculation is usually performed as defined in method B, and the tooth
form factor is calculated with Method C.
8. Bevel gears Klingelnberg KN 3028/KN 3030
This calculation is the same as the Klingelnberg in-house standards KN
3028 and KN 3030. These are mainly based on DIN standards. The
calculation supplies the same results as the reference program used by
Klingelnberg.

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15

9. Bevel gears Klingelnberg KN 3025/KN 3030

This calculation is the same as the Klingelnberg in-house standards KN
3025 and KN 3030. These are mainly based on DIN standards. The
calculation supplies the same results as the reference program used by
Klingelnberg.
10. Bevel gears Plastic
This calculates the equivalent cylindrical gear pair (see also DIN 3991).
Here the calculation is performed in accordance with Niemann/VDI/VDImod. in the same way as the cylindrical gear calculation (see page II-260).
11. DNV41.2, Calculation standard for ships' engines
The Det Norske Veritas calculation guideline [93] for ships' engines
corresponds in principle to ISO 10300 (root, flank) and ISO 13989
(scuffing). However, it does have some significant differences, especially
where Woehler lines are concerned. These differences are detailed in our
kisssoft-anl-076-DE-Application_of_DNV42_1.pdf information sheet,
which is available on request.
12. Hypoid bevel gears in accordance with ISO 10300
Hypoid bevel gears as specified in ISO 10300 with the suggested extension
in accordance with FVA411. ISO 10300 (2001 edition) applies to bevel
gears. The feasibility of extending the calculation method to include
hypoid gears is under discussion. In the Federal Republic of Germany, an
extension as part of the FVA411 research project has been proposed. This
method has already been documented in the "Bevel gears" manual
produced by Klingelnberg [87]. The method specified in FVA411 is only
slightly different from the proposed ISO 10300 extension that has not yet
been published.
13. Hypoid bevel gears, geometry only
14. Hypoid bevel gears, in accordance with Klingelnberg KN3029/KN3030
This calculation is the same as the Klingelnberg in-house standards KN
3029 and KN 3030. These are mainly based on DIN standards. The
calculation supplies the same results as the reference program used by
Klingelnberg.
15. Hypoid bevel gears, in accordance with Klingelnberg KN3026/KN3030
This calculation is the same as the Klingelnberg in-house standards KN
3026 and KN 3030. These are mainly based on DIN standards. The
calculation supplies the same results as the reference program used by
Klingelnberg.

NOTE

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15

You will find more information about the strength calculation in accordance with
Klingelnberg in section 15.5.

15.5.2

Required service life

You enter the required service life directly in this input field.
Click the
button to size this value. Based upon the minimum safety value for
the tooth root and flank strength, this process calculates the service life (in hours)
for every gear and for every load you specify. The service life is calculated in
accordance with ISO 6336-6 with the Palmgren-Miner rule. In the range of
endurance limit you can select a modified form of the Woehler line as an alternative to ISO 6336. The system service life and the minimum service life of all the
gears used in the configuration is displayed. You can size the service life using the
button either with or without defining a load spectrum (see page II-304). You
will find more detailed information about defining load spectra in section 14.19
(see page II-304).

15.5.3

Power, torque and speed

Click the
button next to the power input field (for the torque) to calculate the
power (torque) so that a predefined safety minimum (see page II-459) can be
maintained. Click the
button next to the power input field to apply a frequency
distribution for power, torque and speed in the Define load spectrum
(see page II-304) window. Click the
button on the right of the Speed
input field to open the Define sense of rotation window in which you
can specify the direction in which the bevel gear rotates in accordance with Figure
16.6 on page II-535.

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15.5.4

Strength details

Figure 15.11: Define details of strength dialog window

Click the Details... button in the upper right-hand part of the Strength
group to open the Define details of strength dialog window.
The parameters described in other places are:
Fatigue strength (see page II-290)
The input of the type of profile crowning (barreling): influences
the calculation of the contact area (only for ISO 10300) and the load distribution coefficient ZLS. The 2001 edition of ISO 10300 does not yet use this variant.
Small pitting (see page II-296)
Relative structure coefficient (see page II-297)
Number of load cycles (see page II-298)
Alternating bending factor (see page II-310)

15.5.4 .1
Pro file modi fication
Modifying the profile of bevel gears is unusual. Please contact the manufacturer
first to see whether it is feasible to do so. The run-in amount specified in ISO
10300 is the most commonly used.

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15.5.4 .2
Calc ulate flank safety with 0.85*b (ISO 10300)
Flank safety as defined in ISO 10300 is calculated with the length of the contact
line up to the tooth depth middle lbm. Select this checkbox to perform this
calculation with a modified width instead of using ISO 10300

.
The usual contact pattern width is 0.85*facewidth (for example, as specified by
DIN 3991.) If you have sufficient experience, you can modify this value.

NOTE

You can only input this value if you are using the ISO10300 calculation method.

15.5.4 .3
Load spectra with negative element s
Load spectra with negative load bins (T < 0 and/or n < 0) can also be calculated as
follows (this is only applied to bins whose alternating bending factor is YM=1.0).

IMPORTANT:
A load bin is considered to be negative if the mating flank is placed under load.
The same definition is used for the speed and torque (or power) prefix as in
KISSsys.
Consequently, the following bins are evaluated as negative:
Factor for torque or
power

Factor for
speed

Flank under load

Actual load bin

Working flank (*)

Evaluated as positive

Working flank (*)

Evaluated as positive

Mating flank

Evaluated as negative

Mating flank

Evaluated as negative

(*) Working flank as entered in the Strength tab

Under "Details" in the "Strength" section of the "Load" tab, you can select the
following:

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15

For calculating pitting safety

Evaluate all negative load bins as positive (as up to now)

Consider only positive load bins

Consider only negative load bins

For calculating the tooth root safety

Evaluate all load bins (as up to now)

For negative load bins, increase root stress by 1/0.7

Increase bending stress for positive load bins by 1/0.7

15.5.5

Application factor

The application factor compensates for any uncertainties in loads and impacts,
whereby KA 1.0. Table 15.4 illustrates the values that can be used for this factor.
You will find more detailed comments in ISO 10300, ISO 6336, DIN 3990 and
DIN 3991.

Operational behavior
of the driving machine

Operational behavior of the driven machine

uniform

moderate
shocks

medium
shocks

heavy
shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

Table 15.4: Assignment of operational behavior to application factor

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15.6

Reference profile

Figure 15.12: Reference profile tab

15.6.1

Default values for tip base clearance

The tip base clearance for spiral bevel gears is usually 0.2 to 0.3 times the average
normal module. However, a greater amount of play is used for toothings that are
manufactured with tilt. This prevents the tooth tip intersecting with the root of the
opposing gear.

Default values are (as stated in the "Kegelrder" book produced by Klingelnberg
[87]):
"Gleason, modified slot width" procedure:

0.3

"Gleason, constant slot width" procedure:

0.35

"Klingelnberg, Palloid" procedure:

0.3

"Klingelnberg, Cyclo-Palloid" procedure:

"Oerlikon" procedure:

15.6.2

0.25
0.25

Default values for addendum coeff icients

The addendum coefficient is usually 1.0.

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15.7

Contact Analysis

In the Bevel and Hypoid gears module, the contact analysis calculates the path of
contact under load for bevel gears with straight, helix, and spiral teeth. Hypoid
gears are not supported.
A pair of bevel gears with a substitute cylindrical gear toothing are approximated
for the analysis. Each one of the gears in this cylindrical gear pair has a number of
teeth that varies across the facewidth, an operating pitch diameter, and a helix angle (spiral toothing). For a more detailed description of the theory of contact analysis, refer to the Cylindrical gear contact analysis (see page II-401) section and
[69].

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15

15.8

Rough sizing

Figure 15.13: Rough sizing dialog window

The method is developed by Klingelnberg, in accordance with the suggestions from

technical literature [Kegelrder, Hrsg. Klingelnberg] to size bevel and hypoid gears
provides geometrically satisfying recommendation of gear pairs. This proposal
gives sufficiently precise solutions to the problems of achieving the required
safeties against tooth fracture and pitting because it is based on values gathered
through years of experience. If you verify gear teeth that have been dimensioned in
accordance with this method, you may discover certain deviations from the
required safety values.
However, you can easily achieve these safety levels by simply changing the module and the facewidth.

15.8.1

Face width ratio

Depending on how and where a gearbox is to be used, the facewidth should be in a

specific ratio to the cone distance and correspond to the following values:
Light and medium-heavy load
gear units for machines and vehicles

3.5 (Re/b) 5.0

Heavy load
gearboxes for machines and vehicles

3.0 (Re/b) 3.5

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15

15.8.2

Module ratio

The normal module mn should be in a ratio to the facewidth b within specific limits
which can only be exceeded (or not reached) for exceptional reasons:
surface hardened bevel gears at risk of tooth fracture

7 (b/mn) 12

At risk of pitting or
through hardened or not hardened

10 (b/mn) 14

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15

15.9

Fine Sizing

Figure 15: Conditions I tab in the Fine Sizing window

To start the Fine Sizing process, click the Calculation menu and select
the Fine Sizing option or click the

icon in the tool bar.

If you input a nominal ratio, a center distance, intervals for the module and helix
angle, and the pressure angle, the system calculates and displays all the possible
suggestions for the number of teeth, module, helix angle and profile shift. It also
shows the deviation from the nominal ratio, the specific sliding and the contact ratio. This module can also be used to size planetary stages and cylindrical gear stages with change gears.
All the variants found by this process can be evaluated by a wide range of different
criteria (accuracy of ratio, weight, strength, etc.).
Depending on your requirements, limits can also be set on the most important
parameters (minimum number of teeth, tolerated undercut, etc.). In addition to
creating text reports detailing the solutions and the summary, the summary can also
be displayed as a graphic.

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15

15.9.1

Necessary entries in the input window

Before you start the fine sizing process, you must enter the following data correctly
in the Basic data or Geometry and Strength standard tabs to ensure the
calculation returns the results you require.
Geometry:
Reference profile
Type: Standard, Gleason, Klingelnberg
Strength:
Materials
Power/Speed
Application factor
Service life
Lubrication

15.9.2

Conditions I

15.9.2.1
Maximal no of so lution s
If the program finds more than the specified number of solutions, you see a
warning message and an appropriate note is entered in the report.

NOTE

You should only perform a final evaluation after all the possible solutions have
been displayed. Otherwise you run the risk that the optimum solution will not be
displayed.

15.9.2.2

Normal module (middle), refe rence diameter, length of r efere nce cone
Use the three available options to vary and limit the gear size.

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15

15.9.3

Conditions II

Figure 15: Conditions II tab in the Fine Sizing window

You can vary other parameters in the Conditions II tab.

15.9.3.1

Addendum coefficient gear 1 (middle), addendum coeff icient gear 2 (middle)

You can vary the reference profile of the bevel gears by changing the addendum
coefficients of gear 1 and gear 2. You can then calculate the dedendum coefficients
of the counter gear (gear 2 and gear 1) by specifying the addendum coefficient and
the "Required tip clearance".

15.9.3.2
Addendum angle gear 2, dedendum angle gear 2
By varying the addendum and dedendum angle on gear 2 you can then vary the
tooth height along the facewidth. To calculate the addendum and dedendum angle
on the counter gear (gear 1), input a constant tip clearance (parallel tip cone and
root cone for counter gear).

Restrictions due to gear type: You cannot vary the cone angle for gear types for
which the angle cannot be changed. You cannot vary the addendum angle and root
angle of the "default, Figure 1" type. Although the face angle can be varied for the

Chapter
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15

"Standard, Figure 4" type, you cannot vary the root angle. The addendum angle and
root angle cannot be varied at all for the "Constant tooth depth, Figure 3" types.
NOTE

These options for varying the parameters in Conditions II are useful for differential
bevel gears, which are characterized by major geometric variations during
manufacture. However, do remember that the usual conditions must be met when
using conventional manufacturing methods such as Klingelnberg or Gleason.

15.9.4

Conditions III

Figure 15: Conditions III tab in the Fine Sizing window

You can define more parameters in the Conditions III tab.

1. Show values of KISSsoft main calculation as additional variant with
number 0
The toothing data displayed in the KISSsoft Basic tab can also be displayed as
a variant with number 0 (table and

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15

graphic). However, the data at the start of the fine sizing process must be
consistent before this can happen.

2. Calculate geometry only

If you select this method, no strength calculation is performed

3. Strength calculation with load spectrum

Before you can perform calculations with a load spectrum, you must set a load
spectrum in the main KISSsoft window BEFORE starting fine sizing,
and run the load spectrum calculation once (to ensure the data is consistent). In
this case, when you start the fine sizing process,
you are prompted to confirm whether the calculation is to be performed with a
load spectrum. The flag in the window only shows whether (or not) a load
spectrum is being used.
You cannot change the flag.

4. Suspend results which do not meet required safety factors

Variants which do not meet the predefined minimum safety levels (see
Calculation > Settings > Required safeties) will be
rejected.

5. Transmission error
If the "Calculation of the transmission error" option is selected, contact analysis is performed for every variant.

During the contact analysis for transmission error, the default settings, except
for the coefficient of friction, and accuracy, are used to prevent the
calculation
from behaving in any unusual way. Input the settings in the main program, in
the "Contact analysis" tab. You can also
specify the accuracy of the calculation. However, we strongly recommend you
select "medium" or "low" to reduce the processing time. Therefore,
the transmission error in fine sizing may not be exactly the same as you get in
the contact analysis, depending on the

Chapter
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15

selected settings.

The default values are as follows;

Calculation for: right flank
Torque for gear A: not considered
Torque for gear B: not considered
Partial load for calculation: 100 %
Center distance: Mean center distance allowance
Single pitch deviation: 0 mm
Then, the results list shows;
Transmission error (PPTE)
Medium wear on the tooth flank (delwn1, delwn2)
Maximum flash temperature (theflamax)
Variation in bearing force (VarL)
The calculation time increases significantly with the transmission error
calculation option. For this reason, we recommend you limit the number of
variants to be calculated
before you start the calculation

15.9.4.1
Ratio o f length of refe rence cone to facewidth
A standard sizing characteristic value for bevel and hypoid gears is "Ratio of length
of reference cone to facewidth". If this flag is set, solutions which lie outside this
range are rejected.
NOTE

Make this range relatively small when calculating bevel gears with spiral teeth.
Select a larger range for differential gear bevel gears.

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15

15.9.4.2
Ratio facewidth to normal module
A standard sizing characteristic value for bevel and hypoid gears is "Ratio of
facewidth to normal module". Small values result in modules that tend to be large
and sizings that are optimized for root strength. If this flag is set, solutions which
lie outside this range are rejected.
NOTE

Make this range relatively small when calculating bevel gears with spiral teeth.
Select a larger range for differential gear bevel gears

15.9.4.3

Only tak e solut ions int o account if the following conditions

are ful fill ed
The user can also define other criteria to ensure unsatisfactory solutions are
rejected. These values are calculated and checked on the virtual cylindrical gear
toothing.

1. Minimum distance of active diameter to form diameter df - dFf

Meshing errors occur if the active root diameter is less than the root form diameter. This is where you input a minimum value for the distance between
the active root diameter and the root form circle, in other words, between the
used and manufactured involutes. The value you input here is the
minimum difference between the two diameters. Only solutions greater than, or
equal to, the input value are taken into account in the results view.

2. Minimum transverse pressure angle at a point on root form diameter

alphafF
For differential bevel gears, a minimum profile angle in the transverse section
is required to ensure the axial demoldability
of the material from the forging tool. Only solutions greater than, or equal to,
the input value are taken into account in the results view.

3. Minimum root rounding radius in the reference profile rhofp

Chapter
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15

A minimum root rounding radius may be required for reasons of

manufacturability (absolute value in mm). Only solutions greater than, or
equal to,
the input value are taken into account in the results view.

4. Minimum tip clearance c

A minimum tip clearance may be required for reasons of manufacturability
(absolute value in mm). This is compared with tip clearance c. Only solutions
with a tip clearance greater than, or equal to, the input value are displayed in
the results view.

5. Minimum tooth thickness on tip form circle sFvan

The minimum tooth thickness on the tip form circle, sFvan, is critical for
achieving the required tip rounding radius. The
This calculation takes into account the tip alterations from the "Modifications"
tab. Only solutions with a tooth thickness
on the tip form circle that is greater than, or equal to, the input value are
displayed in the results view.

6. Manufacturing must be possible with tip rounding rK (in the

"Modifications" tab).
Only solutions in which the tip rounding rK as defined by the entries in the
"Modifications" tab can be executed are displayed in the results view.

NOTE

If the flag has been set in ""Module specific settings Differential gears", these
criteria are also checked in an "inside" and "outside" section. Only solutions which
meet the predefined criteria are then taken into account.

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15

15.9.5

Results

Figure 15: Results tab in the Fine Sizing window

Click the Report button to open the editor and display a list of the best results. A
brief description of the criteria used to evaluate the best variants is given here.
Please note that these criteria are not relevant to every case, and only need to be
queried in particular applications!

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15

15.9.6

Graphics

Figure 15: Graphics tab in the Fine Sizing window

The Graphics tab in the Fine Sizing window gives you a quick overview of the
number of solutions. Three parameters can be displayed simultaneously. You can
change them in the selection lists. In addition to the two axes, the third parameter is
displayed as a color.

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15

15.10

Notes on calculations in accordance with

the Klingelnberg standard

15.10.1

Bevel gears with cyclo-palloid gear teeth

Geometry, practicability of manufacturing and strength calculation of bevel gears

in accordance with the Klingelnberg cyclo-palloid process.
As stated in the Klingelnberg KN 3028 in-house standard (geometry and
manufacture) and KN 3030 (strength calculation) a complete calculation is
performed for cyclo-palloid toothing:
Calculate machine distance for machine types FK41B, AMK400, AMK635,
AMK855, AMK1602 with all corresponding cutters, cutter radii and numbers
of starts. A warning is displayed if you select an incorrect machine type or cutter tip.
You can specify any shaft angle, or angle modification here.
Overall geometry, modules (inside, middle, outside), spiral angle (inside, outside), checks on cut back, undercut space, calculation of profile shift for balanced sliding, checks on backwards cut, checking and calculating the necessary
tip reduction on the inside diameter, profile and overlap ratio, tooth form factor
and stress correction factor.
Calculation of all toothing dimensions.
Calculation of pitting, tooth root and resistance to scoring (as defined by the
integral temperature criterion) with all modifications in the in-house standard
KN 3030.

15.10.2

Hypoid gears with cyclo-palloid gear teeth

Geometry, manufacturability and strength calculation of hypoid gears (bevel gears

with offset(center distance)) as defined in the Klingelnberg process.
As stated in the Klingelnberg KN 3029 in-house standard (geometry and
manufacture) and KN 3030 (strength calculation) a complete calculation is
performed for cyclo-palloid toothing:
Calculation of machine distance for machine types FK41B, KNC40, KNC60,
AMK855, AMK1602 with all corresponding cutter head, cutter radii and numbers of blade groups. A warning is displayed if you select an incorrect machine
type or cutter tip.

Chapter
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Bevel and Hypoid gears

15

You can use any value as the shaft angle, angle modification, pressure angle
for the driving and driven flank.
Overall geometry with calculation of the facewidths, modules (inside, middle,
outside), spiral angle (inside, outside), undercut boundary, calculation of gap
widths, checks on backwards cut, checking and calculating the necessary tip
reduction on the inside diameter, profile and overlap ratio, tooth form factor
and stress correction factor either for the tension (driving) or coast (driven)
flank.
Calculation of all toothing dimensions.
Calculation of pitting, tooth root and resistance to scoring (as defined by the
integral temperature criterion for the replacement spiral-toothed gear wheel)
with all modifications in the in-house standard KN 3030.

15.10.3

Normal module ranges for Klingelnberg mach ines (cyclo-palloid)

Machine

Cutter radius
r

Normal module
mmn

FK41B

25

0.25 ...

1.6

30

0.25 ...

1.6

40

0.25 ...

1.6

55

1.1 ...

4.0

100

2.4 ...

5.2

135

3.5 ...

8.0

170

3.5 ...

13.0

55

1.1 ...

4.0

100

2.4 ...

5.5

135

3.5 ...

8.0

170

6.5 ...

13.0

210

7.0 ...

13.0

135

3.5 ...

8.0

170

6.5 ...

13.0

210

7.0 ...

15.5

260

7.0 ...

15.5

270

8.0 ...

17

AMK400

AMK635

AMK855

AMK1602

Chapter
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Bevel and Hypoid gears

15

KNC25

KNC40

KNC60

350

14.0 ...

25.0

450

17.0 ...

34.0

30

0.5 ...

5.5

55

0.5 ...

5.5

75

0.5 ...

5.5

100

0.5 ...

5.5

30

1.0 ...

1.6

55

1.1 ...

4.0

75

2.0 ...

4.5

100

2.4 ...

5.5

135

3.5 ...

8.0

75

2.0 ...

4.5

100

2.4 ...

5.5

135

3.5 ...

8.0

170

6.5 ...

14.0

Table 15.11: Normal module ranges for Klingelnberg machines

15.10.4

Bevel gears with Palloid toothing

Calculate the geometry and strength of bevel gears using the Klingelnberg procedure.

A complete calculation for palloid toothing is performed in accordance with the

Klingelnberg KN3025 in-house standard (Geometry, Edition No. 10) and KN3030
(strength calculation).

Taking into account Palloid cutter dimensions by including a smaller diameter

dK and cutter cut length SF, you can also input special cutters here
A warning is issued if the cutters do not cover the crown gear at either the inner or outer end of the tooth
You can select any shaft angle, or angle modifications
Overall geometry, modules (inside, middle, outside), spiral angle (inside,
middle, outside), checks on profile shift for balanced sliding and undercut

Chapter
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Bevel and Hypoid gears

15

space, checking and calculating the necessary tip reduction on the inside diameter, profile and overlap ratio, tooth form factor and stress correction factor
Calculation of all toothing dimensions
Calculate forces for contact pattern position for cone distances length Rpr and
Rm
Calculate pitting, tooth root and resistance to scoring (as defined by the integral
temperature criterion for all modifications in the Klingelnberg standard KN
3030 (taking into account the forces of cone distance Rpr)
NOTE

The forces at bevel length Rm are used for the transfer to KISSsys, to ensure that
forces can be calculated independently of the toothing procedure. However,
including the theoretical contact pattern core in the Klingelnberg in-house standard
is very difficult to implement in the manufacturing process.

15.10.5

Definitions and dimensions of standard cutters

for palloid toothing

Figure 15.14: Dimensions of standard cutters

Chapter
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Bevel and Hypoid gears

15

15.10.6

Minimum safeties

We recommend you use the following minimum safeties:

Application

Minimum safeties

Flank

1.1 ... 1.2

Root

1.5 ... 1.6

Scuffing

1.8 ... 2.0

Table 15.12: Recommended minimum safeties

15.10.7

Surface roughness at tooth root

Treatment

Roughness [mm]

through hardened

0,016

lapped

0,016

hard-cut

0,008

Table 15.13: Surface roughness values

15.10.8

Accuracy grade bevel gears

Treatment

Quality number

through hardened

lapped

hard-cut

Table 15.14: Accuracy grade for bevel gears

15.10.9

Characteristic number

The product of the lubrication, speed and roughness factor ZLZV ZR for different
surface treatments is shown in Table 15.15:

Treatment

Characteristic number ZLZV ZR

through hardened

0.85

Chapter
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Bevel and Hypoid gears

15

lapped

0.92

hard-cut

1.0

Table 15.15: Characteristic number ZLZV ZR for different surface treatments

NOTE

You will find a similar definition in ISO 10300-2:2001, Section 14.4. Here the
characteristic number is also dependent on the defined level of roughness Rz.

15.10.9.1 Single normal pitch deviat ion

This is calculated in accordance with DIN 3965.

15.10.9.2 Contact spring stiffness

The contact stiffness is assumed to be constant.

Chapter
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Bevel and Hypoid gears

15

15.11

Settings

In the Calculation menu you will find the Settings option. Click this sub
menu to open the Module specific settings window. From here you can
access the tabs listed below to input other calculation parameters. (the following
parameters not described here (see page II-446))

15.11.1

Calculations

15.11.1.1
Coefficie nt of friction for hypoid gears
Due to longitudinal sliding, hypoid gears have more power loss than spiral bevel
gears. For this reason, the calculation of toothing forces in KN3030 takes the
coefficient of friction account. If necessary, you can enter the size of the coefficient
of friction in the Module-specific settings.

15.11.2

Differential gears

If the extensions for differential gears are enabled, the geometry parameters are
calculated at positions Li and Le. The data for the replacement cylindrical gear
toothing at these two positions is then also documented in the report. The tip alteration can then also be applied up to underneath the cone length.

Chapter
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Bevel and Hypoid gears

15

15.11.3

Helpful information about the Generation of 3D

model tab

<Figure 15: Generation of 3D model in Module-specific settings

NOTE:

For more precise instructions about these entries, please contact KISSsoft Support
and request the document KISSsoft-anl-068-E-3D Geometry of Spiral Bevel
Gear.pdf.

Chapter
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Bevel and Hypoid gears

15

15.11.4

Factors

Figure 15.10: Load input window

15.11.4.1
Bearing applicat ion factor
Tables 15.5 15.7 show the bearing type bearing application factor for different
standards.
Support for pinion and ring
gear

Bearing application factor

a

both on both sides

1.00

1.05

1.20

one on both sides, one floating

1.00

1.10

1.32

both floating

1.00

1.25

1.50

Contact pattern in the gearbox tested under full load

Contact pattern in the gearbox tested under part load

Contact pattern only tested in specific tests

Table 15.5: Bearing application factor according to ISO 10300

Support for pinion and ring

gear

Bearing application factor

Chapter
II-520

Bevel and Hypoid gears

15

both on both sides

1.10

one on both sides, one floating

1.25

both floating

1.50

Table 15.6: Bearing application factor according to DIN 3991

Support for pinion and ring

gear

Bearing application factor

both on both sides

1.10

one on both sides, one floating

1.10

both floating

1.25

Table 15.7: Bearing application factor according to AGMA 2003

The face load factors KH,KF and KB are calculated as follows from the bearing
application factor KHbe as defined in the standard:

(15.7)

15.11.4.2 Dynamic facto r

To calculate the dynamic factor Kv, as defined by Klingelnberg, use the coefficient
K1 either for preliminary calculations based on the planned manufacturing method
(lapped, HPG) or on the basis of the derived accuracy grade (see also Klingelnberg
standard KN 3030, Table 5.2-1 or 5.2-2).

15.11.4.3 Bevel gear factor at flank and root

To calculate the strength of bevel gears, you use the virtual cylindrical gear with
equations that apply to strength calculation for cylindrical gears. The bevel gear
factors are then used to correct the systematic differences in the calculation
between cylindrical gears and bevel gears. These factors are defined in the
corresponding standards.
Standard

Bevel gear factor of flank ZK

Chapter
II-521

Bevel and Hypoid gears

15

ISO 10300

0.80

Niemann

0.85

Table 15.8: Bevel gear factor of flank ZK as defined in the standard

Standard

Bevel gear factor of root YK

ISO 10300

is calculated, see Part 3 of the standard

Niemann

1.00

Table 15.9: Bevel gear factor of root YK as defined in the standard

15.11.5

Contact Analysis

Unit of transmission error: Here you can select either the length on the length of
path of contact (transmission error) or the angle on the gear (angle of rotation error).
Calculation method contact stiffness: Here you can select either the calculation
method defined by Weber/Banaschek [69] (dynamic stiffness analysis: default setting), the method defined in ISO 6336-1 Method B and Own Input.
Single contact stiffness: If "Own Entry" has been selected as the contact stiffness
calculation method you can enter your own value for the single intervention
stiffness.
Slices Linking factor: Linking factor used to link the individual slices of the
discretized toothing model.
Border weakening factor: Border weakening factor for a weakening of stiffness
on the edge of helical gear teeth.
Stiffness correction factor (according to Winter): Correction factor for Hertzian
flattening as described in the experiments performed by Winter/Podlesnik [95].
Draw data for path of contact: If this option is enabled, the results of contact analysis are displayed quadratically in the 3D diagrams. This makes the data suitable
for export as a matrix.

Chapter
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Face gears

16

16

Face gears

Chapter 16
Face gears
Face gears are a special type of bevel gears. Although the pinion is a normal
cylindrical gear, a face gear has a complex 3D-tooth form. Unlike a bevel gear, a
face gear is absolutely not affected by axial displacement. For this reason, face
gears are much easier to assemble.
The KISSsoft Face gears calculation module calculates the geometry of pairs
of straight or helical cylindrical gear pinions with face gears with offset (center
distance) and with any shaft angle . In this case, the strength and 2D geometry are
calculated for an offset (center distance) of 0 mm and a shaft angle =90. In every
other case, you can perform the presizing with these restrictions and then add the
required offset (center distance) and shaft angle to the 3D volume model. In the
Geometry docking window you can display the tooth form of a face gear for its
inside, middle and outside diameter or for any number of sections all at the same
time. You use this tool to check for undercut and pointed teeth on the inside or
external diameter of the face gear. In the Modifications input window (tab),
you will find the value/length of the tip alteration at outside (inside) hake(i), lake(i)
input fields which contain additional parameters that will help you prevent pointed
teeth occurring in the gear. The tooth form on a face gear is calculated by
simulating manufacture with a pinion type cutter. The strength calculation is based
on the use of established standards for cylindrical or bevel gears.

Chapter
II-523

Face gears

16

16.1

Underlying principles of calculation

A face gear has features in common with a curved rack. However, unlike this
simplest of all gears, when assembling and installing a face gear, engineers are
always confronted with the restrictions posed by that very bending. As the tooth
flank in a spur geared face gear must run parallel to one radius of the face gear - the
contacting pinion has flanks parallel to its own axis - the immediate result of the
theorem of intersecting lines is that the pressure angle must reduce from outside to
inside. The equation shown here can be regarded as the main formula used to size
the geometry of face gears. To keep this as simple as possible, only a gear with
spur-toothed gear teeth is considered here. Equation [3]

(16.1)

contains
d2

diameter of face gear

mn

normal module pinion

z2

number of teeth on face gear

pinion pressure angle on the reference circle

pressure angle on face gear for diameter d2

From this, you can, for example, define the pressure angle from the external diameter to the inside diameter. If the inside tooth flanks are steep, the involute will be
short and only bear a small part of the tooth depth. The risk of an undercut grow in
the direction of the crown gear center. Any undercut here would further reduce the
usable area. The result is a minimum inside diameter and a maximum external
diameter, which limit the total face width of the face gear. This is where a face gear
differs fundamentally from a bevel gear: whereas you can increase the facewidth
on a bevel gear to enable it to transmit higher torques, strict limits are set here for
face gear to cylindrical gear-pinion pairs. However, if you select the right axial offset bv, i.e. by moving the facewidth middle compared to the reference circle, you
can optimize the maximum permitted facewidth.
When assembling a face gear it is a good idea to define a minimum and a maximum pressure angle and then the achievable inside and external diameter. If
external conditions limit this diameter (this usually affects the external diameter),
you can use the conversion in equation (16.1) to change the range available for the
module.

Chapter
II-524

Face gears

16

(16.2)

In addition to having the figures to hand, you may find it helpful to view the teeth
as a graphic in this situation.
The vast majority of applications use face gears with spur gears. However face
gears with helical teeth, when arranged correctly, do offer a number of benefits
such as noise reduction and strength. Unfortunately, these benefits are offset by the
problem that the tooth flanks are not symmetrical, i.e. the left flank no longer
corresponds to the right flank. In practice this means that any undercut that occurs
will happen earlier on one flank than on the other. This differences in the flanks
also have a significant influence on strength, which results in a difference between
the directions of rotation when the gear transmits power. However, if only one sense of rotation is used, such as for electrical tools, you can optimize the flank
involved without having to take the effect on the rear flank into account.
Experience has shown that theoretical observations of geometry to decide which
involute functions, lines, and arcs of circles, to use, to describe a tooth form, will
sooner or later reach their limit. A tried and tested, and much more reliable, means
of calculating tooth forms is to simulate the generation process or, even better
simulate the manufacturing process. To do this, the trajectory of a point on the active surface of the tool is followed until its speed relative to the tool surface
normally reaches a zero crossing (see Figure 16.1).

Figure 16.1: Spur curve (blue) of the pinion type cutter tool (red) on the face gear (green)

Chapter
II-525

Face gears

16

These points are potential points on the tooth form surface. You must then separate
the actual points on the surface from the imaginary points at which the nominal
speed also disappears but the underlying points are shown as being outside the material. How to separate the real from the imaginary points is one of the most
difficult aspects of the process described here. In addition to referring to the usual
standard algorithms for classifying points in a level, you must also use empirical
approaches that use the known properties of the tooth form in order be sure of
achieving a well-defined tooth form with sufficient safety. You can therefore match
the data derived from calculating a 3D tooth form of a face gear with the data
derived from generating using a pinion type cutter using a classic manufacturing
method. By outputting the 3D body in IGES, STEP or SAT format you can then
design the form in any CAD system. The face gears can then be manufactured in
either an injection molding, sintered or precision forging process. However 2D
cross section view is much more suitable if you want to check a face gear for
undercut or pointed tooth tips. This displays the inside, middle and outside of the
face gear tooth form all at the same time. If you then rotate the gears step by step,
you can check every aspect of the gear generation very precisely. If a tooth is
pointed, or if the meshing ratios are not good enough, you must reduce the tooth
depth in the same way as you do for hypoid gears. To reduce the gear's sensitivity
to errors in the axis alignment or the center distance, you can allow crowning on
the tooth flank (tooth trace). You can generate this quite easily for face gears by
using a pinion type cutter that has one or more teeth more than the pinion in the
manufacturing process [79]. When you compare the tooth forms you can see the
effect the increased number of teeth on the pinion type cutter had on the generated
tooth form. However, if the face gear has a large axial offset bv, you can move the
barreling to one side! In every axis section through the cylindrical gear, the face
gear drive corresponds to a pinion-rack gear drive. Using the rack theory as a basis,
you can therefore define the pressure angle, the lines of contact and the contact ratio in each section.
The examples in this section are based on a publication in [50].

Chapter
II-526

Face gears

16

16.2

Basic data

Figure 16.2: Basic data input window in the Face Gears module

16.2.1

Normal module

Enter the normal module. However, if you know the pitch, transverse module, or
diametral pitch, instead of this, click on the
button to open a dialog window in
which you can perform the conversion. If you want to transfer the diametral pitch
instead of the normal module, you can select Input normal diametral
pitch instead of normal module by selecting Calculation >
Settings > General.

Chapter
II-527

Face gears

16

If you have already defined all aspects of the geometry of a face gear, the
following message appears after you click the

button:

Figure 16.3: Information window for sizing the normal module

As part of the bevel gear calculation performed in accordance with ISO 10300 or
DIN 3991, the strength calculation is performed for the middle diameter of the face
gear. If the axial offset bv <> 0, the conditions for this type of calculation have not
been met. For this reason the
button supports the conversion of normal module
mn and pressure angle n, to ensure that bv = 0. Although this changes the root radius of the pinion, the shape of flank remains the same.

Chapter
II-528

Face gears

16

NOTE

We recommend you only use this conversion method when you perform the
strength calculation. The conversion changes the module and you can no longer use
the tool. This is why you must save your geometry data before you perform the
conversion.

16.2.2

Pressure angle at normal section

The normal pressure angle at the reference circle is also the flank angle of the reference profile. For standard toothings the pressure angle is n = 20o. You can use
smaller pressure angles for a larger number of teeth to achieve higher contact
ratios. Greater pressure angles increase the strength and allow a smaller number of
teeth to be used without undercut. In this situation, the contact ratio decreases and
the radial forces increase.

NOTE

The operating pressure angle wt changes across the width of the toothing.

16.2.3

Helix angle at reference circle

Enter the helix angle in [o]. You can either convert this from the helix angle on the
base circle b or from the helix angle at tip circle a by clicking the
button in
the Convert helix angle window. Helical gear teeth usually generate less
noise than spur-toothed gear teeth. However, they also have the disadvantage that
they involve additional axial force components.

Chapter
II-529

Face gears

16

Figure 16.4: Helix angle

16.2.4

Axial offset

The axial offset is the distance of the pinion center from the middle diameter of the
face gear.
Click the
button to the right of the Axial offset input field to calculate the
largest possible width of the face gear (see page II-540) b2 and the corresponding
axial offset bv, so that the pressure angle lies within the predefined limits.

Figure 16.5: Axial offset of the face gear

16.2.5

Profile shift coefficient (on the pinion)

The tool can be adjusted during manufacture. The distance between the production
pitch circle and the tool reference line is called the profile shift. To create a positive
profile shift, the tool is pulled further out of the material, creating a tooth that is
thicker at the root and narrower at the tip. To create a negative profile shift the tool
is pushed further into the material, with the result that the tooth thickness is smaller
and there is more danger of undercut. In addition to the effect on tooth thickness,
the sliding velocities will also be affected by the profile shift coefficient.
You can modify the profile shift according to different criteria. To do this, use the
various sizing options in the Sizing of profile shift window. Here,
click the

button:

For undercut boundary

For minimum topland per gear.
You can specify the minimum thickness of the topland in Calculation >

Chapter
II-530

Face gears

16

Settings > General > Coefficient for minimum tooth

thickness at the tip.
NOTE

The pinion should have a reasonable high value for the tooth thickness at the tip
because the pinion type cutter used to manufacture a face gear has a somewhat higher tip and, despite that, must not be permitted to become pointed.
Click the
button and KISSsoft will determine whether the profile shift
coefficient (see page II-265) is to be taken from measured data or from values
given in drawings.

16.2.6

Quality

In this input field, you specify the accuracy grade in accordance with the standard
shown in brackets. To change the standard used for this calculation, select
Calculation > Settings > General > Input of quality. The
accuracy grade according to ISO 1328 is very similar to that in DIN 3961 or
AGMA 2015.
Achievable qualities are shown in Table 16.6.
Manufacturing process

Quality according to DIN/ISO

Grinding

...

Shaving

...

Hobbing

(5)6

...

Milling

(5)6

...

Shaping

(5)6

...

Punching, Sintering

...

12

Table 16.6: Quality values for different manufacturing processes

NOTE

The values in brackets can only achieved in exceptional situations.

Chapter
II-531

Face gears

16

16.2.7

Geometry details

Click the Details... button in the upper right-hand part of the Geometry group
to open the Define details of geometry dialog window. You can enter
these parameters here.

16.2.7.1
Shaft angle
You can select your own shaft angle here. However, to perform a strength
calculation you should set it to = 90.

Chapter
II-532

Face gears

16

16.2.7.2
Inside di ameter
The inside diameter is needed to calculate the mass moment of inertia. As defined
in ISO or AGMA, the gear rim thickness does affect the strength. For complete
gears, enter 0, for external gears with a gear teeth, enter the appropriate diameter di
as shown in Figure 16.7.

Figure 16.7: Dimesnsioning the diameter

The inside gear rim diameter is required for calculations in accordance with ISO or
AGMA. Where thin gear rims are used, this factor can greatly influence the
calculation results. as illustrated by Figure on page II-570.

16.2.7.3
Height of face gear
For information on defining the height of face gear haFG see Figure (see page II538)

16.2.8

Material and lubrication

The materials displayed in the drop-down lists are taken from the materials database. If you cannot find the material you require in this list, you can either select Own
Input from the list or enter the material in the database (see section "External
tables" on page I-132) first. Click the
button to open the Material
pinion(face gear) window in which you can select a list of materials that
are available in the database. Select the Own Input option to enter specific material characteristics. This option corresponds to the Create a new
entrywindow in the database tool.

Chapter
II-533

Face gears

16

16.3

Load

Figure 16.3: Load input window in the Face gears module

16.3.1

Methods used for strength calculation

To allow developers to use the calculation method they require, KISSsoft

can perform strength calculation in accordance with ISO 6336, DIN 3990, DIN
3991, ISO 10300 or DIN 3991.

16.3.1.1
Only geometry calculat ion
If you select this method, no strength calculation is performed. Therefore you no
longer need to enter the data that is only required for the strength, such as power,
application factor, etc.

16.3.1.2
Static strength
The strength calculation for cylindrical gears (see section "Calculation methods" on page II-279) is implemented here.

16.3.1.3
Method ISO 6336 -B/Literatu re
We recommend you use the method described here.

The method used to calculate the strength of face gears as originally proposed by
Crown Gear [3], is based on the cylindrical gear calculation in accordance with
DIN 3990. The inclined lines of contact in a face gear increase the total contact
ratio due to pitch overlap. This can be compared with the overlap ratio in helical
gear cylindrical gears (an overlap ratio is also present in helical face gears due to
the helix angle n). You can therefore derive the virtual helix angle v from the
inclination of the lines of contact.In the strength calculation this effect is taken into
account by helix angle factors Y and Z. The value at the middle of the facewidth
is then used as the transverse contact ratio a. It is clear that the face load factor KH

Chapter
II-534

Face gears

16

and transverse coefficient KHa in accordance with DIN 3990 cannot be used for
face gears. In crown gear calculations these values are usually set to KH = 1.5 and
KHa = 1.1, and therefore allow for the same procedure to be used as the one used to
calculate bevel gears (DIN 3991, ISO 10300). However, the international
acceptance of the strength calculation method specified in ISO 6336 makes it a logical alternative to DIN 3990. As ISO 6336 is very similar to DIN 3990, the same
restrictions also apply.
In contrast to the Crown Gear program, the following data is used in the
calculation:
- The arithmetical facewidth (pitting) corresponds to the minimum line of contact
length (Lcont)
- The circumferential force Ft is derived from dPm (middle facewidth)

16.3.1.4
Method Crown Gear (DIN 3990)
This calculation method produces results that correspond to those produced by the
Crown Gear program. The underlying principle of calculation is described earlier
in the "ISO 6336/Literature" method (see page II-533).

The main differences between it and the "ISO6336/Literature" method are:

The calculation is based on the method defined in DIN3990.
The mathematical facewidth (pitting) corresponds to the facewidth (also in cases where the minimum line of contact length is shorter than the facewidth).
The circumferential force Ft is derived from dPd (reference circle = module *
number of teeth), even if dPd is not the middle facewidth.

16.3.1.5
Analog to ISO 10300, Method B
As already mentioned, you can use ISO 10300 as a good alternative method for
calculating the strength of bevel gears. Face gears are classified as bevel gears and
can therefore be regarded as bevel gears where the cone angle is 0o (pinion) and 90o
(face gear). The strength of bevel gears is calculated on the basis of the virtual spur
gear (cylindrical gear with the same tooth form as the bevel gear). However, for a
face gear, the virtual gear number of teeth for the pinion is z1v = z1 and for the gear
z2v it is infinite. If you verify the examples, using the Crown Gear program (method matches DIN 3990) and the ISO 10300 method in KISSsoft you will get a
good match of values. The variation in root and flank safeties is less than 10% and
usually less than 5%. This shows that both calculation methods in DIN 3990 and
ISO 10300 (DIN 3991) are reliable and effective.

Chapter
II-535

Face gears

16

16.3.1.6
Analog to DIN 3991, M ethod B
The same notes as for the "Analog to ISO 10300" method (see page II-534) also
apply here.

16.3.2

Service life

The value in the Service life input field is used together with the speed to
calculate the number of load cycles.

16.3.3

Power, torque and speed

Click the
button next to the power input field (for the torque) to calculate the
power (torque) so that a predefined safety minimum (see page II-459) can be
maintained. Click the
button next to the Speed input field to enter the direction
of rotation of the face gear as specified in the Define sense of rotation
window in 16.9 .

Figure 16.9: Helix angle on a face gear:right; helix angle on the pinion: left; sense of rotation: to
the right

16.3.4

Application factor

The application factor compensates for any uncertainties in loads and impacts,
whereby KA 1.0 applies. Table 16.8. illustrates the values that can be used for this
factor. You will find more detailed comments in ISO 6336.

Chapter
II-536

Face gears

16

Operational behavior
of the driving machine

Operational behavior of the driven machine

uniform

moderate
shocks

medium
shocks

heavy
shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

Table 16.8: Assignment of operational behavior to application factor

Chapter
II-537

Face gears

16

16.4

Factors

Figure 16.4: Coefficients input window in the Face gears module

16.4.1

Face load factor

The face load factors KH take into account the effect of uneven load distribution
across the facewidth on flank pressure, tooth root load and resistance to scoring.
For face gears, we recommend you use approximately the same coefficients (see
page II-519) as for bevel gears.

Chapter
II-538

Face gears

16

16.5

Modifications

The Modifications (see page II-356) (tab) input window in the

Face gears calculation module basically includes the same functionality as for
cylindrical gears. Its special features are listed below:

16.5.1

Addendum reduction

You specify the tip alteration hak and the length of the tip alteration lhak (see Figure
16.7) in the Modifications input window in the Modifications area. The
tip is then altered to prevent the tooth becoming pointed. When you specify a tip
alteration, we recommend you display the entire modification for the 3D export, so
that you can increase the number of sections calculated under Calculation >
Settings > General ( Additional information (see page II-539)).

Figure 16.11: Characteristic values of a face gear

16.5.2

Type of modification

In the List of modifications (see section "Type of modification" on page II-358)

you can only make changes to the pinion.

Chapter
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Face gears

16

16.6

Settings

In the Calculation menu you will find the Settings option. Click this sub
menu to open the Module specific settings window. From here you can
access the tabs listed below to input other calculation parameters.

16.6.1

General

Figure 16.12: General tab in the Module-specific settings window

The Number steps for tooth form calculation input field defines
how many equidistant section levels N 3 are to be distributed between the outside
and inside diameter of the face gear. The default value here is N = 3 which defines
section levels r2 = d2i/2, r2 = d2e/2 and r2 = (d2i + d2e)/4.

Chapter
II-540

Face gears

16

NOTE

You should select N > 10 to ensure an adequate spatial resolution for your 3D export.

16.6.2

Sizings

Figure 16.13: Sizings tab in the Module-specific settings window

The Minimum/maximum pressure angle in transverse section t,min/max input fields

define the range in which the values for the pressure angle for the tooth flank for
the face gear across its width may lie. These values are used, for example, when
sizing the facewidth of face gear b2 and axial offset bv.

Chapter
II-541

Face gears

16

16.7

Notes on face gear calculation

16.7.1

Dimensioning

The complexity of dimensioning the tooth forms in face gears means that
KISSsoft uses various procedures that differ extensively from other commonly
used procedures, such as for cylindrical gears. For a face gear, the geometry you
select must be such that it prevents the creation of pointed teeth on the outside face
of the gear and ensures that no undercut (or only very little undercut) occurs on the
inside face. You must perform these checks when you calculate the tooth form. The
actual geometry calculation procedure converts the replacement bevel gear and the
replacement cylindrical gear. In the tooth form calculation process, a face gear is
calculated in a number of sections set along its facewidth. To specify the number of
required sections, select the Calculation menu and then, under Settings >
General > Number of sections for the tooth form
calculation , define the number of sections. The Geometry (meshing)
graphics window allows you to display the tooth form simultaneously on the inside
diameter, outside diameter, and in the middle of the tooth. You can see here
whether the normal crest width and undercut are tolerable.
You can take these measures to prevent pointed teeth and/or undercut:
change facewidth bv
zoom out the facewidth
change the pressure angle
tip alteration in the outside part of the facewidth
NOTES

To generate a crowned tooth form: You can generate crowning on the tooth
trace of face gears by using a pinion type cutter that has one or two more teeth
than the meshing pinion. Use the storage function in the Graphics > Geometry > Meshing 2D display to check the difference between the generated tooth forms. To do this, define a pinion type cutter with the same number of
teeth as the pinion used to calculate the tooth form. Then save this cutter data
by clicking the Gear 2 Save button
and then increase the number of
teeth on the pinion type cutter. If the face gear has a large axial offset bv, you
can displace the crowning to one side.

Chapter
II-542

Face gears

16

16.7.2

Pinion - Face gear with Z1 > Z2

No provision has been made for calculating a pinion face gear pairing when the
number of teeth on the face gear (Z2) is less than the number of teeth on the pinion
(Z1), because this situation does not happen very often. However, under certain
conditions, you can still determine the geometry of this type of pairing.

To do this, go to Settings and set the Do not cancel when geometry

errors occur flag. Then, we recommend you follow these steps:
Reduce the facewidth of the face gear (for example, by half)
Starting with Z2 = Z1, zoom Z2 step by step, performing a calculation after
every step and correcting the inside, middle, and outside aspect of the cuts and,
if necessary the tooth depth, in the 2D display.
Once you achieve the required number of teeth Z2, try to increase the facewidth of the face gear again, and modify it if necessary.

Chapter
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Worms with enveloping worm wheels

17

17

Worms with e nvelop ing worm wheels

Chapter 17
Worms with enveloping worm
wheels
Calculate worm geometry in accordance with ISO 14521 and DIN 3975. Tooth
thickness and control mass (base tangent length, rollers and measurement over
balls of the worm gear) as specified in ISO 21771. Manufacturing tolerances in
accordance with DIN 3974.
You can size the facewidth, the center distance, the lead angle etc. Strength
calculation as defined in ISO 14521 or DIN 3996 with: efficiency, temperature
safety, pittings safety, wear safety, tooth fracture and bending safety. Data for
various different worm wheel materials are supplied.
You can also calculate the starting torque under load, which is a critical value when
sizing gear drives.
Flank forms: ZA, ZC, ZH, ZI, ZK, ZN.
For more information about the dimensions of a worm wheel, refer to Figure 17.1.

Figure 17.1: Dimensions of the worm wheel

Chapter
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Worms with enveloping worm wheels

17

17.1

Underlying principles of calculation

The underlying geometric relationships are defined in ISO 14521 or DIN 3975.
You will find additional information, and other important definitions, such as the
various worm flank forms (ZA, ZC or ZI, ZH, ZK, ZN), in [66]. You calculate
strength (tooth fracture, pitting, wear and temperature safety) according to ISO
14521 or DIN 3996. These calculations take much less time and effort to perform
than those required for cylindrical gears. Worms can be checked throughout the
manufacturing process by using what are known as "three wire measurements".
This corresponds to the principle of the measurement over two balls that is used for
worm wheels (and also for cylindrical gears). However, the calculations involved
in ascertaining the three wire measurement are very complex. A very useful method for standard flank forms has been developed by G. Bock [4] at the physikalisch-technisches Bundesanstalt (German national metrology institute) in Berlin.
This method takes into account the shape of the worm's flank, which is why it is
used in KISSsoft.

NOTE

When you use the term "module" you must differentiate clearly between the axial
and the normal module.

Note about how to use the application factor

In cylindrical gear and bevel gear calculations, application factor CA is usually
multiplied by the power, for example, so that CA=1 with P= 5 kW gives exactly
the same safeties as CA=2 and P=2.5 kW. However, this is different for worm
calculations performed according to ISO or DIN standards and may lead to
confusion.
The forces and torques are multiplied with the application factor. In contrast, the
power is not multiplied with the application factor when determining power loss
PVLP and when calculating the total efficiency etaGes. Therefore, for CA=2 and
P=2.5 kW instead of CA=1 with P= 5 kW - power loss [PV] will be smaller, and
the total efficiency etaGes will be far too low.
Results for the example "WormGear 1 (DIN 3996, Example 1).Z80":
KA=1; P= 5 kW

KA=2; P=2.5 kW

PVLP

0,140

0,070

<< ( * 1/KA)

PVD+PV0

0,199

0,199

PVZ

0,530

0,530

PV

0,869

0,799

<

Chapter
II-545

Worms with enveloping worm wheels

17

etaz

90.00

90.00

etaGes

85.19

75.77

<<

theS

76.6

76.6

theM

80.9

80.9

SW

1,386

1,386

SH

1,143

1,143

Sdel

2,369

2,369

SF

2,251

2,251

ST

1,306

1,306

This difference in the results is not logical so therefore, to determine PVLP and
etaGes, the power is also multiplied with CA to achieve the same results.

Chapter
II-546

Worms with enveloping worm wheels

17

17.2

Basic data

Figure 17.2: Basic data input window in the Worms with globoid worm
wheels module

17.2.1

Axial/transverse module

The axial module of the worm and of the transverse module on a worm wheel are
identical. In the Calculation menu, select Settings > Calculations
> Calculation with normal module instead of axial module
to use the normal module mn instead of the axial module in future calculations.
NOTE

This changes the way the tip and root circles (see page II-562) are calculated.

17.2.2

Pressure angle at normal section

The normal pressure angle at the reference circle is also the flank angle of the reference profile. For standard toothings the pressure angle is n = 20o. You can use
smaller pressure angles for a larger number of teeth to achieve higher contact
ratios. Larger pressure angles increase the strength and allow a smaller number of
teeth to be used without undercut. In this situation, the contact ratio decreases and
the radial forces increase.

17.2.3

Lead angle at reference circle

The lead angle in a worm (gear 1) is the complement of the helix angle and is
calculated in accordance with equation 17.1.

Chapter
II-547

Worms with enveloping worm wheels

17

(17.1)

Click the
button to open the Convert lead angle dialog window in
which you can calculate the lead angle from other toothing values. These options
are available here: from center distance, from reference diameter and from the reference circle and the center distance
(x2* is modified). A larger lead angle produces greater efficiency, whereas you
can design self-locking toothing if you use a smaller lead angle.

17.2.4

Center distance

Click the
button to calculate the center distance from the values of profile shift
*
coefficient x , number of teeth z and lead angle . In this case, you do not receive a
message telling you that the calculation has been performed correctly.

17.2.5

Number of teeth

The number of teeth on a worm usually is in the range 1 z1 4.

Chapter
II-548

Worms with enveloping worm wheels

17

17.2.6

Facewidth

For more information about the dimensions of gear teeth and wheel flange widths,
please refer to Figure 17.3. Enter the width of the worm wheel in the facewidth b2R
input field. The facewidths b2H and b2 of the worm wheel are then calculated from
this value.

Figure 17.3: Dimensions of gear tooth and wheel flange width

17.2.7

Profile shift coefficient

In the Worms with globoid worm wheels calculation module, the profile
shift for worm/gear 1 is set to zero (as defined in the ISO 14521 standard). You can
only change the tooth thickness of the worm in the Tolerances input window.

NOTE

You should use the Crossed helical gears and precision

mechanics worms calculation module if you require a worm where the profile
shift coefficient is x1*

0.

Chapter
II-549

Worms with enveloping worm wheels

17

17.2.8

Tooth thickness modification factor

This factor should only be used in special cases. The factor xs changes the tooth
thickness with As = 2 * xs * as it does with bevel gears. xs2 = -xs1 always applies
so the clearance does not change if xs1 is changed Reasonable values for xs1 lie in
the range -0.1 to +0.1.
It is useful to apply this factor in situations where: The worm is significantly harder
than the gear. In operative use, the gear will wear and cause the drive to fail. This is
because the gear teeth will have become thinner and thinner, and will break. If the
worm's tooth thickness is changed, for example to xs1 = -0.1, the gear tooth will be
thicker. This will result in a much longer service life.

17.2.9

Quality

In this input field you specify the accuracy grade in accordance with the standard
shown in brackets. To change the standard used for this calculation, select
Calculation > Settings > General > Input of quality.
Achievable qualities are shown in Table 17.1.
Manufacturing process

Quality according to DIN/ISO

Grinding

...

Shaving

...

Hobbing

(5)6

...

Milling

(5)6

...

Shaping

(5)6

...

Punching, Sintering

...

12

Table 17.1: Quality values for different manufacturing processes

Chapter
II-550

Worms with enveloping worm wheels

17

17.2.10

Geometry details

Figure 17.4: Define details of geometry window

Click the Details... button in the Geometry group to open the Define
details of geometry window in which you can modify the parameters listed
below.

17.2.10.1
Shape of fl ank
The flank shape is a result of the manufacturing process. ZA, ZN, ZK and ZI
worms have very similar levels of efficiency and flank load capacity. Although ZC
and ZH worms (hollow flanks) have better load capacity in some situations, they
do have other major disadvantages.

ZA form:

manufactured on turning machine with tool (straight flanks),

mounted in axial section

ZN-form:

manufactured on turning machine with tool (straight flanks),

mounted in normal section

ZI form:

manufactured with hobbing cutter (worm flank is involute)

ZK form:

manufactured with grinding wheel (straight flanks), mounted

in normal section

ZC, or ZH
form:

Manufacturing with special tools to generate a hollow flank

Chapter
II-551

Worms with enveloping worm wheels

17

For more information, please refer to: Dubbel [38], with figures on pages G136 and
S79.

17.2.10.2 External diam eter and throat radiu s

You specify values for the external diameter de2 and throat radius rk as specified in
DIN 3975-1:2002-7. In accordance with equations (59) and (67) the following values are suggested for these two dimensions:

with:
da2

- Tip diameter

mx

- Axial module

- Center distance

17.2.11

Material and lubrication

Materials
The strength calculation method used for worms in accordance with ISO 14521 is
based on empirical values determined using these materials:
Worm:
Case hardening steels (especially 16MnCr5), HRC = 58 to 62
Heat treatable steels (especially 42CrMo4), heat or induction-hardened, HRC =
50 to 56
Nitriding steels (especially 31CrMoV9), gas-nitrided
Worm wheel:
Bronze (GZ-CuSn12, GZ-CuSn12Ni, GZ-CuAl10Ni)
Grey cast iron (GGG40, GG25)
Polyamide (PA-12, cast)

Chapter
II-552

Worms with enveloping worm wheels

17

To calculate strength you require very special materials data, in particular the wear
values. The standard only specifies these values for the most commonly used worm
wheel materials (mostly bronze). This is why the selection of materials in KISSsoft
is limited. As defining data for materials that are not already documented takes a
great deal of time and effort, we strongly recommend you select a material from
the list that is closest to the material you actually want to use.
Lubricants
Selecting the right lubricant for a worm gear is extremely important. Synthetic
lubricants (polyglycols or polyalfaolephine) can reduce loss and wear enormously.

Chapter
II-553

Worms with enveloping worm wheels

17

17.3

Load

Figure 17.3: Rating input window in the Worms with globoid worm wheels
module

17.3.1

Strength calculation methods

The calculations defined in ISO 14521 and E DIN 3996:2006 are identical.
However, strength calculation as defined in ISO 14521 includes a number of different methods (A,B,C,D;). KISSsoft uses the most precise documented method
which usually corresponds to Method B. This calculation method is not suitable for
every material (see section "Material and lubrication" on page II-551) because
some of the empirical values are missing.
The ISO 14521 standard provides a calculation method for determining:
Efficiency
Wear and Wear safety
Pitting safety
Root safety
Bending safety
Temperature safety
NOTES:

Chapter
II-554

Worms with enveloping worm wheels

17

To calculate strength you require very special materials data, in particular the
wear values. The standard only specifies these values for the most commonly
used worm wheel materials (mostly bronze). This is why the selection of materials in KISSsoft is limited.
Grease lubrication: grease lubrication is not mentioned in DIN 3996. In this
situation, KISSsoft performs the calculation as for oil bath lubrication. This assumption is permissible, because the lubrication type has very little influence
on the calculation.
Endurance limit values for tooth root load capacity: The standard provides two
different values. If you enter the smaller value in the database, no decrease in
quality due to plastic deformation of the teeth will be accepted.

17.3.2

Service life

The value in the Service life input field is used together with the speed to
calculate the number of load cycles.

17.3.3

Application factor

The application factor compensates for any uncertainties in loads and impacts,
whereby KA 1.0. Table 17.2. illustrates the values that can be used for this factor.
You will find more detailed comments in ISO 6336.

Operational behavior
of the driving machine

Operational behavior of the driven machine

uniform

moderate
shocks

medium
shocks

heavy
shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

Table 17.2: Assignment of operational behavior to application factor

17.3.4

Permissible decrease in quality

Depending on the construction type of the worm wheel, it may experience a

decrease in quality over time due to wear. This value must not sink below the value

Chapter
II-555

Worms with enveloping worm wheels

17

specified in this input field. A decrease in quality is linked to the plastic deformation of the material and therefore a higher material property. This, in turn, results in
a higher safety against plastic deformation in the root.

17.3.5

Power, torque and speed

Click the
button next to the power input field (for the torque) to calculate the
power (torque) so that a predefined safety minimum (see section "Required safeties" on page II-459) can be maintained.

17.3.6

Strength details

Figure 17.5: Define details of strength window

Click the Details... button in the Strength group to open the Define
details of strength window in which you can change the following
parameters.

Chapter
II-556

Worms with enveloping worm wheels

17

17.3.6.1
Support of gearing
The calculation method used to ascertain bearing power loss of the integral worm
shaft identifies two different types of bearing.

17.3.6.2
Bearing power lo ss
If roller bearings are used, the power loss is calculated using the empirical
formulae defined in ISO 15451. If sliding bearings are used, you must specify the
power loss manually.

17.3.6.3
Number of radi al sealing rings, worm shaft
To calculate the power loss in sealing, you must enter the number of radial sealing
rings on the integral worm shaft. The sealing gaskets on the worm shaft are not
taken into account because their slow rotation speed means they lose very little
power (the calculation formulae are defined in ISO 15451).

17.3.6.4
Permi ssib le tooth thic kness decre ase
The permissible tooth thickness decrease (on the gear) is necessary for calculating
the wear safety and taken into account when calculating the root safety. If this input field contains the value 0, the permissible tooth thickness decrease is not
checked.

17.3.6.5
Permi ssib le mass decrease
You can limit the permissible mass decrease in kg on the worm wheel (for
example, by specifying oil change intervals). This limiting value is also used to
define wear safety. If this input field has the value 0, the mass decrease will not be
checked.

NOTE

The decrease in mass experienced on the worm is not calculated, because the standard assumes that the worm is harder than the worm wheel and therefore will not
be subject to wear.

Chapter
II-557

Worms with enveloping worm wheels

17

17.3.6.6

Dimension of the integral wo rm shaft

Figure 17.6: Dimensions of the worm-worm wheel

l1

Distance between the bearings on the integral worm shaft

l11

Distance from bearing 1 to the middle of the worm

You need these values to calculate the bending safety. The position of the drive has
no effect on the calculation.

17.3.6.7
Load spectra with negative element s
Load spectra with negative load bins (T < 0 and/or n < 0) can also be calculated as
follows (this is only applied to bins whose alternating bending factor is YM=1.0).

IMPORTANT:
A load bin is considered to be negative if the mating flank is placed under load.
The same definition is used for the speed and torque (or power) prefix as in
KISSsys.

Chapter
II-558

Worms with enveloping worm wheels

17

Consequently, the following bins are evaluated as negative:

Factor for torque or
power

Factor for
speed

Flank under load

Actual load bin

Working flank (*)

Evaluated as positive

Working flank (*)

Evaluated as positive

Mating flank

Evaluated as negative

Mating flank

Evaluated as negative

(*) Working flank as entered in the Strength tab

Under "Details" in the "Strength" section of the "Load" tab, you can select the
following:
For calculating pitting safety

Evaluate all negative load bins as positive (as up to now)

Consider only positive load bins

Consider only negative load bins

For calculating the tooth root safety

Evaluate all load bins (as up to now)

For negative load bins, increase root stress by 1/0.7

Increase bending stress for positive load bins by 1/0.7

Chapter
II-559

Worms with enveloping worm wheels

17

17.4

Tolerances

The structure and functionality of the Tolerances (see page II-352)

input window in the Worms with globoid worm wheel calculation
module is the same as the Tolerances input window for cylindrical gears. When
you enter dimensions for worm calculations, we recommend you click on the
Tooth thickness tolerance drop-down list and select either the Worm
as defined in Niemann or Worm wheel as defined in Niemann
option. The corresponding data is based on recommendations in Niemann [66].

Chapter
II-560

Worms with enveloping worm wheels

17

17.5

Settings

In the Calculation menu you will find the Settings option. Click this sub
menu to open the Module specific settings window. From here you can
access the tabs listed below to input other calculation parameters.

17.5.1

General

Figure 17.7: General tab in the Module-specific settings window

(entries that are not detailed here (see page II-446))

17.5.1.1
Power-on time
To calculate the service life, multiply the power-on time with the number of load
cycles. The temperature calculation also takes into account the power-on time
when it determines the amount of heat generated.

Chapter
II-561

Worms with enveloping worm wheels

17

17.5.1.2
Shaft angle
The default value of the shaft angle is set to 90 degrees because this is the default
value specified in the strength calculation method defined in DIN 3996. However,
you can calculate the geometry with shaft angle that is not 90 degrees by using the
Crossed helical gears and precision mechanics worms (see
page II-565) calculation module.

17.5.2

Reference gearing

Figure 17.8: Reference gearing tab in the Module-specific settings

window

This calculation is based on a standard reference gearing, on which tests have been
performed. The default data corresponds to the reference gearing in ISO 14521.
However, if you have the results of your own tests or empirical values, you can
modify this calculation to take advantage of this expertise. For a more detailed description, please refer to ISO 14521.

Chapter
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Worms with enveloping worm wheels

17

17.5.3

Calculations

Figure 17.9: Calculations tab in the Module-specific settings window

17.5.3.1
Calculation wit h normal module instead o f axial m odule
The geometry of worm gear pairs is usually calculated with the axial module (or
transverse module of the worm wheel). If you click on this checkbox, all the values
used for the reference profile are calculated with the normal module (tool module).
This particularly affects the tip and root circle. In contrast, the profile shift x*x mx
(mx for the axial module) remains unchanged.

The formula for the tip circle (mn for the normal module) is then:
da1 = dm1 + 2 mn haP
da2 = d2 + 2 mx x2 + 2 mn haP
For the root circle, the following apply:
df1 = dm1 - 2 mn hfP
df2 = d2 + 2 mx x2 - 2 mn hfP

Chapter
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Worms with enveloping worm wheels

17

17.5.3.2

Calculation wit h enhan ced formulae (diffe rs from sta ndard)

If you select this checkbox, alternative calculation methods are used at these
points:

Effective tooth thickness on the tip (instead of formula (84): calculated in accordance with DIN or formula (110) in accordance with ISO)
Loss of power on toothing PVZ with coefficient 1/9.550 Instead of 0.1

17.5.4

Required safeties

Figure 17.10: Required Safeties tab in the Module-specific Settings

window

KISSsoft issues an error message if the specified required safeties have not been
reached after you completed the calculation. Sizing is always calculated on the basis of the required safeties for tooth fracture, pitting and wear. If you do not wish to
use one or more of these criteria, set the appropriate required safety to zero. In
accordance with ISO 14521 you must ensure the following safeties:

Chapter
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Worms with enveloping worm wheels

17

Root safety

: 1.1

Pitting safety

: 1.0

Wear safety

: 1.1

Bending safety

: 1.0

Temperature safety

: 1.1

You can change these values as required to reflect your own findings.

Chapter
II-565

Crossed helical gears and precision mechanics worms

18

18

Crossed he lica l g ears a nd prec ision me cha nics wor ms

Chapter 18
Crossed helical gears and precision mechanics worms
Crossed helical gears are helical gears that are mounted on crossed axes. The shaft
angle is usually = 90o. In contrast to the line contact shown in enveloping worms,
crossed helical gears only contact at one point when they are generated. As a result,
they can only transmit very small forces and are primarily used for control
purposes.
In precision engineering, a worm wheel is often manufactured in the same way as a
helical gear. This makes it easier to produce and assemble than a globoid gear
manufactured using a worm-shaped cutter. In this situation, you should calculate
the geometry of the worm wheel in the same way as a helical gear. This is because,
if the profile shift total is not equal to zero, the helix angle of the gear will not
match the lead angle of the worm. Both gears have the same hand of gear. If the
worm has right hand teeth, then the worm wheel is also right hand. The total of
both helix angles at the operating pitch circle/spiral is exactly the same as the shaft
angle. However, due to the profile shifts, the total of helix angles at the reference
circle is not identical to the shaft angle.
In special cases, the shaft angle can also be smaller than the helix angle of gear 1.
In this situation, gear 2 has the opposite hand of gear to gear 1.

Chapter
II-566

Crossed helical gears and precision mechanics worms

18

18.1

Underlying principles of calculation

The method used to calculate crossed helical gears (cylindrical gears with crossed
axes) is defined in [66]. The current version of this standard describes methods
used to calculate and check the geometry of spiral toothed gears for any shaft angle. The measures used for checking and fabrication are determined arithmetically.
Although the method detailed in Niemann [66] is used to calculate the root and
flank strength and the scuffing safety as concept, the individual equations used are
following ISO 6336. (Niemann uses equations from an old edition of DIN3990).

Chapter
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Crossed helical gears and precision mechanics worms

18

18.2

Basic data

Figure 18.1: Basic data input window

18.2.1

Normal module

Enter the normal module. However, if you know the pitch, transverse module or
diametral pitch instead of this, click on the
button to open a dialog window in
which you can perform the conversion. If you want to transfer the diametral pitch
instead of the normal module, you can select Input normal diametral
pitch instead of normal module by selecting Calculation >
Settings > General.

18.2.2

Pressure angle at normal section

The normal pressure angle at the reference circle is also the flank angle of the reference profile. For standard toothings the pressure angle is n = 20o. You can use
smaller pressure angles for a larger number of teeth to achieve higher contact
ratios. Greater pressure angles increase the strength and allow a smaller number of
teeth to be used without undercut. In this situation, the contact ratio decreases and
the radial forces increase.

18.2.3

Helix angle reference circle gear 1

The center distance, number of teeth, profile shift (x*1, x*2) and shaft angle are used
to calculate the helix angle of gear 1. It often happens that several helix angles
meet the requirements of the toothing geometry. In this situation, when you click
the
button you see an Information window that lists the possible values.
Here the solution that is closest to the current value is selected automatically.
However, if only one value is suitable for the sizing, it is transferred into the input

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field without any messages being displayed. If the sizing function is unable to find
any solutions, it displays a warning message and you must then change either the
center distance or the module.

18.2.4

Center distance

The center distance is calculated on the basis of the helix angle of gear 1, the shaft
angle, the profile shift (x*1, x*2) and the number of teeth.

18.2.5

Facewidth

Because the facewidth must have a minimum value, the input field has a
button
which you can use to define the minimum width based on the parameters you have
already defined.

18.2.6

Profile shift coefficient

The tool can be adjusted during manufacture. The distance between the production
pitch circle and the tool reference line is called the profile shift. To create a positive
profile shift, the tool is pulled further out of the material, creating a tooth that is
thicker at the root and narrower at the tip. To create a negative profile shift the tool
is pushed further into the material, with the result that the tooth is narrower and
undercutting may occur sooner. In addition to the effect on tooth thickness, the
sliding velocities will also be affected by the profile shift coefficient.
Click the
button and KISSsoft will determine whether the profile shift
coefficient (see page II-265) is to be taken from measured data or from values
given in drawings.

NOTE

If one of the two profile shift values appears in gray, this means it will be
calculated by KISSsoft. This is what happens when you activate the checkbox for
entering the center distance. If you overwrite a gray field, it will become active and
KISSsoft will calculate the value for one of the other gears.

18.2.7

Quality

In this input field, you specify the accuracy grade in accordance with the standard
shown in brackets. To change the standard used for this calculation, select
Calculation> Settings > General > Input of quality. The

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accuracy grade in accordance with ISO 1328 is very similar to that in DIN 3961 or
AGMA 2015.
Achievable qualities are shown in Table 18.1.
Manufacturing process

Quality according to DIN/ISO

Grinding

...

Shaving

...

Hobbing

(5)6

...

Milling

(5)6

...

Shaping

(5)6

...

Punching, Sintering

...

12

Table 18.1: Quality values for different manufacturing processes

18.2.8

Define details of geometry

Click the Details... button in the Geometry group to open the Define
details of geometry window in which you can modify the parameters listed
below.

Figure 18.2: Geometry details input window

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18.2.8 .1
Shaft angle
The shaft angle is usually = 90o, but you can specify your own value here.

18.2.8 .2
Inside di ameter
The inside diameter is needed to calculate the mass moment of inertia. As defined
in ISO or AGMA, the gear rim thickness does affect the strength. For complete
gears, enter 0, for external gears with a web, enter the appropriate diameter di as
shown in Figure 18.3. For internal wheels, enter the external diameter of the gear
rim.

Figure 18.3: Measures of the diameter

The inside diameter of the gear's flange is required for calculations in accordance
with ISO or AGMA. Where thin gear rims are used, this factor can greatly
influence the calculation results. See also the figure shown above <Kap16:>.3.

18.2.9

Material and lubrication

The materials displayed in the drop-down lists are taken from the materials database. If you cannot find the material you require in this list, you can either select Own
Input from the list or enter the material in the database first ( Additional information (see page I-124)). Click the
button to open the Material gear
1(2) window in which you can select a material from the list of materials
available in the database. Select the Own Input option to enter specific material
characteristics. This option corresponds to the Create a new entrywindow
in the database tool.

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18.3

Load

Figure 18.2: Load input window

18.3.1

Methods used for strength calculation

As yet, no binding standard has been drawn up for the calculation of crossed
helical gears. KISSsoft therefore recommends you use the ISO 6336 (see page II572) Calculation of load capacity of spur and helical gears.
You can use one of three different methods to calculate the strength of worms:

18.3.1.1
Strength calculation in acc. with Hirn
The method used to calculate worms as defined by H.Hirn is based on an obsolete
edition of Niemann's machine elements. It calculates the temperature safety, the
flank safety, the root safety, and the bending safety. Although the material values
cannot be compared with the values for worm calculation as defined in DIN 3996,
the safeties are, however, similar.

We do not recommend you to use this obsolete method.

NOTE

The calculation method defined in Hirn also selects a material pairing. This must
match the material pair selected in the Materials and lubrication area.
Shaft angle = 90o and z1 < 5.

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18.3.1.2
Strength calculation in acc. with Hoechst
You can use the strength calculation in accordance with Hoechst for worm wheels
made from Hostaform (POM), paired with steel worm gears [80]. The permitted
load coefficient is c [N/mm2], see Gln. (18.1) (18.3) is a value that defines the
temperature resistance. This method also checks the worm's permitted flank
pressure and blocking safety. The decisive value for blocking safety is maximum
load, not continuous load.

(18.1)

(18.2)

(18.3)

where
F2

circumferential force on the worm

wheel

fz

coefficient for number of teeth

usable width

mn

normal module

mean lead angle

da1

tip diameter of worm

dm1

reference diameter of worm

NOTE:

Shaft angle = 90o and z1 < 5. The calculation method involves a worm made of
steel and a crossed helical gear made of plastic.

18.3.1.3
Strength calculation in acc. with ISO 6336/Niemann
You can perform the strength calculation for crossed helical gears with z1 5 as
defined in Niemann [66]/ISO 6336. As stated in Niemann, the contact ellipse is
calculated using a for the width and b for the height of the half axes. An effective
facewidth of 2a is assumed for flank safety (pitting). The same value plus twice the

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module value is used to calculation the strength of the tooth root. This corresponds
to the specifications given in ISO 6336, if the facewidth is greater than the contact
width. Scuffing safety is calculated as defined in Niemann [66]. This method
differs from the DIN 3990-4 guideline because of the high sliding velocities of the
crossed helical gears. It is more similar to the method applied to hypoid bevel
gears. It supplies proof of tooth root resistance, flank load capacity and resistance
to scoring.

NOTE:

If the number of teeth is z < 5, this calculation supplies tooth root and contact stress
safeties that are too high.

18.3.1.4
Strength calculation as defined in VDI 2736
This VDI guideline is still at the draft stage. It defines how precision mechanics
worms are to be calculated.

18.3.1.5
Static calculation
The static calculation performs a static estimate of safety against fracture and yield
point. This calculation is performed in accordance with the formulae documented
in 13.2.11 Static calculation.

The calculation for worm gears returns safeties that tend to be too great, because
worms are usually checked for safety against shearing.

18.3.1.6
Static calculation on shearing
Verification of a worm wheel on shearing

F = Ft2*KA*YE/A
A = bmax/5*(4*stda2-stdx2)
dx2 = 2* a-da1

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This calculation is performed automatically and is documented in the report in

Section 6A.

Figure 18.4: Dimensions of the shear cross section.

18.3.2

Service life

The system displays the required service life in the input field. To enter it directly,
and perform sizing, click the
button. Based upon the minimum safety value for
the tooth root and flank strength, this process calculates the service life (in hours)
for every gear and for every load you specify. The service life is calculated in
accordance with ISO 6336-6:2006 using the Palmgren-Miner Rule. In the range of
endurance limit, you can also select a modified form of the Woehler line instead of
ISO 6336 or DIN 3990. The system service life and the minimum service life of all
the gears used in the configuration is displayed. You can size the service life using
the
button either with or without defining a load spectrum (see page II-304).
You will find more detailed information about defining load spectra in section
14.19 (see page II-304).

NOTE

Only the ISO 6336 method includes a calculation for the service life.

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18.3.3

Application factor

The application factor compensates for any uncertainties in loads and impacts,
whereby KA 1.0. Table 18.4 illustrates the values that can be used for this factor.
You will find more detailed comments in ISO 6336.
Operational behavior
of the driving machine

Operational behavior of the driven machine

uniform

moderate
shocks

medium
shocks

heavy
shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

Table 18.4: Assignment of operational behavior to application factor

18.3.4

Power, torque and speed

Click the
button next to the power input field (for the torque) to calculate the
power (torque) so that a predefined safety minimum (see page II-459) can be
maintained. Click the
button next to the power input field to apply a frequency
distribution for power, torque and speed in the Define load spectrum
(see page II-304) window.

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18.3.5

Strength details

Click on the Details... button to open the Define details of load

window which is divided into System data, Pair data and Gear data.

18.3.5.1
Pro file modi fication
You can modify the theoretical involute in high load capacity gears by
grinding/polishing the teeth. You will find suggestions for sensible modifications
(for cylindrical gears) in KISSsoft Module Z15 (see section "Modifications" on
page II-356). The type of profile modification has an effect on how scuffing safety
is calculated. The load sharing factor X is calculated differently according to the
type of profile modification used. The main difference is whether the profile has
been modified or not. However, the differences between for high load
capacity and for smooth contact are relatively small. The strength
calculation standard presumes that the tip relief Ca is properly dimensioned but
does not provide any concrete guidelines. The resulting load sharing factor X in
accordance with DIN 3990, depends on the type of profile modification:

(a) no profile modification

(b) high performance gears; pinion

drives

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Crossed helical gears and precision mechanics worms

18

(c) high performance gears; gear drives

(d) balanced contact

Figure 18.9: Load sharing factor X for different profile modifications

18.3.5.2
Li fetime factors as defined in ISO 6336
The fatigue limit factor ZNT reduces the permitted material stress in accordance
with ISO 6336-2:2006:

(12.14)
(12.15)

As stated in ISO 6336, this value is important for cylindrical gear calculations and
is the reason for the lower safety values for the range of endurance limit when
compared with DIN 3990.
1. normal (reduction to 0.85 at 1010 cycles): The permitted material stress in
the range of endurance limit (root and flank) is reduced again. Fatigue
strength factors Y NT and ZNT are set to 0.85 for 1010 load cycles.
2. increased with better quality (reduction to 0.92): Y NT and ZNT at 1010
load cycles are set to 0.92 (in accordance with the data in ISO 9085).
3. with optimum quality and experience (always 1.0): This removes the reduction and therefore corresponds to DIN 3990. However, this assumes the
optimum treatment and monitoring of the materials.

18.3.5.3
Relat ive welding factor (scuffing)
The relative welding factor takes into account differences in materials and heat
treatment at scoring temperature. However, the standards do not provide any details about how to proceed when different types of material have been combined in
pairs. You must input this coefficient yourself because it is not set automatically by
KISSsoft.

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Relative welding factor as defined in DIN 3990, Part 4:

Heat-treated steels

1.00

Phosphated steel

1.25

Coppered steel

1.50

Nitrided steel

1.50

Case-hardened steels

1.15 (with low austenite content)

Case-hardened steels

1.00 (with normal austenite content)

Case-hardened steels

0.85 (with high austenite content)

Stainless steels

0.45

The standard does not provide any details about how to proceed when the pinion
and gear are made of different material types. In this case it is safer to take the
lower value for the pair.

18.3.5.4
Number of load cycles
KISSsoft calculates the number of load cycles from the speed and the required service life. If you want to influence the value, you can define it in the Number of

load cycles for gear n window. Click the

button to access this. In
this window you can select one of five different options for calculating the number
of load cycles.
1. Automatically The number of load cycles is calculated automatically from
the service life, speed, and number of idler gears.
2. Number of load cycles Here you enter the number of load cycles in millions. You must select this option for all the gears involved in the calculation
to ensure this value is taken into account.
3. Load cycles per revolution Here you enter the number of load cycles per
revolution. For a planetary gear unit with three planets, enter 3 for the sun
and 1 for the planets in the input field.
Note:
If the Automatically selection button in the calculation module is selected, KISSsoft will determine the number of load cycles in the Planetary stage calculation module, while taking into account the
number of planets.
4. Load cycles per minute Here you enter the number of load cycles per minute. This may be useful, for example, for racks or gear stages where the
direction of rotation changes frequently, but for which no permanent speed
has been defined.

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5. Effective length of rack The rack length entered here is used to calculate
the number of load cycles for the rack. The rack length must be greater
than the gear's perimeter. Otherwise, the calculation must take into account
that not every gear tooth will mesh with another. You must enter a value
here for rack and pinion pairs. Otherwise the values NL(rack) =
NL(pinion)/100 are set.
NOTE

This calculation method is used for transmissions with a slight rotation angle.
This scenario assumes that a reduction is present

and a pivoting angle w in [o] from gear 2, where gear 2 constantly performs forwards and backwards movements by the angle value w. The effective endurance is
given as the service life. The two coefficients N1 and N2, which reduce the absolute
number of load cycles, NL, are now calculated. To do this:
a) Set the alternating bending factor of the pinion and gear to 0.7, or calculate
it as defined in ISO 6336-3:2006. In this case, a complete forwards/backwards movement is counted as a load cycle.
b) For the pinion, coefficient N1 is determined as follows:

c) The number of load cycles of teeth in contact in gear 2 is smaller by a

coefficient of N2 when compared with the number of load cycles during
continuous turning.

The coefficient 0.5 takes into account both the forwards and backwards
movements.
d) Enter coefficients N1 and N2 in the Load cycles per revolution
input field.

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18

The correct number of load cycles can now be calculated on the basis of the data
entered in steps a to d.

18.3.5.5
Optimal tip rel ief
To calculate safety against micropitting as specified by Method B in ISO 15144,
you must specify whether or not the profile modification is to be assumed to be
optimal. The same applies to calculating the safety against scuffing. The software
checks whether the effective tip relief (Ca) roughly corresponds to the optimum tip
relief (Ceff). If this check reveals large discrepancies, i.e. Ca < 0.333*Ceff or Ca >
2.5*Ceff, a warning is displayed. In this case, the value you input is ignored and
documented accordingly in the report.

18.3.5.6
Hardening depth, know n by its abbre viation "EHT"
You can input the intended hardening depth (for hardness HV400, for nitrided
steels, or HV550 for all other steels). You can also input the hardness HV300. This
value is then used to display the hardening curve as a graphic. The input applies to
the depth measured during final machining (after grinding).

When you input this data, the safety of the hardened surface layer is calculated
automatically according to DNV 41.2 [93]. Here a minimum value of t400 (nitrided
steel) or t550 (all other steels) is used. If only the value for HV300 is known, this
value is then used. However, the calculation should then only be seen as an
indication. The calculation is performed as described in the section in [93]
"Subsurface fatigue". The values required to define the EHT coefficient YC as
specified in DNV 41.2 are also needed. The calculation is performed using different solutions than the calculation of the proposal for the recommended hardening
depth, but still returns similar results (proposal for hardening depth). To obtain a
proposal for a sensible hardening depth, we recommend you call the calculation in
Report->Proposals for hardening depth. A maximum value for the
hardening depth is only used to check the hardening depth at the tooth tip. It is
mainly used for documentation purposes.

18.3.5.7
Load spectra with negative element s
Load spectra with negative load bins (T < 0 and/or n < 0) can also be calculated as
follows (this is only applied to bins whose alternating bending factor is YM=1.0).

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18

IMPORTANT:
A load bin is considered to be negative if the mating flank is placed under load.
The same definition is used for the speed and torque (or power) prefix as in
KISSsys.
Consequently, the following bins are evaluated as negative:
Factor for torque or
power

Factor for
speed

Flank under load

Actual load bin

Working flank (*)

Evaluated as positive

Working flank (*)

Evaluated as positive

Mating flank

Evaluated as negative

Mating flank

Evaluated as negative

(*) Working flank as entered in the Strength tab

Under "Details" in the "Strength" section of the "Load" tab, you can select the
following:
For calculating pitting safety

Evaluate all negative load bins as positive (as up to now)

Consider only positive load bins

Consider only negative load bins

For calculating the tooth root safety

Evaluate all load bins (as up to now)

For negative load bins, increase root stress by 1/0.7

Increase bending stress for positive load bins by 1/0.7

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18.4

Settings

In the Calculation menu you will find the Settings option. Click this sub
menu to open the Module specific settings window. From here you can
access the tabs listed below to input other calculation parameters. (the following
parameters are not described here (see page II-446))

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18

18.5

Notes

18.5.1

Checking the contact pattern

The collision check shown in the 2D graphic (Meshing (see page II-617)) can only
be used to a limited extent for crossed helical gears because it only works for a
shaft angle of 90, does not take flank line modifications into account, and only
represents generating in the axial section.
A better option here is to generate a 3D model which includes all the flank line
modifications and works for any shaft angle. The "Skin model" 3D variant can be
used to represent the contact pattern and check it exactly when the gears are being
generated. To do this, click the appropriate function button to rotate one gear
slightly against the other until the contact pattern appears, and then generate the
two gears. To ensure the gears do not engage too fully, we recommend you set the
number of rotation steps to 30 or higher (in Properties).

Figure 18: Contact pattern of a worm gear toothing

Chapter
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19

19

Bevelo id gears

Chapter 19
Beveloid gears
Beveloid gears, also known as coned gears, are generated by a rack-like cutter/tool
which is tilted by a predefined angle (see K.Roth, Zahnradtechnik - Evolventen_Sonderverzahnung [79])
Beveloid gears are primarily used in two particular areas: to generate a shaft angle
between two meshing gears. Alternatively, two beveloid gears with opposing cone
angles can be used to generate backlash-free toothing.
Beveloid gears with a single shaft angle can be used to achieve a compact type of
gear unit.
Unfortunately, no standards or guidelines have yet been drawn up for the
calculation of complex geometry, or for strength.
For this reason, the geometry calculation method used in KISSsoft is based on
standard technical literature and publications. The main data used is taken from the
publications mentioned in the next section.
For simplicity's sake the strength in the mid section is calculated as if for a
cylindrical gear pair.

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19

19.1

Underlying principles of calculation

The basic calculation of the geometry and tooth form for a single beveloid gear is
based on K.Roth [79], and on well known standards for cylindrical gears (e.g. DIN
3960, DIN 867, etc.).
Therefore, the beveloid gear is generated using the same process as a cylindrical
gear, except that the profile shift changes along the facewidth. And this therefore
changes all the parameters which are affected by the profile shift.
When spiral toothed gears are involved, the cutter is also angled towards cone angle by helix angle . In the transverse section, this creates a trapezoidal reference
profile with different pressure angles on the left and the right. This has a
significant effect on the tooth form, because it changes the base circles.
The changes to the profile shift across the facewidth mean that beveloid gears often
run the risk of undercut at the root or having teeth that are too pointed. The profile
shift at the toe and heel is calculated by

The undercut limit and minimum topland are only output in the error message if the
values are exceeded with the data that has just been entered. As the two sizes on
the left and right may be different (in the case of helical gear teeth), the system displays the more unfavorable value in each case.
The beveloid pair's meshing conditions are calculated on the basis of the publications by S. J. Tsai [98] [99]. In this case it is important to note that the parameters
are sub-divided into manufacturing and working parameters ("Manufacturing Data
and Working Data" chapter).

Chapter
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19

19.2

Basic data

19.2.1

Normal module

You can enter the normal module here.

However, if you know the "Pitch", "Transverse Module" or "Diametral Pitch"
instead of this, click on the conversion button to open a dialog window in which
you can perform the conversion. If you want to transfer the "Diametral Pitch"
instead of the normal module, you can select "Input normal diametral pitch instead
of normal module" by selecting Calculation > Settings > General".

19.2.2

Pressure angle at normal section

This entry relates to the reference profile's flank angle. The normal pressure angle
on the beveloid gear's reference circle is dependent on the cone angle and helix
angle. [79]

19.2.3

Helix angle

Here you can enter the helix angle, or else select a spur gear toothing. The helix
angle entry only applies to gear 1. Gear 2 may have a different helix angle value
from gear 1, and is calculated. For toothing with total profile shift 0, the following
equation applies for determining the second helix angle from the entered parameters:

19.2.4

Shaft angle

You can specify the shaft angle between the two axes of rotation here.
The shaft angle between any two straight pitches can be determined from the scalar
product of the direction vectors of the two straight pitches. This corresponds to the
angle between the two straight pitches in the plan view along the distance vector
between the two straight pitches.

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19

19.2.5

Number of teeth

The number of teeth defines the transmission ratio of the gearing. Only even
numbered, positive values are permitted.

19.2.6

Width

Facewidth of the gears. Please note that, when the width and cone angle are very
large, the profile shifts between the toe and heel may be very different. For this
reason, you cannot input just any value for the width, because this might, for
example, create a tooth that is too pointed.
At present, you cannot specify an axial offset. This means the gear pair contact is
always in the middle of the gear.

19.2.7

Cone angle

The specified cone angle corresponds to the manufacturing parameter used to set
the misalignment of the milling cutter to the gear. Both positive and negative cone
angles are permitted, however, the total cone angle must be at least 0.

19.2.8

Profile shift coefficient (center)

The profile shift coefficient is defined in the same way as for a standard cylindrical
gear, but the value relates to the value at the middle of the beveloid gear. When this
calculation is performed, the Results window displays the size of the profile shifts
at the toe and heel of the gear.

19.2.9

Quality

The quality achieved when generating the beveloid gear.

19.2.10

Material and lubrication

The entry is the same as the normal entry, as for cylindrical gears.

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19

19.3

Reference profile

In the "Reference profile" tab, you can either input the reference profile for the manufacturing process in the same way as for a cylindrical gear calculation, or define
the tools directly.
In this case, you must modify the height in the reference profile as follows to
calculate the tooth form in transverse section (see K.Roth [79], section 5.2.6):

,
Here, the subscript C represents the heights in the transverse section of the beveloid
gear (calculated values) and P represents the heights of the reference profile (input
values). You can check these values in the main report by selecting "Summary /
Reference profile / Gearing".

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19

19.4

Modifications

The selection options for modifications in the beveloid gear module are limited.
In general, the contact pattern for beveloid gears with a shaft angle that is not 0
improves if negative crowningis used. To do this, you can input the "Crowning"
modification and define a negative value.

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19

19.5

Factors

The face load factor

cannot be calculated automatically for beveloid gears,
and must therefore be set by the user. A value of 1.5 is usual here.

Chapter
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19

19.6

Dimensioning

As far as we know, no standards or research projects have yet been completed

which involve the calculation of loads on beveloid gears. For this reason, the
calculation of strength is performed using a replacement cylindrical gear toothing
in the mid section.
Here, note that there is a major difference
from the values calculated in the
standard gearing standards in this case. For this reason, the factor must be entered
manually.
This means that minor differences may occur in the calculated safeties produced
during cylindrical gear calculation and beveloid gear calculation, which are caused
by a slight difference in the way the contact ratio is calculated.

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19

19.7

Manufacturing Data and Working Data

We perform the calculation of the beveloid pair according to J. Tsai [98], so it is

important to know the difference between "manufacturing data" and "working data".
Manufacturing data is the data that is decisive for manufacturing. This category
includes the values that the user enters in the 'Basic data' tab. In contrast to this is
the working data, which relates to the generation geometry of the beveloid gears
that are in use. An example is the cone angle of the angle at which the tool is
tilted during manufacturing. In contrast, the working cone angle wis the angle of
the pitch cone of the beveloid gears in the meshing.
The working data is required to calculate a correct pairing, at which the contact
point of the gears is in the middle of both beveloid gears. For example, if all the
other parameters result in the helix angle value w from gear 2 at the operating
point, this is then converted into a helix angle for the manufacturing process.
The working data is also needed to position the two gears relative to each other. To
position a gear pair in a 3D CAD environment, gear 2 is positioned relative to gear
1 as follows:
1. Displacement along the Y-axis at rw1
2. Rotation around X-axis with w1
3. Rotation around negative Y-axis with w1 + w2
4. Rotation around X-axis with w2
5. Displacement along the Y-axis at rw2

Kapitel 20

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Non circular gears

20

Non circu lar gears

Kapitel 20
Non circular gears
KISSsoft's noncircular gear analysis allows you to calculate gears with noncircular
gear bodies.

Kapitel 20

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Non circular gears

20.1

Input data

Input the geometry, generation and tolerance values in the Basic data tab.
Then, enter the details for generating noncircular gears in the Reference profile
tab.

20.1.1

Geometry

Figure 20.1: Basic data tab: entries for a noncircular gear pair

Kapitel 20

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Non circular gears

The module is defined from the "Results window" (total length of contact
curve/[number of teeth* ]=module).

Figure 20.2: Results window

To save time in the first phase of the sizing process, we recommend you do not
enter the total number of teeth z. We suggest you perform the calculation with a
lower number of teeth (e.g. 2). In this case, although all the contact curves are
calculated completely, only the specified number of teeth (2) are calculated and
displayed.
Initially, start the calculation with a pressure angle in the normal section n of 20.
Later on you can change this angle instead of the profile shift or to optimize the
tooth form.

20.1.1.1
Generate
The start and end angles a and e are important values because they determine the
contact curve area of gear 1, i.e. the area that will be generated. In closed curves
the angle a is 0 and e is 360.

The contact curves or the ratio progression are then defined in files. The files must
be in either "dat" or "dxf" format. These files can be stored in any directory. It is
important to register these files correctly using the

button.

Kapitel 20

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Non circular gears

Contact curves are also stored in the *.Z40 file. As a consequence, when you load a
new calculation, you do not need to access the *.dat file. In this case you see a
message to tell you the file cannot be found, and existing data will be used instead.

Figure 20.3: Message

NOTE

The progression (ratio or contact curve) must be defined from at least the starting
angle to the end angle. To achieve clean intermeshing for the curve, the curve must
have approximately 30 forward motion and follow-up movement. If the curve has
no forward motion and/or follow-up movement, the software extends it
automatically.

In p ut f or ma t f or da ta i n i mp or t e d fi le s

You can predefine one or two contact curves or the ratio progression. The imported
files must have "dat" as their file extension.
A maximum of 7800 lines can be processed during noncircular gear calculation.
Lines that start with # are comments and are ignored. To predefine the ratio progression, input the angle on gear 1 and the ratio.

Figure 20.5: Example of ratio progression

Kapitel 20

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Non circular gears

To predefine the contact curve progression, input the radius and the angle.

Figure 20.6: Example of a contact curve

20.1.2

Tolerances

We recommend you enter sufficiently large tooth thickness allowances Asn (e.g. 0.10/-0.12 for module 2).

20.1.3

Reference profile

You must specify a topping pinion type cutter. The same pinion type cutter is
usually defined for both Gear 1 and Gear 2.

Figure 20.6: Reference profile tab: : entries for a noncircular gear pair

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Non circular gears

Problems may arise unless the profile shift coefficient of the pinion type cutter is
set to 0. You must then carefully check exactly how the gears are generated.

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Non circular gears

20.2

How to use KISSsoft

20.2.1

Angle error

When you input a closed curve (gear 1), using a contact curve or gear reduction
progression, it must start at 0 and finish at 360. For this reason, the rotation of
gear 2 must also be 360 (or a multiple of this). If not, this will result in an error.

Figure 20.7: Minor error for Gear 2: e is 179.9489 instead of 180

However, this error has no effect because the predefined intermeshing allowance is
large enough.

20.2.2

Checking the meshing

A useful way of checking the meshing is to change the number of rotation steps
(per 360) to rotate the gear in larger or smaller steps. You change the step sizes, as
usual, in the Graphics window.

Figure 20.8: Changing the rotation steps

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Non circular gears

When you generate gears with allowances, we recommend you click the
ton to bring the gears into flank contact with each other.

but-

NOTE

If, when you click the "Rotate independently to the right" button,
the torsion exerted by one gear rotates against the other is too large (or not large
enough) , you must adjust the number of "rotation steps" accordingly!

20.2.3

Improve tooth form

You can change the tooth form of circular gears quite significantly by changing the
profile shift. In the current version of the program for noncircular gears, we
recommend you set the profile shift coefficient of the pinion type cutter x*0=0.
Despite this, you can still modify the tooth form by changing the pressure angle n.

20.2.4

Accuracy of the tooth form

Select Calculations -> Settings to predefine the accuracy (and therefore

also the size of the file) for an IGES or DXF export.

Figure 20.9: Module specific settings

This input only influences IGES or DXF files.

In the program, the tooth form (for each flank) is calculated with 100 points. You
will find these results in the TMP files (and in the report). If you want to modify
the number of internally calculated points, simply change the corresponding entry
in the *.Z40 file:
Go to a saved *Z40. file and search for the lines:
ZSnc.AnzPunkteProFlanke=100;

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Non circular gears

and enter, for example, 40 instead of 100. As a result, only 40 points per flank will
be calculated.

20.2.5

Export individual teeth

Go to a saved *Z40. file and search for the lines:

ZRnc[0].AusgabeKontur=0, for Gear 1 or
ZRnc[1].AusgabeKontur=0, for Gear 2.
There, change the variable to the required value, e.g. ZRnc[0].outputcontour=3.
The LEFT flank of the x-th tooth space (therefore the 3rd gap of Gear 1 in the
example) is always output.

Figure 20.10: Temporary file for exporting teeth (ZRnc[0].outputcontour=3, for Gear 1)

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Non circular gears

20.2.6

Report

If you select (Detailed) in Report settings this report will also be very extensive. If you want a shorter version, set "Extent of data" to 5 (standard).

Figure 20.11: Report settings with a changed amount of data for output to a report

20.2.7

Temporary files

When a calculation is performed, KISSsoft automatically generates temporary files. The directory in which these files are generated by KISSsoft must be specified
in KISS.ini in the "Path" section. You will find KISS.ini in the KISSsoft main directory. Before changing the default setting you must ensure that you have read and
write permissions for the changed directory. You will find more detailed information in Section 2 of the manual, "Setting Up KISSsoft".
ZF-H1_Gear 1 (step 1).tmp:
ZF-H1_Gear 2 (step 1).tmp:
ZF-H1_Gear 1 (step 2).tmp:
ZF-H1_Gear 2 (step 2).tmp:

Insignificant, contains information about generating the

pinion type cutter (cutter/tool)
Not important information: contains details, flank for
flank, about generating the noncircular gear

ZF-UNRUND-1.TMP:

Contains interesting information about operating pitch

line 1; defining contact points on operating pitch line 1
calculating operating pitch line 2 from operating pitch
line 1 operating pitch line lengths documentation about
the intermeshing (individual points) of noncircular gear
1 with X

ZF-UNRUND-2.TMP:

Contains interesting information

Documentation
about the intermeshing (individual points) of noncircular
gear 2 with X, Y, normal, diameter and angle

ZF-UNRUND-DAT-1.TMP:

Possible further uses of the intermeshing (individual

points) X,Y coordinates

ZF-UNRUND-DAT-2.TMP:
ZF-UNRUND-OPLINE-1.TMP:

Possible further uses of the intermeshing (individual

Kapitel 20

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Non circular gears

ZF-UNRUND-OPLINE-2.TMP:

points) X,Y coordinates

Z-WalzKurve-1.TMP:

Possible further uses of the contact curve (individual

points) r, -coordinates (*); the format corresponds
exactly to the format of the DAT file (see "Import format" section)

Z-WalzKurve-2.TMP:

Z-OpPitchPoints-1.TMP:
Z-OpPitchPoints-2.TMP:

Can be used in further calculations of pitch points for

each tooth in r, coordinates

Chapter
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21

Repor t men u

Chapter 21
Report menu

Chapter
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21

21.1

Drawing data

To display the toothing data you require to add to a drawing, select Drawing
data. Use the Z10GEAR1?.RPT file (for Gear 1), and the Z10GEAR2?.RPT
file (for Gear 2), etc. (? = d/e/f/i/s for the required language) to modify the template
to your own requirements.
All the angle data for the user-specific Z10GEAR1?.rpt to Z10GEAR4?.rpt reports
is given in degrees-minutes-seconds, and displayed in brackets after the decimal
point.
For example the number 20.3529 is displayed as:
20 21' 10" (20.3529)

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21.2

Manufacturing tolerances

Click on the Manufacture tolerances menu item to generate a report that

displays all the manufacturing tolerances as defined in the ISO 1328, DIN 3961,
AGMA 2000, AGMA 2015 and BS 436 standards.

You will find notes on how to calculate tolerances as defined in ISO 1328 and DIN
3961
This calculation is performed in accordance with the formulae documented in the
standard. As specified in the standard, these formulae use the geometric average of
the edge values in the corresponding area instead of the effective geometric values
(such as module, reference circle, etc.).
Example:
As specified in ISO1328-1:1995 the following area limits are predefined for the
module mn:
0.5 / 2 / 3.5 / 6 / 10 / 16 / 25 / 40 / 70 mm
For module mn = 2.1, the equations use the geometric mean value of the range limits 2 and 3.5 instead of the ratio 2.1. Therefore sqrt(2*3.5)=2.645.

Exceptions (the standards do not provide any notes about exceptions):

- If the size is less than the lowest range limit, the lower range limit is used as the
value if the value >= 0.8*range limit, otherwise, the effective value is used.
- If the size is greater than the upper range limit, the effective value is used.

Example:
Module mn = 85

-> 85 is used.

Module mn = 0.44 -> 0.5 is used (0.8*0.5 = 0.4 is less than 0.44).
Module mn = 0.31 -> 0.31 is used.

Note:
In some circumstances, calculations performed in accordance with the formulae in
ISO 1328 may return data that is slightly different from the tables specified in the
standard. We have also discovered that the formulae in DIN 3961 may return
slightly different values from the data given in the tables in DIN 3962 and 3963.
However, the majority of the variations are at most 1m.

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21.3

Summary

You use the summary function to compare the current toothing with the results of
fine sizing.

Chapter
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21.4

Service life

This report shows the most important data that is used to calculate service life
either with or without a load spectrum (see page II-304). You can also call the service life calculation by clicking the Sizing button next to the Service life input
field. This then displays the service life that should be achieved if required safeties
are used.

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21.5

Sizing of torque

The sizing of torque displays the most important data required to calculate the
transmissible torque (or the maximum transmissible power) with or without load
spectrum. You can also call the sizing of torque function directly by clicking the
checkbox next to the Torque or Power input fields. You then see a value for the
torque that should be achieved if required safeties are used.

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21.6

Proposal for the hardening depth EHT

A wide range of different proposals for the hardening depth EHT as specified in the
standards have been documented. The data specified in the ISO, AGMA and Niemann standards are often very different, because of the very rough approximations
involved. The most accurate calculation, which uses the shear stress criterion from
the Hertzian law to define the required hardening depth, is documented in the upper
part of the report. You can also specify the safety factor which is to be used for the
calculation (safety factor for calculating shear stress for EHT (see page II-458)).
You will see this displayed as a graphic in the "Hardening depth" section.

Chapter
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22

Graph ics men u

Chapter 22
Graphics menu

Figure 22.1: Graphics menu in the KISSsoft menu bar -User interface

In the Graphics menu you can select various menu items to help you display
toothing and functional processes.

NOTE

In the Graphics window, hold down the left-hand mouse button and move the mouse to select the range of values you want to increase. Click the right-hand mouse
button to open a context menu that contains other zoom functions.
Table 22.1 shows which of the options in the Graphics menu are supported by
particular tooth calculation modules and where you can find the relevant
documentation in this section.

Menu item

Options

Sectio
n

AGMA 925

Temperature in contact

22.1.1

Chapter
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22

Thickness of lubrication
film
Hertzian pressure
Specific thickness of film
Evaluation

Contact Analysis

Specific sliding

22.4.1

Flash temperature

22.4.2

Hardening depth

22.4.3

Theoretical contact
stiffness

22.4.7

S-N curve (Woehler line)

22.4.4

Safety factor curves

22.4.5

Stress curve

22.5.9

Path of contact
(pinion/face gear)

22.4.8

Safety scuffing

22.4.10

Sliding velocity

22.4.10

Oil viscosity

22.4.6

Axis alignment

22.5.1
(see
page II638)

Specific sliding

22.5.8

Transmission error

22.5.2

Transmission error
acceleration

22.5.3

FFT of the transmission

error

22.5.4

Normal force curve (line

load)

22.5.5

Normal force distribution

(line load)

22.5.5

Chapter
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22

Torque progression

22.5.6

Stiffness curve

22.5.7

FFT of the contact

stiffness

22.5.8

Bearing force curve

22.5.9

Bearing force curve in %

22.5.9

Direction of the bearing

forces

2D geometry

Kinematics

22.5.10

Specific sliding per gear

22.5.11

Specific power loss

22.5.12

Heat development

22.5.13

Heat development along

the tooth flank

22.5.13

Flash temperature

22.5.15

Lubricating film

22.5.16

Specific thickness of film

22.5.16

Safety against micropitting

22.5.16

Stress curve

22.5.14

Bending stress in root area

22.5.14

Stress distribution on tooth

22.5.14

Wear along the tooth flank

22.5.17

Meshing

22.2.4

Tooth form

22.2.1

Tool

22.2.2

Manufacture

22.2.3

Profile diagram

22.2.5

Tooth trace diagram

22.2.5

Flank curvature

22.2.6

radii
Angle of flank normal

22.2.7

Chapter
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22

3D geometry

Drawing

22.2.8

Assembly

22.2.9

Tooth system

22.3.1

Tooth form

22.3.2

Graphics list

Graphics
list

Manufacturing
drawing

Manufacturin
g drawing

Table22.1: Graphics menu in the KISSsoft interface menu bar.

- Single gear, - Cylindrical gear pair, - Pinion with rack, - Planetary

gear, - Three gears, - Four gears, - Bevel and Hypoid gears, - Face gears,
- Worms with double enveloping worm wheels, - Crossed helical gears and
precision mechanics worms, - Splines (Geometry and Strength)

Chapter
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22

22.1

AGMA 925

22.1.1

Thickness of lubrication film and specific oil

film thickness

The thickness of lubrication film he in accordance with AGMA 925 is shown over
the meshing cycle. Another figure shows the specific density of film , which is a
critical value for evaluating the risk of micropitting. is the ratio of the thickness
of lubrication film to the surface roughness, expressed in simple terms.

Chapter
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22.2

2D geometry

Figure 22.2: Graphics window: Geometry

You can select a number of different output options from the drop-down list in the
tool bar of the Geometry 3D graphics window (see Figure 22.2:

22.2.1

Gear tooth forms

Display a gear tooth form.

NOTE:

Click the Property button above the graphic to specify the number of teeth that are
to be displayed. You can select whether to display it in transverse section, normal

Chapter
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22

section or axial section. Selecting the "Half tooth for export" option is also very
useful if you want to export the tooth form and reimport it into KISSsoft later on.

22.2.2

Gear tool

This displays the tool associated with the gear, if one is present.

22.2.3

Manufacturing a g ear

Display the pairing: gear with cutter. Here the gear is shown in blue and the cutter
in green.

22.2.4

Meshing

Displays the meshing of two gears.

NOTE ABOUT FACE GEARS:

In KISSsoft, the face gear is calculated by simulating the manufacturing process in

different sections. You can display different sections at the same time. To do this,
go to the Property browser (PB) in the graphics window and set the property in the section you require to True (see Figure 22.3).

Figure 22.3: Graphics window: Meshing with Property Browser

The difference between the theory and the effective tooth form means that the tooth
has an undercut! You can see this more clearly in the 2D view.

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Collision check:
When generating two gears (in the graphical display) you can activate the collision
display option. In the graphic, this shows (with squares) the points where the gears
touch or where collisions may occur.
shown in brown: touch (between 0.005 * module distance and 0.001 * module
penetration)
shown in red: collision (greater than 0.001 * module penetration)
The system identifies and marks collisions in all the meshing teeth. This option is
particularly useful for analyzing the generation of non-involute tooth forms or
measured tooth forms (using a 3D measuring machine) with a theoretical single
flank generation check.
This functionality is also available for cylindrical gears and worm gears (but with
restrictions for worm gears (see page II-583)).

22.2.5

Profile and tooth trace diagram

These diagrams are generated by placing two lines diagonally over the tolerance
band, as described in ANSI/AGMA: 2000-A88 (figures 1 and 2).

Figure 1 Profile diagram

Figure 2: Tooth trace diagram

In the figures shown above, V is the profile tolerance and V is the tooth
alignment tolerance which correspond to the profile total deviation (F) and the
tooth helix deviation (F) as detailed in ISO 1328-1.

Chapter
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22

Although every company has its own method of creating profile and tooth trace
diagrams, the AGMA method is recognized as the standard in the industry. ISO TR
10064-1 (and ISO FDIS 21771) also include a general description of profile and
tooth trace diagrams, but without any explanations about the construction method.
In KISSsoft the profile and tooth trace modifications are defined in the
Modifications tab. The corresponding diagrams are then generated using this
data.

Figure 22.4: Modifications tab with modifications

Chapter
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22

Figure 22.5: Profile diagram for gear 1 in accordance with the predefined modifications

The horizontal axis of the profile diagram shows the profile deviation values and
the vertical axis shows the coordinates along the profile. You can select different
values for the left-hand vertical axis (roll angle or path of contact length)
(CalculationSettingsContact analysis). The values for the
right-hand flank are always given as the diameter. You can also specify the
tolerance type by clicking on CalculationSettingsGeneral. If you
select the tolerance band type as specified in AGMA 20000-A88, the diagrams are
construed in accordance with the method mentioned above. If you set the tolerance
band type to constant, the tolerance remains constant along the length or the width
of the tooth flank. Click on the "Display profile in the middle of the tolerance
band" checkbox to specify whether the central profile (see below) should usually
be displayed.
Describe the specific diameter of the right-hand vertical flank:
dSa: end diameter of the modifications (starting diameter of the modifications
at the tip)

Chapter
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22

dSf: starting diameter of the modifications (starting diameter of the modifications at the root)
dCa: active tip diameter (starting diameter of the modification)
dCf: tip form circle diameter (starting diameter of the modification)
dCm: center point of the functional profile measured along the path of contact
NOTE:

The profile diagram is in the middle of the facewidth. The Twist profile
modification is not possible.

Show curves in the diagram:

green curve: Modifications of "1. Tip relief, linear" and "2. Tip relief, arc-like"
blue curve: Reference profile (current function profile used for checking and
generated from the total of the modified curves)
red line: Tolerance curve generated by subtracting the profile total deviation
from the reference profile. The profile deviation values are listed in the main
report.
green line (middle): Central profile, which can be entered as the target value
for processing because it lies in the middle between the reference profile and
the tolerance curve.
gray lines: Tolerance range, which shows the range (as a crosshatched area) in
which the actual manufacturing profile can lie.
The manufacturing profile (with tolerance) should lie between the tolerance curve
and the reference profile.

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You can use the properties to change the colors of the lines or to display or hide the
individual curves.

Figure 22.6: Tooth trace diagram for gear 1 with the predefined modifications

In the figure, the reference profile is shown in blue and the tolerance line is shown
in red. The horizontal axis shows the coordinates along the tooth trace (facewidth)
and the vertical axis shows the flank allowance as specified in the usual industrial
conventions. The value of the total tooth trace deviation Fb is shown in the main
report.
The manufacturing tooth trace (with tolerances) should lie between the tolerance
curve and the reference tooth trace.

22.2.6

Flank curvature radii

In this graphic you see the flank curvature radii along the tooth flank. Along with
the normal force, these are critical values for Hertzian pressure.

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22.2.7

Angle of flank normal

The normal angle to the flank is shown in this graphic. Every point on the tooth
form has a normal.

22.2.8

Drawing

Use this menu to display gears in diagram form. The gears are shown in transverse
and axial section.
This option is primarily used for bevel gears and worms.

22.2.9

Assembly

Use this menu to create a diagram of how gears are assembled. The buildup (pair)
of the gears is shown in transverse and axial section.
Two views, section and overview, are given for bevel gears with a shaft angle of
90. For shaft angles <>90 only the section of the bevel gear pair is displayed.

22.2.10 Manufacturing drawing

22.2.10.1 General
Manufacturing drawings are designed to display a number of graphics on the same
surface, and therefore create a print-ready image that can be used to manufacture a
gear. You can also display the drawing data report at the same time. Use a control
file to tailor the display to suit specific requirements. The control file is stored in
the template directory (usually under KISSDIR\template). It has the module name
and the file extension .grc (e.g. Z012gear1.grc).

You can also save the graphic generated here as a .dxf file in the usual way.

22.2.10.2 Editing the control file

By making changes to the control file you can modify the manufacturing drawing
to suit your own requirements. The commands used to control the manufacturing
drawing are described in the following table.

papersize: A4
papersize: A4 portrait

Specifies the required paper format. This refers to the standard

terms used to describe commonly used paper sizes (A3, A4, A5,
B4, B5, Letter, Legal and Ledger), and also enables you to input

Chapter
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22

papersize: 297, 210

your own dimensions for width and height.

The default setting is for landscape format. However, you can
switch to portrait format by entering the key word "portrait".

fontsize: 5

Specifies the required font size. The font size influences the size of the report
and also the diagram titles.

units: inch

The default setting is that input values are assumed to be in mm. The system
can handle these units: inch, mm and cm.

You can now add graphics that have specific characteristics. The table below gives
an overview of the correct inputs.
draw 2DDiaProfileChart1

"draw" is the key word used to specify that a graphic is to be added.

It is followed by the ID of the graphic you want to insert. The number at the end is part of the ID, and identifies the gear.

window: 160, 285, 0, 85

"window" identifies the window in which the graphic is displayed. The values
show the limits on the left, right, bottom and top.

scaletofit

This optional command forces the graphic to distort so that it fills

the window in every direction. We recommend you do this for
diagrams, but not for geometric figures.
If this term is not used, the original size and shape of the graphic is
retained.

You can insert these graphics:

Tooth form

2DGeoToothDrawing

Drawing

2DGeoGearDrawing

Assembly

2DGeoAssemblyDrawing

Tool

2DGeoToolDrawing

Profile diagram

2DDiaProfileChart

Tooth trace diagram

2DDiaFlankLineChart

Angle of flank normal

2DDiaNormal

Finally, you can now display the report in the required location:
write report1

"write" is the key word used to create a gear data

report. Enter report1 to select the gear data of
gear 1, report2 to select the gear data from gear 2
etc.

topright: 297, 218

Unlike graphics, you must specify an alignment here.

You define this with the first word. The correct
commands are topright:, topleft:, bottomright: and
bottomleft:. They represent the alignment (top right, top
left, bottom right and bottom left). The next two values

Chapter
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22

represent the particular reference point.

Chapter
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22.3

3D geometry

Figure 22.3: Graphics window Tooth system

The gears are displayed in the 3D Parasolid viewer.

You can select a number of different output options from the drop-down list in the
tool bar of the Geometry 3D graphics window (see Figure 22.3). You can store
the Parasolid viewer graphics in different file formats such as:
Windows Bitmap (*.bmp)
Joint Photographic Experts Group (*.jpg, *.jpeg)
Portable Network Graphics (*.png)
Standard for the Exchange of Product Model Data (*.stp, *.step)
Parasolid Text File Format (*.x_t)
Parasolid Binary File Format (*.x_b)

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22.3.1

Tooth system

The tooth system displays the assembled system of gears in 3D.

You can display these gears in different views.

22.3.2

Tooth form

In the Tooth form menu, an individual gear is shown in 3D in the Parasolid

viewer. There are the following restrictions on how these gears are generated. Only
forms ZI and ZA can be generated for worm gears.

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22.4

Evaluation

22.4.1

Specific sliding

Figure 22.4: Display of Specific sliding in the Evaluation graphics window

The graphic shows the progression of specific sliding (ratio between the sliding
velocity and the tangential speed) for the pinion and the gear over the length of
path of contact. This takes into account two situations: maximum tooth thickness minimum center distance and minimum tooth thickness - maximum center distance.
When you specify the profile shift (see section "Profile shift coefficient" on page
II-265), click the

button to see a suggested value for balanced specific sliding.

Chapter
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22.4.2

Flash temperature

Figure 22.5: Flash temperature option in the Evaluation graphics window

The flash temperature is the local temperature on the tooth flank at the moment of
contact is displayed over the meshing cycle. The point that has the highest
temperature can be seen. Therefore it can be decided which action (i.e. a profile
modification) can be taken to reduce this value.

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22.4.3

Hardening depth

Figure 22.6: Hardening depth option in the Evaluation graphics window

This calculates the optimum hardening depth (for case hardened or nitrided gears).
It shows the stress progression in the depth vertical to the flank surface. This value
is displayed directly in the HV values, because HV or HRC values are always used
when specifying hardening depth and hardening measurements. If the materials
database already contains values for a measured hardening progression, the
hardening progression is displayed, accompanied by a warning message if the
existing hardening is insufficient.
Proposed values for the recommended hardening depth are displayed in a special
report, classified by calculation method, selected material and heat treatment process.
The various different methods are:
The shear stress progression in the depth of the gear pair is calculated in accordance with Hertzian law. The shear stress is multiplied by a safety factor (enter
this under "Settings". The default setting is 1.63). This defines the depth of the
maximum shear stress (hmax). The program suggests the value 2*hmax as the
hardening depth (EHT).

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For each individual gear in accordance with the proposals given in Niemann/Winter, Vol.II [65] (page 188)
For each individual gear in accordance with the proposals given in AGMA
2101-D [1] (pages 32-34)
For each individual gear in accordance with the proposals given ISO 6336 Part
5 [44] (pages 21-23) (to avoid pitting and breaking up of the hard surface layer)

22.4.4

Woehler line for material

Figure 22.7: Woehler line option in the Evaluation graphics window.

Displays the Woehler line for the tooth root and flank. This calculation is
performed in accordance with the selected calculation standard.

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22.4.5

Safety factor curves

Figure 22.8: Safety factor curves option in the Evaluation graphics window

The graphic displays the progression of safety depending on the service life.

22.4.6

Oil viscosity, depending on temperature

This displays the course of kinematic viscosity over the operating temperature range of the oil.

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22.4.7

Theoretical contact stiffness

Figure 22.9: Theoretical contact stiffness option in the Evaluation

graphics window

Displays the contact stiffness as a graphic. The contact stiffness is calculated on the
basis of the real tooth forms. The calculation takes into account tooth deformation,
gear body deformation, and flattening due to Hertzian pressure. Calculation as
defined in Weber/Banaschek [69].
For helical gear teeth the overall stiffness is calculated with the section model (the
facewidth is split into 100 sections and stiffness added over all sections), see also
[58], page 203. The transmission error is defined in accordance with [65], and the
transmission variation in the peripheral direction is :

(22.5)

(22.6)

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where (q/c') is replaced by cgam.

NOTE:

The theoretical contact stiffness and the contact stiffness of the effective toothing
under load can be quite different.

22.4.8

Contact line (face gear)

To display the contact line on the pinion and on the face gear, select Graphics >
Evaluation > Contact line pinion or Contact line face
gear, see Figure 22.10:

Figure 22.10: Graphics window Face gear contact line

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22.4.9

Stress curve (face gear)

Select Graphics > Evaluation > Stress curve to calculate and display the progression of stress across the facewidth of the gear (see Figure 22.11).
This splits the facewidth into segments which you can then calculate as pairs of
racks as specified either in ISO 6336, DIN 3990, or AGMA2001. The calculation
assumes a constant line load (which results in a slightly different torque for each
segment due to the different pitch circle).

Figure 22.11: Stress curve graphics window

When you calculate data in order to represent the contact line and the stress curve,
the most important values are calculated in separate sections and saved to two
tables. This data is stored in the Z60-H1.TMP and Z60-H2.TMP files.

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22.4.10 Scuffing and sliding velocity (face gear)

To display scuffing safety, select Graphics > Evaluation > Safety
scuffing (see Figure 22.12). However, due to the very different sliding
velocities and the changing flank pressure across the tooth flank, calculating the
scuffing safety is actually very difficult. Akahori [2] reports massive problems with
scuffing at high sliding velocities. For this reason it is appropriate to think about
way in which you can calculate the risk of scuffing. One sensible option, as
described above for stress distribution, is to calculate scuffing safety in separate
sections. Figure 22.12 shows the progression of scuffing safety as defined by the
flash and integral temperature criterion along the tooth flank. To achieve realistic
results from this calculation, it must be ensured that every section is calculated with
the same mass temperature. However, when you work through the calculation you
will see there are significant changes in safety when the calculation is performed
on the basis of the integral temperature. In particular, this happens as point E on the
path of contact gets closer to the pitch point. If you then use the formulae in DIN
3990 to convert the flank temperature at point E to the average flank temperature
the results you get will not be particularly precise. For this reason, we recommend
you use the flash temperature as the criterion when you perform this calculation for
face gears.
Select Graphics > Evaluation > Sliding speed to display the
sliding velocity. The sliding velocities are important for a number of different applications (for example, plastic, dry run).

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Figure 22.12: Graphics window: Scuffing safety

Select Graphics > Evaluation > Sliding speed to display the

sliding velocity. The sliding velocities are important for a number of different applications (for example, plastic, dry run).

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22.5

Contact Analysis

NOTES:

The usual strength and speed calculations performed on gears assume that an
involute tooth form is being used. However, if you use this program module, you
can calculate and evaluate any type of toothing, such as cycloid toothing, just as
accurately as involute tooth forms.
All the graphics can be exported:
2D diagrams as:

BMP

JPG

PNG

DXF

IGES

TXT

2D curves as:

TXT

3D diagrams as:

BMP

JPG

PNG

DAT (the Y axis is only output for the contact analysis if the "Draw data
for path of contact" option is selected in the module-specific settings)

22.5.1

Axis alignment

Display the axis alignment of gear B relative to the axis of gear A. This display is a
very useful way of checking the deviation error and inclination error of axis.

22.5.2

Transmission error

The path of contact under load is used to calculate transmission errors. The
diagram shows the displacement of the contact point () of the second gear on the
length of the path of contact or the torsional angle () of the driven gear.

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The amplitude of the transmission error plays a role in how much noise is
generated but, despite this, you should not ignore the pitch, because high speeds
also generate high additional loads.

22.5.3

Transmission error acceleration

The acceleration of transmission error (second derivative with reference to time) is

available as a graphic.

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22.5.4

Amplitude of transmission error

The FFT of Transmission Error displays the results of the spectroscopic analysis of
the transmission error by fast Fourier transformation. Here, the first harmonic
shows the base vibration (fundamental wave) with the frequency f and the second
harmonic shows the first harmonic with the double frequency 2f.
You can compare the amplitudes of the spectra with the harmonic frequencies of
transmission error in the comment window.

22.5.5

Contact lines on tooth flank

In this graphic you can examine the contact line along the facewidth. All the gear
pairs in the contact are shown at the same time in a contact position.

22.5.6

Normal force curve

The normal force curve represents the line load per width for each tooth face in the
middle of the cylindrical gear. In a well arranged profile modification, the normal

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force should increase steadily from zero. If you do not have a profile modification,
an overlap length in the normal force curve shows the corner contact.

22.5.7

Normal force distribution

This graphic shows the normal force curve along the tooth flank and facewidth on a
3D gear.

22.5.8

Torque curve

The default value for torque defined in the main screen is kept constant during the
calculation. The graphic then shows the torque for gear 1 and the torque for gear 2
divided by the transmission ratio. If these two torque values are different, it means
that torque has been lost. The loss is due to friction in the tooth contact.
Variations in the displayed moment course depend on the level of accuracy you
have specified and are caused by the accuracy of the iteration.

22.5.9

Single contact stiffness

This graphic shows the individual elements of single tooth contact stiffness. These
are the stiffness of both gears and the single tooth contact stiffness of the gear pair.
As this is a series-connected spring system, the following applies:
1
C Pair

1
C Gear 1

1
C Gear

22.5.10 Stiffness curve

The stiffness curve shows the local stiffness at the operating point. It is calculated
from the torsion under load at every point of contact. The stiffness value for gears
is usually specified per mm facewidth. To calculate the stiffness of the toothing of
two gears, multiply the value you specify (c) with the tooth facewidth.

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22.5.11

Amplitude of contact stiffness

The FFT of contact stiffness displays the spectroscopic analysis result of the contact stiffness according to fast Fourier transformation.
The user can compare the amplitudes of the spectra with the harmonic frequencies
of contact stiffness in the comment window.

22.5.12 Bearing force curve and direction o f the bearing forces

The bearing force curve assumes that the support is mounted with a symmetrical
bearing position. The value given for the face load factor calculation is used as the
distance between the bearings. The purpose of this graphic is not to display the
correct bearing forces, but to represent the variations in these forces.
Variations in the bearing forces cause vibrations in the shafts and changes in gear
case deformations.

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22.5.13 Kinematics
The effective tooth form and the effective path of contact are used to calculate a
wide range of kinematic values which are then displayed along the length of path
of contact:
specific sliding
sliding coefficients Kg
sliding velocity
variation in transmission ratio

22.5.14 Specific sliding

You can display specific sliding either alongside the meshing cycle under
Kinematics or alongside the tooth depth. You can also see it clearly in the area
of the tooth flank with contact.

22.5.15 Power loss

This calculates the power loss for a pair of teeth. Power loss is usually greatest at
the start and at the end of the mesh because this is where the highest sliding
velocities are generated. However, with a profile modification, you can reduce the
load at these points so that the maximum value is shifted to the width between start
of mesh and the operating pitch point and to the width between end of mesh and
the operating pitch point.

22.5.16 Heat development

Heat development links power loss with specific sliding. If the contact point of a
gear moves slowly, it creates a higher heat value per length than if the contact point
moves more quickly.
High temperatures generated on the tooth flank should be in correlation with the
tendency to scuffing. However, this is not directly attributable to temperature.

22.5.17

Stress curve

The effective tooth form is used to calculate and display the exact Hertzian
pressure during generating. The same applies to calculating tooth root stress, as

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defined in the Obsieger process (see page II-292), where the maximum stress in
the tooth root area is shown by the angle of rotation.
Stresses are calculated with KH = 1.0, KH= 1.0, KF= 1.0, KF= 1.0; only KA,
Kvand K are included.

22.5.18 Flash temperature

The effective local temperature shown in the diagram at each point in the path of
contact is defined by the gear base temperature (the tooth mass temperature) plus
additional local warming (the flash temperature)

Use this data at each contact point from the path of contact calculation to calculate
the flash temperature on the tooth flank:
Sliding velocity
Speed in a tangential direction to the pinion and gear
Bevel radii on the tooth flanks
Hertzian pressure
The friction value introduced to the calculation of the path of contact is used as the
coefficient of friction . The tooth mass temperature is calculated as specified in
ISO TR 15144.
Flash temperature is calculated for:
ISO as defined in ISO TR 15144

AGMA in accordance with AGMA925 with equation 84

22.5.19 Safety against micropitting

Calculation method
The calculation is performed in accordance with ISO 15144, Method A. All the
required data is taken from the contact analysis.
Lubrication gap thickness h and specific thickness of lubrication film GFP
The calculation of the progression of the effective lubrication gap thickness h and
the effective specific lubrication gap thickness GF across the meshing is precisely

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defined in the ISO TR 15144 proposal. The lubrication gap can vary significantly
depending on local sliding velocity, load and thermal conditions. The location with
the smallest specific lubrication gap thickness is the decisive factor in evaluating
the risk of micropitting.
Permitted specific thickness of lubrication film GFP
To evaluate the risk of micropitting it is vital that you know how large the required
smallest specific lubrication film GFmin is to be. The calculation rule states that:
GFmin >= GFP to prevent frosting (micropitting), or to ensure safety against frosting
Sl = GFminP/ GFP.
If the lubricant's micropitting load stage is known, the permitted specific thickness
of lubrication film is calculated in accordance with ISO TR 15144.
Otherwise, reference values for GFP can be derived from the appropriate technical
literature.
In [81] you will see a diagram that shows the permitted specific lubrication gap
thickness GFP for mineral oils, depending on oil viscosity and the frosting damage
level SKS.

Figure 22.13: Minimum necessary specific thickness of lubrication film GFP

The frosting damage level SKS, determined in accordance with the FVA information sheet [82], is nowadays also stated in data sheets produced by various lubricant
manufacturers. The data in the diagram applies to mineral oils. However, synthetic
oils with the same viscosity and frosting damage level show a lower permitted

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specific lubrication film GFP [81]. Unfortunately, as no systematic research has

been carried out on its effects, no properly qualified values are available.
Furthermore, you must be aware that the predefined values GFP only apply to casehardened materials. As specified in ISO TR 15144, for other materials, the
permitted specific lubrication gap thickness GFP can be multiplied by the
coefficient Ww.
Ww
Case hardening steel, with austenite content <= 25%

1.00

Case hardening steel, with austenite content > 25%

0.95

Gas-nitrided (HV > 850)

1.50

Induction or flame-hardened

0.65

Heat treatable steel

0.50

Table 22.1: Material coefficient

It is interesting to note that, according at least to the table shown above, when the
same lubrication gap is used, nitrided materials are more prone to micropitting than
case-hardened materials. In contrast, through hardened materials that are not
surface hardened are much more resistant.
You should be aware that the data shown here must be used with caution because
information about the micropitting process is still incomplete and even technical
publications will sometimes present contradictory data.

Safety against micropitting

If the load stage against micropitting as defined in FVA C-GF/8.3/90[82] is
specified for the lubricant, the minimum required thickness of lubrication film GFP
is calculated. The safety against micropitting can therefore be defined as S=
GFmin/ GFP.

22.5.20 Wear
To calculate local wear on the tooth flank, you must first determine the wear factor
of the material Jw. This coefficient can be measured using gear testing apparatus or
by implementing a simple test procedure (for example, pin/disc test gear) to
determine the appropriate value. Investigations are currently being carried out to
see how the Jw coefficients determined using a simpler measurement method can
be applied to gears. For exact forecasts, you will also need to determine the

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coefficient Jw for the material pairing. For example, POM paired with POM does
not supply the same results as POM paired with steel.
Plastics
You can input the wear factor Jw, in the polymer data file, for plastics, depending
on the temperature (for example, Z014-100.DAT for POM). The data is input in 106
mm3/Nm.

As an example:

Steel
Plewe's investigations have revealed that a rough approximation of the wear factors
for steel materials can be defined. See also the calculation of wear factors for steel
(Calculation of wear factor kw for steel) (see page II-276)
Calculation
Wear is calculated in accordance with the following base equation:

(w [mm], Jw [mm3/Nm], P: Pressure [N/mm2], V:speed [mm/s], T:time[s])

As modified to suit gear conditions, local wear results from:

( i = 1.2)
(w_i [mm], Jw [mm3/Nm], NL: Number of load cycles, w:Line load [N/mm], _i:
specific sliding)

This equation also corresponds to the data in [83], Equation 6.1.

The calculation to determine wear on the tooth flank uses the following data at
each point of contact taken from the calculation of the path of contact:
Specific sliding

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Line load
For POM against steel (at 23C), [83] gives a Jw of 1.03 * 10-6 mm3/Nm. For PBT
against steel it gives a Jw of 3.69 * 10-6 mm3/Nm.
When you interpret the results, you must note that the increasing wear on the tooth
flank to some extent changes local conditions (line load, sliding velocity) and
therefore also changes the increase in wear itself. For this reason, after a number of
load changes, you must select the worn flank (red line in the figure) and use it to
recalculate the path of contact.

Figure 22.14: Graphics window Wear

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22.6

Gear pump

Eleven different diagrams document in detail the progressions of the characteristic

values in a gear pump when it is generated. You will find more detailed information about how to calculate gear pumps (see section "Gear pump" on page II-411) in
KISSsoft-anl-035-E- GearPumpInstructions.doc [77] (available on request).

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22.7

3D export

Click Graphics > 3D Export to export the geometry of the gears you have
just designed to a specified CAD system. The next section (see page II-651)
provides more detailed information about which CAD system you should use, and
its interface.
NOTE:

Before you call this function for the first time, make sure you are using a suitable
CAD system. If you have specified a CAD program that has not yet been installed
you may cause a problem when you call this function.

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22.8

Settings

Click Graphics > Settings to define the background for 3D graphics and
select your preferred CAD system. Here you can select any of the interfaces for
which you have the appropriate licenses.

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22.9

Graphics list

The graphics list is where you save the graphics with

, as in all the other
toothing modules. This is attached to the end of the report, unless otherwise
specified in the report template. In the graphics list you can open every graphic
with

and

, depending on the graphic type, and then modify

enable/disable its properties or delete it with

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23

Answers to Fr eque ntly Aske d Ques tio ns

Chapter 23
Answers to Frequently Asked
Questions

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23.1

Answers concerning geometry calculation

23.1.1

Precision mechanics

KISSsoft is an ideal tool for calculating the gears for precision mechanics.
The reference profile and the geometry are calculated as defined in DIN 54800 etc.
The strength calculation is performed in accordance with ISO 6336, VDI 2545 or
DIN 3990, since no special strength calculation exists for precision gears. For this
reason, "Defining required safeties for gear calculation (see section "Required
safeties for cylindrical gears" on page II-664)" is important when you are
interpreting the results.
If gears are manufactured using topping tools, the tip circle can be used to measure
the tooth thickness. In this situation, it is critical that you specify precise value of
the addendum in the reference profile to match the corresponding cutter or tool.
This is because this value is used to calculate the tip circle. The tip alteration k*mn
is not taken into account in the calculation of the manufactured tip circle. The
following formula is used:

(23.1)

23.1.2

Deep toothing or cylindrical gears with a high

transverse contact ratio

Using deep toothed gears is recommended for some specific applications (for
example, for spur gears that should not generate a lot of noise).
In KISSsoft, you can easily calculate all aspects of deep toothed gears. To calculate
the geometry, you must select a profile of a suitable height when you select the
reference profile:
Normal profile height: e.g. mn * (1.25 + 1.0)
For deep tooth form: e.g. mn * (1.45 + 1.25)
You must be aware that this type of gear is more prone to errors such as undercut
or pointed teeth. Experience has shown that you must select a value of 20 or higher
as the number of pinion teeth to ensure that you can create a functionally reliable
pair of gears. KISSsoft also has very effective and easy to use strength calculation

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functionality; as specified in DIN 3990, Part 3, calculation of gears with a transverse contact ratio greater than 2.0 tends to be on the conservative side.
The Geometry-Variants calculation (Modules Z04 and Z04a) is very good at sizing
optimum arrangements of deep toothed pairs of gears!
See also section 14.16.

23.1.3

Pairing an external gear to an inside gear that

has a slightly different number of teeth

When you pair a pinion (for example, with 39 teeth) with an internal gear (for
example, with 40 teeth) that has a slightly different number of teeth, the teeth may
have a collision ("topping") outside the meshing area. This effect is checked and an
error message is displayed if it occurs.
To size a functioning pairing of this type, select this strategy:
Reference profile: Short cut toothing
Pressure angle: the bigger the better
Sum of profile shift coefficients: select a negative value
Pinion profile shift coefficient: approximately 0.4 to 0.7

23.1.4

Undercut or insufficient effective involute

(this triggers frequent error messages when you calculate the geometry of
cylindrical gears.)
An insufficient effective involute occurs if the tip of the other gear in the pair
meshes so deeply with the root of the other gear that it reaches a point where the
involute has already passed into the root rounding. These areas are subject to
greater wear and tear. Some gear calculation programs do not check this effect and
suffer recurrent problems as a consequence.
To keep a close eye on the undercut and effective involute, you should always
work with the Calculate form circle from tooth form (see page II454) option. This function checks the tooth form every time a calculation is
performed. It defines any undercut it discovers and takes it into account in the
calculation.
The tooth form calculation takes into account all aspects of the manufacturing process. In contrast, calculating geometry in accordance with DIN 3960 uses
simplified assumptions.

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23.1.5

Tooth thickness at tip

The tooth thickness at the tip circle is calculated for a zero clearance status. In addition, the maximum and minimum value is calculated using all tolerances.
When you check the tooth geometry, the tooth thickness at the tip must usually be
at least 0.2 * module (in accordance with DIN 3960). If this limit is not reached,
KISSsoft displays the appropriate warning message. Click on Calculation >
Settings > General to change this coefficient if required.

23.1.6

Special toothing

The term "special toothing" is used to describe toothing with non-involute flanks.
The reference profile (or the normal section through the hobbing cutter or rackshaped cutter) of special toothing is not straight (unlike involute toothing).
However, the same generating process is used to manufacture both toothing types.
As part of the tooth form calculation, special toothing can either be imported from
CAD or defined directly (cycloid, arc of circle toothing). In addition, a suitable
counter gear can then be generated by clicking Generate tooth form from
counter gear.
By simulating the generation process, the tooth form and, from this, the geometry
can then be defined for special toothing. As no standards or documentation are
available for strength calculations, analogies for these tooth form types must be
drawn from the calculations used for the cylindrical gear process. For more information see the Path of contact (see section "Contact Analysis" on page II-638)
section.

23.1.7

Calculating cylindrical gears manufactured

using tools specified in DIN 3972

Profiles I and II are profiles for the final machining. They can all be handled easily
by KISSsoft. Simply select the tool you require from the selection list (Reference
profiles).
Profiles III and IV belong to tools used in pre-machining. However, you should
always use a finished contour to calculation the strength of a gear, these profiles
should therefore only be used as a pre-machining cutter.

The reference profiles are dependent on the module as defined in the following
formulae:

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Profile III

hfP = 1.25 + 0.25 mn-2/3

haP = 1.0

fP = 0.2

Profile IV

hfP = 1.25 + 0.60 mn-2/3

haP = 1.0

fP = 0.2

In the Reference profile tab, if the configuration is set to Tool:

Hobbing cutter, you can click the plus button in the hobbing cutter row to see
a selection list that includes Profiles III and IV in accordance with DIN 3972.
Remember that the data you enter here depends on the module. If you want to
change the module, you must select a the correct reference profile again.

Use the recommendations in the standard to select the correct allowances for premachining:
Profile III

Grinding allowance = +0.5 mn1/3 tan(n)

Profile IV

Grinding allowance = +1.2 mn1/3 tan(n)

If Pre-machining has been selected (in the Reference profile tab), you can set the
appropriate Grinding allowance for Profile III or IV in the list in the Grinding
allowance field.
Click on the +button next to Grinding allowance q to input a tolerance interval for
the grinding allowance qTol (=qmax-qmin). The grinding allowance for premachining then lies in the range qmin ... qmax, where qmin = q - qTol/2; qmax = q
+ qTol/2 applies.
The control masses (base tangent length etc.) for pre-machining are then calculated
with the following allowances:
Maximum grinding allowance with As.e + qmin*2 / cos(an)
Minimum grinding allowance with As.i + qmax*2 / cos(an)

Note:
If you want customer-specific tolerances to be processed automatically, you can
define them in a file called "GrindingTolerance.DAT". The \dat directory has an
example of this type of file, which is called "GrindingToleranceExemple.DAT".
When this file is renamed to "GrindingTolerance.DAT" its tolerance values are
used in the calculation.

23.1.8

Variations in rolling as defined in DIN 58405

DIN 58405 specifies the base tangent length allowances and permitted composite
errors for toothing used in precision mechanics. In this case, the reference profile
specified in DIN 58400 assumes a pressure angle of n=20. If you use a operating

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pressure angle that is not 20, DIN 58405 Sheet 3, sections 1.2.10 and 1.2.11, state
that the permitted composite error and the permitted rolling deviations must be
multiplied with a coefficient L = tan(20)/tan(abs). This must be performed
because the base tangent length allowances are standardized and the center distance
error increases as the pressure angle is reduced. KISSsoft takes coefficient L into
account when calculating tolerances to comply with DIN 58405, because it is
specified in the standard.
However, the tolerances specified in ISO 1328 and DIN 3961 do not include this
coefficient because it is not listed in the standard.

23.1.9

Automatic change of reference profiles

Some calculations have revealed the problem that the reference profile changes
automatically when the center distance changes. In the Reference profiles tab, the
factors for the tool tip and dedendums change automatically. Why?
This is because the "Retain tip circle or dedendum when the profile shift changes"
checkbox is active in the General tab in the module-specific settings.
If you change the center distance, the profile shift coefficient also changes. The
setting you make automatically changes the factors for the reference profile.

23.1.10

Non-identical (mirrored symmetry) tooth flanks

If the tooth flanks (left, right) are not identical, will this cause an error when the
tooth contour is exported?
The tooth flanks used in the calculation (sizing) are identical.
The export function used in the system not only exports the involutes but also the
entire tooth form. This is an approximated curve.
With the export precision (permitted variation ) you can define how closely you
want to approximate the calculated tooth form.
In each case, an approximate curve in the specified level of accuracy is given for
either half of the tooth or the whole tooth. You can only use mirror symmetry with
approximation accuracy.
This is the error you specified as the permitted variation.
The smaller the selected variation, the more detailed the curve.

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23.1.11

Internal teeth - differences in the reference

profile if you select different configur ations

A gear pair with internal teeth has been calculated in the KISSsoft system. A
pinion type cutter is then to be used to manufacture this internal gear. The tool is
manufactured to suit particular customer requirements and is influenced by the
particular tooth form which is used. This must reflect the reference profile
geometry of the internal gear. How can you then determine the pinion type cutter
geometry?
A gear's reference profile is the corresponding rack profile. regular hobbing cutter
for an outside gear has this rack geometry, and therefore makes it easy to define the
hobbing cutter profile. However, you must reverse the gear profile to achieve the
hobbing cutter profile (the addendum of the gear reference profile becomes the
dedendum of the hobbing cutter and so on).
If the manufacturing tool is a pinion type cutter, the limited number of teeth on the
pinion type cutter result in a different situation. Basically speaking, the inverse gear
reference profile corresponds to that of the pinion type cutter. However after this,
you must change the addendum of the cutter in such a way that you can achieve the
necessary root diameter on the internal gear.
First of all, you must define the number of teeth on the pinion type cutter.
Depending on the type of machine tool used to manufacture the gear, the reference
diameter of the pinion type cutter is already predefined to some extent. This reference diameter must be greater than the diameter of the main shaft of the machine
tool that is to be inserted in the pinion type cutter tool. However, if this diameter is
too large in comparison with the size of the pinion type cutter, the shaft diameter
will be too small. This will cause powerful vibrations during the production process and result in a poor accuracy grade. To prevent this, you must know the
approximate pinion type cutter diameter. The reference diameter is then divided by
the module to determine the number of teeth on the pinion cutter.
If you want to use the KISSsoft system to design the pinion type cutter geometry,
you must first input the number of teeth on the pinion type cutter. You can start
with 0.0 for the profile shift coefficient of the pinion type cutter. A pinion type
cutter's profile shift changes as it is used. Every time the pinion type cutter is
resharpened, the profile shift is reduced slightly. A new pinion type cutter usually
has a positive profile shift (for example +0.2), a worn tool therefore has a negative
profile shift.
After you have input the data for a pinion type cutter, you must first check all the
entries, i.e. whether the required root form diameter has been achieved. If not, you
must reduce the tip fillet radius of the pinion type cutter. If that does not help, you
must increase the addendum of the tool reference profile. However this also
changes the active root diameter.

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The same problem can also happen with the tip form diameter dFa. It often happens that you cannot generate the entire involute part up to the tooth tip. In this situation, you must either increase the number of teeth on the pinion cutter tool or
reduce the tip diameter of the gear.
If you develop a gear that is manufactured by a pinion type cutter, it is always
critically important that you investigate the production process early on in the development process. This is because not every gear geometry can be created with
this production process.

23.1.12

Effect of profile modifications

Profile modifications are a popular topic of discussion. Where should these

modifications start, and which values should be used to make these modifications?
Linear tip relief is a type of profile modification. It has the following
characteristics: Starting from a particular point, ever increasing amounts of material are removed from the involute toothing part up to the tip diameter.
The tooth contact in the modified area is disrupted. This is only a benefit when subject to the corresponding load. This entire area is taken into account when
calculating the contact length to determine the transverse contact ratio a. Shouldn't
this be different?
If you use profile modifications you "delete" the real involute. Why is this a good
idea?
This is a complex problem that must be taken into consideration when you design
profile modifications. The amount of material removed (tip relief C a is the
reduction of tooth thickness at the tip due to the profile modification) and must be
applied according to the tooth bending.
For example, if the tooth had infinite stiffness, and you ignore any of the possible
effects of compensating for production errors, the profile modification would
simply reduce the transverse contact ratio. If you did not take this profile
modification into account, you would make an error in the geometry calculation.
This is basically correct for a gear that is subject to a lower load. However, you
will usually need to design gears for optimum performance at operating torque and
the strain that this places on the teeth.
If the tip relief Ca is well arranged, the profile modification then compensates for
the tooth deformation, so that the tooth contact across the entire tooth depth is not
compromised. In this case, the transverse contact ratio is not reduced. Here you
have, when compared to a gear without profile modification, a changed normal
force curve over the meshing.

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However, the maximum force (in the operating pitch diameter), where only one
gear pair is in contact, is not changed. For this reason, the maximum root and flank
strains, which determine the service life of the drive, remain unchanged. This profile modification reduces the normal force at the start and at the end of the meshing.
This also leads to a significant reduction in the risk of scuffing. The risk of scuffing
is due to flank pressure and sliding velocity. Sliding is greatest at the start and the
end of the tooth contact and therefore, by reducing the flank pressure in this area,
you can also reduce the risk of scuffing. A profile modification can reduce the
influence of tooth strain on stiffness fluctuations across the meshing and therefore
limit the number of transmission errors. This also lowers the levels of vibration and
noise.
This clearly illustrates that a profile modification does not reduce the transverse
contact ratio, as long as this has been properly arranged, i.e. for the operating
torque of the drive. However, where lower loads are involved, the contact of gears
where the profile has been modified is not as good as those without profile
modification. This is because the transverse contact ratio has been significantly
reduced. In this case, although the load would increase, it would do so by a
comparatively small amount and can therefore be ignored.

23.1.13

Number of teeth with common multiples

A toothing with 15:55 teeth has been sized. Different documents state that you
should avoid gear reductions (like 11:22) that are whole numbers. Furthermore,
you will also discover that you should also avoid using numbers of teeth that are
common multiples (in this case the 5 in 3*5 to 11*5). Is that true and is it displayed
in KISSsoft?
Let's assume we have a gear which has a fault on one of its teeth. In a whole number gear reduction, this tooth will always come into contact with the same tooth in
the counter gear. The error is then transmitted to the counter tooth. However, if the
tooth with the fault comes into contact with a different counter tooth in every rotation, this error will be reduced as the gears wear in.
Nowadays, most gears are surface hardened. Unlike weak gears, they hardly ever
wear in. As a result, this problem is now less critical than it used to be, where it
was important that whole number gear reductions (such as 11:22) were avoided
even when hardened gears were used. In contrast, whole number toothing
combinations with common multiples (such as 15:55) are quite unobjectionable for
surface hardened gears.
In KISSsoft you will find notes about whole number combinations with common
multiples in both fine sizing and rough sizing under the keyword "hunting". If you
see YES in the hunting table, this means: no common multiple is present.

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23.1.14

Allowances for racks

From Release 10/2003 onwards, allowances for racks are defined in conjunction
with the paired gear.
This conforms to DIN 3961.
"The tolerances for the toothing of a rack should not be greater than the tolerances
of its counter gear. If the counter gear's manufacturer is not known, the rack length
should be the same as the counter gear circumference."

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23.2

Answers to questions about strength ca lculation

23.2.1

Differences between different gear calculation

programs

You will always discover differences in the results when you compare calculations
performed with different gear calculation programs. Many of these differences are
due to the different data entered. However, even if all the data entered is the same,
you will still get different results.
One of the questions our users often ask is whether the results calculated by KISSsoft are
correct.

The main calculation process used in the KISSsoft cylindrical gear calculation
functions is based on DIN 3990, ISO 6336, and AGMA, It faithfully follows the
procedure described in Method B. However, as DIN 3990, or ISO 6336 offer
various different Methods (B, C, D) and sub methods, it is no surprise that the
results they supply are slightly different from other calculation programs. Most
programs do not perform calculations that consistently use method B, instead they
partially use Method C or even D, which are easier to program.
To give our users an additional safety, we have therefore integrated the FVA program calculation variant into KISSsoft. This variant supplies exactly the same
results as the FVA program ST+, that was developed by the Technical University
in Munich and which can be used as a reference program.
The minor differences between KISSsoft's calculations in accordance with DIN
3990 and the FVA programs are due to the slight (permissible) deviations of the
FVA program from the standard process defined in DIN 3990.

23.2.2

Difference between cylindrical gear calculation

following ISO 6336 or DIN 3990

The strength calculation method used in ISO 6336 is virtually the same as that
defined in DIN 3990. The majority of the differences only affect minor details
which have very little effect on the safeties calculated for tooth root, flank and
scuffing.
The only significant difference happens to be the life factor (ZNT and YNT ). In the
endurance area (in accordance with DIN, depending on material type and
calculation method 107 to 109 load cycles) this coefficient in ISO 6336 decreases

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from 1.0 to 0.85 at 1010 load cycles. Only with "optimum material treatment and
experience" does the coefficient remain 1.0.
As a result, gears in the range of endurance limit range supply much smaller
safeties (15% lower) when calculated in accordance with ISO 6336 for root and
flank! In the case of optimum material treatment or for the number of load cycles
in the limited fatigue strength range, the safeties are practically identical.

23.2.3

Calculation using Methods B or C (DIN 3990,

3991)

Cylindrical gears:
Calculation using Method B or C is described in DIN 3990. Method B is much more detailed and is therefore the method we recommend KISSsoft usually uses Method B. However, we do not consider Method B to be precise enough to calculate
the form factors for internal teeth, which is why we recommend Method C.
Converting to using Method C means that most of the calculation is performed in
accordance with Method B and only the tooth form factor is calculated as defined
in Method C.
Note: The most precise way of calculating internal teeth is to take the exact tooth
form into account (see "Tooth form factor using graphical method", chapter
14.3.16.3).
Bevel gears:
Tooth form factors are calculated in accordance with standard Method C.

23.2.4

Required safeties for cylindrical gears

Defining the necessary safeties (for tooth root, flank, scuffing) for gears in a
particular application, for example, in industry standard drives, vehicles, presses
etc., is a very important step in the gear calculation process.
The (DIN 3990 or ISO 6336) standards give hardly any information about this;
DIN 3990, Part 11 (industrial gears) has this data:
Minimum safety for root:

1.4

Minimum safety for flank:

1.0

AGMA2001 does not specify minimum safeties. The AGMA 6006 guideline (for
gearboxes in wind power installations) has a note that SFmin = 1.56 is specified for
root safety for calculation in accordance with ISO6336. In contrast, SFmin = 1.0 is
sufficient for calculations in accordance with AGMA. This matches our findings

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that calculations performed in accordance with AGMA give much lower root
safeties.
We therefore recommend a minimum safety of 1.4*1.0/1.56 = 0.90 for industrial
gears calculated in accordance with AGMA.
Scuffing is calculated in accordance with DIN 3990, Part 4:
Minimum safety for scuffing (integral temperature):

1.8

Minimum safety for scuffing (flash temperature):

2.0

The standards do not specify this value for precision mechanics (module under
1.5). Despite this, in accordance with empirical values the required safeties are
much smaller than for gears with a larger module (root 0.8; flank 0.6)! The reason
for this: The formulae and methods used in strength calculation are all taken from
tests with larger gears and only supply very conservative factors (values that err on
the side of safety) for small modules.
De fi ni ng r eq uir e d s af e ti e s f or g ear cal c ula ti o n

You can use the simple method described here to obtain the required safeties:
1. Examine and define the basic settings of the calculation (e.g. application
factor, lubricant, accuracy grade, processing etc.).
2. Then apply the gear calculation method (without changing the basic settings unless you absolutely have to!) on known set of gears. You should select gears that run reliably under operating conditions and also such that
have failed.
3. You can then use the resulting safeties calculated with these gear sets to
define the point up to which minimum service reliability can be guaranteed.
4. You can then use these parameters to calculate the sizing of new gears.
You can, of course, change these minimum safeties to reflect the results of
your own tests and examinations.

23.2.5

Insufficient scuffing safety

You can increase scuffing safety by:

Oil selection (higher viscosity at high temperatures)
Tip relief (profile modification)
Different distribution of the profile shift

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The methods used to calculate scuffing safety (unlike those used to determine the
tooth root and flank) is still a matter of controversy. For this reason, you should not
pay too much attention to it, especially if the results of scuffing safety at flash
temperature and the integral temperature process are very different.

23.2.6

Material pairing factor (strengthening an u nhardened gear)

When pairing a hardened gear with an unhardened gear (e.g. pinion made of
17CrNiMo6 and gear made of 42CrMo4) you get the positive effect of increased
load capability on the flank of the unhardened gear. This effect is taken into
account by the material pairing coefficient (coefficient in the range 1.0 to 1.2). As
stated in ISO 6336, the surface roughness of the hardened gear should be low
(polished surface), otherwise the load capability will not increase; on the contrary,
the tooth of the weaker gear may actually be ground off.

23.2.7

Defining the scoring load level (oil specificat ion)

In accordance with Niemann [65], page 166, on a test rig the torque on the test gear
is gradually increased until scuffing occurs. This torque level is then entered in the
oil specification parameters (example: no scuffing at load 10; scuffing at load 11:
scuffing load level of the oil is therefore 11).
To calculate the resistance to scoring you must then enter this load level (for the oil
specification). In the example described above this is the value 11 (in accordance
with Niemann [65], page 341). The scuffing safety calculation defines the safety
against scuffing with predefined safeties greater than 1.0. This creates a necessary
reserve, because the gradual increase in torque used in the test only approximates
the effective scuffing torque.

23.2.8

The influence of the face load factor KH for

tooth trace deviation fma is due to a manufa cturing error.

When calculating a cylindrical gear in accordance with ISO 6336, a higher value
was determined for the tooth trace deviation fma when calculating the face load factor KH. This was due to a manufacturing error. The value for KH does not change.
Why then, does this value for KH not change if a higher value for fma is used ?

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Before you can calculate KH you must input the position of the contact pattern. If
the contact pattern has been defined as "economical" or "optimum", KH is
calculated in accordance with the formulae in ISO 6336 or DIN 3990. f ma has no
influence on the calculation of KH and is therefore ignored.
See formulae: (53) or (55) in ISO 6336:2006.
The reason for this is that a well designed contact pattern can compensate for manufacturing variations and variations due to deformation. If a higher value of f ma is
to be used in the calculation, this means, in reality, that a good contact pattern can
never be present. That is why, in this situation, you should select the contact pattern position "not verified or inappropriate" when calculating the face load factor.

23.2.9

Load spectrum with changing torque

Load bins can also be entered with negative torques.

The problem:
until now, no calculation guidelines have been drawn up to describe how to
calculate gears with changing load spectra.
The only unambiguous case is when a change in torque takes place, during every
cycle (and in each element of the collective). At this point, the load change
corresponds exactly to a double-load with +torque and then with torque. This instance can be calculated correctly by entering the load spectrum of the +moments
and the alternating bending factor YM for the tooth root. The flank is also
calculated correctly, because the +moments always apply to the same flank.
If, in contrast, the drive runs forwards for a specific period of time and then runs
backwards, the experts agree that the tooth root is not subjected purely to an
alternating load (and possibly this is the only point at which an alternating load
change takes place). However, discussions are still raging as to how this case can
be evaluated mathematically. It is even more difficult to define how mixed load
spectra with unequal + moments and moments for the tooth root are to be
handled. For this type of case, only the +moments are considered for the flank
(with the prerequisite that the +moments are equal to, or greater than, the
moments).
Note about handling load spectra with reversing torque:
A load progression as represented in Figure 13.10 below, where the tooth is
subjected to a load a few times on the left flank, and then a few times on the right
flank, can be converted into a load spectrum as shown below. This is represented in
an example here.

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Load progression (example):

13 loads with 100% of the nominal load (100 Nm) on the left flank, then
9 loads with 80% of the nominal load (80 Nm) on the right flank, etc.
This results in the following process:
11 load cycles with 100% load, positive torque, pulsating; then
1 load cycle with 100% load on the left and 80% load on the right; then
7 load cycles with 80% load, negative torque, pulsating; then
1 load cycle with 80% load on the right and 100% load on the left;
then repeated again from the start.
This can be represented as a load spectrum as follows:
Frequency

Torque

Load left flank

Load right flank

11/20 = 0.55

100 Nm

100%

0%

7/20 = 0.35

80 Nm

0%

100%

2/20 = 0.10

100 Nm

100%

80%

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23.2.10 Strength calculation with several geometries

on one gear
How can you take several simultaneous meshing points on a motor pinion into
account in the calculation?

Figure 23.1: Fourfold meshing

You can solve this problem with a normal face gear pair calculation (Z12).
Simply divide the power by a factor of 4 (reduce by 25%)
Then press the "Details" button in the Strength area behind the reference gear.

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Figure 23.2: Details Strength

Then press the plus button after the number of load cycles to perform the next
change. The number of load cycles for gear 1 changes "Automatically" to 4 load
cycles per revolution.

Figure 23.3: Define number of load cycles for gear 1

23.2.11

Bevel gears: Determine permitted overloads

Can maximum overloads be taken into account when calculating bevel gears in
accordance with ISO standards?
AGMA norms have definitions that allow for a standard overload of 250%. This
overload is defined as being present for less than 1 second, not more than 4 times
in an 8 hour time period. Does the ISO standard have comparable regulations with
regard to overloads (shock)? No references could be found about this subject in the
ISO standard.

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ISO 10300 does not give any information about permitted overloads. However,
ISO has a different Woehler curve (for YNT and ZNT factors) than AGMA.
Therefore, in principle if ISO 10300 is strictly adhered to, the total number of load
changes including the overload must be input. The application factor is 2.5 (which
corresponds to 250% overload). After this, you must calculate and check the safety
factors.
If the load only occurs very infrequently, (less than 1000 times during the entire
service life), this can be handled in a static calculation. KISSsoft has a simplified
version of the strength calculation process, specifically to cover this situation. This
is based on the ISO method, but only takes into account the nominal stress in the
tooth root (without stress correction factor YS). Here you must note, that in this
case, you must maintain a minimum safety level of 1.5 with regard to the material's
yield point!

23.2.12 Take shot peening data into account in calcul ating the strength of toothed gears
On page 47 of AGMA 2004-B89 you will see a note about shot peening. This states that shot peening improves tooth root strength by 25%.
If you are using KISSsoft to perform calculations in accordance with DIN or ISO,
you can achieve the increase in strength due to shot peening by inputting the
corresponding technology factor. To do this, go to the Factors tab and click on "ZY factors..." in the General factors group.

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You will find the details of useful entries as specified in Linke, Bureau
Veritas/RINA or ISO 6336 in the manual. If you want to perform the calculation in
accordance with AGMA, you do not have the option of inputting the technology
factor. In this case, you must increase the foot endurance limit by inputting the
corresponding percentage rate directly when you enter the material data. To do this,
go to the Basic data tab and then click the plus button behind the material selection.
In the dialog window, then activate "Own input". Input the endurance limit as
shown in the following figure.

Figure 23.5: Material own input

23.2.13 Calculation according to AGMA 421.06 (High

Speed Gears)
In the KISSsoft system, you perform calculations as specified by AGMA 421.06
for high speed gears in the following way.

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AGMA 421 is an old, well-established standard (1968), and has since been
replaced by AGMA 6011-I03 (2003).
Please note the information on this topic in section Calculation method (see section
"Calculation methods" on page II-279)

23.2.14 Comparison of a FEM calculation with sp iraltoothed gear wheel calculation

The accepted wisdom is that the differing results in the tooth root stress were
primarily due to the lower value of the "Reference Facewidth" in the KISSSOFT
calculation.
The effective contact of spiral-toothed gear wheels is included in our calculation of
the "Reference Facewidth". This results from the pressure ellipse (flattening of the
point of contact) In addition, if sufficient facewidth is present, 1x module per
facewidth is added to each side, as specified in ISO 6336-3.

23.2.15 Estimate the strength of asymmetrical spur

gear toothings
At present, KISSsoft does not have any algorithms that can be used to perform a
direct strength calculation for asymmetrical gears. Safeties are determined using
the calculation methods in ISO10300 for hypoid gears (hypoid teeth are
asymmetrical and have an unequal pressure angle on the right-hand and left-hand
flank).
This procedure is described below:
The calculation is run twice, each time with a symmetrical tooth, once with a high
pressure angle (calculation I), once with small pressure angle (calculation II).
The safety factor for the required safety against pitting that corresponds to the
calculation with the flank under load is applied here. Therefore, if the load flank is
the one with the small pressure angle, the safety against pitting from the calculation
with the smaller angle (SHII) is used.
Root safety is determined with the nominal stress (tooth form factor YF), which is
derived from the loaded flank. The tooth thickness at root sFn is determined from
both these calculations, so therefore:
sFn = (sFnI + sFnII)/2

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The stress concentration (factor YS) is calculated with the formula given above,
and using the root radius and the application of force lever arm of the flank under
load, and also sFn. All the remaining factors for defining the root fracture safety SF
are the same.

23.2.16 Determine the equivalent torque (for load

spectra)
Some calculation guidelines require you to determine the equivalent torque of a
load spectrum and therefore perform sizing. How can I define the equivalent torque
in KISSsoft?
The fundamental issue here is that the verification of a toothing with equivalent
torque must give the same safeties as the verification with the actual load spectrum.
For this reason, you can follow this procedure:
1. Input the load spectrum and calculate the toothing.
2. Make a note of the lowest root safety and the lowest flank safety for each gear.
3. In the Module specific Settings window, which you access from
Calculation -> Settings, input the safeties you have noted as required
safeties in the "Required safeties" tab. At this stage we recommend you deactivate
the "Securities depend on size" tab.
4. Delete the load spectrum by setting "Individual load".
5. Then click the Sizing button next to the torque input field. This field is now
filled with the equivalent torque.
6. Now run the calculation to check the data. The safeties you have now defined for
the root or flank of a particular gear must be exactly equal to the previous smallest
value (as in step 2). None of the gears can have a safety that is less than the safeties
you recorded in step 2.

23.2.17

Check changes in safeties if the center distance changes

Is it possible to check how the safeties change when gears are mounted with a different center distance?
Select Calculation-> Settings ->Module specific settings in the
Calculations tab and select Calculation with operating center
distance and profile shift according to manufacture. You
can then input the profile shift coefficients and center distance independently of

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each other. The calculation then uses the circumferential forces in the operating
pitch diameter instead of the circumferential forces in the reference circle.

23.2.18 Warning: "Notch parameter qs . outside RANGE

(1.0 to 8.0) ..."
Stress modification factor YS is calculated with a formula that complies with ISO
6336, Part 3 or DIN 3990, Part 3. This formula uses a notch parameter qs, which is
also documented in these standards:

(23.4)

The validity area for the formula for Y S in accordance with the standard lies in the
range 1.0 ...qs... 8.0. This formula should not be used outside this range.

If q s <1, YS (calculated with qs=1), should be somewhat too large. In this case, the
calculation results will fall in the validity area.

If qs > 8, YS, (calculated with qs=8) is rather too small. The calculation results in
this case then fall outside the validity area. However, you should ensure that the
calculation is not too imprecise.

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23.3

Abbreviations used in gear calculation

Abb. in standards etc.

Abb. in
KISSsoft

Center distance (mm)

ad

a.d

Reference center distance (mm)

Aa

A.a

Center distance allowance (mm)

Ase

As.e

Tooth thickness allowance at the normal section

(mm)

en

alf.en

Angle at which force is applied (degree)

alf.n

Pressure angle at the normal section (degrees)

Pro

alf.Pro

Protuberance angle (degrees)

alf.t

Pressure angle on the reference circle (degrees)

wt

alf.wt

Operating pressure angle (degrees)

Facewidth (mm)

BM

B.M

Thermal contact coefficient (N/mm/s.5/K)

beta

Helix angle at reference circle (degree)

beta.b

Base helix angle (degree)

Tip clearance (mm)

c'

c'

Single spring stiffness (N/(mm*m))

c.g

Contact spring stiffness (N/(mm*m))

Reference diameter (mm)

da

d.a

Tip diameter (mm)

db

d.b

Base diameter (mm)

df

d.f

Root diameter (mm)

df(xE)

d.f(x.E
)

Root circle with profile shift for Ase (mm)

di

d.i

Inside diameter gear (mm)

dNa

d.Na

Tip active circle diameter (mm)

dNf

d.Nf

Active root diameter(mm)

dFf(0)

d.Ff(0)

Root form diameter (mm)

dsh

d.sh

External diameter of pinion shaft (mm)

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dw

d.w

Operating pitch diameter (mm)

DM

D.M

Theoretical ball/pin diameter (mm)

D.M eff

Effective ball/pin diameter (mm)

efn

e.fn

Normal gap width on the root cylinder (mm)

tot

eta.tot

Total efficiency

eps.a

Transverse contact ratio

eps.b

Overlap ratio

eps.g

Total contact ratio

ff

f.f

Profile form deviation (mm)

fH

f.Hb

Helix slope deviation (mm)

fma

f.ma

Tooth trace deviation due to manufacturing

tolerances (mm)

fpe

f.pe

Single pitch deviation (mm)

fsh

f.sh

Tooth trace deviation due to deformation of the

shafts (mm)

Fa

F.a

Axial force (N)

Fy

F.by

Actual tooth trace deviation (mm)

Fn

F.n

Normal force (N)

Fr

F.r

Radial force (N)

Ft

F.t

Nominal circumferential force in the reference

circle (N)

Fase.d

Tip chamfer (mm)

g.a

Length of path of contact (mm)

Gamma

Gamma coordinates (point of highest temperature)

Tooth depth (mm)

haP

h.aP

Addendum reference profile (in module)

hF

h.F

Bending lever arm (mm)

hfP

h.fP

Dedendum reference profile (in module)

hk

h.k

Protuberance height (in module)

ha

ha

Chordal height (mm)

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Service life in hours

AGMA: Geometry factor for pitting resistance

Impulse

Impulse

Gear driving (+) / driven (-)

jn

j.n

Normal backlash (mm)

jt

j.t

Rotational backlash (transverse section) (mm)

jtSys

j.tSys

Backlash of the entire system (mm); for planetary

stages

Number of teeth spanned

k * mn

k * m.n

Tip alteration (mm)

KA

K.A

Application factor

KB

K.Ba

Transverse coefficient - scuffing

KB

K.Bb

Width factor - scuffing

KB

K.Bg

Pitch factor - scuffing

Kf

K.f

AGMA: Stress correction factor

KF

K.Fa

Transverse coefficient - tooth root

KF

K.Fb

Width factor - tooth root

KH

K.Ha

Transverse coefficient - flank

KH

K.Hb

Width factor - flank

KHbe

K.Hbbe

Bearing application factor

KV

K.V

Dynamic factor

Kwb

K.wb

Alternating bending coefficient

Bearing distance l on pinion shaft (mm)

mn

m.n

Normal module (mm)

mRed

m.Red

Reduced mass (kg/mm)

mt

m.t

Transverse module (mm)

MdK

M.dK

Diametral measurement over two balls without

backlash (mm)

MdKeff

M.dKeff

Effective diametral measurement over two balls

(mm)

MdReff

M.dReff

Effective diametral roller mass (mm)

MrK

M.rK

Radial measurement over one ball without

Chapter
II-679

Answers to Frequently Asked Questions

23

backlash (mm)
MrKeff

M.rKeff

Effective radial measurement over one ball (mm)

mu.m

Average friction factor (as defined in Niemann)

my.m

Averaged friction factor

my.my

Friction factor

Speed (RpM)

E1

n.E1

Resonance speed (min-1)

Nominal speed

NL

N.L

Number of load changes (in mio.)

100

nu.100

Kinematic nominal viscosity of oil at 100 degrees

(mm2/s)

40

nu.40

Kinematic nominal viscosity of oil at 40 degrees

(mm2/s)

pbt

p.bt

Base circle pitch (mm)

pet

p.et

Transverse pitch on path of contact (mm)

pt

p.t

Pitch on reference circle (mm)

Nominal power (kW)

PV Z

P.VZ

Loss of power due to tooth load (kW)

PV Ztot

P.VZtot Total power loss (kW)

PWaelzL

P.Waelz Meshing power (kW)

L

RZ

R.Z

Average total height (mm)

ro.F

Tooth root radius (mm)

fP

ro.fP

Root radius reference profile (in module)

Oil

ro.Oil

Specific Oil density at 15 degrees (kg/dm3)

Distance on pinion shaft (mm)

san

s.an

Normal tooth thickness on the tip cylinder (mm)

sFn

s.Fn

Tooth root thickness (mm)

smn

s.mn

Normal tooth thickness chord, without backlash

(mm)

s.mn

Effective normal tooth thickness chord with

Chapter
II-680

Answers to Frequently Asked Questions

23

e/i

clearance (mm) (e: upper, i: lower)

SB

S.B

Safety factor for scuffing (flash temperature)

SF

S.F

Safety for tooth root stress

SH

S.H

Safety for pressure at single tooth contact

SHw

S.Hw

Safety for flank pressure on operating pitch circle

SSint

S.Sint

Safety factor for scuffing (integral temperature)

SSL

S.SL

Safety for transmitted torque (integral temperature)

sig.F

(Effective) tooth root stress (N/mm2)

F0

sig.F0

Nominal tooth root stress (N/mm2)

Flim

sig.Fli Endurance limit tooth root stress (N/mm2)

m

FP

sig.FP

Permitted tooth root stress (N/mm2)

sig.H

Flank pressure on the operating pitch circle (N/mm2)

H0

sig.H0

Nominal flank pressure on the pitch circle (N/mm2)

HB/D

sig.HB/ Flank pressure HPSTC (N/mm2)

D

Hlim

sig.Hli Endurance limit Hertzian pressure (N/mm2)

m

HP

sig.HP

Permitted flank pressure (N/mm2)

sig.s

Yield point (N/mm2)

xi

Total
x.i

Total profile shift coefficients

Torque (Nm)

the.B

Highest contact temperature (oC)

int

the.int Integral flank temperature (oC)

the.m

M-C

the.M-C Tooth mass temperature (oC)

Oil

the.Oil Oil temperature (oC)

the.s

Sint

the.Sin Scuffing integral temperature (oC)

t

Tooth mass temperature (oC)

Scuffing temperature (oC)

Chapter
II-681

Answers to Frequently Asked Questions

23

Gear ratio

Circumferential speed reference circle (m/s)

vga

v.ga

Maximum sliding velocity on tip (m/s)

Vqual

Accuracy grade in accordance with DIN 3962 or

ISO 1328

Nominal circumferential force reference circle per

mm (N/mm)

Wk

W.k

Base tangent length (no backlash) (mm)

W.k e/i Effective base tangent length (mm) (e: upper, i:

lower)
x

Profile shift coefficient

xE

x.E

Profile shift coefficient at manufacturing for Ase

X.alfbe Angle factor

t

XB

X.B

Geometry factor

XBE

X.BE

Geometry factor

XCa

X.Ca

Tip relief factor

Xe

X.e

Contact ratio factor

X.Gam

Distribution factor

XM

X.M

Flash factor

XQ

X.Q

Meshing factor

XS

X.S

Lubrication factor (scuffing)

XWrelT

X.WrelT Relative structure coefficient (scuffing)

ya

y.a

Run-in amount (m)

yb

y.b

Run-in amount (m)

AGMA: Tooth form factor

Yb

Y.b

Helix angle factor

Y drel

Y.drel

Support factor

Ye

Y.e

Contact ratio factor

YF

Y.F

Tooth form factor

Y NT

Y.NT

Lifetime factor

Chapter
II-682

Answers to Frequently Asked Questions

23

YR

Y.R

Surface-factor

YS

Y.S

Stress correction factor

Y st

Y.st

Stress correction factor test gear

YX

Y.X

Size coefficient (tooth root)

Number of teeth

zn

z.n

Virtual gear no. of teeth

Z.b

Helix angle factor

ZB/D

Z.B/D

Single contact point factor

ZE

Z.E

Elasticity factor (N1/2/mm)

Z.e

Contact ratio factor

ZH

Z.H

Zone factor

ZL

Z.L

Lubricant factor

ZNT

Z.NT

Lifetime factor

ZR

Z.R

Roughness factor

ZV

Z.V

Speed factor

ZW

Z.W

Material hardening factor

ZX

Z.X

Size factor (flank)

zet.W

Wear sliding coef. by Niemann

zet.a

Specific sliding at the tip

zet.f

Specific sliding at the root

III Shafts a nd Be arin gs

Part

III

Shafts and Bearings

Chapter
III-684

Defining Shafts

24

24

Defini ng Sha fts

Chapter 24
Defining Shafts
This program consists of a basic package and different expert add-ins. The
following calculations are available here:
Deformation, force, torque, and stress diagrams
Eigenfrequencies (bending, torsion and axial movements)
Buckling loads
Static and fatigue strength
Roller bearing calculation
Sliding bearing calculation (hydrodynamic)
Necessary width modification of pinion

Bas e pa cka g e

In this module you can input and correct geometry and material data, shaft
specifications, drawing numbers, support, peripheral conditions, external forces
and moments (simplified input for couplings, spur and bevel gears, worms, worm
gears, belt pulleys etc.).
A shaft with the machine elements mounted on it (for example, gears or bearings)
is defined in the graphical shaft editor.
The properties required to define a shaft in this editor are:
Any dimensions (cylindrical and conical), axially symmetric cross section, solid and hollow shafts, beams (H, I, L profiles etc.).
Integrated drawing tool that allows simple corrections to be made to the shaft
contour (diameter, lengths). You can change any of these elements by simply
clicking on them with the mouse.
Definition of notch geometries for the automatic calculation of notch factors.
The following notch geometries are available here:

Radius

Chamfer

Relief groove

Interference fit

Chapter
III-685

Defining Shafts

24

Longitudinal keyway

Circumferential keyway

Square keyway

V-notch

Spline

Cross hole

You can enter these values for force and moment in any spatial positions. However, the following values are already predefined:

Cylindrical gear

Bevel gear

Worm

Worm wheel

Coupling

Rope sheave/V-belt

Centrical force

Eccentric force

External masses with moment of inertia (additional mass)

Power loss

Calculation of:

Shaft weight

Moment of inertia

Axial force

Static torsion of the shaft

Chapter
III-686

Defining Shafts

24

Clear representation of geometry data and the calculated bearing and peripheral
forces both on screen and on paper.

Figure 24.1: Flow-chart of the modules for shaft and bearing calculation in KISSsoft.

Chapter
III-687

Defining Shafts

24

24.1

Input window

The KISSsoft system offers a range of different input windows in which you can
define shafts. The Shaft editor (see page III-687) shows a graphical representation
of the shaft system. The Elements tree (see page III-689) illustrates the structure of
the shaft system in a tree structure. Outer contour (see page III-697), Inner contour
(see page III-704), Forces (see page III-704), Bearing (see page III-710) and
Cross sections (see page III-715) values for a shaft are shown as a table in the
Elements list (see page III-690). You define the parameter of an element in the
Elements editor (see page III-691).

Figure: The different input windows where you can define shafts

24.1.1

Shaft editor

The shaft editor shows a graphical representation of the shaft system. Use the
vertical tool bar on the right-hand edge of the shaft editor to add the most
frequently used elements. If your system has several shafts, the new element is
always added to the active shaft. A shaft becomes active when one of its elements
is selected. If no element has been selected, the last shaft is the active one. The active shaft is also displayed in the Elements list (see page III-690).

Chapter
III-688

Defining Shafts

24

Via the Context menu you can print the graphics in the shaft editor and save them
as picture files. Each of the different elements also have interactive Context menus.

Figure: Context menu in the Shaft editor

Chapter
III-689

Defining Shafts

24

24.1.2

Elements tree

The Elements tree illustrates the structure of the shaft system in a tree structure.
Shafts are at the highest level. The connecting elements in systems with several
shafts are also shown here. Each shaft groups its main elements by Outer contour
(see page III-697), Inner contour (see page III-704), by Strength (see page III698), Bearings (see page III-710)and Cross sections (see page III-715). For the
cylinder and conus main elements, the sub-elements are located on a further sublevel.

Figure: Levels in the Elements tree

Chapter
III-690

Defining Shafts

24

You can select, copy, insert and delete elements via the Elements tree. In a Context
menu you see which actions are available for each element. Special actions are
available, depending on the element type. You can also arrange shafts, roller
bearings and cross sections. You can also import (see page III-702)/export (see
page III-704) outer and inner contours to DXF.

Figure: Context menu in the Elements tree

24.1.3

Elements list

The Elements list lists groups of elements in table format. Two selection lists show
the active shaft and the currently displayed elements. You can edit the parameter

Chapter
III-691

Defining Shafts

24

listed in the table directly in the Elements list. The context menu allows you to insert elements quickly and easily.

Figure: Context menu in the Elements list

24.1.4

Elements editor

In the Elements editor you can edit any of the parameters of the selected element.

Chapter
III-692

Defining Shafts

24

24.2

Element overview

24.2.1

The Shaft element

To input a shaft, click on the first icon in the vertical tool bar in the Shaft editor
(see page III-687). You will also find the Add shaft option in the context menu
of the Elements tree (see page III-689). A new entry appears at the end of the Elements tree. Single click on the shaft element in the Elements tree to input parameters for the shaft in the Elements editor (see page III-691), as shown in Figure
24.4).

Figure 24.4: Elements editor for inputting shaft parameters

The next section describes the individual input fields in which you enter parameters
for a specific shaft.

24.2.1.1
Drawing number
In the Drawing number input field you can enter a string of any characters
apart from ";" (semicolon). The drawing number you enter here does not affect the
calculation.

Chapter
III-693

Defining Shafts

24

24.2.1.2
Positi on
The Position input field is where you enter the Y coordinate of the starting point
of the shaft with regard to the global co-ordinates system.

NOTE

Global coordinates are indicated by upper case letters. Lower case letters indicate a
shaft's local coordinate system.

24.2.1.3
Temperature
The shaft may undergo thermal expansion if the shaft's temperature is not the same
as the Reference temperature (on page III-718). In addition to the thermal expansion of the shaft, the thermal expansion of the gear case can also be taken into
account by the Housing temperature (see page III-719).

24.2.1.4
Ambient densit y
Bodies placed in hydrostatic fluids experience buoyancy. The value here is the same as the weight of the displaced medium, and is defined by the volume and the
density of the displaced medium. KISSsoft takes the buoyancy effect into
account, if you enter the appropriate ambient density value. The default setting is
for air density. The next table lists technical values for other media.
Medium

Air

Water

Oil

Density

1.2

998

772

Table 24.1: Densities [kg/m3] of a few important fluids where = 20oC and p = 1016 mbar

NOTE

If a shaft is operated in different ambient media, for example, as is the case for input shafts in ships, you can combine two individual shafts, each of which has different ambient density data, by using the Connections element in the Elements
tree and calculate them as a single shaft.

24.2.1.5
Speed
Shaft speed [1/min] around its longitudinal axis. If you click the checkbox to the
right of the input field, you can change the speed independently of other shafts.

Chapter
III-694

Defining Shafts

24

However, if this checkbox is not active, the value is taken from the Speed (see
page III-717) input field in the Basic data input window.

24.2.1.6
Sense of rot ation
The sense of rotation can influence the way loads are distributed along the shaft,
for example, as the result of helical toothed gears, and therefore affect the service
life of the bearing. Click the checkbox to the right of the Speed input field to view
and select these entries from the drop-down list. However, if this checkbox is not
active, the value is taken from the Sense of rotation (see page
III-718) input field in the Basic data input window.

24.2.1.7
Material
You can select a shaft material from this drop-down list and therefore assign a
specific material to each individual shaft. If you use this function together with the
Connections element in the Elements tree you can generate shafts made of different materials.

24.2.1.8
Base size
The Base size input field is decisive for strength calculation. However, if you
select the Pre-turned to actual diameter option in the Strength
input window in the State during heat treatment drop-down list, the
setting of the raw measure value has no effect on the calculation. In contrast, if the
selection is set to Raw diameter, the largest, rounded shaft diameter will be
selected and the strength calculation will be performed using this value. Click the
checkbox to the right of the input field to specify your own diameter for the blank
before it is turned.

24.2.1.9
Surface factor
In this selection list, you can define if an additional surface factor should be applied or not. Here you can select either Rollers or shot peening.

24.2.1.10 State during heat tre a t ment

To define the technological size coefficient K1,deff, select one of these two options:

Chapter
III-695

Defining Shafts

24

Pre-turned to actual diameter. The raw diameter has no influence on the technological size coefficient. The value K1,deff is recalculated for each cross section
based on the actual diameter size.
Raw diameter. K1,deff is determined once from the raw diameter and applied
cross section.
NOTE

You can also define the Base size field in the Elements editor of the
corresponding shaft. To do this, input the dimension of the raw material which was
used to generate the final material characteristics during the last heat treatment. If
this involves a solid shaft, enter the external diameter of the unworked part. For a
pipe, enter the wall thickness and, for a cast part, enter the greatest wall thickness.

24.2.1.11 Material prope rtie s

From the Material characteristic values drop-down list, specify how
KISSsoft is to define the material characteristic values that are relevant to strength.

1. at reference diameter Values are taken from the database and

multiplied by K1
2. Rp, Rm as stated in database, SW for reference diameter The values Rp and Rm are determined according to size (excluding
K1), and the fatigue strength W is determined for the reference diameter
entered in the database and then it is multiplied with K1.
3. Rp, Rm as stated in database, W constant The values Rp
and Rm are determined according to size, and the fatigue strength W is taken from the database without being influenced by the geometric size factor. The size coefficient K1 is not taken into account here.
4. Rp, RM according to the database, W is calculated
from Rm The values Rp and Rm are taken from the database, and W is determined from the tensile strength Rm in accordance with the standard.
The data of the material used to calculate the shaft strength is derived from the values in the database as follows:
Fatigue limit factors (for tension/compression, bending, etc.) are taken directly
from the material database. There, these values are defined for every calculation method. If data for these materials has been specified in the calculation method, it is these values that are used.
Tensile strength values are stored in the database according to their diameter as
defined in the specific EN standard. The raw diameter is used to fetch the tensi-

Chapter
III-696

Defining Shafts

24

le strength value from the database and use this in the calculation. This method
of defining the actual tensile strength is very reliable and can be used for every
calculation method. It has the effect that the same values are used for each calculation method.
When you specify a calculation method, you can decide to use the material database on the basis of the requirements given in the corresponding standard.
Then, the actual tensile strength is defined using the thickness factor taken
from the base tensile strength of the sample diameter (normally 10 mm), in accordance with the standards (either FKM or DIN: if you use Hnchen this triggers an error message).
The yield point or strain limits are taken either from the database or from the
standard, in the same way as for the tensile strength.

24.2.1.12 Own data fo r Woehler line (S -N curve)

Click the Own data for Woehler line checkbox to define your own
Woehler line. You can also enter values for the sustainable damage or Miner total
here. If you do not activate this checkbox, the program will define the Woehler line
in accordance with either DIN 743 or FKM. You should specify your own Woehler
line, or modify the sustainable damage value if you are modifying your calculation
to suite the results of specific tests.

24.2.1.13 Taking the resu lts into account in the report

If this flag is set, the corresponding shaft is output in the main shaft report, along
with all its elements (external/internal contour, force elements, bearing). However,
this is only valid for inputs and does not affect the results of the calculation. The
default setting is that this flag is set.

Chapter
III-697

Defining Shafts

24

24.2.2

Outer contour

Figure 24.5: Display the outer contour in the Shaft editor

You can use (hollow) cylinders, (hollow) cones and beams to define the shaft
geometry. To enter a new element, select the element you want at group level in
the Elements tree, e.g.Outer contour. Click the right-hand mouse button on
this element to add it to the group at the right-hand end of the shaft. Alternatively,
you can select an existing element at element level (e.g. cylinder) and then
right-click with the mouse to open a context menu. The Add element
before(after) option opens another sub menu in which you select an element
to be inserted at a position relative to the existing element.
Possible profiles for beams are:

Rectangular profile

Double T profile

Chapter
III-698

Defining Shafts

24

H profile

Rectangular profile (hollow)

L profile

24.2.2.1
Defining sub element s
Before you can define a sub element, first select the main element to which you
want to add this sub element in the Elements tree. Then right-hand mouse click to
select the sub element you require. The inserted sub element now appears in the
Shaft editor and its corresponding notch factors are defined in the strength
calculation. Once you have defined a sub element, you can activate it in the same
way as a main element (see Activate).

Adding sub elements:

Radius right/ left
Input values:

Radius: Size of the radius

Surface roughness: Radius surface

Chamfer right/left
Input values:

Length: Chamfer length

Angle: Chamfer angle

Chapter
III-699

Defining Shafts

24

Relief groove right/left

Input values:

Relief groove form: Select the relief groove form in accordance with DIN
509 or FKM

Series (DIN 509): (Selection: series 1, radii as defined in DIN 250; Series
2, special radii)

Stress (DIN 509): (with conventional stress; with increased fatigue

strength)

relief groove length: Length of the relief groove in the direction of the axis

Transition radius: Radius between the end of the relief groove and the next
element

Depth of recess: Recess depth

Surface roughness: Recess surface

Interference fit
Input values:

Interference fit length: Interference fit length

Type of interference fit: (Selection: Slight interference fit, interference fit

and interference fit with end relief)

Reference measure: this specifies the measurement from the left-hand end
of the selected element up to the start of the thread

Longitudinal groove
Input values:

Groove length: Groove length

Surface roughness: Groove length surface

Reference measure: this specifies the measurement from the left end of the
selected element up to the start of the groove

Circumferential groove
Input values:

Depth: Depth of the circumferential groove

Rounding in the groove bottom: Radius of the circumferential groove

Surface roughness: Surface of circumferential groove

Reference measure: this specifies the measurement from the left end of the
selected element up to the middle of the circumferential groove

Chapter
III-700

Defining Shafts

24

Square groove
Input values:

Width: Width of the square groove

Depth: Depth of the square groove

Radius: Radius of the square groove

Surface roughness: Surface of the square groove

Reference measure: this specifies the measurement from the left end of the
selected element up to the middle of the square groove

V-notch
Input values:

Depth: Depth of the V-notch

Surface roughness: Surface of the V-notch

Reference measure: this specifies the measurement from the left end of the
selected element up to the middle of the V-notch

Spline
Input values:

Standard: Normal range of the spline (click the

required size from a list)

Tip circle: you can either select this from a list of standards or input your
own value

Root circle: you can either select this from a list of standards or input your
own value

Number of teeth: you can either select this from a list of standards or input
your own value

Module: you can either select this from a list of standards or input your
own value

Surface quality: Spline surface quality

Length: Spline length

Reference measure: this specifies the measurement from the left end of the
selected element up to the start of the spline

Spline shaft
Input values:

Tip circle: Tip circle of the spline shaft

button to select the

Chapter
III-701

Defining Shafts

24

Root circle: Root circle of the spline shaft

Number of keys: Number of keys

Spline shaft root rounding: (Selection: Shape A, Shape B and Shape C)

Length: Length of the spline shaft

Reference measure: this specifies the measurement from the left end of the
selected element up to the start of the spline shaft

Surface quality: Spline shaft surface

Cross hole
Input values:

Bore diameter: Diameter of bore

Surface roughness: Axial boring surface

Reference measure: this specifies the measurement from the left end of the
selected element up to the position of the cross hole

Thread
Input values:

Label: Thread label

Thread depth: Thread depth

Rounding: Rounding in the notch bottom of the thread

Length: Thread length

Reference measure: this specifies the measurement from the left-hand end
of the selected element up to the start of the thread

Surface roughness: Thread surface

General notch effect

Input values:

Width: Width of the overall sub element

Notch factor bending/ torsion/tension-compression/shearing force: you can

enter the notch factors directly here.

Surface roughness: Surface of the overall sub element

Reference measure: this specifies the measurement from the left end of the
selected element up to the middle of the overall sub element
You can enable the "Conical shoulder" notch type directly in the Strength
calculation (see section "Cross-section types" on page III-763).

Chapter
III-702

Defining Shafts

24

24.2.2.2
Importing the sh aft ge ometry
Right-hand mouse click next to the outside or inner contour to open a pop-up menu
(see figure). Click Import to import a .ktx or a .dxf file.

Figure 24.6: Importing the shaft geometry from a dxf file

Reading (importing) a ktx file:

In KISSsoft, go to the Shaft calculation Elements tree and right-hand click on the
Outer contour element to open a pop-up menu in which you select the Import option. Select the required *.ktx file and click on Open. The shaft contour is
now uploaded into KISSsoft.

Reading (importing) a dxf file:

The outside and inner contour (if present) of the shaft should be output individually
by the CAD system.
NOTE:

You can use the default value ALL for the layer name so that all layers are
imported. You can also import the contours as variants in different layers. To do
this, enter the layer name in the appropriate input field. If you don't know the exact

Chapter
III-703

Defining Shafts

24

layer name, you can input an invalid name as a test (for example, xxx) If you then
try to read (import) this, the resulting error message will list the valid layer names.
Draw the shaft contour with a mid line in a CAD system. Use the x, y plane as
the coordinates system (X-axis as rotational axis) to ensure the contour is interpreted correctly after it has been read imported and so that the shaft is drawn in
KISSsoft in the Y, Z plane (rotational axis Y-axis). Save the shaft geometry as
a *.dxf file.
In KISSsoft, go to the Shaft calculation Elements tree and right-hand click on
the Outer contour element to open a pop-up menu in which you select the
Import option. Now select the *.dxf file you require and click Open.
This opens another dialog in which you can define the layer, the point of origin
(x/y) and the angle of the symmetry axis. After you have input this data, click
OK to close this dialog. The shaft contour is then loaded with these details.

Figure 24.7: Import dialog for loading dxf files

Chapter
III-704

Defining Shafts

24

24.2.2.3
Export shaft geometry
Right-hand mouse click next to the outside/ or inner contour to open a pop-up menu (see figure). If you select Export, you can create either a *.ktx or *.dxf file.

Figure 24.8: Export shaft geometry in a dxf file

Procedure for importing in a file:

You can export previously-defined shafts from the Shaft editor. In the KISSsoft Elements tree for shaft calculation, right-hand mouse click on the required
element e.g. Outer contour, start the Popup menu start and select Export. You can export inside or outer contours of the different shafts.
After you select a contour, a dialog opens in which you can define the name of
the *.ktx or *.dxf file.

24.2.3

Inner contour

The inner contour is generated from left to right (just like the outer contour). For
example, if you want to generate a shaft with an axial hole from the right-hand side, you must first input data for an inside cylinder starting from the left-hand side
with a diameter of 0 that extends up to the point where the bore begins.

24.2.4

Forces

24.2.4.1
Forces
Forces can be applied to any point on the shaft and even outside(!) the shaft. Different methods are available for defining force transmitting elements (such as gears)

Chapter
III-705

Defining Shafts

24

or even individual forces. In most force elements, the direction of the torque is
defined by setting them as "driving" or "driven". "Driving" means that the shaft is
the driving element or that the torque of the sense of rotation is counter to the sense
of rotation. See also 24.3.5 (see page III-718).
Comments about special elements:
Cylindrical gear
Position of contact: specify the location of the point of contact with the paired
gear according to Figure 24.3 on page III-716 (this point is where the forces
apply).
Instead of simply entering the reference diameter, you get a more accurate result if you enter the operating pitch diameter and the operating pressure angle
instead of the nominal pressure angle.
Click the Convert button to calculate these values.
The center point of the load application is by default the center of the gear.
This can be changed by defining the load application position offset yF, according to the following formulae:

Original starting position of gear load application: L0 = middle of the gear (gear width/2)
Original final position of the load application on the gear: R0 = middle of the
gear + (gear width/2)
* If yF > 0
New starting position of the load application on the gear: L1 = L0 + 2 * yF
New final position of the load application on the gear: R1 = R0
* If yF < 0
New starting position of the load application on the gear: L1 = L0

Chapter
III-706

Defining Shafts

24

New final position of the load application on the gear: R1 = R0 + 2 * yF

The calculations shown above are only valid if the corresponding setting is
enabled in the module-specific settings. Use the same procedure for all the gear
elements.
Bevel gear
Position of contact: refer to the data for cylindrical gears.
The position of the bevel gear can be converted using the bevel gear data. The
reference point for positioning is the middle of the bevel gear width on the reference cone. The position of the bevel gear can be converted using the position of the axis crossing point on the shaft and other bevel gear data.
An additional force component due to friction ( = 0.05) is taken into account
when calculating hypoid gears.
Face gear
The reference cone angle for face gears is always set to 90 (this input cannot
be changed).
The worm
is usually a driving element. Its efficiency is included in the calculation of
force components. Position of contact: refer to the data for cylindrical gears.
The worm wheel
is usually "driven". Its efficiency is included in the calculation of force components. Position of contact: refer to the data for cylindrical gears.
Rope sheave
Direction of rope sheave: Input the direction of the resulting belt forces as
shown in Figure 24.3 on page III-716.

Chapter
III-707

Defining Shafts

24

The direction of the helix angles and the positions of the elements are defined in
Figure 24.9.

Figure 24.9: Defining the direction of force elements.

E cc e n tri c f or c e

Figure 24.10: Cartesian/polar coordinates for eccentric force

You can enter values for eccentric force either in Cartesian or polar coordinates
(see Figure24.10). You can change the coordinates system in the
Drawings/Settings tab in the Shaft editor.
Tra n sf err in g da ta fr om ge ar cal cu la ti o n

Chapter
III-708

Defining Shafts

24

In the Elements editor, you can import the data used to define spur and bevel
gears from a gear calculation file. Select the element you require in the Elements
tree and then click on the Read data from file checkbox. Then select the
gear number (1 to 4). The data relevant to these gear pairs is then imported directly.
In this situation, the data at the pitch point is used instead of the data at the reference circle.
Important: If the Read data from file option in this input window remains active,
data will be imported again from the gear calculation every time you call the shaft
calculation function. If you then change the gear data later on, the new data will
automatically be transferred with it! If the flag is not set, the data is only copied
once from the gear calculation, and not updated later on. For this reason, you
cannot change the contents of most input fields in the gear data input screen when
linked files are involved. You can only change the Position of contact and the Ycoordinate.

24.2.4.2
Coupling
A coupling transmits torque and can also be subject to radial and axial forces. From
the torque (or the specified power and speed) you can calculate the circumferential
force to

(24.2)

Ft

= Circumferential force

Mt

= Torque

= Effective diameter

Cal cu la ti ng r ad ial fo rc e fo r a c o u pli n g:

(24.3)

Ft

= Circumferential force

K2

= Radial force factor

Chapter
III-709

Defining Shafts

24

Define the direction of the force in the input window. You are also prompted to
enter the mass of the coupling so it can be included in the calculation as a
gravitational force.

Cal cu la ti ng axi al f or c e f or a c o up li ng:

(24.4)

Ft

= Circumferential force

K3

= Axial force factor

The axial force acts along the center line of the shaft.

24.2.4.3
Mass
Masses placed on the shaft are used as moments of inertia to determine the critical
speeds. They are to be considered as a gravitational force.

24.2.4.4
Magnetic tension
The radial and axial forces produced by electromagnetic windings are included in
the calculations.

Calculating radial force:

(24.5)

K1

= 0.1 for three-phase motors where the number of poles is 2

0.2 otherwise

= (mm) inside diameter of the stator of three-phase motors

or external diameter of the rotor of direct current motors

= (mm) Length of the active "packet of plates" (excluding the cooling slits)

= Damping factor:
Three-phase current asynchronous motor: Squirrel cage: v = 0.25
Three-phase current asynchronous motor: Wound rotor: v = 0.7

Chapter
III-710

Defining Shafts

24

Three-phase current synchronous motor v = 0.5

DC motor with wave formation v = 1.3
f/del0

= Ratio of the mean eccentricity and the nominal air gap

= 0.2 for three-phase motors
= 0.1 for DC motors

Cal cu la ti ng axi al f or c e:
F*A

35 . /D

F*A

Axial force factor

Torque (Nm)

Axial groove lead (deg)

(mm) inside diameter of the stator of three-phase motors

or external diameter of the rotor of direct current motors

24.2.5

Bearing

In addition to calculating the shaft, you can export roller bearings and general
bearings as separate roller bearing or plain bearing files (File > Export).

24.2.5.1
General bearing
All elements of a bearing (rigid or elastic) are considered to be a bearing. Input a
fixed bearing, right mounted, left mounted, or thrust, bearing to determine the point
on the shaft at which axial force is transmitted. This information is also used in the
roller bearing calculation. In taper roller bearings (or similar configurations) it is
not always obvious which bearing is subject to the axial force. In this case, you
must enter the mounting data for the bearings. You can also specify a radial or axial offset in the bearing alignment. This enables you to take into account other
factors such as the simulation of assembly error.

24.2.5.2
Rolli ng bearing s
In addition to general bearings, you can also select specific rolling bearings. The
bearing data is then taken from the bearing database. This means the bearing's
geometry data is already available, and you can draw the bearing using the width

Chapter
III-711

Defining Shafts

24

and external diameter values. In addition, for a bearing with an inclined contact
angle, the direction of the force can be taken into account in the calculation. You
can either use the bearing stiffness value taken from the bearing database (if
available) or specify your own value here. You can also define a bearing clearance
for each rolling bearing (according to DIN 620 C2, C0, C3, C4 or Own input).
A preload force, applied on the outer ring, can be used instead of the offset to
define the preload force on the bearing. This is only taken into account for bearings
with inner geometry, and only if the corresponding bearing can accept an axial
preload force. The preload force is then transformed internally to an equivalent
axial offset of the outer ring. For bearings with inner geometry, you can also
specify a rotation around axis X and Z of the outer ring. This could then be used,
for example, to model the housing deformation, and make it possible for you to
enter the FEM results directly.
The diametral pitch bearing clearance defines the diameter-related clearance of a
bearing. The diametral pitch bearing clearance for a deep groove ball bearing is
defined as:
Pd = do di 2 * Dw
Here, Pd is the diametral pitch bearing clearance, do is the external raceway diameter, di is the internal raceway diameter and Dw is the rolling body diameter. Similar
definitions are used for other bearing types, which vary depending on which
particular type is involved.

24.2.5.3
Constraints on var iou s bearing s
Options for selecting a roller bearing with displacement and rotation options:
Roller bearing selection list

ux

uy

uz

rx

ry

rz

Non-locating bearing

fixed

nonlocating

fixed

nonlocatin
g

nonlocatin
g

nonlocatin
g

Fixed bearing adjusted on both sides <->

fixed

fixed

fixed

nonlocatin
g

nonlocatin
g

nonlocatin
g

Fixed bearing adjusted on right side ->

fixed

right

fixed

nonlocatin
g

nonlocatin
g

nonlocatin
g

Fixed bearing adjusted on left side <-

fixed

left

fixed

nonlocatin
g

nonlocatin
g

nonlocatin
g

Thrust bearing attached on both sides <-

non-

fixed

non-

non-

non-

non-

Chapter
III-712

Defining Shafts

24

>

locating

Thrust bearing attached on right side ->

nonlocating

Thrust bearing attached on left side <-

nonlocating

locatin
g

locatin
g

locatin
g

locatin
g

right

nonlocatin
g

nonlocatin
g

nonlocatin
g

nonlocatin
g

left

nonlocatin
g

nonlocatin
g

nonlocatin
g

nonlocatin
g

Options for selecting a Bearing (in general) with displacement and rotation options:
Bearing (in general) selection list

ux

uy

uz

rx

ry

rz

Own Input

Own definition

Own definition

Own definition

Own definition

Own definition

Own definition

Non-locating bearing

fixed

nonlocating

fixed

nonlocating

nonlocating

nonlocating

Fixed bearing adjusted on both sides

<->

fixed

fixed

fixed

nonlocating

nonlocating

nonlocating

Fixed bearing adjusted on right side ->

fixed

right

fixed

nonlocating

nonlocating

nonlocating

Fixed bearing adjusted on left side <-

fixed

left

fixed

nonlocating

nonlocating

nonlocating

Thrust bearing attached on both sides

<->

nonlocating

fixed

nonlocating

nonlocating

nonlocating

nonlocating

Thrust bearing attached on right side >

nonlocating

right

nonlocating

nonlocating

nonlocating

nonlocating

Thrust bearing attached on left side <-

nonlocating

left

nonlocating

nonlocating

nonlocating

nonlocating

Fixed

fixed

fixed

fixed

fixed

fixed

fixed

ux, uy, uz: Displacement in X-, Y-, Z-direction.

rx, ry, rz: Rotation about X-, Y-, Z-direction.

Chapter
III-713

Defining Shafts

24

24.2.5.4
Pure th rust bearing
If a bearing is defined as a pure thrust bearing (attached left/right/both sides) no
radial forces can be transferred to it. Any radial forces created by the pressure of
the outer ring on the housing and the corresponding coefficients of friction will be
ignored.

24.2.6

Connection elements

A number of coaxial shafts can be connected by two different connection elements:

a general connection or a connecting roller bearing. The connection between these
shafts, one defined as "shaft outside" and the other as "shaft inside", defines the
constraints on the shafts over all possible degrees of freedom at that connection
point, i.e. three relative displacements along axis x, y (the axial direction) and z,
and three relative rotations around axis x, y and z.

Chapter
III-714

Defining Shafts

24

NOTE

The number of coaxial shafts is limited to 30.

24.2.6.1
Connection, gener al
In general, you can define three different configurations of a connection element: a
joint, a stiff connection or Own input.
J oi n t

All displacements are prohibited, but all rotations are permitted.

Sti ff c o n ne c ti o n

All degrees of freedom (3 displacements and 3 rotations) are prohibited.

Ow n I n p ut

The user can define their own constraints on the translational and rotational degrees
of freedom (DOF). The options are:
free: no restrictions on the corresponding degrees of freedom.
fixed: the associated DOF is constrained in both directions.
fixed with stiffness: the associated DOF is constrained in both directions with
additional stiffness.
one sided: the associated DOF is constrained on one axis direction (positive or
negative, depending on the choice), but free on the opposite direction. The
amount of allowable movement on the non-constrained direction can be input.
one sided with stiffness: similar to above, but an additional stiffness can be
input
double-sided: the associated DOF is constrained on both directions. However,
an allowable clearance can be input for both directions
double-sided with stiffness: as above, but with the option of specifying stiffness.

24.2.6.2
Connecting rolle r bearing
A roller bearing can be used to connect two shafts. The only additional information
needed, compared to above, is to define the inside and outside shaft for that roller
bearing.

The bearing inner ring is assumed to be fixed on the inside shaft, and the bearing
outer ring is assumed to be fixed on the outside shaft. The type of the bearing (fi-

Chapter
III-715

Defining Shafts

24

xed adjusted on left/right side, etc) defines how the axial forces are transmitted
between the shafts through the bearing. Roller bearings never constrain y axis rotation, so different rotation speeds between the connected shafts are permitted.
Due to the fact that moments as well as forces need to be transmitted through a
connecting element, we strongly suggest that you perform an inner geometry
bearing calculation when using roller bearings as connecting elements.

24.2.7

Cross sections

For information about the significance of cross sections in strength calculation,

please refer to the corresponding section (see page III-761) in theCalculating
Shafts section (see page III-735).

24.2.7.1
Free cro ss sectio n
Free cross sections allows you to input the effects of notch, no matter what the
actual definition of the shaft geometry.

24.2.7.2
Limited cro ss section
You should define the restricted cross section as the preferred cross section type in
shaft calculations. The effect of notch is determined automatically in accordance
with the geometry data at this position in this cross section. If you make changes to
the shaft geometry, you do not need to modify the cross section manually. The
changes are transferred automatically. However, if you are working with restricted
cross sections, you must input shaft geometry in detail.

24.2.7.3
Documentation point
Set a documentation point to document the equivalent stress, displacement, rotation, force and torque at a particular position on the shaft in the report.
NOTE:

If you want to document the reaction force/moment at a bearing area, you need to
place the documentation point's position slightly to the right of the bearing area's
position, and not exactly in the same spot. For more details, please refer to the
diagrams of bending report.

Chapter
III-716

Defining Shafts

24

24.3

Basic data

Figure 24.6: Basic data input window in Shaft Calculation module

In the Basic data input window you can control the basic preliminary settings
for shaft calculation. You can enter values for these parameters:

24.3.1

Position of shaft axis in space

You define the position of the shaft axis in space as shown in Figure 24.7.
The consequence of the shaft arrangement in space (horizontally, vertically or in a
defined angle to the horizontal) is:
The mass of the shaft (in a horizontal position) is considered a gravitational force
in the plane ZY when the deflection is being calculated. However, if the shaft is
positioned vertically the resulting axial force is, for example, included in roller
bearing calculations. If a shaft is positioned at an angle, the corresponding force
components are distributed on the ZY plane and as axial force.

Chapter
III-717

Defining Shafts

24

Alternatively, you can enter the shaft weight direction vector using the 3coordinate format.

Figure 24.7: Defining the position of the shaft and the position of contact.

24.3.2

Number of eigenfrequencies

In this input field, specify the number of eigenfrequencies (see page III-742) that
KISSsoft is to determine.

24.3.3

Number of buckling cases

In this input field, specify the number of buckling cases (see page III-744) that
KISSsoft is to determine.

24.3.4

Speed

Enter the speed in revolutions per minute (rpm). Click the

button to open the
Define speed window. You will see the default values for speed and shaft rotation direction for all the shafts. If you click the checkbox next to the Speed input
field, you can overwrite the speed for a particular shaft.
The shaft speed used for the calculation can also be found in the corresponding
"Report" -> "Shaft speeds" report.

Chapter
III-718

Defining Shafts

24

NOTE

If you change the speed, the effective torque and power change accordingly.

24.3.5

Sense of rotation

The shaft axis runs along the positive ydirection (left to right in the graphical
Shaft editor). In the Shaft editor, the Zaxis points upwards, the Xaxis points
towards the user. A right-hand rotation of the shaft around the positive y-axis
direction is specified as "clockwise".
The next figure shows the direction of these co-ordinates and the positive direction
of forces and moments. Please note that weight has an effect in the negative Z
direction if the shaft is positioned horizontally (see section "Position of shaft axis
in space" on page III-716).

In most force elements, the directions of the moments is usually defined by the
terms "driving" and "driven". The entry "driving" means either that the shaft drives
(an external application) or that the torque runs counter to the sense of rotation (i.e.
the shaft loses power). The entry "driven" means either that the shaft is driven from
outside (e.g. by a motor) or that the torque runs in the same direction as the sense
of rotation (i.e. the shaft is supplied with power).

24.3.6

Reference temperature

The Reference temperature is the temperature specified for the shaft dimensions. This is the temperature on which the drawing data or element testing is
based.

Chapter
III-719

Defining Shafts

24

24.3.7

Temperature of housing

When used together with the thermal expansion coefficient, the housing
temperature defines a strain which changes the distance between the bearing points.
In addition, the thermal expansion and Young's modulus of the gear case has an
effect on the nominal operating clearance of rolling bearings.
NOTE

If you want to investigate the influence of thermal expansion in greater detail, you
must also take the axial stiffness of bearings into account. If the bearings are
assumed to be rigid, the load peaks will be too high.
The bearing's outer ring and the housing have the same temperature. The bearing's
inner ring and the shaft also have the same temperature.
Reference point housing
According to the previous paragraph (Temperature of housing), the position of the
bearing outer ring follows the thermal expansion of the housing (if the bearing is a
connecting bearing, this has no effect). The magnitude of the thermal expansion
which is applied to the bearing's outer ring is given by L, where
L Tc T r y b y

Tc

is the temperature of the housing

Tr

is the reference temperature

is the coefficient of thermal expansion of the housing material

yb

is the global axial coordinates of the bearing (relative to the global frame of reference, not the shaft)
y

is the housing temperature thermal reference point used to perform the calculation
For example, if y= 0, this means all thermal expansion is considered relative to
the global frame of reference.

Chapter
III-720

Defining Shafts

24

24.3.8

Lubricant temperature

The value entered for the lubricant temperature is only used to calculate
the extended working life of the bearing. The lubricant temperature changes the
lubricant's viscosity.

24.3.9

Load spectra

If the loads defined in the Shaft Editor have been assigned a load spectrum, the
deformation can be calculated either for the nominal load or for any element of the
load spectrum. To do this, select the Consider load spectra option from
the Load spectra drop-down list. If you only want to take into account one
element from the load spectrum, you should select Consider only one
element of the load spectrum. Enter the appropriate element number in
the input field to the right of the drop-down list.
If you select Consider load spectra, and define a load spectrum for a force
element, the following adjustments are made, if the individual load bins have been
defined incorrectly:
if the frequency H = 0 is set, this is set to the value 10 ^-10
if the speed factor nfact = 0, this is set to 10^-5 and the torque/load factor is set
to 10^-10
if the torque/load factor is set to Tfact = 0, this is set to 10^-10

24.3.9.1
Load spectrum with ne gative bin s
Load spectra with negative load bins (T < 0 and/or n < 0) are treated as follows:

Factor for torque or Factor for

power
speed

Shaft direction of rotation

Force element

- = unchanged
C = direction of rotation changes clockwise/counterclockwise

Chapter
III-721

Defining Shafts

24

D = driving/driven changes

24.3.10 Gears
Select an option from this drop-down list to specify how gears are to be handled in
the shaft calculation:
Gears are only handled as load applications. The masses and stiffness of the
gears are not taken into account.
Consider gears as masses. The gear is handled as a mass in the bending calculation. The mass results from the difference between the reference circle and
the outer shaft diameter as well as the gear width (same specific weight as the
shaft).
Consider gears as mass and as stiffness. The gear is handled as part of the shaft
contour (for example, pinion shaft).
Consider gears mounted by interference fit, with stiffness according to ISO
6336-1. The shaft is stiffened at the mid diameter dm, with dm = (d1+d2)/2, d1 =
shaft diameter, d2 = reference circle of the gear.
NOTE

Gears set on shafts with a firm interference fit always pose the problem of how
much they stiffen the shaft. Although KISSsoft cannot solve this problem, it can
estimate how much influence the interference fit has: It is sufficient to perform the
calculation for Gearas mass and for Gear as mass and stiffness
and note the difference in the diagrams of bending. If the difference is small, the
interference fit has no influence. However, if the difference is significant, you must
enter more precise information. To do this you must integrate a part of the gear in
the shaft contour in the graphical shaft input.
If a gear has multiple contacts (for example, a sun wheel in a planetary system),
then multiple identical gear elements must be defined at the same position.
However, the weight is considered only once.

24.3.11

Rolling bearings

The Rolling bearings drop-down list contains four options:

Rolling bearings, classic calculation (contact angle not taken into consideration), calculation using the classic method (as described in manufacturers' catalogs).
Rolling bearings primarily place constraints on the degree of freedom of movement found in displacement and/or rotation, which is why they are modeled

Chapter
III-722

Defining Shafts

24

in this way when you select this option. You can enter any value as the stiffnesses for translation and rotation no matter what type or size of bearing is involved. Any interrelationships between axial and radial forces (i.e. as in taper
roller bearings) are ignored.
Rolling bearings, classical calculation (contact angle taken into consideration).
The information in point one also applies here, with the difference that the correlation between axial and radial forces is included in the calculation, as it is
for taper roller bearings.
Rolling bearing stiffness calculated from inner geometry, lifetime calculation
using the classic method (as described in manufacturers' catalogs).
Rolling bearing service life according to ISO/TR 16281
In this option, the diagrams of bending are affected by the finite bearing stiffness, which is calculated on the basis of the bearings geometry. Nevertheless,
the service life is calculated according to the manufacturer's catalog on the basis of the forces (i. e. tilting moments are ignored by the service life calculation).
Both the diagrams of bending and the bearing lifetime are based on the inner
geometry of the bearings.
You will find more detailed information in the description of the Bearing
calculation (see page III-775).

24.3.12 Tolerance field

The definition of the bearing clearance class does not yet provide a definitive statement about bearing clearance because only one range of values has been defined
for the bearing clearance class. The Minimum and Maximum options define the
upper and lower limits of the range, whereas the Mean value is the arithmetical
average of the Maximum and Minimum for (radial) bearing clearance.
The operating bearing clearance is defined using the selected bearing clearance
class (e.g. "C0"), the selected tolerance (e.g. "mean value") and the working
conditions, i.e. speed and temperature. For every rolling bearing the calculation of
operating clearance is described in the following. Starting from Fig. 1 a range of
variables are included in the calculation:
Inside and outside diameter of the shaft.
Inside and outside diameter of the hub. If the bearing is a connecting
element, then these represent the inside and outside diameter of the external

Chapter
III-723

Defining Shafts

24

shaft. For simplicity's sake the term "housing" is used here to mean either the
housing or the external shaft (if present).
Inside and outside diameter of the bearing, and
of the inner or outer race.

for the diameter

Figure 1: Diameters used for the calculation of bearing clearance

All diameter values represent actual diameters, that is taking the allowance of each
part into account. The calculation steps are as follows:
The ring race allowance is taken from the corresponding table (e.g. for tolerance "PN"), for the inner ring i and the outer ring o.
The allowance for the shaft w and housing nis calculated from the data input by the user (e.g. "K6").
The interference is calculated on the inner ring Uwi and on the outer ring Uwo.

As specified in DIN 7190, 0.4(Rz1 + Rz2) is to be deducted from an interference

between two bodies, where Rz is the surface roughness of each part. As no
roughness was specified for the
bearing races, it is assumed that the
surface roughness of the rings is the same as the surface roughness of its connecting shaft. The allowances calculated in step 3 are therefore adjusted by the
surface roughness of the shaft

and the housing

The effect of temperature is also taken into account,

Chapter
III-724

Defining Shafts

24

where s, h, b is the thermal expansion coefficients of the shaft, housing

and bearing, shRare the shafts temperature, housing temperatures, and
reference temperatures and dnom, Dnom is the reference diameter of the
bearing as defined in the catalog.
An interference fit calculation is performed for the inner ring if condition A
holds and for the outer ring if condition B holds, taking into account the operating speed as well.

The pressure generated in the interference fit changes the operating diameter of the bearing races, and therefore also changes the Pd of the nominal
bearing clearance.

NOTE

The selection you make in the Tolerance field has no effect on the general behavior
of the bearing.

24.3.13 Modified rating life according ISO 281

Click on this checkbox to include the lubricant state in the bearing life calculation.
However, to achieve an accurate result you must first have set the parameters for
the Lubricant and Impurity drop-down lists, and entered a value in the
Lubricant temperature input field. After the calculation is complete, you see a
value for the modified service life Lmnh in the Results window and/or in the report.

Chapter
III-725

Defining Shafts

24

24.3.14 Consider weight

Click this checkbox to include the shaft's dead weight in the section dimension
calculation. Depending on the orientation of the shaft arrangement (see section
"Position of shaft axis in space" on page III-716) you will see additional axial and
shear forces which may have an influence on the diagram of bending and/or axial
displacement.

NOTE

In a global coordinates system, gravitational forces act on the shafts in the negative, Z-direction.

24.3.15 Consider gyroscopic effect

Click this checkbox to include the properties of rotating shafts that have weights
attached to one end and which rotate either in the same (or opposite) direction
around the longitudinal axis. Whereas, in situations that are not technically critical,
the eigenfrequency sinks when the speed increases in a counter direction, the
eigenfrequency increases when the speed is in the same direction. The number of
eigenfrequencies that appear here is double the number that appear when the effect
of spinning is not taken into account.

24.3.16 Housing material

The housing material value is only used to calculate the thermal expansion of the
housing. The materials available for housings are identical to those used for shafts.

24.3.17

Lubrication

Your choice of lubricant only affects the bearing life calculation. Click the
ton for your own input for the lubricant parameter.

but-

24.3.18 Impurity
As defined in ISO 281, the impurity coefficient eC depends on the type of oil filter,
the bearing size, and the viscosity of the lubricant. This value varies within the range 0 (high level of impurity) eC 1 (ideal). Select the Own Input option and
then click the

NOTE

button to specify your own eC values.

Chapter
III-726

Defining Shafts

24

Click the
button to enter your own values. You can define new values for
Housing and Lubricant that are based on existing data. However, these values
are not stored permanently in the database.

Chapter
III-727

Defining Shafts

24

24.4

Module specific settings

Figure 24.8: Module specific settings dialog window

24.4.1

Non-linear shaft

Click this option to perform a calculation using geometric non-linear beam elements. Due to the planet shaft deflection, the results here also show a displacement
in the axial direction because the arc length remains constant. In most situations
where shafts are used, this non-linear model is irrelevant.

EXAMPLE

A shaft, which is fixed to its mounting on both sides, is subjected to centrical force.
The linear beam model does not allow for an elongation of the beam because it
ignores axial displacement during shear and moment loads. If you click on the

Chapter
III-728

Defining Shafts

24

Non-linear shaft field you can select a calculation method that takes into
account the bending effect on the shaft and therefore the elongation of the beam.
This results in axial forces.

24.4.2

Take into account deformation due to shearing

and shear correction coefficient

If this checkbox has not been selected, the shaft is modeled to be infinitely stiff. In
this case, shearing forces have no effect on the diagram of bending. However, if
you do want to include deformation due to shearing, you can specify your own
shear correction coefficient :

(24.1)

where
A

shear section

Cross-sectional area

The shear correction coefficient 1 includes the irregular distribution of stress

across the cross section and applies to the entire shaft system. For circular-shaped
cross sections, = 1.1 applies, and = 1.2 applies for rectangular-shaped cross
sections.

NOTE

Note the definition of the shear correction coefficient used in KISSsoft, as shown
in the previous equation. Some sources also use the reciprocal value for the formula symbol.

24.4.3

Activate offset of load center point

This enables the gear load elements to define their load application center point
offsets, as described in the corresponding chapter of the manual.

Chapter
III-729

Defining Shafts

24

24.4.4

Use 2013 solver

The new solver is generally used for shaft calculations. However, you can use the
previous "2013 solver" instead. The new solver is more stable, which is why we
recommend it.

24.4.5

Standard radius at shoulder

To calculate the effect of notch on shoulders, you require a radius. This can be input as a sub-element. If no radius has been defined, you can use the standard radius
defined for calculating the effect of notch.
Generally, we recommend you define radii for each shoulder.

24.4.6

Node density

The user can influence how many nodes are used to calculate a beam. If you are
performing a linear calculation, this has no effect on the result, apart from line
moments which are distributed across the existing nodes. The beam elements
supply the exact solution in the linear model independently of the length.
Reasons for influencing the density of nodes are, on one hand to speed up
calculations (for example, in series calculations in KISSsys) and, on the other hand,
to ensure the accuracy of the display of the diagram of bending and the
corresponding report.
The density of the nodes affects the accuracy of non-linear beam elements. For this
reason, the maximum distance between two nodes for non-linear calculations when
compared with a linear calculation is halved, no matter what value is predefined.

Chapter
III-730

Defining Shafts

24

24.4.7

Iterative calculation of load distribution

If this selection box is enabled then the load distribution is calculated iteratively for
the selected gear in the "Tooth trace modification" tab. The initial gear is replaced
by a particular number of identical gears. The number of gears is set in the "Number of slices" field. The load on each replacement gear is set according to the
current load distribution and the load on each gear is adjusted iteratively until the
quadratic mean value (or "root mean square" - RMS) of the error in the line load
difference between two sequential calculations is less than 1%.
You will find details of how KH is calculated in "Tooth trace modification" (see
III-73).
Note: In the case of bevel gears the selection box must be selected so that the effect
of the changeable operating pitch circle of the gear can be taken into account.
Otherwise the bevel gear is handled as a cylindrical gear whose pitch circle dw
equals the pitch circle in the middle section.

24.4.8

Input different load cycles for bendi ng and torsion (for finite life calculations)

Every time a shaft rotates, the bending load cycle changes. For this reason, the
number of bending load cycles is calculated using the service life and the speed.
The number of torsional load cycles is often very much lower, because not every
rotation causes a torsional load cycle. For example, a gear unit may be started in
the morning and run throughout the day with a constant torque; resulting in exactly
one torsional load cycle per day. In contrast, a shaft running at 1000 rpm for 8
hours would be subject to 8000 bending load cycles in the same space of time. As a
consequence, in this example, the ratio between the number of bending load cycles
is: torsion would be 8000: 1. You can enter this ratio here.

24.4.9

Axial clearance

This is where you define the axial clearance for rigid fixed bearings. The clearance
applies to both directions. As a result, a bearing that is fixed on both sides may
deviate either to the right or to the left by this value. However, this clearance value
is not used if the bearing stiffness is taken into account by the inner bearing
geometry. Axial clearance only applies to rigid roller bearings. You can either use
this clearance value, or enter your own stiffness values for general bearings.

Chapter
III-731

Defining Shafts

24

If an axially elastic shaft is mounted on several fixed bearings, for example, two
bearings in a face-to-face arrangement, and the shaft is subject to a tension load,
relatively high reaction forces are caused in the roller bearings which are not
present in elastic bearings in real life. You can prevent this by entering a relatively
small axial clearance for the bearings.

24.4.10 Failure probability

The failure probability value n is used to calculate the service life of roller
bearings. The default value is 10% but you can overwrite this here. The valid input
range is 0.05% < n < 10%.

24.4.11

Required service life

Required service life of roller bearings. However, this value does not actually
affect the roller bearing calculation. However, if the calculated bearing service life
is less than this value, the program displays a warning message. Click the sizing
button next to the input field to size the service life of individual shafts. Sizing can
only be performed in the fatigue strength range of the Woehler line.

24.4.12

Maximum service life coefficient

In this input field you define the upper limit for the service life coefficient aISO:

The default value, as defined in ISO 281-2007, is aISO,max = 50.

24.4.13 Display critical bearing

The shaft editor displays critical rolling bearings with colors to identify their service life. The color "orange" is used for critical bearings with a service life which is
less than the required service life. The color "deep orange" is used for bearings
with a minimum service life which is much less than the required service life. The
color "blue" is used for bearings whose service life is longer than the required service life.
The lifetime value used to determine the bearing colors depends on which bearing
calculation method has been selected, and whether the user has requested for the
extended bearing service life to be calculated.

Chapter
III-732

Defining Shafts

24

Table 1: Lifetime value used for the bearing colors, based on the calculation settings

Nominal service life

requested
Rolling bearings, classic (w/o contact angle) Lnh

Modified service life

requested
Lnmh

Rolling bearing, classic (inc. contact angle )

Rolling bearing stiffnesses, int. geom.
Rolling bearing serv. life acc. to ISO/TS
16281

24.4.14

Lnrh

Lnmrh

Surface roughness of housing

The value of the surface roughness of the gear case is used to calculate the nominal
operating clearance for roller bearings. The pressure is calculated for a housing
with an infinitely large external diameter. If different roughnesses are needed for
different bearings, or if you want to define the external diameter, you can specify
an additional shaft that is then used for that purpose.

24.4.15 Calculation method for friction

From this list you can select whether the calculation method described in SKF catalog 1994 or in SKF catalog 2004 should be used to calculate friction. These
methods are described in more detail in the Roller bearing chapter, under Torque of
friction (see page III-790).

24.4.16 Oil level

If you select the calculation method described in the SKF catalog 2004 to calculate
friction, the oil level has an effect on the moment of friction which is determined
by the amount of oil lost in the process. This is described in greater detail in the
Torque of friction (see page III-790) section.
You input the oil level with reference to the left-hand end of the first shaft (but
only if "Oil bath lubrication" has been specified). The position of the shaft is then
used to define a separate oil level for each bearing (h and H) which is then taken
into account when calculating the loss. The oil level is displayed in the shaft editor,
so you can check it.

Chapter
III-733

Defining Shafts

24

24.4.17

Type of oil lubrication

The type of oil lubrication used is important if you are using the method described
in SKF catalog 2004 to calculate friction. The method differentiates between oil
bath and oil injection lubrication. This is described in greater detail in the Torque
of friction (see page III-790) section.

24.4.18 Moment of friction, seals

This is where you select which method is to be used to determine the moment of
friction for the seals. You can select:
according to SKF main catalog 6000 EN: 2005
You will find values for the seal types used in your bearings in the SKF catalog, which is integrated in the KISSsoft software. If the KISSsoft system finds
a familiar seal label in the bearing label, it calculates the moment of friction for
grinding seals using the coefficients listed in the catalog. Otherwise it is set to
zero.
In KISSsoft, the diameter of the mating surface is calculated with ds = d + (D d) * 0.2
according to ISO/TR 13593:1999 Viton Mseal this diameter is calculated with
the formula: Mseal = 3.736*10^-3*dsh; Mseal in Nm, dsh shaft diameter in mm
according to ISO/TR 13593:1999 Buna N Mseal this diameter is calculated
with the formula: Mseal = 2,429*10^-3*dsh; Mseal in Nm, dsh Shaft diameter in
mm

24.4.19 Bearing manufacturer

Only bearings made by selected bearing manufacturers are listed in the selection
options.

24.4.20 Show coordinate system

This option toggles the coordination system in the Shaft editor on and off.

24.4.21

Show automatic dimensioning

This option toggles the mass line in the Shaft editor on and off.

Chapter
III-734

Defining Shafts

24

24.4.22 Equivalent stress for sizings

This is the equivalent stress used to size a shaft for strength.

24.4.23 Maximum deflection for sizings

The maximum permitted deflection for sizing a shaft for deflection.

Chapter
III-735

Calculating Shafts

25

25

Calc ula tin g S hafts

Chapter 25
Calculating Shafts
Once you have finished defining the shafts, either click the
button in the tool
bar or press F5 to calculate all the shaft-specific values. The results are shown
either as a graphic or as a table of values. For example: click the Graphics menu
in the menu bar, to display the shaft's diagrams of bending in Shaft >
Displacement (see Figure 25.1).

Figure 25.1: Opening the Graphic window via the Graphic menu

Chapter
III-736

Calculating Shafts

25

Alternatively, go to the Report menu and select the Diagram of bending

option to display a list of the calculated values.

Figure 25.2: Calculation report for Diagram of bending

The sections that follow provide more detailed information about the interim
results of the values you are interested in.

Chapter
III-737

Calculating Shafts

25

25.1

Deflection and Bearing Forces, Distrib ution and Force of Torque

The stress, displacement and rotation calculation is based on the one-dimensional

Finite Element Method (FEM). The program determines the diagrams of bending
by automatically splitting the shaft into 50 to 100 sections and by using as many
points for the diagrams of bending. Boundary conditions and internal boundary
conditions (bearing forces and moments) are found by solving a set of
simultaneous equations with the same number of unknown variables.
Elastic bearings are considered by setting stiffness values (displacement and
torsional stiffness).
The calculation enables you to:
Calculate the diagrams of bending, course of transverse force, and torque diagram, in the XY and the ZY plane (shaft axes always along the Y axis) with or
without taking the dead weight into account.
Calculate the axial force taking into account the mass (depending on the length
of the shaft).
Graphical display of all critical dimensions on screen and as a printout: course
of deflection, shearing force, bending moment in different levels, torsional
moment and static comparative stress (GEH and SSH).
Calculate the forces and torques in bearings (and ends of shafts) for an unlimited number and any type of bearing.
The utilization of a rolling bearing is calculated as follows:

usage

P
Preq

L req

L

1/ k

In this case Lreq is the required rolling bearing service life, Pref is the equivalent
load which corresponds to Lreq , L is the achieved service life and k is a coefficient that depends on the type of rolling bearing ( k = 3 for ball bearings, k =
3/10 for roller bearings).
Bearing clearance is always considered. If the bearing calculation method according to inner geometry is selected, then the bearing stiffness at the operating
point and the static safety are also reported. 2 static safeties - S0w and S0r - are
calculated.
S0w is calculated as

Chapter
III-738

Calculating Shafts

25

where pmax equals the maximum Hertzian pressure on the bearing ring. For ball
bearings p0 = 4200 N/mm2 and n = 3. For roller bearings p0 = 4000 N/mm2 and
n = 2.
S0r is calculated with the following formula
where C0 is the static load rating of the bearing, and P0r is the equivalent nominal load (i.e. tilting moments are ignored) which causes the same maximum
contact pressure. The same calculations are available for standalone bearing
calculations with internal geometry.
The relative deformation and the rotation of the inner ring to the outer ring is
calculated and recorded.
Note: the calculation assumes that the inner ring of the bearing is connected to
the shaft. If a hollow shaft is connected to the inside of a rolling bearing, the
bearing displacement and rotation are documented with the reversed sign.
Calculate the inclination of the diagrams of bending in bearings, e.g. when calculating cylindrical roller bearings. The progression of the angle of inclination
can also be displayed on screen and printed out.
The diagrams of bending can be calculated with or without taking shearing deflection into account.

Chapter
III-739

Calculating Shafts

25

Figure 25.3: Displacement graphic displaying the diagrams of bending in the plane =
63.53o

NOTE

Although the data about equivalent stress gives an initial indication of the static
strength of a shaft, it cannot be used to calculate fatigue resistance. To do this, you
must perform the actual strength calculation. However, this equivalent stress data is
useful for carriers, because the load they are subjected to is usually only a static
load. If the moment of resistance in torsion has not been defined for carriers,
torsional stress is not included in the equivalent stress calculation. Despite this you
can still perform the calculation.

25.1.1

Calculating force on bearings with a contact

angle

Figure 25.4: Representation of bearings with contact angles

Bearings with contact angle must be handled as a special case when you calculate
shafts and bearings. The bearing center used to calculate the bearing reactions is
determined at the point at which the compression force line of action intersects
with the shaft centerline. In the roller bearing manufacturers' catalogs this is
described as the axial forces resulting from the oblique position of the bearing
housing. You can use this to define the data (radial and axial loads) required to

Chapter
III-740

Calculating Shafts

25

calculate the roller bearing service life expectancy. It is harder -and also not clearly
documented in the technical literature- to calculate the load progression in the
shaft. Here, two modeling types are possible:
In bearings that have a contact angle, the effective bearing force line of action passes through the pressure center point. For this reason, you can calculate the bearing
forces because, for calculation purposes, the bearing can be considered as being at
the pressure center point. This corresponds to the procedures used to define the
roller bearing load (Variant I).
However, you cannot introduce the bearing force on the shaft outside the bearing
width. This is why KISSsoft places the bearing force in the center of the bearing.
At the same time, the eccentric application of force creates an additional bending
moment which equals the product of the distance of the bearing- and pressure center point, times the radial force (Variant II).
Both variants supply the same progression of bending moment between the
pressure centers. There is, however, a difference in the area of the pressure/bearing
centers. The shoulder on the right of the picture would be considered as not subject
to a force in Variant I (it could, therefore be ignored), whereas Variant II displays
both shearing force and a bending moment.
In real life, the load is not necessarily applied to the center of the bearing but to the
entire area of the bearing. Therefore, the bending moment can be placed precisely
on the shaft shoulder. However, this then causes a problem in the strength
calculation if the load is applied directly on the proof point (i.e. when the proof
point lies between the bearing center and the shaft shoulder).
The calculation of the diagram of bending produces a difference in that, in Variant
I, the deflection is zero in the pressure center and, in Variant II, it is at the bearing
position. Here, Variant II is certainly more precise, especially when large contact
angles are involved where the pressure center lies outside the bearing width. Only
Variant II allows the calculation to include cases in which the pressure center point
lies outside the shaft.
As often happens, in such cases the reality lies somewhere between Variant I and
II. More precise calculations can only be performed using time-consuming FEM
calculations which take into account the properties of the bearing housing. Variant
II is more precise and convenient for shaft calculations, (because it allows for
pressure center points being outside the shaft), which is why this variant has been
included in KISSsoft shaft calculation functions from release 04-2004 onwards. In
special cases, when the modeling in Variant II is queried, you can modify the loads
in the strength verification according to more precise observations when the proof
point lies between the bearing center and the pressure center points.
One more point about the shaft strength calculation: any strength verification based
on the nominal stress concept (DIN 743, . . has limited validity, in the load appli-

Chapter
III-741

Calculating Shafts

25

cation zone (e.g. internal roller bearing ring on the shaft shoulder) when the local
stress distribution does not correspond to the estimated nominal stress. In practice,
the results calculated on these points must be interpreted with caution.
In KISSsoft, the additional internal axial force that is present in the case of
bearings with a contact angle is calculated as Fr * 0.5/Y, as described in "Die
Wlzlagerpraxis" and different bearing product catalogs. [FAG as here, NSK with
a factor 0.6 instead of 0.5, SKF for taper roller bearings, as here, and for angular
contact ball bearings with a factor 1.14 (Catalog 2004 as a function of Fa/C)]. If
factor Y is not present in the bearing database, no additional axial force is taken
into consideration. Therefore the calculation process is the same as the KISSsoft
bearing calculation.

Chapter
III-742

Calculating Shafts

25

25.2

Eigenfrequency

Figure 25.5: Graphics window: Eigenfrequencies

Click on Graphics > Shaft > Eigenfrequency to access the results of

eigenfrequency calculation on the modeled shafts system with or without additional
masses. The calculation is based on a one-dimensional Finite Element Method
(FEM) which takes into account the type of bearings and their stiffness.
The calculation enables you to:
Calculate any number of Eigenfrequencies6
Display natural modes
You can include the gyroscopic effect of large spinning masses if you click on
the Consider gyroscopic effect checkbox in the Basic data input window. The critical speed (bending mode) is calculated for the forward
and backward whirl. In a synchronous parallel run, an imbalance increases the
bending oscillations because the angular speeds of the rotating shaft and the
shafts peripheral center point are the same. However, the synchronous counter
run is, in most cases, not technically important.

Only limited by computing power.

Chapter
III-743

Calculating Shafts

25

For beam profiles, the critical bending mode (eigenfrequency) is calculated in

both main planes.
Gears can be included automatically and handled like masses. In this situation,
KISSsoft takes into account the mass and the moments of inertia of the gear
(see section "Gears" on page III-721) seated on the shaft.

25.2.1

Bending critical speed

The calculation of critical speed takes into account any masses located on the shaft.
However, applied forces have no effect on the calculation. For this reason, additional masses must be handled as masses and not as loading forces.
The nodal points of the bending eigenmodes (vibration on plane x-z) are also
documented in "Report" -> "Eigenmode nodes".

25.2.2

Torsion critical speed

Calculation of the critical rotating eigenfrequencies of shafts.

Calculation of any number of rotating eigenfrequencies.
Graphical display of natural oscillation.

Chapter
III-744

Calculating Shafts

25

25.3

Buckling

You use this function to calculate the buckling load of shafts and beams. All
peripheral conditions, bearings and effective axial forces (point or line loads) are
taken into account in the calculations. Only the axial forces you specify are used to
calculate the buckling load. This function calculates the factor by which all these
forces have to be multiplied to create a situation under which buckling occurs. This
factor therefore corresponds to the safety against buckling.

Chapter
III-745

Calculating Shafts

25

25.4

Strength

To access the strength calculation, click the Strength tab in the Shaft
calculation module user interface.

Figure 25.6: Strength input window in the Shaft Analysis module with the associated tab (above)

In KISSsoft, you can use the following methods to calculate the strength of shafts
and axes:
Hnchen & Decker
DIN 743:2012-12
Load capacity of shafts and axes [9] including FVA proposed update concerning fatigue strength and tensile strength []
FKM Guideline (2012)
Analytical strength verification of steel, cast iron and aluminum materials in
mechanical engineering, 6th Edition 2012
AGMA 6101-E08/ AGMA 6001-E08
Design and Selection of Components for Enclosed Gear Drives
No strength calculation
In this case, the strength verification is not performed. However, all the other

Chapter
III-746

Calculating Shafts

25

results (diagrams of bending, equilibrium of forces, bearing reactions etc.) will

still be calculated.
A static proof and proof of fatigue strength can be applied in each case. The proof
according to FKM, DIN and AGMA can also be performed using a load spectrum.
Some of the shaft-specific data for the strength calculation can be defined in the
Elements editor of a particular shaft.

25.4.1

Calculation method

In this drop-down list, you can select one of the calculation guidelines mentioned
above. The sections that follow describe the guidelines in greater detail.

25.4 .1.1
Hnchen & Decker
The calculation in accordance with R. Hnchen and H. K. Decker: [42] is an older,
but tried and tested, method. If insufficient notch factor data is present, the
equations produced by the TV in Munich, Germany, are used: they are derived
from known test results.
Ma t eri al val u e s

As shown in Figures 52, 56, 60 in accordance with [42] for construction, heat
treatable and case hardening steels. The empirical formula used is in accordance
with Hnchen [42], page 37

You can enter the material data in the database (see page I-124).
Cal cu la ti o n of e qu iv al e n t s tr e ss

In the case of bending and torsion, KISSsoft calculates the equivalent stress value
V in accordance with the hypothesis of the largest distortion energy (see [42],
section 3.2.5.).

Cal cu la ti o n of saf e t y a g ain s t fa ti g u e f ail ur e

Maximum load in accordance with [42] equation (4a); Operating factor as defined in [42] Table 1 (page 24).
Design bending fatigue limit in accordance with [42] Equation (42a).

Chapter
III-747

Calculating Shafts

25

Safety against fatigue failure in accordance with [42] Equation (46).

Required safety against fatigue failure in accordance with [42] Figure 156, depending on the frequency of the maximum load.
Result of the calculation is the ratio of the required safety margin and the calculated safety margin as a percentage.

Im po rt a nt f orm u la e

A)= Comparative stress (fatigue stress)

(25.1)

(25.2)

(25.3)

A1) Comparative stress (strength against overload failure and deformation (t = 0)

(25.4)

(25.5)

(25.6)

B) Calculation of the safety against fatigue failure:

(25.7)

Chapter
III-748

Calculating Shafts

25

(25.8)

a.0

Stress ratio factor

Cross section area

bd

b.d

Thickness number

bkb

b.kb

Notch factor (bending)

bo

b.o

Surface number

Total load factor

Fq

F.q

Shearing force

(N)

Fz

F.z

Tension/Compression force

(N)

Mb

M.b

Bending moment

(Nm)

Mt

M.t

Torque

(Nm)

s.b

Bending stress

(N/mm2)

bW

s.bW

Fatigue strength under reversed bending

stresses

(N/mm2)

bWG

s.bWG

Deformation strength under reversed

bending stresses

(N/mm2)

s.v

Equivalent stress

(N/mm2)

SD

S.D

Safety against fatigue failure

t.q

Shear stress (shearing force)

(N/mm2)

t.t

Torsional stress

(N/mm2)

Wb

W.b

Axial moment of resistance

(cm3)

Wt

W.t

Polar moment of resistance

(cm3)

(cm3)

Str e ss ra ti o f ac t or

Table 25.2. contains values for the stress ratio factor.

Bending

alternating

alternating

static

static

static

static

torsion

pulsating

alternating

pulsating

alternating

static

static

Chapter
III-749

Calculating Shafts

25

Structural
steel

0.7

0.88

1.45

1.6

1.0

1.0

Case
hardening
steel

0.77

0.96

1.14

1.6

1.0

1.0

Heat
treatable
steel

0.63

0.79

1.00

1.6

1.0

1.0

Table 25.2: Stress ratio factor 0 in accordance with Hnchen page 28 [42] or Niemann, I, page
76 [64]

25.4 .1.2
DIN 743 (2012)
The German DIN 743 standard [9] uses the most up to date information to calculate
shafts and includes the following points:

Consistent distinction between the different load classifications (tension/compression, bending, torsion) and between mean stress and stress amplitude.
Surface factor: The influence on the strength is documented when using thermal processes (nitriding, case hardening) and mechanical processes (shot peening, rolling).
Notch factors: Data for construction elements other than the usual notch factors
is mentioned in all specialized books. This data, such as relief grooves, interference fit with relief groove or square notches (recesses for a Seeger ring) is widely used nowadays but has, until now only been poorly documented. All notch
factors are documented for tension/compression, for bending and for torsion.
Materials: An extensive list of materials, as well as instructions on how to derive estimated values for undocumented steels.
Fatigue strength: the calculation of load strength in accordance with the "Miner
extended" method is described in part 4 of the standard.
The critical limitations of the DIN 743 standard are:
Shearing load (shear forces) is not included. This is not a disadvantage except
for shafts with a very short distance between bearings.
It only applies to steels and operating temperatures between -40oC and +150oC.

Chapter
III-750

Calculating Shafts

25

As defined in the standard, the minimum safety margins for deformation and
fatigue failure are defined as stated in 1.2. However, these safety margins only
cover the lack of precision in the calculation method, and do not cover the
problems encountered in load assumptions, or the consequences if the material
fails. The required safety margins must therefore be checked or agreed by both
the customer and contractor.

25.4 .1.3
FKM-Richtl inie, Edition 2012
The FKM guideline (FKM: Forschungskuratorium Maschinenbau e.V., Frankfurt
[Board of Research in Mechanical Engineering]) is based on the standards of the
former German Democratic Republic ("East Germany" as was), and includes the
latest knowledge on materials theory. It will probably form the basis of a new VDI
guideline. The FKM guideline is extensive (running to approximately 175 pages
plus 400 pages of commentaries), and includes not only fatigue strength
calculations, but also endurance strength calculations and service life calculations,
taking into account load spectra. It also provides calculation approaches for special
problems such as operating temperatures above 100oC.

The calculation is performed in accordance with the 6th edition (2012) of the FKM
Guideline, using the solutions proposed by Haibach.
Fa tig u e st re n g t h

The service strength coefficient KBK,S is determined in accordance with section 2.4
of the guideline. The number of cycles at knee point ND is 106.
KBK,S is greater than 1.0 if the number of load cycles is less than ND. Above ND,
KBK,S usually equals 1.0.
Normal calculations with a given load (without load spectrum) are referred to as an
"individual load". This is calculated in accordance with Section 2.4 of the
guideline. For load spectra, three different processes (see section "Type of
calculation" on page III-751) are available.

25.4 .1.4
AGMA 6101 -E08/AGMA 6001 -E08
AGMA 6101-E08/ 6001-E08 [9] describes how to calculate a closed gear.
Calculations are described for shafts, interference fits, keys, bearings, housings and
bolts in this AGMA standard.

It distinguishes between the different load classifications (tension/compression,

bending, torsion and shearing) and between mean stress and stress amplitude.

Chapter
III-751

Calculating Shafts

25

Notch factors: the few notch factors given are only shown for bending. The
same ones are used for the other loads.
Materials: it includes an extensive list of materials, as well as instructions on
how to derive estimated values for undocumented steels. The permitted values
are converted from the core hardness value entered by the user.
In KISSsoft, load spectra are not taken into consideration when the AGMA
method is applied (as it is not described adequately).
The critical limitations of the AGMA standard are:
Only for cylindrical steel shafts, but could maybe also be used for other materials.
The only notch types defined in detail are shoulder, circumferential groove and
cross hole.
According to the standard, the set minimum safeties against peak load and fatigue are 1.0. However, these safety factors only cover the lack of precision in
the calculation method, and do not cover the problems encountered in load assumptions or the consequences if the material fails. The required safety factors
must therefore be checked or agreed by both the customer and contractor.

25.4.2

Type of calculation

You can perform a safety analysis using one of these four different methods:
Static. Proof for yield safety.
Endurance limit. Proof for endurance limit (in the horizontal section of the SN curve (Woehler line), no load spectrum used)
Fatigue strength. Calculates the safety against fatigue for a given number of
cycles. Here, a constant load is used (no load spectra).

Chapter
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25

Miner consistent/elementary/extended. These methods differ in the way they

calculate the inclination of the S-N curve (Woehler line) above the number of
breakpoint cycles.

Figure 25.7: Miner hypotheses

Legend:
1) Miner elementary according to FKM guideline
2) Miner extended according to DIN 743-4:2012
3) Miner consequent according to FKM guideline
4) Miner original according to Haibach
5) Miner elementary according to Haibach
The gray fields are the fractions that are ignored.

Chapter
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25

NOTES

The calculation methods according to Miner are only available if you have selected
the Consider load spectra option in the Load spectra drop-down list
in the Basic data input window. As you can define load spectra (see section
"Define load spectrum" on page II-304) in the KISSsoft database tool, you then
only need to select them in the calculation.

25.4.3

Service life

The required service life in number of revolutions is calculated from the required
service life in hours.

25.4.4

Strength parameters in accordance with H nchen and Decker

25.4 .4.1
Frequency of l oad
This value refers to the load value you entered previously (such as torque). If a load
applies to the whole service life of the shaft, the frequency is 100%, otherwise it is
correspondingly lower.

25.4 .4.2

Notch factors

Thickness number: in accordance with [42], Figure 120.

Surface number: as stated in [42], Figure 119, Definition of the associated machining process in [42], Table 4.
The following graphs have been preprogrammed:
Coarsely cut out

Graph with bo = 0.50 at 150 kp/mm2

Milled/finely turned

Graph with bo = 0.70 at 150 kp/mm2

Ground

Graph with bo = 0.94 at 150 kp/mm2

Polished

Graph with bo = 0.97 at 150 kp/mm2

Chapter
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25

Shoulder notch effect coefficient during bending in accordance with [42], Figure 131.
Wheel seat with key: proposed values after consulting with TV, Munich. Only very few details are given in [42], section 6.4.
Interference fit: proposed values after consulting with TV, Munich. Details
given in [42], section 6.4.
Bearings are handled as weak interference fits. Only very few details given in
[42], section 6.4.
Shaft-hub connections (multi-wedge toothing): Diameter quotients and section
modulus in accordance with [42], section 8.5. Conversion of the diameter quotient into the notch effect coefficient in accordance with [42], section 5.6, Formula (36) and (37b) or (37c) with the radius of the substituting notch in accordance with [42], Figure 112.
Thread: Diameter quotient in accordance with [42], Figure 123. Conversion
into notch effect coefficient as shown above.

25.4 .4.3
Safety ag ain st deform at ion/fracture
KISSsoft calculates the required safety against fatigue failure, depending on the
frequency of the maximum load, using Hnchen's definitions. If the frequency is
100%, the specified margin of safety is 2.0. At 0% it is 1.0. However, in between
these two extremes, the margin of safety does not follow a linear progression.

The required safety against overload failure is 3.5 to 5.0, depending on the type of
application or guideline involved. The required safety against deformation (yield
point) is usually 2.0 to 3.5.

25.4.5

Strength parameters in accordance with FKM

25.4 .5.1
Temperature duration
The FKM guideline takes into account thermal creep in various materials. Constant
high temperatures will reduce the shaft's strength and therefore also reduce its
safety.

Part temperatures in the range from -40oC +500oC are taken into consideration in
accordance with the FKM guideline. For temperatures above 100oC (for fine grain
steels above 60 degrees C), temperature factors (for tensile strength, yield point,
and resistance to change) are used to take the reduction in strength into account.

Chapter
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25

NOTE

You can define the shaft temperature in the Elements editor. To do this,
click on the shaft you want in the Elements tree and then enter the
corresponding value in the Temperature field.

25.4 .5.2
Protecti ve layer thickn ess, Aluminum
If you have selected aluminum as the shaft's material, enter the value for the
thickness of the aluminum oxide layer in this field.

25.4 .5.3
Enter safetie s
Click on this checkbox to set required safety values on the right-hand side of the

Calculation group. Alternatively, click the

button to open the Define
safeties dialog window where you can specify required safeties as defined in
FKM.
The safety factors for the static strength calculation, j m (for overload failure) and jp
(for deformation), are determined in accordance with section 1.5 of the guideline,
and the safety factor for fatigue resistance, jD, is determined in accordance with
Part 2.5 of the guideline. You will find detailed comments in the guideline.

Steel
GS, GJS

GJL, GJM

jm = 2.0

jp = 1.5

jF = 1.5

jF = 1.5

-not checked

jm = 2.8

jp = 2.1

jG*jF = 2.6

jG*jF = 2.6

-non-destruction tested

jm = 2.5

jp = 1.9

jG*jF = 2.4

jG*jF = 2.4

-not checked

jm = 3.3

jp = 2.6

jG*jF = 3.1

jG*jF = 3.1

-non-destruction tested

jm = 3.0

jp = 2.4

jG*jF = 2.9

jG*jF = 2.9

jm, jp: The values apply for

- severe damage as the result of failure

- high probability of load occurrence

If only minor damage results from the fracture, the safety factors can be reduced by
about 15%. Provided the probability of the same load occurring again is low, the
safety factors can be reduced by about 10%.
jG*jF: The values apply for

- severe damage as the result of failure

Chapter
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25

- irregular inspection
If only minor damage results from the fracture, the safety factors can be reduced by
about 15%. Provided inspections are carried out regularly, safety factors can be
reduced by about 10%.

25.4 .5.4
Load case
The load case identifies four hypothetical scenarios for the development of the
stress ratio a/m if load increases, starting at the operating point.

25.4.6

Strength parameters in accordance with DIN

25.4 .6.1
Load case
The load case identifies two hypothetical scenarios for the development of the
stress ratio a/m if load increases, starting at the operating point.

25.4 .6.2
Calculation wit h experimental data
Use this option to define a Haigh diagram, which has been determined from experimental data. If you input a file name (e.g. WMAT-001.dat) in the Experimental
data field for module-specific material data as defined in DIN 743, a selection list
appears in the Strength tab.

Not taken into account: the data is ignored.

Use in DIN 743 (KFaccording to DIN 743): the data is imported from the
file which was defined for the materials under Experimental data, and the KF
coefficient is defined according to DIN 743.
Use in DIN 743 (KF=1): the data is imported from the file which was defined for the materials under Experimental data, and the KF coefficient is always set to 1.
The method used to define data from the file requires separate instructions, which
we will supply upon request. The measured Haigh diagram is not interpreted

Chapter
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25

exactly as described in DIN 743. The overall influence coefficient divides the
Haigh diagram into X- and Y-coordinates so that the results are much smaller.
The influence of mean stress as defined in DIN 743 increases as the notches
become sharper, and should not decrease. This modification ensures that this
influence always increases.
If the comparative medium stress is mv<0, the line of the Whler diagram is extended into the negative area of the Haigh diagram, and the curve is then broken in
the negative area by compression yield point Dk. For more information, see also
the description in DIN 743-1, p. 21.

25.4 .6.3
Safety ag ain st fat igue/deformat ion
In these input fields, you specify the required safeties for endurance/yield. A
warning message appears if these values drop below the limit you specified for any
one cross section.

25.4.7

Strength parameter according to AGMA

25.4 .7.1
Coefficie nts used to determine fatigue st reng th
The following coefficients are required to calculate the modified fatigue strength
f:

Surface finish coefficient ka

You can set the surface finish for each individual element in a list. The ka
coefficient is then determined from the list entry, using the method shown in Figure
4, AGMA 6101-E08.
Size factor kb
The size factor kb is determined on the basis of the shaft diameter, using the method shown in Figure 5, AGMA 6101-E08.
Reliability coefficient kc
In the Strength tab you can define the reliability (default 0.99%). This value is
used to determine reliability coefficient kc, using the method shown in Figure 6,
AGMA 6101.
Temperature coefficient kd
The coefficient kd=1 is set for temperatures between -30C and 120C. The entries
for the shaft can be modified if the shaft temperature lies outside this range.

Chapter
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25

Life factor ke
This coefficient is defined by the stresses e and u and the number of load cycles,
NL.
Surface processing coefficient kf
For key ways, this coefficient is taken directly from AGMA 2101, Table 2.
For straight-side or normal splines, a Kt coefficient of 2.0 is assumed.
If a combination of a key and a press fit is present, a kf coefficient of 0.33 to 0.4 is
specified. In KISSsoft, the default kf coefficient is 0.33.
The notch effect type of the circumferential groove is used for V-notches and
threads. It has a fixed ratio of h/r = 20.
The system takes an individual Kt coefficient from the diagrams for the shoulder,
circumferential groove and cross hole (Figure 8-10, AGMA 2101) and uses them,
together with coefficient q (Figure 7, AGMA 2101) to calculate coefficient kf.
Miscellaneous effects factor kg
This factor can be used to take into account, for example, heat treatments, residual
stresses (shot peening, cold rolled, etc.), corrosion, and surface coatings.
The default value set for this factor is kg=1, however, it can be overwritten with the
values entered for the shaft.

25.4 .7.2
Calculating the Safetie s
Load spectra are not taken into consideration when the AGMA method is applied.

To calculate the fatigue safety FSf, the average stress and the amplitude are
determined using the von Mises stresses.
These values are later required, together with the modified fatigue strength and the
tensile strength, to determine the fatigue safety.
The total stress is determined using the von Mises stresses to calculate peak load
safety. The peak load safety coefficient is calculated using the total stress, the
tensile strength, a coefficient for the yield point, and a peak load coefficient.
The peak load coefficient can be defined individually in the Strength tab for all
loads (tension/compression, bending, torsion, thrust). In the KISSsoft system, the
default setting for the peak load coefficient is 1.0. As specified in the standard, the
setting for this coefficient is 2.0 for cylindrical gears with straight and helical
flanks, bevel gears, and double helical gearing. For worm wheels, the setting for
this coefficient is 3.0.

Chapter
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25

The yield point coefficient can be also defined in the Strength tab. In the
KISSsoft system, the default setting for the yield point coefficient is 0.75. (As
specified in the standard, it is 0.66 to 0.8).
The resultant safety factors for fatigue FSf and peak load FSp must be >= 1
according to the standard.

25.4.8

Stress

This is where, in particular, you define how the loads calculated by KISSsoft (e.g.
bending moment) are to be converted into amplitude or means stress. You can select usual loads (alternating, pulsating, static load) from the list. For exceptional
situations, select Own Input from the Stress drop-down list and enter the
required value in the Stress ratio input field (see next section). Rotating
shafts normally have an alternating bending and a pulsating or static torsion.

25.4.9

Stress ratio

You must also enter a stress ratio because KISSsoft requires this value to split the
load on the corresponding cross section into mean load and load amplitude.

Maximum stress per load cycle:

Minimum stress per load cycle:

Stress ratio

R = u/o

Mean stress:

= (o + u)/2
= (o + R . o)/2
= o . (1 + R)/2

Stress amplitude:

= (o - u)/2
= (o - R . o)/2
= o . (1 - R)/2

For:
Pure alternating stress

(u = - o)

R=-1

Chapter
III-760

Calculating Shafts

25

Pulsating stress

(u = 0)

R=0

Static stress

(u = o)

R=1

Normally valid for rotating shafts or axes:

Bending and shearing force:

R = -1

Torsion and tension/compression:

R = 0 (ev. R = 0...1)

NOTE

In contrast to the calculation in accordance with DIN or FKM, where there is a

clear differentiation between the mean stress and amplitude stress, when a strength
calculation in accordance with Hnchen (see page III-746) is performed, the loads
that are entered are converted into an equivalent stress that is then compared with
the fatigue limit for bending. For this reason, if you select this method, the stress
ratio only affects the value of the stress ratio factor 0.

25.4.10 Load factor for static analysis

The static calculation normally uses the greatest possible load. The maximum load
factor covers the difference between the load value you specified and the peak value.
Maximum stress: max = o . fmax
You can specify individual factors for every type of stress (bending, tension/compression, etc.).
The load factor is not used if the forces or power ratings are specified in free cross
sections.

EXAMPLE

Electric motor with a permanent torque 100 Nm, starting torque 180 Nm. When
you specify the shaft data, enter 100 Nm and set the maximum load factor to 1.8.

25.4.11

Load factor for endurance calculation

If necessary, the mean stresses and the stress amplitudes can be multiplied by a
load factor. As the DIN743 standard does not include this factor, you should generally predefine it as 1.0. Using a factor > 1 is a good idea if you specify the nominal

Chapter
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Calculating Shafts

25

torque in a shaft calculation without taking into account the increases in torque due
to the vibrations caused when the shaft rotates.
The load factor is not used if the forces or power ratings are specified in free cross
sections.
The calculation in accordance with Hnchen includes the following information:
Total load factor as defined in (Hnchen [42], page 24):

(25.9)

fun

Uncertainty in maximum load (1.0 or 1.2 to 1.4)

fbetr

Operational approach (shocks) (1.0 to 3.0)

fleb

Importance of part (1.0 or 1.2 to 1.5)

NOTE:

The Hnchen method uses only one load factor, which is the larger of the two values entered for bending and torsion.

25.4.12 Cross sections

Yield safeties and safeties for fatigue failure are evaluated at specific cross sections
along a shaft that are defined by you. To define a cross section:

Chapter
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25

In the Elements tree you will see the Cross section entry at group level (
see Figure on page III-687). Click the right-hand mouse button on this entry to
open a context menu in which you can select either Free cross section or
Limited cross section.

Figure 25.7: Elements editor for setting parameters for Limited cross sec-

tion

Figure 25.8: Elements editor for setting parameters for Free cross section

Chapter
III-763

Calculating Shafts

25

25.4 .12.1 Surface roughness

If you enter a value for surface roughness as defined in ISO 1302, the
corresponding surface roughness, RZ, is displayed in the selection list. This value,
RZ, is then used in the calculation. In the calculation in accordance with DIN or
FKM, the surface roughness has already been included in the notch factor in some
cases. In such situations, the surface factor is always 1.0, no matter what value you
input as the roughness.

25.4.13 Sizing
You can select the Size option in the context menu for the Cross section
entry in the elements tree, to make it easier for you to define the cross sections that
need to be recalculated.
In this sizing, KISSsoft automatically finds cross sections (shaft shoulders,
interference fits in bearings, key-grooves and special notch effects) which have
been defined in the graphical shaft input and in which a notch effect
occurs. It displays the cross sections that have the lowest safety. You must check
these cross sections carefully.

NOTE

Check for further notch effects, which KISSsoft cannot find, such as thread or
cross hole.

25.4.14 Cross-section types

Shoulder

Shoulder with relief groove

Chapter
III-764

Calculating Shafts

25

FKM Form B

FKM Form D

DIN 509 Form E

DIN 509 Form F

According to FKM, these shapes are handled like shape B.

DIN 509 Form G

DIN 509 Form H

According to FKM, these shapes are handled like shape D.

Shoulder with interference fit

Chapter
III-765

Calculating Shafts

25

With Hnchen+Decker not possible

and AGMA 2101:
In DIN 743:

The notch factor will be calculated like a shoulder, but with

the relationship d/(1.1*D). The maximum transmission for
D/d ~ 1.1 and for r/(D/d) ~2. This condition is only applied if
D/d >= 1.1, otherwise the notch effect of the shoulder is used.

In the FKM guideline: The notch effect coefficient is determined for the fit H7/n6.
The notch effect coefficient is also calculated for a shoulder
and then used, in the worst case, in subsequent calculations.
Notch factors are documented in the different methods. The notch factors
calculated in FKM are usually significantly larger than in DIN.

Shoulder with conical transition

Chapter
III-766

Calculating Shafts

25

Shaft grooves
With the following variants:

Thread
Notch factors for threads are not described as a separate topic in the specialist
literature. For this reason, notch factors for threads are handled like those for
V-notches.

Interference fit
Interference fit (Firm interference fit, Slight interference fit, Interference fit
with relief grooves).

Chapter
III-767

Calculating Shafts

25

Above: Interference fit with relief grooves.

Below: Interference fit with end relief.

Key
In every method, the moment of resistance for bending is determined from shaft
diameter d. As described by Hnchen, the moment of resistance for torsion is
calculated from the incorporated circle d - t. According to FKM, DIN and AGMA,
it is calculated from the outer shaft diameter d.
Notch factors are documented in the different methods. However, Hnchen
provides very little information about this that can be used to extrapolate values for
steel of higher strength (with the appropriate comment about the calculation). In
contrast, these values are well documented in the DIN standard and the FKM
guideline (in the tables for Interference fit with feather key). Two different produc-

Chapter
III-768

Calculating Shafts

25

tion methods are described for keys in AGMA 6101 (side milling cutter or keyway
cutter). This standard also distinguishes between 2 different hardness ranges.
The program includes tables for cross-sections with keys. The data is imported
from a data file which includes the DIN 6885.1 (corresponds to ISO/R 773), DIN
6885.2 and DIN 6885.3 standards. You can also specify other standards.

Groove meshing and spline shaft

Shape of the spline shaft (straight-sided spine)

To calculate groove meshings or spline shafts you must first enter tip and root
diameter data. All other values are used purely for documentation purposes.
To calculate the section modulus:
In Hnchen+Decker:
In the case of the FKM guideline,
DIN 743 and AGMA 6101:

From the mean value (da/2 + df/2)

From the root circle

Notch factors are documented in the different methods.

Cross hole

Chapter
III-769

Calculating Shafts

25

Smooth shaft
If you select Smooth shaft the notch factor is set to 1. You should select
this for the cross section with the maximum stress.

Define your own input notch factors (see page III-761)

Intersecting notch effects (see page III-834)

25.4.15 General entries

25.4 .15.1 Thickness factors from the shaft diameter
You can derive material values that depend on the diameter either from the
effective shaft diameter (d or D) or from the thickness of the raw material. The first
choice of shaft diameter gives more reliable safety results but can only be used if
the shaft is through hardened before it is turned.

However, if you select Pre-turned to actual diameter (for

shoulders K1 from d) the material data for shoulders is derived from the
smaller diameter (d). If you select Pre-turned to actual diameter it is
derived from the larger diameter (D). Although deriving these values from D gives
slightly lower strength values, the results are therefore on the slightly safer side.
The standard does not comment on this.

Chapter
III-770

Calculating Shafts

25

25.5

Tooth trace modification

For various purposes, it is important that you know how much a specific point in
the shaft cross section moves in a particular direction due to elastic deformation
(bending and torsion). An example of this is calculating the gap between the two
halves of a coupling that are mounted on each end of the same shaft. In this situation, the displacement of a point on the shaft cross section is calculated in the axial
direction.
The most important application of this calculation is to determine shaft deformation in the meshing area. The deformation for the pitch point is calculated along the
facewidth. In this situation, the displacement of a point on the shaft cross section
due to bending and torsion is calculated only in the direction of the normal to the
flank. A displacement parallel to the flank only results in a very minimal change in
sliding velocity and can therefore be ignored.
In the "Tooth trace modification" tab, you can directly select the toothing currently
present on the shaft. The data you have already input is used to define the
necessary defaults for the calculation (Facewidth from and to, Coordinates meshing
point, Direction of the normal to the tooth flank in the pitch point) which are
displayed in the user interface. Therefore, assuming that the counter gear has infinite stiffness, the progress of the meshing point displacement due to deformation can
be determined along the facewidth.
NOTE:

during the tooth trace modification calculation, any gear load application offset for
the gear selected for the particular calculation (Calculation A or B) is temporarily
deactivated. This means the gear load application offset of gear A is disabled when
Calculation A is performed, but is re-enabled when Calculation B is performed.

Chapter
III-771

Calculating Shafts

25

To display this deformation, also called "gaping", click Graphics -> Tooth
trace modification -> Deformation.

Figure 25.9:Diagrams for tooth trace modification and> de-

formation

This shows the deformation in the pitch point. It also shows a proposed value for
an optimum tooth trace modification. This modification would achieve a
homogeneous load distribution along the facewidth.

You can input the tooth contact stiffness c in another input field. For steel gears,
the tooth contact stiffness per mm facewidth is approximately 20 N/mm/. The values of c are calculated precisely and documented in the cylindrical gear
calculation. This stiffness can then be used to calculate the load distribution along
the facewidth. Click Graphics -> Tooth trace modification ->
Load distribution to see the result.

Calculate the load distribution coefficient KH for gear calculations

Chapter
III-772

Calculating Shafts

25

The results window also shows the load distribution coefficient KH, calculated
according to ISO 6336, with equation KH = wmax/wm from the average line load
(wm) and the maximum line load (wmax). This calculation enables the face load
factor to be estimated with significantly more accuracy, similar to Method B in ISO
6336. The procedure is basically similar to Appendix E of ISO 6336. However, you
must be aware that the shaft of the counter gear used here is assumed to have infinite stiffness. This is permitted if the shaft of the counter gear has much greater
stiffness. Manufacturing allowances are also only included if, for example, they
have been defined by inputting an angular deviation of the shaft (bearing
displacement) as part of the shaft data.
The addendum modification of the gear body determined from an FE (Finite Element) calculation can also be taken into account as a displacement matrix. To do
this, select the "Take additional displacement matrix into account" option in the
cylindrical gear force element. You will find the deviation.dat file, which gives an
example of a displacement matrix, in the dat. directory.
NOTE:

If KH is to be determined whilst taking into account the deformation of the two

shafts: The deformation components of two shafts can be combined in the
cylindrical gear calculation in the "Contact analysis" tab.

Sizing the tooth trace modification

This calculation module has been designed to enable you to define the best possible
tooth trace modification both quickly and accurately. To do this, you can input a
modification consisting of crowning or end relief and flank angle deviation. You
can specify the flank angle deviation either as a positive or negative number,
depending on the required progression. The modification input here is then also
displayed in the "Deformation" graphic. In the "Load distribution" graphic you can
then clearly see the improved load distribution achieved by this calculation. Click
"Graphic" -> "Tooth trace modification" -> "Tooth trace diagram " to call the graphic for creating the modification (gear drawing).

Figure 25.10: Determining the gap in the meshing point

Chapter
III-773

Calculating Shafts

25

25.6

Campbell diagram

Select Calculation > Campbell diagram to enable the special calculation tab for the
Campbell diagram. The user can set the shaft to be analyzed, range of shaft speeds,
number of calculations of the speed range, and number of resonance curves
(synchronous speed curves) to be displayed.

The Campbell diagram shows the eigenfrequencies in a wider range of shaft

speeds, and then we can follow the forward and backward whirls associated with
the eigenmodes. In order to calculate the Campbell diagram, the number of
eigenfrequencies should be set in the Basic data tab. The gyroscopic effect causes
large changes in the eigenfrequencies and can be taken into consideration by setting the "Consider spinning effect" checkbox in the Basic data tab.

Chapter
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25

In normal situations, the backward mode drops in frequency, while the forward
mode increases. For forward whirl, as shaft speed increases, the gyroscopic effects
essentially increase the spring stiffness and increase the eigenfrequencies. The
effect is reversed for backward whirl, and increasing shaft spin speed reduces the
effective stiffness, thus reduces the eigenfrequency. The eigenfrequencies are also
affected by the stiffness of the bearings.

Chapter
III-775

Bearing calculation General

26

26

Beari ng calc ula tion Gener al

Chapter 26
Bearing calculation General

Chapter
III-776

Bearing calculation General

26

26.1

Classification of bearings

Bearings can be classified according to:

the type of motion as for plain bearings, where the gliding motion takes place
between the bearing and the supported part, and as for roller bearings where the
rolling elements describe a rolling motion.
the direction of the bearing forces for radial and thrust bearings.
the function in fixed bearings which can take up shearing forces and axial
forces in both directions and in non-locating bearings which allows displacement in a longitudinal direction.

26.1.1

Properties

The most important properties for the operational performance and use of plain and
roller bearings can often be identified by examining their advantages and
disadvantages.
There are hardly any rules to tell you how and when to use roller bearings. The
choice of bearing depends partly on the properties which are determined from the
advantages and disadvantages and partly from the operational requirements such as
size and type of load, maximum speed, required service life and practical experience.

26.1.1.1
Rolle r bearing
Advantages: If used correctly, hardly any friction occurs when roller bearings are
used, therefore the starting torque is required is only slightly higher than its working moment (major benefit when used for driving units!); they use little lubricant;
they are easy to maintain; they do not require any running-in time; a large degree
of standardization means roller bearings are easy to purchase and are widely
exchangeable with each other.

Disadvantages: They are especially sensitive to impacts and shocks, when they are
not in use or running at low speed; their service life and maximum speed are limited; their sensitivity to pollution can lead to added expense for sealing the bearing
(wear, loss in efficiency!).

26.1.1.2
Plain beari ng
Advantages: Due to their large, load-absorbing and lubrication area, plain bearings
are insensitive to impacts and shocks, and they can run at unlimited speed; if fluid
friction is used, they have an almost unlimited service life; split construction allows

Chapter
III-777

Bearing calculation General

26

easy mounting and dismounting; adjustable bearings give outstanding operational

accuracy.
Disadvantages: Plain bearings require a larger starting torque (major
disadvantage!); because of their initial dry friction they consume large quantities of
lubricant and require constant supervision; they are generally slightly less efficient
than roller bearings.

Chapter
III-778

Roller Bearings (Traditional Analysis)

27

27

Roll er b earin g

Chapter 27
Roller Bearings (Traditional Analysis)
Manufacturer catalogs (such as SKF) include fairly comprehensive methods for
verifying the service life and the static load capacity of roller bearings. Specialized
technical literature is also available to help you resolve more detailed problems
[39].
KISSsoft includes bearing data from well-known bearing manufacturers. The user
can extend these values.
In the KISSsoft initial window, select Shaft and Bearings -> Roller
bearings from the Module tree.

Figure 27.1: Basic data: Roller bearings

There is not much to explain here because the calculation provides numerous options, such as extended service life calculation or load spectra.
In the Basic data tab you will see a
button for every bearing, next to its Label
field. This function shows the service life of every bearing in the database
(including the type and diameter). This makes it easy for you to select the best
bearing for your purpose.

Chapter
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27

27.1

Selecting the type of roller bearing

27.1.1

Properties of the most important bearing types

Selecting the most suitable type of roller bearing is sometimes no easy matter. The
table below presents an overview of the critical properties of the most important
types of roller bearing:
Deep groove ball bearing (DIN 625):
The single row radial deep groove ball bearing is the most commonly used, because it is both extremely versatile and inexpensive. This bearing can withstand
relatively high radial and axial forces in both directions.
Single row angular contact ball bearing and four-point contact bearing
(DIN 628):
Each ring of a self-holding single row angular contact ball bearing has one lower shoulder and one higher shoulder. The grooves on the higher shoulder are
positioned so that the contact angle is normally = 40o. The higher number of
rollers in this configuration means it can withstand not only radial forces but
also larger axial forces in one direction (towards the higher shoulder) than deep
groove ball bearings. Axial reaction forces due to the angle of the groove will
be generated when the bearing is subjected to a radial load. You must take this
into account when sizing the bearing. Because of its one-sided axial loading
capacity, these types of bearings are usually installed in pairs where the second
one is mounted in the opposite direction. The axial force that acts on the bearing in the case of a back to back or face-to-face arrangement is calculated and
displayed in the screen. See also 27.3.17.
Double row angular contact ball bearing (DIN 628):
The double row angular contact ball bearing corresponds to a pair of mirror
image compounded single row angular contact ball bearings (back-to-back arrangement) with = 25o or 35o, and can therefore withstand radial and high
axial forces in both directions.
Areas of use: To support the shortest possible bending-resistant shaft that is
subject to strong radial and axial forces: integral worm shafts, shafts with
angled spur gears and bevel gears.
Double row self-aligning ball bearing (DIN 630)
This is a double row bearing with a cylindrical or conical bore (bevel 1:12). It
can compensate for shaft displacement and misalignment (up to approximately
4o angular deviation) thanks to its hollow sphere race in the outer ring. It can be
subjected to radial loads and axial loads in both directions.

Chapter
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27

Areas of use: Bearings which are inevitably subject to inaccurate mounting and
bending of the shaft, e.g. transmissions, conveyors, agricultural machinery, etc.
Cylindrical roller bearing (DIN 5412):
Cylindrical roller bearings can support larger radial loads than ball bearings of
the same size (point contact area!) because the contact between the rollers and
the races is made along a line. Demountable cylindrical roller bearings can only support small axial forces (if at all) and require accurately aligned bearings.
Depending on the rim arrangement, you can identify (construction) types N and
NU that have an unconfined outside and inside ring and which can be used as
non-locating bearings, type NJ as a step bearing, and types NUP and NJ which
can be used as a fixed bearing or locating bearing for axial shaft support in
both directions.
Areas of use: In gearboxes, electric motors, for axles of rail vehicles, for rollers
in a rolling mill. In general for bearings that are subject to large radial loads.
Needle roller bearings (DIN 617):
are a special type of cylindrical roller bearing in which a cage separates the
needle rollers to keep them at a specific distance from, and parallel to, each
other. The bearing is supplied with or without an inner ring and is only suitable
for radial forces. It can be characterized by its small overall diameter, its high
degree of rigidity in the radial direction, and by its relative insensitivity to an
uneven load.
Areas of use: Predominantly used at low to medium speed and in oscillatory
motion, e.g. as connecting rod bearings, rocker-shaft bearings, swivel arm bearings, jointed cross-shaft axle bearings (vehicles), spindle bearings, etc.
Taper roller bearing (DIN 720):
The ring races in taper roller bearings are cone-shaped shells which must converge into one point due to the action of kinematic forces. The bearings with
= 15o(30o) can support high loads both in radial and axial directions. The detachable outer ring makes them easy to assemble and dismantle. Taper roller bearings are installed in mirror image pairs. The bearing clearance can be set and
adjusted as required. Due to the angle of the race, a radial force produces an
axial reaction force.
Areas of use: Hub bearings of vehicles, cable pulley bearings, spindle bearings
in machine tools, shaft bearings in worm gears and bevel gears.
Calculation: The axial force which you must specify when calculating a dynamic equivalent load is defined in several theories (for example page 296 of the
FAG Wlzlager catalog WL 41520DE (1995)). The axial force acting on the

Chapter
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27

bearing is displayed in the screen. See also section 27.3.17. The bearing forces
that include the contact angle can be calculated directly.
Barrel-shaped bearings (DIN 635), toroidal roller bearings (CARB), and
double row self-aligning ball bearings (DIN 635):
Spherical races in the outer ring and barrel-shaped rollers (toroidal-shaped for
CARB bearings), as in double row self-aligning ball bearings, enable barrelshaped, toroidal roller (CARB) and double row self-aligning ball bearings with
a cylindrical and conical bore (1:12) to compensate for misalignment and for
the angular dislocation of the shaft (oscillating angle 0, 5o to 2o). Barrel roller
bearings are suitable for high radial loads but can only withstand low axial
forces. In contrast, double row self-aligning roller bearings ( = 10o) can be
used for the highest radial and axial forces. Toroidal roller bearings (CARB)
have an extensive range of uses in many load applications. Toroidal roller bearings combine the angular flexibility of double row self-aligning roller bearings
with the axial displacement options of cylindrical roller bearings.
Areas of use: For heavy wheels and cable pulleys, propelling shafts, rudder
posts, crank shafts, and other heavily loaded bearings. Toroidal bearing: Paper
making machinery, blowers and, generally, in planetary gear units.

27.1.2

Comparing types

Selecting the most suitable type of roller bearing is sometimes no easy matter. The
table below presents an overview of the most important properties. The bearing
you select for specific operating conditions has often already been determined by
its properties and characteristics. You can use this information to select the bearing
you require for frequently occurring working cases and for specialized
requirements. However, results may overlap, and therefore the cost factor may be
decisive.
Radi al b e ari n g:
Features

Radial load capability

Axial load capability

Inside position adjustment

Mounting position
adjustment

Dismountable bearings

Alignment error
adjustment

Chapter
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Increased precision

High speed running

Quiet running

Conical bore

Gasket on one/both sides

High stiffness

Low friction

Fixed bearing

Non-locating bearing

+ very good
good normal/possible
suitable/no longer relevant

Deep groove ball bearing

Angular contact ball bearing (single

row)

Angular contact ball bearing (double

row)

Four-point contact bearing

Double row self-aligning ball bearings

Cylindrical roller bearings NU, N

Cylindrical roller bearings NJ

Cylindrical roller bearings NUP, NJ+HJ

Cylindrical roller bearings NN

Cylindrical roller bearings NCF,

NJ23VH

Cylindrical roller bearings NNC, NNF

Taper roller bearing

Barrel roller bearing

Double row self-aligning roller bearings

with restrictions

- not

T hr us t b eari n g:
features

Radial load capability

Axial load capability

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Inside position adjustment

Mounting position
adjustment

Dismountable bearings

Alignment error
adjustment

Increased precision

High speed running

Quiet running

Conical bore

Gasket on one/both sides

High stiffness

Low friction

Fixed bearing

Non-locating bearing

+ very good
good normal/possible
suitable/no longer relevant

with restrictions

Axial deep groove ball bearing (one-sided)

Axial deep groove ball bearing (two-sided)

Axial angular contact ball bearing (one-sided)

Axial angular contact ball bearing (two-sided)

Cylindrical roller thrust bearing

Spherical thrust roller bearings

- not

Chapter
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27

27.2

Load capacity of roller bearings

The dynamic load capacity of the rotating bearing, and the static load capacity at
standstill, vary at very slow speed or very small oscillations, depending on the
working state, but not on the effect of the load.

27.2.1

Dynamic load capacity

The dynamic load capacity is a property of the entire bearing. In accordance with
ISO 281, a number of various properties of a roller bearing are included, that the
bearing has when it experiences specific mechanical loading under specific
conditions at specific speeds. This data is then used to calculate the number of operating hours (this is usually based on a failure probability of 10%).

27.2.2

Permissible static stress

The static load capacity includes properties that a roller bearing must display in
order to withstand certain mechanical loading situations at standstill, at very low
speed (n < 20 rpm), or during oscillatory motion.
Plastic deformation (indentation) occurs between the rolling elements and the races
when the bearing is subjected to a moderate static stress due to the weight of the
shaft and the other elements. Its size gradually increases as the stress increases.
However, the plastic deformation must not be so great as to influence the operational properties of the bearing in its rotational movement. As defined in ISO76, the
static characteristic value S0 = C0/P0 is a safety factor against detrimental plastic
deformation which is a measure of the sufficient static load capacity.
The static load number, which is used to determine the bearing size, can be
determined by taking into account the safety margin which depends on the operating conditions:
S0 > 2

for shocks and impacts as well as exacting requirements for

smooth operation and for axial double row self-aligning roller
bearings

S0 = 1

for normal operating conditions and low noise requirements

S0 = 0.5...0.8

for smooth and non-impact operating conditions with few

requirements (non-loaded bearings with adjusting or swivel
motion)

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27.2.3

Bearing calculation with inner geometry

The calculation of the bearing reference rating life is based on ISO/TS 16281.
The results of this calculation are the reaction forces, torques, the displacements
and rotations, the maximum Hertzian pressure on the inner and outer race (right
and left ring for a thrust bearing), the static safety, the reference and modified reference rating life in hours, the stiffness matrix at the operating point, and the load
distribution and pressure curve on each rolling element.
For more detailed information, see 25 - Roller bearing inner geometry (see section
"Roller Bearings (Inner Geometry)" on page III-803)
If the bearing inner geometry is given by the manufacturer then it is used in the
calculation. If it is unknown then KISSsoft runs an approximation method that tries
to determine the inner geometry using the bearing load ratings (both static C0 and
dynamic C) given by the manufacturer. This procedure is based on ISO 76 and ISO
281-4 and normally gives quite useful results.
In the special case that the user only knows the number of the rollers or balls, and
wants to use this data when performing a calculation in accordance with the standard, we suggest the following:
Run a calculation based on bearing inner geometry. Since you don't know the
geometry, it will be approximated for you.
Create a bearing report, and note down the bearing inner geometry data.
Open the KISSsoft database with write access authorization. Navigate to the
required bearing type, and add a new bearing. In the "Internal geometry" tab,
copy in all the internal geometry data you noted down in step 2. In the number
of rolling elements field (Z), input the number of bearings you know are being
used.
Save and close the database.
Go to the Elements editor, and update your bearings to the one you added to
the database above. Rerun the calculation and get the results.
If the internal geometry the user added to the database is not sufficient or incorrect,
then the input is ignored and the internal geometry is approximated. The log then
contains a note to say that an approximate value has been used for the inner
geometry.

The internal geometry cannot be taken into account in the calculations for every
bearing type. The calculations where this is currently possible are listed in the Roller bearing inner geometry (see page I-157) database chapter.

Chapter
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27

27.3

Thermally permissible service s peed

The definition of the thermally permissible operating speed is described in DIN

732 [8]. The calculation of the thermally permissible operating speed is based on a
heat balance at the bearing. The thermally permissible operating speed is derived
from the thermal reference speed and by using the thermal nominal speed. The
result of this calculation is the speed that will be reached by the bearing running at
the permitted temperature in an actual situation. This thermally admissible speed
may differ greatly from other operating speed limits, depending on lubrication type, because the reference conditions only apply to quite specific cases. In order to
define the thermally permissible operating limit, you must first define the thermal
nominal speed for each case.

Figure 27.2: Thermally admissible operating speed

27.3.1

Thermal reference speed

The definition of the thermal nominal operating speed is defined in DIN ISO 15312
[7]. The thermal nominal speed is the bearing-specific speed reached under a given
set of nominal operating conditions such that equilibrium is achieved between heat
development (friction) and heat dissipation (through bearing contact and lubricant).
Mechanical or kinematic criteria are not taken into account for this speed. The reference values (temperatures, load, viscosity of the lubricant, reference face of the
bearing, . . . ) are fixed so that the reference speed using oil or grease lubricated
bearings will result in identical values.

Chapter
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Roller Bearings (Traditional Analysis)

27

27.3 .1.1
Dissip ated Heat Flows
The heat flow Qr is calculated from the reference heat flow density specific to a
roller-bearing arrangement qr (for heat flow dissipated through bearing contact and
lubricant) as well as heat dissipation through the reference surface Asr.
Qr = 10-6 * qr * Asr
qr, Asr are defined under reference conditions in accordance with DIN ISO 15312.

27.3 .1.2
f0r and f1r coefficient s
The coefficients f0r and f1r used to define the reference thermal operating speed
are different, depending on which bearing type/series (also lubrication type for f0r)
is used. They are shown in Table A.1 of the standard. Not all bearing variants are
listed in the table.

The following values have been assumed for bearings and bearing types for which
no data has been defined in the standard:
f0r (tabular value)

f1r

Ball bearing

1.7

0.00015

Roller bearing

0.0003

Thrust ball bearing

1.7

0.00015

Thrust roller bearing

3.5

0.0015

27.3 .1.3
Calculating the the rmal nominal speed
The dissipating heat flows and the friction power are set as equal values so that the
energy balance of the bearing is correct. The equation for the energy balance is:

NFr = 103 * Qr
NFr: Friction power [W]
Qr : dissipated heat flow: [kW]
The subsequent equation becomes:
( *nr)/30 * (10-7 *f0r * (r*nr)2/3 *dm3 + f1r *P1r *dm) = qr *ASr
nr: thermal reference speed [1/min]
f0r: Coefficient from Table A.1, DIN ISO 15312 [-]
r: Reference viscosity[mm2/s]

Chapter
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Roller Bearings (Traditional Analysis)

27

dm: average roller bearing diameter [mm]

f1r: Coefficient from Table A.1, DIN ISO 15312 [-]
P1r: Reference load [N]
qr: Roller bearing specific reference heat flow density (bearing contact, lubricant)
[kW/m2]
ASr: Reference surface area dissipating heat [mm2]
The value nr can be determined from this equation.

27.3.2

Process for calculating thermally permitted

operating speed (DIN 732-2)

As, when calculating the reference thermal operating speed, this calculation is based on equilibrium in the bearing. Dissipating heat flow:
Q = QS + QL + QE
QS: heat flow
QLdissipated across the bearing contacts by lubrication (only when there is
circulatory lubrication) (the lubricant density = 0.91 kg/dm3 and specific heat
capacity cL = 1.88 KJ/(kg *K) are predefined.)
QE: additional heat flow (it is assumed that QE= 0 for the calculation)

27.3 .2.1
Friction coefficient s f0 and f1
The coefficient values f0 and f1 and the dynamic equivalent Load P1, are only
needed to define the load and lubrication parameters. These values differ
depending on the specific bearing type/model, lubrication type, or load direction.
They are listed in Table 1 in the standard. Not all bearing variants are listed in the
table. The following values for various types of lubrication have been defined (and
incorporated in KISSsoft). They are based on the notes about f0 in Table A.1 in the
standard.

Oil, dip lubrication, bearing in oil mist: f0 = 0.5 * f0 (tabular value)

Oil, dip lubrication, oil level up to middle bearing: f0 = 2.0 * f0 (tabular value)
Oil, dip lubrication, oil level up to middle of the lowest rolling element: f0 =
1.0 * f0 (tabular value)
Oil, circulatory lubrication: f0 = 2.0 * f0 (tabular value)
Grease, run-in bearing: f0 = 1.0 * f0 (tabular value)

Chapter
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Roller Bearings (Traditional Analysis)

27

Grease, newly greased: f0 = 2.0 * f0 (tabular value)

The following values have been assumed for bearings and bearing types for which
no data has been defined in the standard:

Ball bearing

P1

f0 (tabular value)

f1

3.3*Fa - 0.1*Fr

1.7

0.0007*(P0/C0)^0.5

(P1 <= Fr) where P1 = Fr

Roller bearing

Fr

0.0003

Thrust ball bearing

Fa

1.7

0.0007*(P0/C0)^0.5

Thrust roller bearing

Fa

3.5

0.0015

27.3 .2.2

Calculating the the rmally perm issible operating speed l imit

The thermal permissible operating speed is calculated from the reference thermal
operating speed with the help of the speed ratio, n = fn * nr

The load and lubrication parameters have to be calculated before the speed ratio
can be iterated from the following equation.
KL * fn5/3 + KP * fn = 1
Load parameter KL:
KL = 10-6 * (/30) * nr*10-7 * (f0r * n2/3 * nr2/3 * dm3)/Q
Lubrication film parameter KP:
KP = 10-6 * (/30) * nr*(f1 * P1 * dm)/Q
nr: thermal reference speed [1/min]
f0: Coefficient of friction from Table A.1, DIN 732 [-]
f1: Coefficient of friction from Table A.1, DIN 732 [-]
n: Lubricant viscosity [mm2/s]
dm: average roller bearing diameter [mm]
P1: Reference load [N]
Q: Total dissipated heat flows [kW]

Chapter
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Roller Bearings (Traditional Analysis)

27

27.4

Moment of friction

In a roller bearing, the heat development, and therefore the operating temperature,
is caused by the friction between individual components. The moment of friction in
the roller bearing is indicated by several distinct losses due to resistance during
operation. Select this calculation method under Calculation > Settings.
You can only perform this calculation by clicking the "Modified rating life
according to ISO 281" option (Basic data/Strength tab).

27.4.1

Calculation according to SKF Catalog 2004

As this calculation has to take into consideration a myriad of factors and

influences, it is only performed if selected as an option in the extended service life
calculation. However, this calculation can also be performed without these default
values. The calculation of the total moment of friction according to the 2004 SKF
catalog is determined by a combination of rolling and sliding friction in the roller
contacts (between rolling bodies and cage, the bearing surface, the lubricant, and
the sliding friction from grinding seals caused in sealed bearings). The calculation
of the moment of friction depends on various coefficients:
Rating
Type of bearing
Bearing size
Operating speed
Lubricant properties
Lubricant quantities
Seals
The following working conditions must be present for the calculation to be
performed:
Grease or oil lubrication (oil bath, oil mist, or oil injection process)
Load equal or greater than minimum load
Load constant in size and direction
Nominal operating clearance

Chapter
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Roller Bearings (Traditional Analysis)

27

If the rating is less than the minimum load, the calculation continues using the
minimum load. If a minimum load value has been entered in the database, this value is used. If not, the software will determine this value. In the case of radial
bearings, the minimum load is converted into a minimum radial force. In thrust
bearings, the minimum axial force is defined by the software. The value for the
minimum load is not used here.
The formula for the total moment of friction is:
M = ish*rs*Mrr + Msl + Mseal + Mdrag
ish: Lubricant film thickness factor
In a lubricant flow, the lubricant is exposed to shear forces caused by the movement of the rolling body. This produces heat and therefore reduces the rolling moment of friction.
rs: Lubricant displacement factor
The constant rolling action squeezes excess lubricant away from the contact zone
of the rolling body. This reduces the thickness of the lubrication film and therefore
reduces the rolling moment of friction.
Mrr: Rolling moment of friction
The rolling moment of friction depends on the type of bearing, the average diameter, the radial and axial loading, the rotation speed, and the viscosity of the
lubrication. The design coefficients required to calculate the rolling moment of
friction are defined using the rolling bearing's series. The design coefficients and
coefficients used in the calculation are taken from the SKF Catalog 2004.
Assumptions have been made for those bearing types and bearing series for which
no design coefficients were defined in the catalog, so that the moment of friction
can still be calculated despite this.
Msl: Sliding moment of friction
The sliding moment of friction depends on the type of bearing, the average diameter, the radial and axial loading, and the viscosity of the lubrication. The design
coefficients required to calculate the sliding moment of friction are defined using
the rolling bearing's series. You will find the factors used for this calculation in the
SKF 2004 catalog.
Mseal: Moment of friction for grinding seals
The moment of friction for grinding seals depends on the bearing type, the bearing
size, the diameter of the seal-lip mating surface, and the layout of the seal. As the
type of seal, the diameter of the seal-lip mating surface, and the seal layout, differ
from one manufacturer to another, it is difficult to define a generally applicable
moment of friction.
Under Calculation/Settings there are different options for determining
this reference size:

Chapter
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Roller Bearings (Traditional Analysis)

27

According to SKF main catalog 6000 EN: 2005

You will find values for the seal types used in your bearings in the SKF catalog, which is integrated in the KISSsoft software. If the KISSsoft system finds
a familiar seal label in the bearing label, it calculates the moment of friction for
grinding seals using the coefficients listed in the catalog. Otherwise it is set to
zero.
Example of a seal label in the name of a rolling bearing:
SKF: 623-2RS: this means that the bearing has a RS1 type seal on both sides. The KISSsoft system then searches for names containing "-2RS1". If this
label is present, the coefficients from the SKF catalog are applied and the moment of friction for grinding seals is calculated.
In KISSsoft, the diameter of the mating surface is calculated with:
ds = d + (D - d) * 0.2
according to ISO/TR 13593:1999 Viton Mseal this diameter is calculated with
the formula: Mseal = 3,736*10^-3*dsh; Mseal in Nm, dsh Shaft diameter in mm
according to ISO/TR 13593:1999 Buna N Mseal this diameter is calculated
with the formula: Mseal = 2,429*10^-3*dsh; Mseal in Nm, dsh Shaft diameter in
mm
Mdrag: Moment of friction caused by lubrication losses
This moment of friction is caused by flow, splash, or injection losses during oil
bath lubrication. To calculate this torque, you must also input the oil level depth
(hOil), which you can specify in Calculation > Settings. You will find a
more detailed description of this entry in the Oil level and Lubrication type (see
page III-801) section. The design coefficients KZ and KL for rolling bearings with
a cage are also applied to toroidal rolling bearings (CARB).

27.4.2

Calculation in accordance with SKF Catalog

1994

The prerequisite for calculating the moment of friction is that the bearing rotating
surfaces must be separated by a film of lubrication. The total bearing moment of
friction results from the sum:

(27.1)

M0: load-independent moment of friction

M0 is determined by the hydrodynamic losses in the lubricant. It is especially high
in quickly rotating, lightly loaded bearings. The value M0 depends upon the
quantity and viscosity of the lubricant, as well as the rolling speed.

Chapter
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Roller Bearings (Traditional Analysis)

27

M1: load-dependent moment of friction

M1 is limited by the elastic deformation and partial sliding in the surfaces in contact, especially due to slowly rotating, heavily loaded bearings. The value M1
depends on the bearing type (bearing-dependent exponents for the calculation), the
decisive load for the moment of friction and the mean bearing diameter.
For axially loaded cylindrical roller bearings, an additional axial load-dependent
moment of friction, M2, is added to the formula:

(27.2)

M2: axial load-dependent moment of friction

M2 depends on a coefficient for cylindrical roller bearings, the axial loading, and
the bearing's average diameter.
Coefficients f0, f1 (see page III-788) and P1 (values that depend on the bearing
type and bearing load) used for the calculation have been taken from DIN 732. The
formulae, exponents and coefficients are taken from the SKF Catalog, 1994 Edition.

Chapter
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27

27.5

Maximum Speeds

Roller bearings are reliable and can be expected to reach their calculated service
life as long as the maximum speed (speed limit) is not exceeded. This depends on
the type, size and lubrication.
A warning message appears if the maximum permissible speed is exceeded.
Depending on the lubrication type, the actually permitted maximum speed can be
much lower. For more details, see the "Thermal admissible operating speed"
section 27.3.

Chapter
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Roller Bearings (Traditional Analysis)

27

27.6

Service life

The nominal service life is calculated using the formulae given in ISO 281 and
corresponds to the formulae that can also be found in the manufacturers' catalogs.
Usually the service life is calculated at 90% (10% probability of failure, see also
section 27.7) in hours. The label used here is L10h (h: hours; 10: probability of
failure).

27.6.1

Extended service life calculation in accordance

with Supplement to DIN ISO 281 (2007)

ISO 281 contains the regulations for "modified service life" which take into
account the influence of loads, lubricant conditions, materials specifications, type,
material internal stresses and environmental factors.

Figure 27.3: Dialog for extended service life calculation

The service life coefficient aISO can be defined as follows:

(27.3)

aISO:

service life coefficient from diagram [-]

ec :

impurity characteristic value [-]

Cu :

fatigue load limit [N]

P:

dynamic equivalent load [N]

viscosity ratio = nu/nu1

nu1:

reference viscosity diagram [mm2/2]

Chapter
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Roller Bearings (Traditional Analysis)

27

VT diagram for the lubricant [mm2/2]

nu:

The fatigue load limit Cu is specified by the bearing manufacturer. If none of these
values are known, you can calculate them with the approximate formula as defined
in ISO 281.
The impurity characteristic value ec (between 0 and 1) is taken directly from the
degree of cleanliness.

27.6.2

Service life calculation with load spectra

Figure 27.4: Dialog for selecting the load spectrum

The load spectrum on the bearing has these values:

k

number of bins in the load spectrum

qi:

frequency (load spectrum bin i) (%)

ni:

speed (load spectrum bin i) (rpm)

Fri:

radial force (load spectrum bin i) (N)

Fai:

axial force (load spectrum bin i) (N)

You can take this load spectrum data from the shaft calculation, in which case you
may obtain different load spectra for radial and axial forces. Or alternatively you
can select a load spectrum from the database. For bearing forces, the important factor here is the torque factor (not the load factor) and a negative prefix operator will
only affect the axial force.

Chapter
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27

Ac hi e va bl e s er vic e l if e w it h sim pl e cal c ula ti o n ap pr oac h

You calculate the service life by defining an equivalent design load and the average
speed. You can then use the usual formulae to calculate the service life.

(27.4)

(27.5)

nm:

average speed

exponent in the service life formula (3.0 or 10/3)

Pi:

dynamic equivalent load (load spectrum element i)

Pm:

average dynamic equivalent load

Ac hi e va bl e s er vic e l if e w it h ex t e n d ed s er v ic e li fe cal c ula ti o n:

When the Extended service life calculation is used, the service life is calculated
separately for every equivalent load spectrum element. The result is then used to
determine the total service life:

(27.6)

Lhnai: service life (load spectrum element i) in the case of speed ni and
load Fri, Fai
Lhna:

Total service life

Chapter
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Roller Bearings (Traditional Analysis)

27

27.7

Failure probability

Normally, the failure probability is assumed to be 10%. This means there is a 90%
probability that the nominal service life will be achieved. In this case the
coefficient a1 is equal to 1.0. If the failure probability value has to be lower, this
coefficient must also be lower (at 1%, a1 = 0.21).
You define the failure probability in Calculation > Settings.

27.8

Bearings with radial and/or axial force

For every bearing, you can specify whether it is subject to a radial or axial force. If
the bearing is subject to axial force, you must also specify whether the force is applied in both directions (<>), in the direction of the Y-axis (- >) or in the opposite
direction (< -).

Chapter
III-799

Roller Bearings (Traditional Analysis)

27

27.9

Calculating axial forces on bearings in

face-to-face or back-to-back arrangements

Because of the inclination of the races in the bearing a radial load generates axial
reaction forces in taper roller bearings, high precision angular contact ball bearings
and angular contact ball bearings, this data must be taken into account when the
equivalent design load is analyzed.
Axial reaction forces are calculated in accordance with SKF (roller bearing catalog) which exactly match the values defined in FAG.
For bearings in an back-to-back arrangement, left bearing A, right bearing B, outer
axial force in A-B direction, the following data applies:
Condition

Formula

FrA,FrB

Radial force on bearing A, B

Y A,Y B

Y coefficient of bearing A, B

Fa

External axial force

FaA,FaB

Axial force on bearing A, B

Chapter
III-800

Roller Bearings (Traditional Analysis)

27

For all other cases, (face-to-face arrangement or axial force in the other direction)
simply reverse the formula.
These calculated pretension force values are displayed in the main window. If the
actual internal forces are higher, for example, due to the use of spring packages,
you can change the value manually.

Chapter
III-801

Roller Bearings (Traditional Analysis)

27

27.10

Oil level and Lubrication type

Input the oil level and the lubrication type under Calculation > Settings.
These entries are needed to define the moment of friction due to lubrication losses.
The value h is given in the shaft calculation and results in the following formula for
every bearing:

h0

Figure 27.4: Oil level in the bearing

Two different types of lubrication can be defined:

Oil bath lubrication
Oil injection lubrication
If you select the Oil injection lubrication option, the value determined
for oil bath lubrication is multiplied by 2 to give the lubricant loss.

Chapter
III-802

Roller Bearings (Traditional Analysis)

27

27.11

EHL lubricant film thickness and spin to

roll ratio.

The minimum EHL lubricant film thickness is calculated for rolling bearings with a
known internal geometry, using the methodology described in [96]. The Barus
equation is used to take into account the effect of pressure on viscosity, as
documented in the same reference document.
The spin to roll ratio of ball bearings is calculated based on the equations in [96].
The assumption of outer raceway control is used, meaning that no spin of the ball
is present on the outer raceway. It is known that this assumption is primarily valid
in the case of high speed lightly loaded bearings. Ball gyroscopic motions and cage
effects are not considered any further than that.

Chapter
III-803

Roller Bearings (Inner Geometry)

29

28

Roll er Beari ngs (Inner Geom etry)

Chapter 29
Roller Bearings (Inner Geometry)
In addition to the classic bearing calculation method (see 24 Roller Bearings (see
section "Roller bearing" on page III-778)) KISSsoft also provides a calculation
method that complies with ISO 16281. This method calculates the bearing loads
and the service life of the bearing based on its inner geometry.
This method is available either as an Embedded Feature in shaft calculation (see
20.1.11 Roller bearings (see section "Rolling bearings" on page III-721)) or as an
stand alone KISSsoft module. Unless otherwise specified, this chapter describes the
stand alone module because the majority of the functionalities and features are used
by both these two variants.
This module is designed to be used by bearing experts, or users who know the inner geometry of their bearings. It makes it possible to calculate the life of a
bearing, if you know the loading conditions. To start this module, go to the
KISSsoft modules tree and double-click on "Shafts and Bearings" > "ISO 16281".

Chapter
III-804

Roller Bearings (Inner Geometry)

29

28.1

Bearing data tab

Figure 29.1 Bearing data tab

28.1.1

File interface

The user can use this module to link to a shaft calculation file. This allows bearing
information to be transferred automatically from the shaft calculation file, without
having to reenter the data. The user must input the:
File name: name of the shaft calculation file (extension .W10), from which the
selected bearing data will be extracted
Element type: here the user selects whether the bearing is a roller bearing that
belongs to a shaft, or a connecting roller bearing
Shaft number: if the bearing belongs to a shaft, the user must input the shaft
number here. The program then runs through the shafts Elements tree from top
to bottom (see Figure 29.2)
Bearing number: number of the selected bearing, either on the corresponding
shaft or from the list of connecting elements. The program runs through the
shafts Elements tree from top to bottom (see Figure 29.2)
Data exchange: determines how data is exchanged between the shaft file and
this module. In each case, the geometry of the selected bearing is transferred
from the shaft file.

Bearing loads: the information transferred from the shaft file is the applied
force and torque of the bearing as well as the lubricating conditions

Bearing displacements: the information transferred from the shaft file is the
displacement and rotation of the inner ring of the bearing as well as the
lubricating conditions

Chapter
III-805

Roller Bearings (Inner Geometry)

29

Own input: only the geometry of the bearing is transferred. The user can
determine their own load and lubrication conditions
Example:
a shaft file whose Elements tree has the structure shown in Figure 29.2. To extract
the information for the bearing "Roller bearing 2" which belongs to "Shaft 1", the
correct selection would be:
Element type = Roller Bearing, Shaft number = 1, Bearing number = 2
In contrast, to extract the information for the bearing "Roller bearing 1" from the
list of connecting elements, the correct selection would be
Element type = Connecting Roller Bearing, Bearing number = 1

Figure29.2 Example of selecting the shaft and bearing number when linked to a shaft file.

Chapter
III-806

Roller Bearings (Inner Geometry)

29

28.1.2

Bearing data

This is where the geometry of the bearing is defined. You fill find more detailed
information about this in 24.2.3 Roller bearing inner geometry (see section
"Bearing calculation with inner geometry" on page III-785). In addition to the
geometry data, you can also specify the dynamic load number, if you know it. If
not, this number is calculated using the current geometry data as specified in ISO
281. If you require an extended service life (see 24.6.1 Enhanced bearing service
life (see section "Extended service life calculation in accordance with Supplement
to DIN ISO 281 (2007)" on page III-795)), input the fatigue load limit Cu. If Cu is
not known, it will also be calculated on the basis of ISO 281.
Note for the shaft calculation: In this module, the effect of surface hardness on
the static capacity can be taken into account by entering the Vickers hardness. You
will find the formulae for this in [92]. The hardness value of every bearing
calculated with their inner geometry is predefined as HV 660 for the shaft
calculation.

28.1.2.1
Custom rolle r pro file
The default roller profile used for roller bearings is the logarithmic profile as
defined in ISO 16281. However, a custom roller profile can be used instead if
required. Click on the plus sign next to the roller length input field and enter the
name of the file with the required roller profile function (Figure 29.3a). The definition and coordinate frame of this file are shown in Figure 29.3b). The expected
structure of this file is as follows:

-- this line is a comment

DATA
1

-0.45

0.000581256

-0.41

0.000390587

-0.37

0.000277616

-0.33

0.000200197

21

0.33

0.000200197

22

0.37

0.000277616

23

0.41

0.000390587

24

0.45

0.000581256

...
...

Chapter
III-807

Roller Bearings (Inner Geometry)

29

END
Notes:
Lines that start with "--" are comments and are ignored.
The profile function definition starts with the keyword DATA and ends with
the keyword END
Each line must contain three columns. The first column is the index and is included only as a reference for the user (its values have no effect). The second
column is the non-dimensional position x/Lwe, for which the profile is defined
in mm/mm. The values in this column should range between -0.5 and +0.5. The
third column is the non-dimensional profile f/Dw, in mm/mm. The values in
this column cannot exceed 0.5.
To save space, the data represented by "..." has been omitted

Figure29.3 (a) Definition of a custom roller profile file, (b) Coordinate frame for the definition
of the custom roller profile

28.1.2.2
Bearing ring deform ations
The inside/outer rings are usually assumed to be rigid (non-deformable). To take
ring deformations into account, click on the plus button next to the bearing type
definition (figure 29.4a). The expected structure for both files is as follows:

-- this line is a comment

DATA
0

0.00E+00

0.00E+00

5.00E-03

0.00E+00

6.96E-04

4.95E-03

16

0.00E+00

1.38E-03

4.81E-03

24

0.00E+00

2.03E-03

4.57E-03

...

Chapter
III-808

Roller Bearings (Inner Geometry)

29

...
41

328

0.00E+00

-2.65E-03

4.24E-03

42.336 0.00E+00

-2.03E-03

4.57E-03

43.344 0.00E+00

-1.38E-03

4.81E-03

44.352 0.00E+00

-6.96E-04

4.95E-03

45.360 0.00E+00

-1.23E-18

5.00E-03

END

Notes:
Lines that start with "--" are comments and are ignored.
The ring deformation definition starts with the keyword DATA and ends with
the keyword END
Each row must contain 5 columns. The first column is the index and is included only as a reference for the user (its values have no effect). The second column is the angle for which the deformation is specified. The next three columns are the x, y, and z components of the ring deformation, all defined in
mm.
To save space, the data represented by "..." has been omitted

Figure 29.4 (a) Definition of ring deformations, (b) Coordinate frame of this module (W051),
which defines the axial (x) and the radial directions (y, z). For the sake of clarity, the coordinate
frame of the shaft module (W010) is also displayed.

Note for the shaft calculation: Ring deformations can only be processed in
bearing calculation module W051, not in shaft calculation module W010.

Chapter
III-809

Roller Bearings (Inner Geometry)

29

28.2

Load tab

Figure29.5 Load tab

This tab is where the operating conditions of the bearing are defined.

28.2.1

Load

Four combinations of data can be entered here:

(A) Force-Tilting Moment
(B) Force-Tilting
(C) Displacement-Tilting Moment
(D) Displacement-Tilting
Speed: the speed of the inner ring relative to the outer ring. The outer ring is
always assumed to be fixed (non-rotating).
Oscillation angle: the oscillation angle for partially rotating bearings. The lifetime
in million oscillations is determined in accordance with [39].
Note for the shaft calculation: The default setting for the shaft calculation process is combination D.
Note: A complete oscillation measures

28.2.2

2 s

Enhanced service life calculation in accorda nce with ISO 281

The influence of lubrication, filtration and impurities on the service life can be
taken into account here.

Chapter
III-810

Roller Bearings (Inner Geometry)

29

Lubricant: the lubricant used

Operating temperature: the temperature of the lubricant
Impurity: the class of the impurity

Chapter
III-811

Roller Bearings (Inner Geometry)

29

28.3

Graphics

28.3.1

Load distribution

This shows the load distribution over the rolling bearings (balls/rollers). For axial
bearings, the magnitude of the reaction force is used for the plot.

Figure 29.6 Load distribution

28.3.2

Pressure curve

This shows how the pressure develops along the length of each roller, or at every
contact point in a ball bearing.

Chapter
III-812

Roller Bearings (Inner Geometry)

29

Figure29.7 Pressure curve in a (a) roller bearing, (b) ball bearing

Chapter
III-813

Roller Bearings (Inner Geometry)

29

28.3.3

Stiffness curve

This shows the force-displacement curve of the bearing. Both radial and axial
stiffness are shown.

Figure29.8 Stiffness curve

Chapter
III-814

Roller Bearings (Inner Geometry)

29

28.3.4

Pressure curve for each rolling body

This graphic shows the pressure curve on each roller element along the roller profile.

Figure29.9 Pressure curve along the rolling body

Chapter
III-815

Hydrodynamic plain radial bearing

29

29

Hydrodyn amic pl ain rad ial bear ing

Chapter 29
Hydrodynamic plain radial bearing
Niemann [64] provides a very accurate method for calculating plain radial bearings
that can run at high speeds. This also produces excellent results for oval-clearance
or pivoted-pad plain bearings.
ISO 7902 [33] provides a good, detailed method for calculating stationary,
hydrodynamic plain radial bearings that are to run at low and average speeds.

Chapter
III-816

Hydrodynamic plain radial bearing

29

29.1

Calculation methods

Figure 29.1: Basic data: Plain radial bearings

You can use one of these two methods to calculate oil-lubricated, hydrodynamic
plain radial bearings:
a) In accordance with G. Niemann, Maschinenelemente I, 1981, [64].
This method is very suitable for quickly rotating bearings. This also
produces excellent results for special construction types such as pivotedpad bearings or oval-clearance plain bearings.
This method calculates the power loss, oil flow, oil temperature and minimum lubricant gap thickness in accordance with [64] and [57]. This
calculation can only be used for pressure lubricated bearings (circulatory
lubrication) when the service reliability is also tested.
b) In accordance with DIN 31652, Parts 1 to 3, 1983, [33].
This method is very suitable for slowly rotating bearings. It also
determines the oil consumption, oil flow, and the entire heat balance.
Calculation in accordance with DIN 31652, Parts 1 to 3 (1983 edition) for
pressure-less and pressure lubricated bearings. This takes into account the
way in which lubricant is applied (lubrication holes, lubrication groove,
lubrication glands). It calculates all the operating data in accordance with
DIN 31652, including the operating temperature, minimum lubrication gap
width, power loss, oil flow etc. It also checks service reliability.

Chapter
III-817

Hydrodynamic plain radial bearing

29

29.2

Module-specific inputs

Calculating the volume-specific heat of the lubricant

The volume-specific heat of lubricants can be calculated in two ways:
Take into account dependence on temperature
Simplified assumption (as in ISO 7902): 1.8 . 106J/(m3K)

Figure 29.2: Module-specific settings

Chapter
III-818

Hydrodynamic plain radial bearing

29

29.3

Thermal expansion coefficients

To calculate the clearance, you require the thermal expansion coefficients of the
shaft and (wheel or pinion) center.
These are the coefficients for the most important materials:
Steel

11.5 . 10-6

Cast iron

11 . 10-6

White metal

18 . 10-6

Composite bronze

18 . 10-6

Chapter
III-819

Hydrodynamic plain radial bearing

29

29.4

Average surface pressure

You will find the permitted values in:

Niemann, Volume I, Table 15/1, [64]
DIN 7902, Part 3, Table 2, [33]
Permitted maximum values for surface pressure:
White metal bearing: 1 to 3 N/mm2
Bronze: 1 to 8 N/mm2

29.5

Lubrication arrangement

Figure 29.3: Selecting the lubrication arrangement

Chapter
III-820

Hydrodynamic plain radial bearing

29

The different lubrication arrangements are shown in the next three Figures 29.4,
29.5 and 29.6.

Figure 29.4:
1: One lubrication hole opposite to load direction.
2: One lubrication hole positioned at 90 to the load direction.
3: Two lubrication holes positioned at 90 to the load direction.

Chapter
III-821

Hydrodynamic plain radial bearing

29

Figure 29.5:
4: Lubrication groove (ring groove).
5: Lubrication groove (circumferential groove).
Note: For lubrication with a circular groove, the calculation is performed for each bearing half
with half the load! (see ISO 7902, Part 1, paragraph 3.4 [33]).

Chapter
III-822

Hydrodynamic plain radial bearing

29

Figure 29.6:
6: One lubrication pocket opposite to load direction.
7: One lubrication pocket positioned at 90 to the load direction.
8: Two lubrication pockets positioned at 90 to the load direction.

Chapter
III-823

Hydrodynamic plain radial bearing

29

29.6

Heat transfer surface

If the values of the heat transfer surface are not known, you can take 10 * d * b to
20 * d * b as a guide value.
d : Bearing diameter
b : Bearing width

29.7

Heat transfer coefficient

If the value of the heat transfer coefficient is not known, you can take 15 to 20
(W/m2K) as a guide value.

29.8

Oil temperatures

Oil exit temperature:

Normally approximately 60
Upper limit for usual mineral oils: 70 to 90
Oil entry temperature:
With the usual cooler: 10C lower than the output temperature
With a very efficient cooler: 20C lower than the output temperature

29.9

Sizing the bearing clearance

Bearing clearance = d_bore - d_shaft

In general, a greater bearing clearance makes the bearing more stable and allows it
to cool more effectively, however it also results in a reduction in load capacity.
Suggestion according to Niemann
Suggestion for metal bearings in mechanical engineering according to Niemann, Volume I, Table. 15/2, [64].
The following applies for other materials:
Cast iron bearing

: 0.001 * d

Light metal bearing

: 0.0013 * d

Sintered bearing

: 0.0015 * d

Plastic bearing

: 0.003 * d

d : Bearing diameter

Chapter
III-824

Hydrodynamic plain radial bearing

29

Proposal according to ISO 7902

Proposal for metal bearings in mechanical engineering according to ISO
7902, Part 3, Table 4, [33].
In this sizing method you can either use the proposal according to ISO 7902, or
calculate the clearance from a predefined output temperature (only where the
lubricant is used to dissipate the heat).
Proposal according to K. Spiegel
Proposal for clearance according to K. Spiegel: Goettner equation
clearance: (2.5+50.0/d)/1000.0*d

29.10

Sommerfeld number

You must calculate the Sommerfeld number because it is an important

characteristic value for sliding bearings.
Sommerfeld number > 1 occurs in heavily loaded bearings at the
limit for b/d: 0 < b/d 2
Sommerfeld number < 1 occurs in quickly rotating bearings at the
limit for b/d: 0.5 < d/b 2
d : Bearing diameter
b : Bearing width

29.11

Bearing width

Reference value for bearing width as defined in Niemann, Volume I, table. 15/1,
[64]
Normal range: b/d = 1 to 2
Reference value for bearing width according to ISO 7902, [33]
Normal range: b/d = 0.125 to 1
d : Bearing diameter
b : Bearing width

Chapter
III-825

Hydrodynamic plain radial bearing

29

29.12

Permissible thickness of lubric ation film

The suggested value is taken from DIN 31652, Part 3, Table 1, [33].
The values in this table are all empirical values. They therefore assume an average
roughness height of < 4, low levels of form error, and that the lubricant is to be
filtered appropriately.

Chapter
III-826

Hydrodynamic plain thrust bearing

30

30

Hydrodyn amic pl ain thrust b earin g

Chapter 30
Hydrodynamic plain thrust bearing
The DIN standard provides two methods for calculating hydrodynamic plain thrust
bearings, according to type.
Calculation of pad thrust bearings in accordance with DIN 31653 [34]: This
standard applies to bearings that have fixed sunken surfaces for lubrication (see
Figure 30.2) which are separated from the rotating discs by a film of lubricant.
Calculation of tilting-pad thrust bearings in accordance with DIN 31654 [35]:
This standard applies to bearings that have movable tilting pads (see Figure
30.3) which are also separated from the rotating discs by a film of lubricant.
If you do not consider the influence of the center of pressure on the tilting-pad
thrust bearings, the same calculation procedure is described in both standards,
which is why it is described here only once. However, any significant variations to
these two standards will get a special mention here.

Figure 30.1: Basic data: Plain thrust bearing

Chapter
III-827

Hydrodynamic plain thrust bearing

30

Figure 30.2: Pad thrust bearings as described in DIN 31653

Chapter
III-828

Hydrodynamic plain thrust bearing

30

Figure 30.3: Tilting-pad thrust bearings as described in DIN 31654

Chapter
III-829

Hydrodynamic plain thrust bearing

30

30.1

Calculation

Essentially, both calculation procedures are based on the equation used to ascertain
the thermal balance in the bearing. You can use either convection or circulatory
lubrication in this calculation.
Non pressure lubricated bearings (self-lubricating) dissipate heat out to the surrounding environment by convection. The coefficient of thermal expansion factor kA, in accordance with the standard, lies between 15 . . . 20 W/(m2*K). In
the program the default value is 20 W/(m2*K), but you can change this as required.
Pressure lubricated bearings mainly dissipate heat through the lubricant. Here
you need to define a mixture factor M which must lie between 0. . . 1. Experience shows that this usually lies between 0.4 and 0.6. The default setting is
0.5, but this can be changed.

Figure 30.4: Segment lubricant and heat levels

These calculations provide values for the friction power, lowest thickness of
lubrication film, and operating temperature. For circulatory lubrication they also
calculate the lubricant flow rate.
The bearing force (in standstill) is only used to determine the lowest admissible
thickness of lubrication film, and is otherwise irrelevant. The value of the load
coefficient, the friction coefficient, and the lubricant flow rates, are calculated in
accordance with the formulas stated in DIN 31653/31654 Part 2 (and not in
accordance with the diagram or table). For tilting-pad thrust bearings, the ratio
hmin/Cwed is calculated from the support position of the tilting-pad aF*. For a
tilting-pad thrust bearing, the hmin/Cwed ratio is calculated from the supporting
area of the tilting pad aF*. The formula for this is given in DIN 31654 Part 2.

Chapter
III-830

Hydrodynamic plain thrust bearing

30

30.2

Sizings

You can also calculate the bearing force (nominal load), but before you can do this,
you must enter all the other input values. The bearing force is then calculated using
the value you specified for the lowest thickness of lubrication film, hlim.
The lowest thickness of lubrication film hlim can be calculated in accordance with
DIN 31653 or 31654. This lowest possible thickness of lubrication film is
calculated depending on sliding velocity, average diameter and loading, according
to the formula.
For convection:
If you do not know the value for the heat transfer surface, you can use a formula
for approximating it, as defined in the standard:
A = (15 to 20) * B * L * Z
Click the
button next to the input of the surface value to calculate this value
using the formula A = 15 *B *L*Z.
For circulatory lubrication:
Experience shows that the exit temperature is between 10 and 30 K higher than the
entry temperature. Click the
button next to the Exit temperature to calculate a
default value with a 10 K temperature difference.

Chapter
III-831

Hydrodynamic plain thrust bearing

30

30.3

Calculation of volume-specific heat

In Calculations/Settings there are two methods you can use to calculate

volume-specific heat:
Take into account dependence on temperature
Simplified assumption (as in ISO 7902): 1.8 * 106J/(m3 * K)

Figure 30.5: Module-specific settings

Chapter
III-832

Hydrodynamic plain thrust bearing

30

30.4

Limiting values in the calculation

The standards only apply to laminar flow in the lubrication gap. For this to happen,
the Reynold number must lie below the critical value of 600.
These results are also checked for highest permissible bearing temperature, Tlim,
the lowest possible thickness of lubrication film, hlim, and the specific bearing
load. These limiting values are defined in Part 3 of the 31653/ 31654 standard.

Chapter
III-833

Answers to Frequently Asked Questions

31

31

Answers to Fr eque ntly Aske d Ques tio ns

Chapter 31
Answers to Frequently Asked
Questions

Chapter
III-834

Answers to Frequently Asked Questions

31

31.1

Intersecting notch effects

If at all possible, notch effects - for example in a shoulder with an interference fit should not be overlapped when the shaft is designed. However, if this does happen,
in the worst case scenario, the FKM Guideline should be applied to calculate the
overall notch effect coefficient Kf:

from part notch effect coefficients Kf1 and Kf2. In KISSsoft, this situation can be
resolved by selecting Own Input for the Notch effect (see page III-763) of a free
cross section (see page III-715).
The overall notch effect coefficient can then be calculated as follows:
1. Two cross sections (for example, A-A and B-B) are defined with the same
Y-coordinate.
2. Cross section A-A is calculated by selecting notch type (for example,
shoulder) Kf1. The notch factors are displayed directly in the Elements editor (see page III-691).
3. This procedure described in 2. is then repeated for cross section B-B.
4. The resulting notch factors for both these notches are noted down and the
notch factors Kf are calculated in accordance with the formula given above.
5. Now both cross sections (A-A and B-B) are deleted and a new free cross
section C-C with the same Y-coordinate is added. In the Elements editor,
now select Own Input for the notch effect and the overall notch effect
coefficients calculated in 4. are displayed.

Chapter
III-835

Answers to Frequently Asked Questions

31

31.2

Notch effects on hollow shafts

All the notch factors described in the standards have been determined for solid
shafts. No data is available for hollow shafts. KISSsoft calculates the nominal
stresses for hollow shafts using the section modulus and taking into account the
inside diameter.

31.2.1

Notches on the outer contour

For "small" inside diameters, the error due to calculating notch effect values for
solid shafts is relatively small and you can use the results as approximations.
However, when "large" inside diameters are involved, you must correct the notch
effect values.
According to the FKM Guideline of 1998 you cannot accurately calculate the notch
effect values of a round shaft that has a longitudinal bore for bending and tension/compression using the notch effect values of a round solid shaft. You should use
the notch effect value of a round solid shaft for torsion and round shafts that have a
circumferential notch, shoulder. or conus, but use this value with nominal stress for
a round shaft that has a longitudinal bore.

31.2.2

Notches on the inner contour

You cannot use these calculation methods to determine the notch factors of notches
on the inner contour.

Chapter
III-836

Answers to Frequently Asked Questions

31

31.3

Fatigue Limits for New Materials

If you want to add a new material to the database, you must enter its endurance
limits as well as the yield point and tensile strength.
Hnchen gives

an approximation of the fatigue limit for bending as well as other approximations

from different sources. For the tension/compression fatigue limit, this states

, and for the torsion fatigue limit it states

According to DIN 743 the following approximations can be made:

For heat treatable steels the FKM guideline proposes the following (but for other
material types different values apply):

Chapter
III-837

Answers to Frequently Asked Questions

31

31.4

Taking double helical gearing into a ccount in the shaft calculation

In the shaft analysis process, when you input cylindrical gear data in "Hand of
gear" you can select continuous double helical teeth from the drop-down
list. A gear with this characteristic always has an axial force 0 N. When double
helical gears are transferred from the gear calculation (checkbox Read data
from file active) the total width (= left side + gap + right side) is also
transferred as is the total power. The shaft analysis then takes both the gap and the
effective toothing into account. This generally results in a very useful model.
If you require a more precise model, input the two halves of the gear individually,
one inclined to the right and the other inclined to the left. Unfortunately, you
cannot do this by transferring the data directly from the gear calculation.

IV Con nec tions

Part

IV

Connections

Chapter
IV-839

Cylindrical interference fit

32

32

Cylin drical i nter fere nce fi t

Chapter 32
Cylindrical interference fit
The calculation includes the entirety of the DIN 7190 standard (elastics) with
longitudinal, radial and oil interference fits.
Load in circumferential and axial directions.
Load with bending moment and radial force.
Calculating the maximum torque for a non-slipping fit. If slip occurs in the fit,
micro gliding will cause corrosion due to friction.
Influence of centrifugal force.
Verification of an elastic-plastic loaded interference fit as specified in DIN
7190 with predefined interference (stresses and elongations are calculated only
for the elastic case)
Analysis of hubs with multiple interference fits
Display stress curves (equivalent, tangential and radial stresses)
Display tolerance fields:

only take into account allowances

take into account temperature and centrifugal force (without pressure)

take into account temperature, centrifugal force and pressure

You can calculate the safety of the interference fit against sliding and the safety of
the shaft material and the hub against fracture and yielding. The calculation also
takes into account the effect of centrifugal force on the expansion of the
interference fit and on the stress in the shaft and hub. The tolerance system
specified in DIN 7151 (e.g. with diameter input 60 H7/f6) has been implemented to
make it easier to input data. You can either enter the tolerance manually, or use an
automatic option to calculate the tolerance pairing based on the required safety
against sliding and the permitted material stress. Input values for surface roughness
with qualities as defined in ISO 1302.
Calculating the pressure: For elastic materials according to the theory of
mechanics, for thick cylinders under internal pressure and thick cylinders under
external pressure (e.g. [60], page 399, or [64]).

Chapter
IV-840

Cylindrical interference fit

32

Figure 32.1: Basic data: cylindrical interference fit

Influence of speed: according to the theory of a cylinder in rotation ([38], page

219)
Amount of embedding: as defined in DIN 7190.
Equivalent stress:
you can change the hypothesis of equivalent stress under Calculations/Settings.
The Settings chapter provides more information about this function.
Bending moment and radial force: this takes into account the effect of a bending
moment and a radial force on the pressure. The additional amount of pressure is
calculated as follows:

(32.1)

To ensure no gaping occurs between the hub and the shaft, the additional pressure
must be less than the minimum interference pressure on the connection ((pb + pr) <
pmin).
Other values:

Chapter
IV-841

Cylindrical interference fit

32

Dismounting force

Specified in [64], page 363

Transmission without slip

Specified in [55], equations 2.93 to 2.110

Micro sliding: If the torque of an interference fit is increased continuously until it

exceeds the micro sliding limit, a local slip will occur at the position to which the
torque is applied. As torque decreases continuously in the interference fit, the slip
occurs only in one part of the fit, even if the torque then increases again. This effect
is called micro gliding (shaft moving back and forth in the hub) and can cause
friction rust. Further explanations and details about this calculation are given in
"Welle-Nabe-Verbindungen (Shaft-Hub Connections)", by Kollmann [55].
Comment about the calculation as defined by Kollmann:
To limit torque for micro sliding, use equation 2.110, with k use equation 2.107
and with r use equation 2.93.
Mounting: You will find details about mounting in the report. The temperature
difference for mounting is calculated in such a way that, even if the maximum
interference is reached (worst case scenario) there will still be enough play in the
joint. Define the mounting clearance under Settings. Here the values for
mounting the shaft at ambient temperature and for a cooled shaft (shaft at
approximately -150oC) are calculated.

Verification of an elastic-plastic loaded interference fit according to DIN 7190:

Prerequisites: EI = EA, nyI = nyA, n = 0, diI = 0
If all the prerequisites are fulfilled, as defined in DIN 7190, the plasticity diameter
DPA of the outer part that is to be mounted can be calculated (diameter at which
the plastic range ends). The corresponding compacting pressure, and the
relationship between the ring surface qpA and the overall cross-section qA, are also
calculated. (Experiential limit according to DIN 7190 for heavily loaded
interference fits in mechanical engineering qpA/qA <= 0.3)

Chapter
IV-842

Cylindrical interference fit

32

32.1

Inputting Tolerances

Tolerances in accordance with ISO/DIN:

To enter tolerances in the same way as, for example 60 H7/f6, you must:
Enter 60 (mm) as the joint diameter.
Enter H7 and f6 in the Tolerances fields. Here, the first field is where you
enter the value for the wheel or hub and the second is where you enter the value for the shaft.
The program checks automatically to see whether the tolerances you specified
actually exist and if you entered the data in the correct format!

De fi n e ow n to l era n ce s

Figure 32.2: Tolerance values

Click the
button next to the Tolerances field to display the current
allowances. You can then change them as required.

Chapter
IV-843

Cylindrical interference fit

32

32.2

Coefficients of friction

Tables 32.2 and 32.4 contain coefficient of friction values as defined in DIN 7190.
Materials

Coefficients of friction
dry

lubricated

ll

rl

ll

rl

E 335

0.11

0.08

0.08

0.07

GE 300

0.11

0.08

0.08

0.07

S 235JRG2

0.10

0.09

0.07

0.06

EN-GJL-250

0.12

0.11

0.06

0.05

EN-GJS-600-3

0.10

0.09

0.06

0.05

EN-AB-44000 and following

0.07

0.06

0.05

0.04

CB495K

0.07

0.06

TiAl6V4

0.05

ll: in axial direction - loosen

rl: lengthwise - sliding
Table 32.2: Coefficients of friction for longitudinal fits under continuous stress as defined in
DIN 7190

Material pairs, Lubrication, Joining

Coefficients of friction
r,rl,u

Steel-steel pairing:
Oil pressure connection normally joined with mineral oil

0.12

Oil pressure connection with degreased contact surfaces

0.18

joined with glycerin

Shrink fit normally after warming the

0.14

External component up to 300 C in electrical oven

Shrink fit with degreased contact surfaces after

0.20

heating in electrical ovens up to 300 C

Steel-cast iron pairing:
Oil pressure connection normally joined with mineral oil

0.10

Oil pressure connection with degreased contact surfaces

0.16

Steel-MgAl pairing, dry

0.10 to 0.15

Steel-CuZn pairing, dry

0.17 to 0.25

Chapter
IV-844

Cylindrical interference fit

32

r: Slipping
rl: lengthwise - sliding
u: in peripheral direction
Table 32.4: Coefficients of friction for radial interference fits in longitudinal and peripheral direction subjected to sliding as defined in DIN 7190

Chapter
IV-845

Cylindrical interference fit

32

32.3

Variable hub external diameter

Figure 32.3: Variable external diameter

For a stepped hub out diameter, a single equivalent diameter and length are
determined. These values are then used to calculate the stiffness of the external
component.

Chapter
IV-846

Cylindrical interference fit

32

32.4

Convert external pressure with multiple

interference fit

The effect of outside pressure on the first hub can be taken into account for a
multiple interference fit. This pressure is defined through a series of sequential
interference fits, as shown in the following figure, and is calculated by the software
(no direct user input).

Figure32.3 Multiple interference fit

The following notes apply to this calculation:
The first two elements are the original shaft and hub (the first two lines in the
table correspond to the first interference fit on the shaft), and are just shown in
the table for the sake of completeness. The only user-editable values are the external diameter tolerances of the hub.
The external diameter of each ring also serves as the inside diameter of the
next ring.
When a new ring is added the following default values are used:

External diameter = inside diameter + 50 mm

The Material and Roughness are those of the original hub

The operating temperature is the same as that for the hub

The tolerance class of the inner diameter is the same as the tolerance class
of the shaft (for example, s6)

The tolerance class of the external diameter is the same as the tolerance
class of the hub (for example, H7)
The pressure on the hub is calculated for the following three cases of tolerance values of all elements:
The average tolerance at each contact surface
The worst case, i.e. the maximum oversize at each contact surface
The best case, i.e. the minimum oversize at each contact surface

Chapter
IV-847

Cylindrical interference fit

32

32.5

Materials

Figure 32.4: Materials screen: Cylindrical interference fit

In the selection list, you can select materials in accordance with the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
IV-848

Cylindrical interference fit

32

32.6

Settings

Figure 32.5: Settings: cylindrical interference fit

Select equivalent stress

According to [64], with von Mises stresses:
v = max(|rr|,|rr|)
According to [55], page 13, with the shearing stress hypothesis:

Assembly temperature shaft/hub

The press-on force can be calculated from the assembly temperatures.
Coefficient of friction coefficient (press on)
Here you can define the ea ratio, i.e. the ratio of the coefficient of friction
for press on to the axial coefficient of friction. The default value is 1.3.
Only values for forcing off are given in DIN 7190. Niemann Volume I (1981
edition), Table 18/3 p. 363, also gives values for this press on.
Coefficient of friction coefficient (forcing off)
Here you can define the ea ratio, i.e. the ratio of the coefficient of friction
for forcing off to the axial coefficient of friction. The default value is 1.6.
Only values for forcing off are given in DIN 7190. Niemann Volume I (1981
edition), Table 18/3 p. 363, also gives values for this press on.

Chapter
IV-849

Cylindrical interference fit

32

Calculation of joining temperature

The mounting clearance can be input as either dependent on the diameter of
joint DF (modified for warming) or as a constant mounting clearance. The joining temperature of the external component is then calculated from this value.
You can also define the shaft temperature for joining. This temperature and
the mounting clearance are then used to calculate the joining temperature of the
hub. The joining temperature of the hub is only output in the report
if the shaft temperature during joining lies between -273 C and 20 C.
Calculate material strength with wall thickness as
raw diameter
If you set this flag, the strength of the hub material is calculated using the wall
thickness instead of the raw diameter.
Allow calculation of elastic-plastic loaded interference fits
If you set this flag, the calculation is also performed for elastic-plastic stress
(according to DIN 7190), otherwise, only elastic stress is included.
Required safeties
Under Settings you can input the required safeties against sliding, yield point
and fracture. These safety factors are then used to define the values you require
during sizing. The required safeties against plastic deformation are used to define the plasticity diameter that must be set when an interference fit is placed
under plastic-elastic stress.

Chapter
IV-850

Cylindrical interference fit

32

32.7

Sizings

Tolerance in accordance with ISO/DIN

Figure 32.6: Display of possible tolerance pairings

KISSsoft has a very convenient sizing function that you can use for suitable
tolerance pairs. Standardized tolerance pairs are stored in the M01-001.DAT file. Click the
button next to the Tolerances field in the main screen to start
the sizing process.
Based on the nominal required safety (which you can change in Settings),
you can determine all the tolerance pairs which fulfill the requirements
(sufficient safety against sliding, safety against fracture and yield point) and
display these pairs in a list.
Torque, axial force, diameter of joint, and length of interference fit
KISSsoft can size the maximum transmissible torque, the transmissible axial
force, the required length, and the diameter (according the required safety values you entered in Settings).

Chapter
IV-851

Conical interference fit

33

33

Con ical in terferenc e fit

Chapter 33
Conical interference fit
Calculating the service reliability of a conical interference fit. Defining the
mounting conditions.
The calculation methods are:
- Method as defined by Kollmann [55], Verification and sizing.
- Method as defined in E DIN 7190-2 (2013)

Figure 33.1: Basic data: Conical interference fit

Cone angle: The cone angle is the angle between the flank of the cone and its
axis. The opening angle of the cone is twice the size of the angle of taper.
Calculating the conical interference fit:
All known investigations focus on external and internal components made of
materials that have the same Young's modulus and internal components that do
not have any holes in the area of the cone. (Kollmann)
If you select the method described in E DIN 7190-2, and the shaft and hub are
made of different materials, the material with the higher Young's modulus
should be used for the shaft material.

Chapter
IV-852

Conical interference fit

33

Conical interference fits must always have a stop at the upper end. For this reason, the program only deals with this situation.
Conical interference fits are normally spanned (tightened) axially with a bolt.
You must check the joint carefully by measuring the displacement of the cone.
Just tightening with a torque wrench is not accurate enough. Conical interference fits are only joined by pressing them on in exceptional circumstances.
Adhesive coefficient in the case of slipping in the axial direction: Coefficients of
friction (for slipping in axial direction) after investigations by Galle (see Kollmann
[55], Table 2.20):
Material pairing

Previous

Coefficient for sticktion

Rating
Ck60/16MnCr5

0.299

42CrMo4/16MnCr5

0.269

31CrMoV9/31CrMoV9

0.247

Ck60/16MnCr5

0.407

42CrMo4/16MnCr5

0.297

31CrMoV9/16MnCr5

0.375

31CrMoV9/31CrMoV9

0.468

Ck60/16MnCr5

0.357

42CrMo4/16MnCr5

0.472

31CrMoV9/31CrMoV9

0.387

Load classifications:
-

none

Circumferential bending load

W Fatigue torsion load

No adhesive coefficients for other combinations of materials are available, so you
will have to estimate them.
Adhesive coefficients for radial interference fits in longitudinal and peripheral
direction subjected to sliding: Coefficients of friction as described in DIN 7190
[29], Table 4, see Cylindrical interference fit (see page IV-843) section.

Chapter
IV-853

Conical interference fit

33

33.1

Calculation

Sizing in accordance with Kollmann:

If you select this method, the maximum angular deviation max, the pressing distance for mounting af, and the joining force, can be sized using the required safeties
and the specified load and geometry.
Verification in accordance with Kollmann:
The transmittable torque is also calculated if no angular deviation, or maximum
angular deviation is present.
The safeties against the yield point and against sliding are also calculated in the
verification process.
The safeties defined by Kollmann include the required safeties, which can be
defined under Calculation/Settings.

As specified in E DIN 7190-2:

In this calculation method, the sliding moment, joining force, and axial force are
calculated for the state at which all the elements are already joined, from the input
torque, mounting without force and all the geometry data. The safety against
sliding is calculated in this way. If different external hub diameters or different inner shaft diameters are present these can also be defined as slices (max. 7). The
values are calculated for each individual slice and then added together. The maximum value is used for the pressure in the joint.

In the case of a central load application, the safety against sliding SR should have a
value of SRmin > 1.3.
Furthermore, if you have defined your own joining force at mounting pFA to
calculate the effective equivalent stresses, the maximum equivalent stress is then
compared with the yield point of that particular material in order to define the
safety. The maximum equivalent stresses appear every time for the inner diameter
of the hub or shaft when a hollow shaft is being used.

Safety against the yield point SP (plastic flow) should have a value of SPmin > 1.3 to
ensure that the elements are not affected by plastic deformation when they are
assembled and disassembled.

Chapter
IV-854

Conical interference fit

33

33.2

Application factor

You define the application factor here in the same way as in the cylindrical gear
calculation:
Operational
behavior

Operational behavior of the driven machine

equal-

moderate

medium

strong

Machine

moderate

shocks

shocks

shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

of the driving

Table 33.2 Application factor in calculations in accordance with DIN 6892. You will find more
detailed comments in DIN 3990, DIN 3991, ISO 6336.

Chapter
IV-855

Conical interference fit

33

33.3

Axial spanning with nut

Figure 33.2: Axial spanning of nut

Chapter
IV-856

Conical interference fit

33

Axial spanning (tightening the nut) produces relative axial displacements which are
applied to the individual parts. This causes lateral elongation and therefore
increases the compacting pressure on the active surface. The values required for
this calculation are shown in the diagram below.

Chapter
IV-857

Conical interference fit

33

33.4

Variable external diameter of the hub

Figure 33.3: Variable external diameter

In the case of a stepped outer diameter, a single equivalent diameter is determined

from the diameters and lengths. This value is then used to calculate the stiffness of
the outer part.

Chapter
IV-858

Conical interference fit

33

33.5

Conicity

Figure 33.5: Conicity

This additional input dialog gives two methods for defining the conus:
Conicity:
conicity is defined as follows:
x = l/(D0-D1). Here, x is the value that must be input.
Morse tapers:
Morse tapers are defined in DIN 228 and have a conicity of between 1:19.212
and 1:20.02.

Chapter
IV-859

Conical interference fit

33

33.6

Materials

Figure 33.6: Materials screen: Conical interference fit

In the selection list, you can select materials in accordance with the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
IV-860

Conical interference fit

33

33.7

Settings

Figure 33.7: Settings: Conical interference fit

If you selected Calculate material strength with wall

thickness as raw diameter, the strength of the hub material is calculated
using the wall thickness instead of the raw diameter.
If you select the Consider pressure at both diameters (Kollmann) flag, the pressure at both the large and small cone diameters is taken into
account, otherwise only the pressure at the largest diameter is used. However, this
only applies to the method described by Kollmann. In E DIN 7190-2 the average
diameter is used for the calculation.
Enter the required safety factor for slipping and yield point under Settings. These
safety factors are then used to define the values you require during sizing.
In the method defined by Kollmann, the default value set for required safety
against sliding is 1.0 and the default value for required safety against the yield
point is set to 2.0.
DIN 7190-2 recommends that safety against the yield point should be set to 1.2 to
ensure that the elements are not affected by plastic flow when they are
disassembled hydraulically.
In the case of a central load application, E DIN 7190-2 recommends a safety
against sliding of at least 1.2.

Chapter
IV-861

Conical interference fit

33

33.8

Sizings

KISSsoft can calculate the maximum transmissible torque, the permitted cone angle (for self-locking), and the length of interference fit, for transmitting the maximum torque.
The torque and the length of interference fit are sized using the defined required
safeties.
As specified in E DIN 7190-2 the sizings are calculated using the required safety
against sliding, apart from the joining pressure, which is sized using the required
safety against yield point.

Kapitel 34

IV-862

Clamped connections

34

Cla mped co nnec tio ns

Kapitel 34
Clamped connections
Clamped connections are only used to transfer low or medium torque (little
fluctuation).

Figure 34.1: Basic data: Clamped connections

There are two different configurations of clamped connections that can be

calculated:
Split hub
In the case of a split hub, it is assumed that pressure is distributed uniformly
across the whole joint. The pressure can be equal or cosine-shaped surface
pressure or linear contact.
Slotted hub
We recommend you use as narrow a fit as possible (hubs are also subject to
bending) to ensure that the pressure is mostly of a linear nature. The calculation
is performed for the least practical case of linear pressure.
Calculations of safety against sliding and surface pressure are described in
literature by Roloff Matek [62]. The calculation of bending is performed as
specified by Decker [86].

Kapitel 34

IV-863

Clamped connections

34.1

Calculations

Split hub:
Depending on the type of surface pressure, an additional factor for surface pressure
and safety against sliding is used to calculate a shared hub:
K = 1; uniform surface pressure
K= ^2/8; cosine-shaped surface pressure
K = /2 linear contact
In KISSsoft you can select the type you require from a selection list.
Formula for surface pressure:

Formula for safety against sliding:

Formula to calculate bending:

Slotted hub:
Formula for surface pressure:

Formula for safety against sliding:

Kapitel 34

IV-864

Clamped connections

Formula to calculate bending:

Description of codes:
pF: Surface pressure [N/mm2]
KA: Application factor
T: Nominal torque [N]
SH: Safety against sliding
K: Correction factor surface pressure
l: Joint width [mm]
D: Joint diameter [mm]
lS: Distance bolt to shaft center [mm]
l1: Distance normal force to center of rotation [mm]
l2: Distance from clamp force to center of rotation [mm]
Coefficient of friction
B: Bending stress [N/mm2]
Fkl: Clamp force per bolt [N]
i: Number of bolts
Wb: Moment of resistance [mm3]

34.2

Sizings

In these calculations you can size the torque, the clamp force per bolt, and the
number of bolts, to suit a predefined required safety value.

34.3

Settings

Kapitel 34

IV-865

Clamped connections

Figure 34.2: Settings Clamped connections

The required safety against sticking SSH is used to size the torque, the clamp force
per bolt, and the number of bolts.
If the hub material is gray cast iron, this coefficient times the tensile strength is
used to calculate the permitted pressure.
(pzul =pFact*Rm) (default value ~ 0.35 for an interference fit)
For all other materials, this coefficient times the yield point is used to calculate the
permitted pressure.
(pzul =pFact*Rp) (default value ~ 0.35 for an interference fit)

34.4

Materials

Figure 34.3: Materials Clamped connections

In the selection list, you can select materials in accordance with the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can define to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
IV-866

Key

35

35

Key

Chapter 35
Key
Keys are by far the most commonly used shaft-hub connections. In particular, they
help to transmit the torque. Their geometry has long been standardized in
accordance with DIN 6885 [26]. However, to ensure adequate safety levels are
achieved when transmitting torque, you always had to refer to secondary sources of
technical literature [64]. The DIN standard 6892 [27] documents the different
calculation methods that can be used for key connections.
You must perform two checks for keys:
1. Check the torque transmission by monitoring the surface pressure on the
shaft, hub, and key.
2. Check the fatigue limit of the shaft due to the notch effect caused by the
keyway. This effect is already described in DIN 743 [9]. We recommend
you use this standard to verify the shaft strength rather than DIN 6892.

Special features of calculations in accordance with DIN 6892:

Key connections are mostly used with light interference fits. The calculation
takes into account the decrease in torque on the key due to the interference fit.
The calculation proves the nominal torque as well as the actual pitch torque
over the entire operating period. The fatigue strength calculation based on the
nominal torque also includes the number of load changes, which experience
has shown to have a significant and damaging effect on the key.
The type of load has a considerable effect on the service reliability of keys.
This effect is taken into account by using a wide range of load distribution
coefficients.
The permissible pressure values are derived from the yield point. As a result,
you can derive this for common and more unusual materials in accordance with
the standard. The hardness influence coefficient is used to take the surface
treatment into account.

Chapter
IV-867

Key

35

Calculation Method B as defined in DIN 6892 recommends you use a

differentiated calculation to prove the service reliability of key connections. Method C has been greatly simplified.

Figure 35.1: Basic data: Key connection

Chapter
IV-868

Key

35

35.1

Main screen

For keys as defined in

DIN 6885.1 (ISO/R 773, VSM 15161) Standard
DIN 6885.1 Form G, H, J
DIN 6885.2
DIN 6885.3
ANSI B17.1 Square
ANSI B17.1 Rectangular
Own Input
you can calculate the load on shaft, hub and key (surface pressure) and the key
(shearing) to determine the safeties.
The following calculation methods are available: DIN 6892 B/C [27].
The calculation takes into account the tolerances of the key radii and the direction
of force. You can also enter your own value for the number of keys and the application factor.
Explanations for Figure 35.2:

Application or removal of torque

Start of key

Fu

Center of force application point on hub

Figure 35.2: Key: Load application.

Chapter
IV-869

Key

35

Supporting key length

The supporting key length is defined in accordance with DIN 6892:
Helical key form (A, E, C in accordance with DIN 6885) ltr = leff - b
Straight key form (B, D, F, G, H, J in accordance with DIN 6885)ltr = leff
leff
actual key length
ltr

supporting key length

key width

Frictional torque
Key connections are usually combined with a light interference fit. The calculation takes into account the decrease in torque on the key due to the interference fit. This effect is only relevant if you are performing the calculation as
defined in DIN 6892 B.
Frequency of load peak
To determine the safety regarding the maximum torque, you must enter the approximate number of load peaks. This effect is only relevant if you are performing the calculation as defined in DIN 6892 B.

35.1.1

Additional inputs for DIN 6892 Method B

If you select the calculation method specified in with DIN 6892 B, you can enter
the following data:
Chamfer on shaft
Chamfer on hub
Small hub external diameter D1
Large hub external diameter D2
Width c for external diameter D2
Distance a0 ( see Figure on page IV-868)
Torque curve: indication of whether this is alternating torque.
If alternating torque is present, you can also define the backwards torque here.
If this backwards torque is greater than the minimum effective frictional torque
(TmaxR > TRmin*q; q=0.8), the load direction changing factor fw is set to = 1.
If (TmaxR > TRmin*q and Tmax > TRmin*q; q=0.8), the maximum torque is therefore also greater than the minimum effective frictional torque. In this case, the

Chapter
IV-870

Key

35

frequency of the changes in load direction is taken into account when defining
the load direction changing factor (from diagram; fw<1)
To perform the calculation with the equivalent torsional moment, use factor q=0.5. The formula is the same as the one used for the maximum
torsional moment, therefore (TeqR > TRmin*q; q=0.5).
Frequency of the changes in load direction
In this situation you input the number of torque changes throughout the entire
service life (but only if alternating torque is present).

Chapter
IV-871

Key

35

35.2

Application factor

You define the application factor here in the same way as in the cylindrical gear
calculation:
Operational
behavior

Operational behavior of the driven machine

equal-

moderate

medium

strong

Machine

moderate

shocks

shocks

shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

of the driving

Table 35.2: Suggestions for the application factor in calculations in accordance with DIN 6892.
You will find more detailed comments in DIN 3990, DIN 3991 and ISO 6336.

Suggestions for the application factor from other sources: See tables 35.4 and 35.6.
Type of

characteristic

Type of

working

machine

Operational behavior

Shocks

Factor

Turbines, blowers

uniformly rotating
movements

slight

1.0 . . . 1.1

Internal combustion engine

reciprocating movements

medium

1.2 . . . 1.5

Presses, saw frames

reciprocating, impacting
movements

big

1.6 . . . 2.0

Hammers, stone crushers

impacting movements

very heavy

2.1 . . . 3.0

Table 35.4: Application factor in accordance with Roloff/Matek [61].

surfaces pressed
together

surfaces sliding
against each other
without load

surfaces sliding
against each other
under load

constant load

1.0

2.0

6.0

pulsating load
medium shocks

1.5

3.0

9.0

Chapter
IV-872

Key

35

alternating load
medium shocks

3.0

6.0

18.0

pulsating load
heavy shocks

2.0

4.0

12.0

alternating load
heavy shocks

6.0

8.0

36.0

Table 35.6: Application factor that takes into account the load behavior in accordance with Professor Spinnler [72].

Chapter
IV-873

Key

35

35.3

Load factor

Contact coefficient as defined in DIN 6892, [27]:

K=1/(i*)
=1

for one spring

= 0.75

for two springs to calculate the equivalent surface pressure

= 0.9

for two springs to the calculate the maximum surface pressure

more than two springs is unusual

KISSsoft calculates the contact coefficient on the basis of the number of springs.

Chapter
IV-874

Key

35

35.4

Own inputs

In the Own inputs option you can enter your own geometry data for keys, that
differs from the values given in DIN 6885.

NOTE

If you already know the upper and lower allowance, you must enter the mean value
for the chamfer and the two groove depths. The value for the peak incline a is only
to be defined for key forms G, H, and J, in accordance with the DIN 6885.1 standard.

Chapter
IV-875

Key

35

35.5

Permissible pressure

The permitted values are calculated on the basis of the yield point (or fracture in
the case of brittle materials).

Chapter
IV-876

Key

35

35.6

Materials

Figure 35.3: Materials dialog: Keys

In the selection list, you can select materials in accordance with the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
IV-877

Key

35

35.7

Settings

Figure 35.4: Settings: Key connection

Calculation method
Here you can select either DIN 6892 Method B or Method C. The default setting is method B, because Method C has been greatly simplified.
Take pressure on key into account
With this flag set the pressure on the key is taken into account when sizing the
permissible pressure by clicking the

button.

Calculate material strength with wall thickness as

raw diameter
When the strength values for the hub are being set, either the external diameter
(hub was turned from solid) or the wall thickness of the hub (hub was heat treated as a ring) is used.

Chapter
IV-878

Key

35

35.8

Sizings

During the sizing process, the required value is defined such that the required
safety factor (specified in Calculations/ Settings) is only just achieved.
To view the results in the lower part of the main window, you must perform the
calculation immediately after the sizing.
Possible sizings:
transmissible torque
necessary length of key way in shaft and hub
The "Keys" tutorial has been created specially to describe how you verify these
keys.

Chapter
IV-879

Spline shaft

36

36

Spli ne s haft

Chapter 36
Spline shaft
Spline shaft connections are often used for adjustable, form-closed shaft-hub connections. Main areas of use: Vehicle gear trains, machine tools.
KISSsoft calculates the load on the shaft and hub (surface pressure) for spline
shafts. The load placed on the shaft and hub (surface pressure), together with
determining the safeties, is calculated as described in classic technical literature
[64]). The calculation defined by Niemann forms the basis of DIN 6892 (key
calculation).

Figure 36.1: Basic data: Spline shafts

Chapter
IV-880

Spline shaft

36

36.1

Standard profiles

You can select one of these standards from the selection list:
DIN ISO 14 (light series)
DIN ISO 14 (medium series)
DIN 5464 (heavy, for vehicles)
DIN 5471 (for machine tools)
DIN 5472 (for machine tools)
Own Input
In a spline shaft connection, after you select a standard, the program displays the
corresponding external and inside diameters, and number of keys, along with their
width.
Own Input: select the Own Input option to define your own spline shaft profile.

Chapter
IV-881

Spline shaft

36

36.2

Application factor

The application factor is defined in the same way as in the key calculation:
Operational
behavior

Operational behavior of the driven machine

equal-

moderate

medium

strong

Machine

moderate

shocks

shocks

shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

of the driving

Table 36.2: Application factor in accordance with DIN 6892

Chapter
IV-882

Spline shaft

36

36.3

Torque curve/Frequency of change of load direction

When you select the torque curve you can choose one of two positions:
1. No alternating torque
2. With alternating torque
If you select item 2), the calculation not only defines the Frequency of change of
load direction, as defined in DIN 6892, Figure 6, but also the frequency of change
of load direction coefficient fw. In the case of item 1), the coefficient will be set to
1.0.

Chapter
IV-883

Spline shaft

36

36.4

Occurring flank pressure

This formula is used to calculate occurrences of flank pressure. The formula is used
both for the equivalent load and for the maximum load:
p(eq,max)=k(eq,max) * k1 * T * 2000/(dm * ltr * h * z)
k: Share factor

ltr: supporting length

k1: Length factor

h spline height

T Torque

z Number of keys

dm: average diameter

Chapter
IV-884

Spline shaft

36

36.5

Length factor

A length factor, k1, is multiplied by the loading that takes into account how the load
is distributed across the bearing length as a consequence of the torque action of the
shaft and hub. The length factor depends on the equivalent diameter derived from
the bearing length, the small and the large outside hub diameter, and the width c to
the external diameter. The distance a0 is also used to determine the length factor.
This coefficient is shown in a diagram in Niemann.

Figure 36.2: Spline shafts: Load application.

Chapter
IV-885

Spline shaft

36

36.6

Share factor

To calculate the occurring flank pressure, a share factor of k is taken into account.
This is then multiplied by the load. Interim sizes not shown in the table are
interpolated linearly.
Form-closure

spline connection with involute flank

connection

Tolerance zones in accordance with DIN 5480

H5/IT4

H7/IT7

H8/IT8

H9/IT9

H11/IT11

Maximum
value

keq

1.1

1.3

1.5

z/2

kmax

1.1

1.3

1.7

z/2

Table 36.4: Share factor in accordance with Niemann

Chapter
IV-886

Spline shaft

36

36.7

Permissible pressure

The permitted values are calculated on the basis of the yield point (or fracture in
the case of brittle materials). For continuous stress with Teq:
- for ductile materials:
peq=fs * fH * Rp
- for brittle materials:
peq=fs * Rm

Structur
al steel

Material

fs

Shaft

Structural steel, heat treatable steel, case-hardened steel, GJS, GS

1.2

GJL

1.0

Structural steel, heat treatable steel, case-hardened steel, GJS, GS

1.5

GJL

2.0

Hub

Table 24.6: Support factor as specified by Niemann

The support factor fs takes into account the support effect that appears in components subjected to a compression load.
The hardness influence coefficient, fH, is derived from the ratio of surface to core
strength for surface hardened components.
The hardness influence coefficient for case-hardened steel is 1.15, otherwise it is
1.0. The values used for this coefficient are defined in DIN 6892.
For calculation with peak torque:
pmax=fL * peq
fL is the frequency of load peak factor, which depends on the material type and the
frequency of load peak. This coefficient is shown in a diagram in DIN 6892.

Chapter
IV-887

Spline shaft

36

36.8

Materials

Figure 36.3: Materials screen: Spline shaft

In the selection list, you can select materials in accordance with the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
IV-888

Spline shaft

36

36.9

Settings

In Settings you can specify the required safety for the connection. The values that
are being searched for are defined on the basis of the required safety during sizing.

Figure 36.4: Settings: Spline shaft

If you selected Calculate material strength with wall

thickness as raw diameter, the strength of the hub material is calculated
using the wall thickness instead of the raw diameter.

Chapter
IV-889

Spline shaft

36

36.10

Sizings

During the sizing process, the required value is defined such that the required
safety factor (specified in Calculations/ Settings) is only just achieved.
To display the results in the lower part of the main window, you must perform the
calculation after the sizing. Possible sizings:
transmissible nominal torque Tn
transmissible maximum torque Tmax
supporting length ltr

Chapter
IV-890

Spline (strength)

37

37

Spli ne (str eng th)

Chapter 37
Spline (strength)
Splines are spur gear toothings that have a shortened tooth depth and a large
pressure angle (usually 30o). In KISSsoft, you can use one of two different
calculation modules to calculate splines. The geometry and tolerances required for
manufacture, and the strength calculation, are described in the Splines chapter
(Geometry and Strength) (Z09a (see page IV-902)) under Connections.
For splines, you must calculate the load on shaft and hub (surface pressure). You
can also add additional standards. Teeth data is defined in the database and
therefore you can make the use of in-house profiles mandatory. You can also use
the KISSsoft Spline (Geometry and Strength) module Z09a to calculate the manufacturing mass and the tolerances. The load placed on the shaft and hub (surface
pressure), together with determining the safeties, is calculated as described in classic technical literature [64]).

Figure 37.1: Basic data: Spline (strength)

Chapter
IV-891

Spline (strength)

37

37.1

Standard profiles

You can choose one of these standards from the selection list:
DIN 5480
DIN 5481
DIN 5482
ISO 4156
ANSI B92.1
ANSI B92.2M
Own input (tip diameter of shaft and hub, module, number of teeth, profile
shift coefficient)
For splines, the corresponding values are displayed in the list after the norm selection.
da1: Tip diameter of the shaft

z Number of teeth

da2: Tip diameter of the hub

x Profile shift coefficient

m Module

Chapter
IV-892

Spline (strength)

37

Own input: Select the Own Input option to enter your own data for the spline.
The critical factor here is that the tip diameter of the shaft is greater than the tip
diameter of the hub. If not, an error message is displayed.

Chapter
IV-893

Spline (strength)

37

37.2

Application factor

The application factor is defined in the same way as in the key calculation:
Operational
behavior

Operational behavior of the driven machine

equal-

moderate

medium

strong

Machine

moderate

shocks

shocks

shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

of the driving

Table 37.2: Application factor in accordance with DIN 6892

Chapter
IV-894

Spline (strength)

37

37.3

Torque curve/Frequency of change of load direction

When you select the torque curve you can choose one of two positions:
1. No alternating torque
2. With alternating torque
If you select item 2), the calculation not only defines the Frequency of change of
load direction, as defined in DIN 6892, Figure 6, but also the frequency of change
of load direction coefficient fw. In the case of item 1), the coefficient will be set to
1.0.

Chapter
IV-895

Spline (strength)

37

37.4

Occurring flank pressure

This formula is used to calculate occurrences of flank pressure. The formula is used
both for the equivalent load and for the maximum load:
p(eq,max)=k(eq,max) * k1 * T * 2000/(dm * ltr * h * z)
k: Share factor

ltr: supporting length

k1: Length factor

h spline height

T Torque

z Number of keys

dm: average diameter

Chapter
IV-896

Spline (strength)

37

37.5

Length factor

A length factor, k1, is multiplied by the loading that takes into account how the load
is distributed across the bearing length as a consequence of the torque action of the
shaft and hub. The length factor depends on the equivalent diameter derived from
the bearing length, the small and the large outside hub diameter, and the width c to
the external diameter. The distance a0 is also used to determine the length factor.
This factor is shown in a diagram in Niemann.

Figure 37.2: Splines: Load application.

Chapter
IV-897

Spline (strength)

37

37.6

Share factor

To calculate the occurring flank pressure, a share factor of k is taken into account.
This is then multiplied by the load. Interim sizes not shown in the table are
interpolated linearly.
Form-closure

spline connection with involute flank

connection

Tolerance zones in accordance with DIN 5480

H5/IT4

H7/IT7

H8/IT8

H9/IT9

H11/IT11

Maximum
value

keq

1.1

1.3

1.5

z/2

kmax

1.1

1.3

1.7

z/2

Table 37.4: Share factor in accordance with Niemann

Chapter
IV-898

Spline (strength)

37

37.7

Permissible pressure

The permitted values are calculated on the basis of the yield point (or fracture in
the case of brittle materials). For continuous stress with Teq:
- for ductile materials:
peq=fs * fH * Rp
- for brittle materials:
peq=fs * Rm

Structur
al steel

Material

fs

Shaft

Structural steel, heat treatable steel, case-hardened steel, GJS, GS

1.2

GJL

1.0

Structural steel, heat treatable steel, case-hardened steel, GJS, GS

1.5

GJL

2.0

Hub

Table 37.6: Support factor as specified by Niemann

The support factor fs takes into account the support effect that appears in components subjected to a compression load.
The hardness influence coefficient, fH, is derived from the ratio of surface to core
strength for surface hardened components.
The hardness influence coefficient for case-hardened steel is 1.15, otherwise it is
1.0. The values used for this coefficient are defined in DIN 6892.
For calculation with peak torque:
pmax=fL * peq
fL is the frequency of load peak factor, which depends on the material type and the
frequency of load peak. This coefficient is shown in a diagram in DIN 6892.

Chapter
IV-899

Spline (strength)

37

37.8

Materials

Figure 37.3: Materials screen: Spline

In the selection list, you can select materials in accordance with the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
IV-900

Spline (strength)

37

37.9

Settings

Figure 37.4 Settings for splines

In Settings you can specify the required safety for the connection. The values that
are being searched for are specified on the basis of the required safety during
sizing.
If you selected Calculate material strength with wall
thickness as raw diameter, the strength of the hub material is calculated
using the wall thickness instead of the raw diameter.

Chapter
IV-901

Spline (strength)

37

37.10

Sizings

During the sizing process, the required value is defined such that the required
safety factor (specified in Calculations/ Settings) is only just achieved.
To display the results in the lower part of the main window, you must perform the
calculation after the sizing.
Possible sizings:
transmissible nominal torque Tn
transmissible maximum torque Tmax
supporting length ltr

Chapter
IV-902

Spline (geometry and strength)

38

38

Spli ne (ge ome try a nd stre ngth)

Chapter 38
Spline (geometry and strength)
You can calculate the geometry and the control measures of splines and hub
according to DIN 5480 (1986 Edition), ISO 4156, ANSI B92.1 or ANSI B92.2M.
It also includes strength calculation according to Niemann or DIN 5466.
The geometry profiles according to DIN 5481 (2005) and according to DIN
5482(1973) are saved in files.
When you open the file for the profile you require, the KISSsoft screens are filled
with all the necessary geometry settings.

Chapter
IV-903

Spline (geometry and strength)

38

38.1

Underlying principles of calculation

38.1.1

General

Involute short cut teeth are often used for couplings. Teeth with large pressure
angles n = 30o are very common and, to increase strength, they have a tooth depth
that is half the size of normal cylindrical gears. Couplings with teeth as defined in
DIN 5480 are very widespread, and are precisely described with regard to
geometry and tolerance calculation. The strength calculation is performed in
accordance with the usual methods described in technical literature [5],[42].

NOTE

The moment of inertia is calculated as follows: the inside diameter of the shaft is di
= 0, and the hub external diameter is the rounded result of di = df + 4mn. The moment of inertia is then determined for the cylinder between di and (da + df)/2.

38.1.2

Calculation of spline connections as described

in DIN 5480 with diameter ce ntering

Diameter centered connections are centered in the outside or inside diameters. The
hub root diameter with the shaft tip diameter is used for outside centering, and the
pinion center root diameter and the hub tip diameter is used for inside centering.
Here, the gear toothing is only used for rotational synchronization. The connection
must therefore have sufficient flank clearance to prevent the centering intersecting.
Due to the small tolerances of the centering diameter, diameter-centered connections require more manufacturing effort to limit the central displacement. This is
why they are only used in exceptional circumstances.
To calculate diameter-centered connections:
1. In the Connections > Splines (Geometry and Strength)
calculation module, open the Reference profile input window by
clicking on its tab. Here, select the DIN5480 Major diameter fit
option in the Reference profile drop-down list in the Shaft and
Hub area.
2. Click the Tolerances tab to open the Tolerances input window. Check
that no flag has been set in the checkbox to the right of Tip diameter
deviation (upper/lower) and Root diameter deviation
(upper/lower) input fields, for Shaft or for Hub. The program then
prompts with values from the DIN 5480 recommendations. For the tip circle, the following apply:

Chapter
IV-904

Spline (geometry and strength)

38

for outside centering, H6 for the shaft tip diameter and H11 for the hub tip
diameter

for inside centering, h11 for the shaft tip diameter and H7 for the hub tip
diameter

For the root circle, the following apply:

for outside centering h14 for the shaft root diameter and H7 for the hub
root diameter

for inside centering, h6 for the shaft root diameter and H14 for the hub root
diameter

9H/9e is recommended for the tooth thickness allowance.

Chapter
IV-905

Spline (geometry and strength)

38

38.2

Basic data

Figure 38.1: Basic data input window in the Splines (Geometry and
Strength) module

38.2.1

Geometry standards

In the drop-down list in the upper left-hand part of the Geometry area, you see a
list of the available geometry standards. To view a specific standard, click the
button to the right of the drop-down list to open the Define profile view dialog window. The complete standard and preference sequences are also available for
most of the standards in this list. Use the database tool (see page I-124) to add
your own standards to the list or extend existing guidelines. For example, the preference sequence for DIN 5480 is stored in the M02C-001.dat file in the dat folder of your KISSsoft installation folder. Each line corresponds to an entry in the
Define profile list and uses the following syntax:
da1

da2

mn

i*

where
da1

Tip diameter, shaft

da2

Tip diameter, hub

mn

Normal module

Number of teeth

Chapter
IV-906

Spline (geometry and strength)

38

x*

Profile shift coefficient shaft

EXAMPLE:

Figure 38.2: Example entry in M02C- 001.dat

The marked entry in KISSedit (see Figure 38.2) stands for da1 = 5.5mm, da2 =
4.62mm, mn = 0.5mm, z = 10 and x* = 0.
NOTE

You can only edit the Normal module, Number of teeth, and Profile shift
coefficient, input fields if you have first selected Own Input in the drop-down
list for geometry standards.

38.2.2

Normal module

Enter the normal module. However, if you know the pitch, transverse module, or
diametral pitch, instead of this, click the
button to open a dialog window in
which you can perform the conversion. If you want to transfer the diametral pitch
instead of the normal module, you can select Input normal diametral
pitch instead of normal module by selecting Calculation >
Settings > General.

38.2.3

Pressure angle at normal section an

The normal pressure angle at the reference circle is also the flank angle of the reference profile. For splines the pressure angle is usually n = 30o.

Chapter
IV-907

Spline (geometry and strength)

38

38.2.4

Number of teeth

For internal toothed gears, you must enter the number of teeth as a negative value
as stated in DIN 3960. The shaft and the hub must have the same number of teeth,
but with different signs.

38.2.5

Profile shift coefficient

The tool can be adjusted during manufacture. The distance between the production
pitch circle and the tool reference line is called the profile shift. To create a positive
profile shift, the tool is pulled further out of the material, creating a tooth that is
thicker at the root and narrower at the tip. To create a negative profile shift the tool
is pushed further into the material, with the result that the tooth is narrower and
undercut may occur sooner. For pinion and gear factors:

Click the
button and KISSsoft will determine whether the profile shift
coefficient is to be taken from measured data or from values given in drawings.
The following options are available here:
Base tangent length
Here you must enter the base tangent length (span) and the number of teeth
spanned. This option cannot be used for (internal) helical gear teeth because
their base tangent length cannot be measured.
Measurement over two balls
To do this, enter this dimension and the diameter of the ball. In a gear with helical gear teeth and an odd number of teeth, the measurement over balls is not
the same as the measurement over two pins, see Measurement over pins.
Measurement over 2 pins
To do this, enter this dimension and the diameter of the pin. For helical gear
teeth and gears with an odd number of teeth, you must also enter a minimum
span. This measurement cannot be calculated in internal helical gear teeth.
Tip circle
This is a rather imprecise calculation because the tip circle does not always depend solely on the profile shift.
Tooth thickness at reference circle
Here, you specify the tooth thickness. You can also enter the arc length or
chordal length, and whether the value is in transverse or normal section.
NOTE

Chapter
IV-908

Spline (geometry and strength)

38

The profile shift coefficient of the shaft and hub must be the same value.

38.2.6

Quality

In this input field you specify the accuracy grade in accordance with the standard
shown in brackets. To change the standard used for this calculation, select
Calculation > Settings > General> Input of quality. The
accuracy grade specified in ISO 1328 is approximately the same quality as in DIN
3961 or BS 436/2.
Achievable qualities are shown in Table 38.1.
Manufacturing process

Quality according to DIN/ISO

Grinding

...

Shaving

...

Hobbing

(5)6

...

Milling

(5)6

...

Shaping

(5)6

...

Punching, Sintering

...

12

Table 38.1: Quality values for different manufacturing processes

Chapter
IV-909

Spline (geometry and strength)

38

38.2.7

Geometry details

Figure 38.3: Define details of geometry dialog window

To open the Define geometry details window, click the Details...

button in the upper right-hand part of the Geometry area. Here you can change the
values for:
Shaft and hub center drawing numbers
Shaft bore diameter d
Large hub outside diameter D

Chapter
IV-910

Spline (geometry and strength)

38

If you perform the calculation as defined in Niemann, you must also enter additional values. Depending on the position of the load, you can enter the value a0. If a
shouldered hub is present, you must also enter the small hub external diameter D
and the width of the center part c (with D). The following diagram shows how to
define these values:

Figure 38.4: Niemann parameter definition

38.2.8

Strength calculation method

You can calculate strength either as defined in Niemann [64] or in accordance with
DIN 5466. As DIN 5466 is still being developed, it is not described in any further
detail. To perform the calculation in accordance with DIN 5466 and Niemann, you
must make additional entries in the Define details of strength (see
page IV-912) dialog window.

38.2.9

Application factor

The application factor compensates for any uncertainties in loads and impacts,
whereby KA 1.0. Table 38.2 illustrates the values that can be used for this factor.
You will find more detailed comments in ISO 6336, DIN 3990 and DIN 3991.

Operational
behavior
of the driving

Operational behavior of the driven machine

equal-

moderate

medium

strong

Chapter
IV-911

Spline (geometry and strength)

38

Machine

moderate

shocks

shocks

shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

Table 38.2: Assignment of operational behavior to application factor

38.2.10 Resulting shearing force

Shearing forces vertical to the shaft axis cause flank contact on both sides of the
opposing side of the contact point. (DIN 5466)

Chapter
IV-912

Spline (geometry and strength)

38

38.2.11

Define details of strength

Click the Details... button in the Strength group to open the Define
details of strength window in which you can change the following parameters.

Figure 38.4: Define details of strength dialog window for calculation methods described in Niemann (left) and DIN 5466 (right)

Chapter
IV-913

Spline (geometry and strength)

38

The strength method as described in Niemann is described in more detail in the

Spline (see page IV-890) chapter.

38.2.11.1 Type of loading/F reque ncy of change of lo ad direction

If you open the Type of loading list, you can then select one of the two items
shown in it:

1. No alternating torque
2. With alternating torque
If you select item 2), the calculation not only defines the Frequency of
change of load direction NW, as defined in DIN 6892, Figure 6, but
also the frequency of change of load direction coefficient fw. In the case of item 1),
the coefficient will be set to 1.0. This data is only used for calculations as described
in Niemann.
peq=fw * pzul

Figure 38.5: Graphic as described in DIN 6892 Figure 6: Frequency of change of load direction

Chapter
IV-914

Spline (geometry and strength)

38

coefficient for reciprocal load

38.2.11.2 Number of load peak s

fL is the Load peak coefficient, which depends on the material type and the Number of load peaks NL. This coefficient is shown in a diagram in DIN 6892.
This value is needed for calculations as described in Niemann.

For calculation with peak torque:

pmax=fL * pzul

Figure 38.6: Graphic as described in Niemann (DIN 6892 Figure 7): Load peak coefficient

a: ductile material
b: brittle material

Chapter
IV-915

Spline (geometry and strength)

38

38.2.11.3 Stress rati o R

Stress ratios are the ratios between under and over stress with regard to a particular
type of load, such as torque. Here R = -1 and defines a pure alternating stress ratio,
R = 0 defines a pure pulsating stress ratio.

38.2.11.4 Width and circu mferen tial factor

Click on the checkbox to the right of the input field for one of these factors to enter
a value for that factor. Otherwise, this value is calculated automatically and may
vary within the range [3, 5]. As these are multiplied together to define the load
increase, you can achieve safeties of up to 20 times smaller than is possible with
the calculation method defined in Niemann.

38.2.12 Materials
The materials displayed in the drop-down lists are taken from the materials database. If you cannot find the material you require in this list, you can either select Own
Input from the list or enter the material in the database (see page I-124) first.
Click the
button to open the Material hub/shaft window in which you
can select your material from a list of materials that are available in the database.
Select the Own Input option to enter specific material properties. This option
corresponds to the Create a new entry window in the database tool.

Chapter
IV-916

Spline (geometry and strength)

38

38.3

Tolerances

Figure 38.5: Tolerances input window in the Splines calculation module

38.3.1

Tooth thickness tolerance

Select one of the options from the Thickness tolerance drop-down list.
The allowances for "Actual" (smax, smin, emax, emin) correspond to the individual measurements (base tangent length or measurement over pin measured on the
teeth). The deviations for "Effective" correspond to the measurement with templates (all teeth checked together). The gear tooth play of a spline connection is
therefore derived from the "Effective" deviations. The effective allowances include
not only the tooth thickness allowances of individual teeth but also a pitch and
form error component. The "Effective" allowances are therefore theoretical values,
and are smaller (the tooth is thicker) than for the "Actual" allowances.

NOTE

In accordance with the standard, the allowances for tooth thickness (smax, smin)
are predefined for the shaft. In contrast, for the hub, the allowances apply to the
tooth space (emax, emin).

If the tooth thickness tolerance has been set to your own specific value, you can
input svmax for the shaft ("Effective" maximum deviation) to calculate svmin
because the relationship applies in this case:
svmin smin = svmax smax

Chapter
IV-917

Spline (geometry and strength)

38

In addition, you can then use the flag to predefine the individual measurement
allowances for "Actual". However, if this flag is not set, the difference svmax
smax (pitch and form error component), and the tolerance interval smax-smin are
set according to the standard for the selected quality.

The same also applies to the hub.

38.3.1.1
DIN 5480
Unlike ISO 4156 or ANSI 92.1, DIN 5480 has the special feature that sveffmin =
svmax always applies to the shaft and eveffmax = svmin to the hub. For this reason, sveffmin and eveffmax are not displayed.

NOTE

The tolerance widths for template entries are larger because of Taylor's formula
[25].

38.3.1.2
ANSI 92.1 and ISO4156/ANSI 92.2M
If you have entered your own tooth thickness tolerance value, you
must take the following points into account:
You must enter the tooth thickness allowance sv for the Effective tooth
thickness for the overall measurement (caliber) to suit the tolerance system that you
are using to calculate cylindrical gears. The Actual tooth thickness s for single
measurements is defined using these equations.

(38.1)
(38.2)

These equations apply to the shaft tooth thickness or to the tooth space of the hub.

38.3.2

Effective/Actual

Click the
button to open the Convert total deviation of tooth
thickness Effective(Actual) for shaft window which uses the
corresponding screen to convert the Effective/Actual tooth thickness allowance

Chapter
IV-918

Spline (geometry and strength)

38

deviation. Here you can enter values either for the base tangent length, ball or roller
measurement or the tooth thickness. (see Figure)

Figure 38.6: Convert total Effective(Actual) deviation of

tooth thickness for shaft dialog window

38.3.3

Ball/pin diameter shaft/hub

The implemented DIN 5480, Part 1, contains an extract of the measuring roller
diameter as specified in DIN 3977 that must be used here. You can decide whether
to extend the list of available roller diameters in the Z0Rollen.dat file in the
dat directory in your KISSsoft installation folder.

Chapter
IV-919

Spline (geometry and strength)

38

38.4

Templates

Spline connections are often checked using templates.

Go gauges are always fully toothed (teeth all around the perimeter) and are used to
test the effective tolerance limit. For hubs this is the min. effective tooth space and
for shafts this is the max. effective tooth thickness.

No-go gauges are always toothed by sector (depending on the number of teeth of
the test piece, 2 to 7 teeth located opposite to each other) and are used to test the
actual tolerance limit. For hubs this is the max. actual tooth space and for shafts
this is the min. actual tooth thickness. The externally located flanks of each sector
are given sufficient clearance (flank relief, see 1 in the Figure), as they cannot be
measured exactly.

Figure 38.7: Displaying templates

The KISSsoft system can calculate all the gauge allowances specified in ISO 4156
and DIN 5480-15. To do this, select "Reports" and then "Construction of gauges".
The system does not automatically calculate the gauge dimensions for profiles that
comply with ANSI.
DIN 5480-15 is limited to the pressure angle of 30. The pressure angles 37.5 and
45 are defined in ISO 4156. DIN 5480-15 contains data for a module range of 0.5
to 10 mm and a maximum number of 100 teeth on the sample. No information is
provided in the report for sizes that exceed the data contained in DIN 5480-15.

Chapter
IV-920

Spline (geometry and strength)

38

According to DIN 5480-15, a calculated allowance coefficient AF1 should be

entered for the measuring pins, if the measuring pins do not exactly match the
specified dimension. Then the distance AF1 is calculated as a multiplication
coefficient on the mean value of the allowances of the two measuring pins,
enabling the tolerance for the distance over rollers to be determined. As this value
is not known, this calculation is not performed in KISSsoft.

Chapter
IV-921

Spline (geometry and strength)

38

38.5

Tooth form

If you want to generate the tooth forms of a splined joint, you can select the data
you require from the six different tolerance fields (actual, effective) and the three
different diameter tolerances displayed in the Tooth form tab.
The default settings here are the average allowances for tooth thickness and diameter. After the calculation has been performed, the resulting diameter and tooth
thickness are output in the tooth form report.
NOTE

To ensure the selected diameter tolerance is applied to the root diameter, set the
flag next to the root diameter allowance in the Reference profile tab. If
you do not set this flag, only the tooth thickness tolerance will be included in the
calculation of the root diameter.
If this flag is not set, the calculation uses a default tolerance for the root diameter
as defined in the standard. In other words, the diameter tolerance you selected will
not be used to calculate the root diameter.

Chapter
IV-922

Polygon

39

39

Polygon

Chapter 39
Polygon
You use polygon connections to create shaft-hub connections that can withstand
very heavy loads. In particular, the low notch effect present in this connection does
not reduce shaft strength.
For polygon shafts you must calculate the load on the shaft and hub (surface
pressure). You can also add additional standards.
You can use one of these two methods to calculate the load on the shaft and hub
(surface pressure) and to define the safeties:
Niemann, Volume I (4th Edition) [64].
DIN 32711-2 (P3G profile) [84]/ DIN 32712-2 (P4C profile) [85]

Figure 39.1: Basic data: Polygon

In the calculation in accordance with DIN, only the static load is observed. In the
method in accordance with Niemann, the influence of alternating torque can be
observed or
load peaks can also be calculated.

Chapter
IV-923

Polygon

39

39.1

Standard profiles

You can select one of these standards from the selection list:
DIN 32711-1 (P3G profile)
DIN 32712-1 (P4C profile)

In a P3G profile, which varies according to which standard you select, the list displays the diameter of mean circle, d1, the diameter of outer circle, d2, the diameter
of inner circle, d3, the eccentricity e and the factor y.
In a P4C profile, the diameter of outer circle d2, the diameter of inner circle, d3,
the eccentricity e, and the factor y, are displayed in the list.

Chapter
IV-924

Polygon

39

39.2

Application factor

The application factor is defined in the same way as in the key calculation:
Operational
behavior

Operational behavior of the driven machine

equal-

moderate

medium

strong

Machine

moderate

shocks

shocks

shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

of the driving

Table 39.2: Application factor in accordance with DIN 6892

Chapter
IV-925

Polygon

39

39.3

Torque curve/Frequency of change of load direction

This influence can only be made to apply using the Niemann calculation method.
When you select the torque curve you can choose one of two positions:
1. No alternating torque
2. With alternating torque
If you select item 2), the calculation not only defines the Frequency of change of
load direction, as defined in DIN 6892, Figure 6, but also the frequency of change
of load direction coefficient fw. In the case of item 1), the coefficient will be set to
1.0.

Chapter
IV-926

Polygon

39

39.4

Occurring flank pressure

Method in accordance with Niemann:

This formula is used to calculate occurrences of flank pressure. The formula is used
both for the equivalent load and for the maximum load:
Profile P3G:
p(eq,max)=T * 1000/(ltr * d1 * (0.75 * * e + 0.05 * d1))
Projection area = ltr * n * 2 * e; (n = 3)
d1: Diameter of mean circle

T Torque

ltr: supporting length

e Eccentricity

Profile P4C:
er = (d2 - d3) / 4; dr = d3 + 2 * e
p(eq,max)=T * 1000/(ltr * ( *dr* er + 0.05 * d2^2))
Projection area = ltr * n * 2 * er; (n = 4)
d2: Diameter of outer circle

T Torque

ltr: supporting length

e Eccentricity

dr: Mathematically theoretical er: Mathematical eccentricity

diameter
d3: Diameter of inner circle

Method in accordance with DIN:

The following formula is used to calculate the occurrence of flank pressure:
Profile P3G:
p=T * 1000/(ltr * d1 * (0.75 * * e + 0.05 * d1))
d1: Diameter of mean circle

T Torque

ltr: supporting length

e Eccentricity

Profile P4C:
er = (d2 - d3) / 4; dr = d3 + 2 * e
p=T * 1000/(ltr *dr ( * er + 0.05 * dr))

Chapter
IV-927

Polygon

39

d2: Diameter of outer circle

T Torque

ltr: supporting length

e Eccentricity

dr: Mathematically theoretical er: Mathematical eccentricity

diameter
d3: Diameter of inner circle

Chapter
IV-928

Polygon

39

39.5

Permissible pressure

Method in accordance with Niemann:

The permitted values are calculated on the basis of the yield point (or fracture in
the case of brittle materials). For continuous stress with Teq:
- for ductile materials:
peq=fs * fH * Rp
- for brittle materials:
peq=fs * Rm

Structur
al steel

Material

fs

Shaft

Structural steel, heat treatable steel, case-hardened steel, GJS, GS

1.2

GJL

1.0

Structural steel, heat treatable steel, case-hardened steel, GJS, GS

1.5

GJL

2.0

Hub

Table 39.6: Support factor as specified by Niemann

The support factor fs takes into account the support effect that appears in components subjected to a compression load.
The hardness influence coefficient, fH, is derived from the ratio of surface to core
strength for surface hardened components.
The hardness influence coefficient for case-hardened steel is 1.15, otherwise it is
1.0. The values used for this coefficient are defined in DIN 6892.
For calculation with peak torque:
pmax=fL * peq
fL is the frequency of load peak factor, which depends on the material type and the
frequency of load peak. This coefficient is shown in a diagram in DIN 6892.

Method in accordance with DIN:

The permissible surface pressure on the shaft or hub for polygon profiles P3G and
P4C is:
pzul = 0.9 * Rp0.2

Chapter
IV-929

Polygon

39

39.6

Materials

Figure 39.2: Materials screen: Polygon

In the selection list, you can select materials in accordance with the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
IV-930

Polygon

39

39.7

Settings

Figure 39.3: Settings: Polygon

In Settings you can specify the required safety for the connection. The values that
are being searched for are defined on the basis of the required safety during sizing.
If you selected Calculate material strength with wall
thickness as raw diameter, the strength of the hub material is calculated
using the wall thickness instead of the raw diameter.

Chapter
IV-931

Polygon

39

39.8

Sizings

During the sizing process, the required value is defined such that the required
safety factor (specified in Calculations/ Settings) is only just achieved.
To display the results in the lower part of the main window, you must perform the
calculation after the sizing. Possible sizings:
transmissible nominal torque Tn
Transmissible maximum torque Tmax (only for Niemann)
supporting length ltr

Chapter
IV-932

Polygon

39

39.9

Graphics

The polygon form is defined using the formulae in the relevant DIN standard
(32711-1/ 32712-1) and is displayed as a graphic which can be exported either as a
picture file or as a DXF file.
Polygon curve equation (profile P3G, DIN 32711-1)

Polygon curve equation (profile P4C, DIN 32712-1):

Chapter
IV-933

Woodruff Key

40

40

Woodruff Key

Chapter 40
Woodruff Key
Connections that use Woodruff keys are no longer commonly used, because the
deep keyway in these keys causes too great a notch effect. However, this connection is still used widely in precision mechanics.
For Woodruff keys you calculate the load on shaft and hub (surface pressure). You
can also add additional standards. The load placed on the shaft and hub (surface
pressure), together with determining the safeties, is calculated as described in classic technical literature [64]. The calculation defined by Niemann forms the basis of
DIN 6892 (key calculation).

Figure 40.1: Basic data: Woodruff key

Chapter
IV-934

Woodruff Key

40

40.1

Standard profiles

You can select one of these standards from the selection list:
DIN 6888, series A ( high pinion groove)
DIN 6888, series B (low pinion groove)
Own Input
After you select the standard for calculating the Woodruff key, a list of
corresponding values is displayed.
b: Width

d: Diameter

h: Height

t1: Shaft groove depth

Chapter
IV-935

Woodruff Key

40

Figure 40.2: Woodruff key with circumferential and normal forces for the calculation as defined
in Niemann

Own input: Select the Own Input option to define your own Woodruff keys.

Chapter
IV-936

Woodruff Key

40

40.2

Application factor

The application factor is defined in the same way as in the key calculation:
Operational
behavior

Operational behavior of the driven machine

equal-

moderate

medium

strong

Machine

moderate

shocks

shocks

shocks

uniform

1.00

1.25

1.50

1.75

light shocks

1.10

1.35

1.60

1.85

moderate shocks

1.25

1.50

1.75

2.00

heavy shocks

1.50

1.75

2.00

2.25

of the driving

Table 40.2: Application factor in accordance with DIN 6892

Chapter
IV-937

Woodruff Key

40

40.3

Torque curve/Frequency of change of load direction

When you select the torque curve you can choose one of two positions:
1. No alternating torque
2. With alternating torque
If you select item 2), the calculation not only defines the Frequency of change of
load direction, as defined in DIN 6892, Figure 6, but also the frequency of change
of load direction coefficient fw. In the case of item 1), the coefficient will be set to
1.0.

Chapter
IV-938

Woodruff Key

40

40.4

Occurring flank pressure

This formula is used to calculate occurrences of flank pressure. The formula is used
both for the equivalent load and for the maximum load:
p(eq,max)=k(eq,max) * k1 * T * 2000/(d * ltr * htw * z)
k: Share factor

ltr: supporting length

k1: Length factor

htw: supporting height (shaft)

T Torque

z Number of Woodruff Keys

d Shaft diameter

Chapter
IV-939

Woodruff Key

40

40.5

Length factor

A length factor, k1, is multiplied by the loading that takes into account how the load
is distributed across the bearing length as a consequence of the torque action of the
shaft and hub. The length factor depends on the equivalent diameter derived from
the bearing length, the small and the large hub outside diameter, and the width c to
the external diameter. The distance a0 is also used to determine the length factor.
This factor is shown in a diagram in Niemann.

Figure 40.3: Woodruff key: Load application.

Chapter
IV-940

Woodruff Key

40

40.6

Share factor

To calculate the occurring flank pressure, a share factor of k is taken into account.
This is then multiplied by the load. Interim sizes not shown in the table are
interpolated linearly.
Form-closure

spline connection with involute flank

connection

Tolerance zones in accordance with DIN 5480

H5/IT4

H7/IT7

H8/IT8

H9/IT9

H11/IT11

Maximum
value

keq

1.1

1.3

1.5

z/2

kmax

1.1

1.3

1.7

z/2

Table 40.4: Share factor in accordance with Niemann

Chapter
IV-941

Woodruff Key

40

40.7

Permissible pressure

The permitted values are calculated on the basis of the yield point (or fracture in
the case of brittle materials). For continuous stress with Teq:
- for ductile materials:
peq=fs * fH * Rp
- for brittle materials:
peq=fs * Rm

Structur
al steel

Material

fs

Shaft

Structural steel, heat treatable steel, case-hardened steel, GJS, GS

1.2

GJL

1.0

Structural steel, heat treatable steel, case-hardened steel, GJS, GS

1.5

GJL

2.0

Hub

Table 1.6: Support factor as specified by Niemann

The support factor fs takes into account the support effect that appears in components subjected to a compression load.
The hardness influence coefficient, fH, is derived from the ratio of surface to core
strength for surface hardened components.
The hardness influence coefficient for case-hardened steel is 1.15, otherwise it is
1.0. The values used for this coefficient are defined in DIN 6892.
For calculation with peak torque:
pmax=fL * peq
fL is the frequency of load peak factor, which depends on the material type and the
frequency of load peak. This coefficient is shown in a diagram in DIN 6892.

Chapter
IV-942

Woodruff Key

40

40.8

Materials

Figure 40.4: Materials screen: Woodruff key

In the selection list, you can select materials in accordance with the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
IV-943

Woodruff Key

40

40.9

Settings

Figure 40.5: Settings: Woodruff key

In Settings you can specify the required safety for the connection. The values that
are being searched for are specified on the basis of the required safety during
sizing.
If the Take pressure on key into account flag is set, the values of the
Woodruff key are included in the sizing. Otherwise the sizing procedure will be
carried out on the basis of the shaft and hub.
If you selected Calculate material strength with wall
thickness as raw diameter, the strength of the hub material is calculated
using the wall thickness instead of the raw diameter.

Chapter
IV-944

Woodruff Key

40

40.10

Sizings

During the sizing process, the required value is defined such that the required
safety factor (specified in Calculations/ Settings) is only just achieved.
To display the results in the lower part of the main window, you must perform the
calculation after the sizing.
Possible sizings:
transmissible nominal torque Tn

Chapter
IV-945

Bolts and pins

41

41

Bol ts a nd pins

Chapter 41
Bolts and pins

Figure 41.1: Basic data: Bolts and Pins

The bolt/pin connections are divided into four types of calculation depending on
where they are used:
Cross pin under torque
With cross pin connections where large forces are in play, the surface pressure
of the shaft and hub, and the shearing of the pin, will be checked.
Longitudinal pin under torque
Longitudinal pin connections are subject to surface pressure in the shaft and
hub and shearing force on the pin.
Guide pin under bending force
Guide pin connections are subject to bending stress due to torque and to shearing force caused by transverse forces. The shearing force, surface pressure,
bending of the pin, and surface pressure on the element. are calculated here.
Bolt connection subjected to shearing action (in
double shear)
The bolt is subject to bending and shear stress and to surface pressure in this

Chapter
IV-946

Bolts and pins

41

arrangement. You can use different calculation methods, depending on the fit
of the rod/bolt and fork/bolt connections. Experience shows that the limiting
factor in sizing non-sliding surfaces is the bending stress and in sliding surfaces
it is the surface pressure.
Bolts in a circular array (in single shear)
In this arrangement, the effective torque is distributed uniformly across the individual bolts/pins and therefore the shaft and hub are subject to surface pressure from the individual bolts/pins, creating a shearing force. The maximum
shear stress and the minimum safety for the bolts are also output.
The load placed on the bolts, shaft and hub (or part) is calculated, and the safeties
are determined, as described in classic technical literature (Niemann, Maschinenelemente I, 4th Edition 200564]),
apart from bolts in a circular layout.
The cross-sectional area and moment of resistance to bending in the spring dowel
and coiled spring pins (bushes) is calculated in accordance with Decker [86]. In
configurations in which the bolts, spring dowels and coiled spring pins (bushes) are
only subjected to shearing, the permitted shearing force specified in the relevant
DIN standard can be applied to the pins.

Chapter
IV-947

Bolts and pins

41

41.1

Influence factors

When calculating individual connections you must include a number of influencing

factors which are defined depending on the load, stress, type, etc.:
Application factor
Dynamic factor:
fixed load: Cd = 1; pulsating load: CD = 0.7; alternating load: CD = 0.5;
for coiled spring pins and spiral pins (bushes)
fixed load: Cd = 1; pulsating load: CD = 0.75; alternating load: CD = 0.375;
Reduction factors for full/grooved dowel pin
Full pin: CK = 1; grooved dowel pin (bending, shear): CK = 0.7; grooved dowel pin pressure: Ckp = 0.8;
Since the permissible stress values in the literature are very low, other material
factors have been added to obtain the values in the table.

Chapter
IV-948

Bolts and pins

41

41.2

Materials

Figure 41.2: Materials screen: Bolts and Pins

In the selection list, you can select materials in accordance with the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
IV-949

Bolts and pins

41

41.3

Settings

Figure 41.3: Settings: Bolts and Pins

In this sub window you can view and change the material factors and required
safeties for each calculation.
This factor is multiplied by the tensile strength Rm for all parts/bolts and pins apart
from coiled spring pins and spring dowel pins (bushes) to calculate the permitted
value.
In the case of coiled spring pins and spring dowel pins (bushes), the permitted values are taken directly from the file and do not depend on tensile strength Rm.

Chapter
IV-950

Bolts and pins

41

41.4

Permitted values

Parts/Full pins/Bolts/Grooved dowel pins

For each part/bolt and pin, depending on the load, the coefficient you find under
Calculation/Settings is multiplied with the tensile strength Rm to define
the permitted value.

Coiled spring pins and spiral pins (bushes)

The permitted values for coiled spring pins and spiral pins (bushes), are imported
from a file.
The permitted values for transverse force, for configurations that are only subject
to shearing, can be taken from the relevant DIN standard for the pins.
The permitted values for shear and bending moment under different loads can be
taken from the technical documentation provided by Decker:
Bending Stress: b = 380N/mm2
Shear stress: = 160N/mm2
Surface pressure: p = 208N/mm2
Half the permitted values from other arrangements are used for the arrangement
"Longitudinal pin under torque".
(Recommendation in accordance with Decker)

Chapter
IV-951

Bolts and pins

41

41.5

Sizings

Click the
buttons next to Diameter and Load to size the values that are beside
them to suit the required safeties.

Chapter
IV-952

Bolts

42

42

Bol ts

Chapter 42
Bolts
KISSsoft calculates bolted joint in accordance with VDI 2230 (2014). In addition
to providing tables with standard values, the program also has a range of options
that allow you to enter your own definitions for most of the constraint values (such
as geometry and material data). Although the VDI 2230 standard does not have
iteration functionality, i.e. it can be calculated manually, the flexible input and
modification options give you a user-friendly software solution at your fingertips.
However, you must be familiar with VDI 2230 before you can interpret the results
and enter the required values correctly in the program.
VDI 2230 compares the permissible assembly preload (FM and also, to some
extent, FMzul) with the minimum and maximum assembly preload (FMmax and
FMmin). Here the first is a value calculated with 90% of the bolt yield point and the
last two are determined by the loads required to guarantee that the connection
functions correctly. Assembly preload FMzul is therefore determined from the
strength of the bolt, while assembly preloads FMmin and FMmax are determined from
the function of the connection. The necessary assembly preload FMmin is calculated
from the axial force FA and the resilience of the parts and the bolt , the embedding
loss FZ, the thermal forces FV th and the required clamp load FKerf. FMmax can be
calculated from Mmin while taking into consideration the coefficient of friction
scatter and the tightening technique (tightening factor aA).

(42.1)
(42.2)

The necessary assembly preload FMmax must now be smaller than the sustainable
pretension of the bolt FMzul. Similar to this comparison is the comparison between
the minimum required mounting pretension force FMmin and the minimum
pretension force achieved by tightening at, for instance, 90% of the yield point
FMzul/A:

(42.3)

Chapter
IV-953
42

Bolts

Chapter
IV-954

Bolts

42

42.1

Special features in KISSsoft

In VDI 2230, the values for pretension force FM when utilizing 90% of the yield
point, and for the tightening torque, are to be found in Tables 1 to 4. These values
are rounded (rounding off error <= 1%). However, KISSsoft calculates the values
using the equations on which these tables are based. The results are therefore more
general than the ones that use the values given in the tables and therefore may also
differ slightly from them.

Chapter
IV-955

Bolts

42

42.2

Basic data inputs

The entries you make in the Basic Data tab form part of the service and bolt data,
and include the type of bolting, washers, and tightening technique.

Figure 42.1: Basic data tab.

42.2.1

Operating data

You enter operating data in the Basic data tab. You can then use it for the
following clamping configurations:
1. Bolted joint under axial load
2. Bolted joint under axial and shearing force
3. Flange connection with torque and forces
4. Multi-bolted joint with any bolt position
5. Proof for bolts with FEM results

An axial loading FAmax, FAmin and a required clamp load FKerf are determined each
time, from the operating data.
External forces and torques, which must be transmitted via the bolted joint, are to
be converted into axial force FA and into the required clamp load FK. VDI 2230

Chapter
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42

assumes these values are known. In the KISSsoft system, you can input the
appropriate configuration (bolt under shearing force and flange connection) as
external forces and torques. These values are then used to calculate the axial load
and preload on an individual bolt.
For a bolted connection under shear load, this shear load is represented by the
friction between the bolted parts. The friction is determined by the coefficient of
friction and the pretension force.

Figure 42.2: Bolting configurations: 1/2, 3 and 4

42.2.1.1
Bolted joint under axial and shearing force
In the second configuration, the required clamp load for axial load transmission is
calculated from the shearing force FQ, the torque MT , the coefficient of friction mT ,
the diameter da and the number of force transmitting parting lines qT:

(42.5)

(42.6)

FKQ

Required clamp load for transferring a shearing force and/or a torque

through friction grip (e.g. for friction grip)

FKP

Clamp load required to guarantee a sealing function (required when

Chapter
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42

internal pressure is present)

Interface coefficient of static friction (when shearing force or torques

are present), see Figure on page IV-957.

42.2.1.2
Bolted joint under axial loa d
The occurring axial forces FAmax and FAmin are entered directly. The necessary
clamp load FKerf is defined in accordance with

(42.4)

and the required clamp load for axial load transmission FKQ and the sealing function FKP are calculated. FKA is present to prevent gaping in the required clamp load
and is calculated by the program.

42.2.1.3
Flange connection with torque and force s
The forces on the single bolt in the case of flanged joints (with stress from torque
and/or shearing force and/or bending moment and/or axial force) are calculated
according to [63], and also partially according to [61], Example 8.4:
(42.7)

(42.8)

(42.9)
(42.10)

(42.11)

dt

Bolt pitch diameter

Number of bolts

Chapter
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Coefficient of friction between the parts, see Figure 42.3

FQ

Shearing force on configuration

FAmax

Axial force on configuration (maximum)

FAmin

Axial force on configuration (minimum)

Resultant operating force on the bolt that is subject to the greatest
stress:

FBo

Upper limiting value

FBu

Lower limiting value

FKP

Configuration sealing load

MB

Bending moment on configuration

MT

Torque on configuration

FKerf

Required clamp load

FKQ

Required clamp load (e.g. for friction grip)

FKP

Required clamp load to ensure sealing (for internal pressure)

FKA

Required clamp load to prevent gaping under eccentric load

If you select a flanged joint configuration, we strongly recommend that you define
the geometry of the clamped parts as individual annulus segments. The
program then automatically generates proposed values for the pitch (t) and the bolt
radius of the annulus (rs).

Chapter
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Experience shows that the results of VDI 2230 are usually very conservative for
flanged connections. In order to achieve realistic results, you should increase the
coefficient of friction between the parts.

Figure 42.3: Interface friction grip coefficients according to [75]

42.2.1.4
Multi-bolted jo int with any bolt posit ion
In a multi-bolted joint you can define bolts in any position. These are then affected
by shearing force, a bending moment in two directions, and a torsional moment.
The load distribution on the bolts is calculated on the assumption that rigid plates
are connected by springs at the bolt positions. Forces which do not affect the center
of gravity must be moved to the center of gravity so they can be entered. By using
a stiffness coefficient, you can model different bolt diameters (doubled diameter
equals fourfold rigidity). Set the coefficient = 1 for the bolt with the smallest diameter. For larger bolts, use their diameter ratio to the smallest bolt as the

Chapter
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42

coefficient. The forces are then distributed across the bolts. Only one bolt where
the coefficient = 1 can be proved because otherwise the bolt data is incorrect.

Figure: Definition of forces and torques in KISSsoft

Once you have entered the operating data in the Basic data tab, you can define
the bolt positions in the Position of bolt tab. You can either enter the bolt
positions in a table or import them from a file. The resulting axial forces, and also
the clamp loads required to transmit shearing force, are also displayed in the table.

Figure 42.4: Position of bolt tab

Chapter
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Optionally, you can define an additional coefficient for set screws, in which it is
assumed that compression is transmitted directly via the plates. However, use of
this coefficient assumes you have expertise in this area. In [62], under the keyword
"Multi-bolted Plate Joint", for example, an average pressure point of 1/4 plate
height is assumed. You use the coefficient for set screws to set this status.
The program then automatically selects the bolt with the highest axial force for the
calculation. As a rule, and to ensure that the calculation results are on the safe side,
the maximum required clamp load is used for all bolts. However, you can select a
further option to deactivate this function.
When you calculate the necessary clamp load, you can also take the prefix of the
shearing force into account. Shearing forces caused by torsion and shearing force
are then added at specific points and subtracted at other points. You should only
include the prefix if you know the direction of the shearing force and if this force is
constant.
To save you having to specify the arrangements in which the incremental distances
between the bolts repeat themselves, for every single bolt, you can define the position of particular bolts in the Sizing function. Click the
button in the table
(above, on the right) in the "Position of bolt" tab to open this window, in which you
can enter different configurations.
You can enter these values here:
line (values for: starting point, end point, number of bolts)
circle (values for: center point, radius, number of bolts)
circle segment (values for: radius, starting angle, end angle, number of bolts)

Chapter
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Figure 42.5: Sizing the position of a bolt

Figure 42.6: Position sizing options

You can add positions by transferring existing positions. However, if you only
want to use the positions shown in the configuration, you must delete all the others.

Chapter
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42.2.1.5
Result s from FEM ca lculation
The following behavior can be taken into account in an FEM calculation (instead
of a calculation according to VDI 2230 Sheet 1):

Non linear material behavior (for example, plasticity or yield)

Non linear boundary conditions (for example, load dependency of the contact
surfaces),
Geometric non linear behavior (for example, significant deformation occurs
when the tightening process is simulated)
As specified in VDI 2230 Sheet 2, Multi bolted joints, the FEM modeling is
subdivided into 4 model classes:
Model class I:
The bore is not represented. The interface is either completely integrated or
connected by a rigid coupling and a reference node for every bolt.
Model class II:
The bolt is represented as a beam or a spring element (with the ideal translational
and rotational degrees of freedom for each section). Interface with contact definition.
Model class III:
The bolt is shown in 3D as a cylinder with large cylinders at its ends. The interface
and support areas are assigned contact definitions in the FEM calculation. The
cylinder has the same core diameter as the thread.
Model class IV:
The bolt is modeled with the exact thread geometry. The assembly and working
states are treated separately.

Using VDI 2230 Sheet 1 to prove FEM results is really only a sensible idea for
model classes II and III. Model class I does not supply enough informative results

Chapter
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42

to create a proof according to VDI 2230 Sheet 1. If you are using model class IV,
you already have all the necessary results and should use a different method from
the one in VDI 2230 Sheet 1 for the proof.
Implementation in KISSsoft VDI 2230 Sheet 2 FEM results

You can select these model classes directly from the list.
List items model class II and model class III:
the main difference between the models is that bolt resilience can only be defined
in model class III.
In the case of these list items, the "Bolted joint under axial and shearing force" configuration is required for calculating the amount of embedding.
The integration of FEM results in the calculation according to VDI 2230 Sheet 1.
So that a proof can be performed, this is implemented as follows in KISSsoft (subdivided as specified in VDI 2230 Sheet 1).
R0, R1

according to VDI 2230 Sheet 1

R2

You can input the clamp load for the sealing function FKP directly in the basic data, if it has already
been determined in the FEM calculation. The lifting force can be defined directly in the FEM
calculation, and specified here. If the results have not been defined, the program determines them on
basis of the values in VDI 2230 Sheet 1. The axial load transmission FKQ is determined as specified
VDI 2230 Sheet 1.

R3

In model classes II and III, the resilience of the plates is taken from the results of the FEM calculatio
In model class III, the bolt resilience is also taken from the results of the FEM calculation. In model
class II, the bolt resilience is derived as specified in VDI 2230 Sheet 1. The amounts of embedding a
estimated according to VDI 2230 Sheet 1.

R4

Amounts of embedding defined as specified in VDI 2230 Sheet 1. Fvth can be input directly as a res
from the FEM calculation.

R5

Fvth can be input directly as result from the FEM calculation. Fkerf, en, Famax and Fz can be take
from VDI 2230 Sheet 1 -> determination of FMmin.

R6

Fmmax = A*FMmin.

R7

In KISSsoft, assembly stress is calculated according to VDI 2230 Sheet 1. This would take an
exceptional amount of time and effort if an FEM calculation were used instead.

Chapter
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42

R8

FV'th is included in the calculation of Fsmax (total bolt load). If FV'th > 0, it is set to 0, as specified
R8/1, VDI 2230 Sheet 1.
All others z, max, redB are calculated according to VDI 2230 Sheet 1.

R9

FSA, MSA as input from the FEM results. You can specify the upper and lower limit. Proof of dynam
strength according to VDI 2230 Sheet 1 (R9/2). The permitted values are defined according to VDI 2
Sheet 1.
The effects of temperature are included directly in the FEM results.

R10

pBmax can be derived from the FEM results if model class III is being used, otherwise it is calculate
according to VDI 2230 Sheet 1.

You should only calculate the values for permissible surface pressure pGmax directly in FEM if thes
values are not already available.
R11

The minimum length of engagement cannot be represented realistically in model classes I to III. It
would take a great deal of time and effort to model this in model class IV. The calculation is perform
according to VDI 2230 Sheet 1.

R12

The calculation In KISSsoft is performed according to VDI 2230 Sheet 1. The values you need to inp
here are determined from the FEM calculation.

R13

not applied.

List item model class III (only forces and torques, without resiliences):
The main difference between this and the other methods is that the calculation is
performed without defining the resiliences.
When this list item is used, the amount of embedding is permanently set to n=1.
The FEM results needed to create a proof according to VDI 2230 Sheet 1 are
grouped in the summary of the calculation steps below:
R0

The geometry is to be defined according to VDI 2230 in FEM. In KISSsoft, set this to "Plates" for
clamped parts.

R1

Tightening factor according to VDI 2230 Sheet 1

R2 to
R6

Are determined in the FEM model. The results are: FM, FM/ (may be different, because this is a re
value), FKP, FSmax, FKR.
FKQ which is determined with the values FQ, Mt and ra, is used to calculate safety against sliding.

R7

Mounting conditions:
FMzul = FMtab at 90% load, otherwise redMzul =*Rp0.2. With FM value for calculating redM
from FE.

Chapter
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42

R8

Working conditions:
FSmax is a result in the FEM calculation.
z, max, redB are calculated according to VDI 2230 Sheet 1.
SF = Rp0.2/zmax

R9

FSA and MSA values from the FEM results. You can specify the upper and lower limit. Proof of dyn
mic strength according to VDI 2230 Sheet 1 (R9/2). The permitted values are defined according to V
2230 Sheet 1.
The effects of temperature are included directly in the FEM results.
Abo = FSA,o/As + MSA,o/Ws; Abu = FSA,u/As + MSA,u/Ws
SD = AS/ab
AS calculated according to the formulae in VDI 2230 Sheet 1.

R10

Input values: permissible surface pressure pGzul (under head and nut).
Mounting: pMmax = FMzul/Apmin
Operation: pBmax/Apmin
SP = pGzul/PM,Bmax

R11

Minimum length of engagement is not calculated.

R12

FKR is an input value. FKerf is calculated according to VDI 2230 Sheet 1. FKQ interim results are
calculated from input values FQ, Mt and Ra.
SG = FKR/FKerf

R13

not applied.

42.2.2

Bolt data

The type, geometry, surface roughness and strength class of a bolt can all be
defined as bolt data.
Bolt type: You can use the following standard bolt descriptions from the database to define the bolt type:
DIN EN ISO 4762/

Hexagon socket head cap screw

DIN 912

Standard thread M1.6 to M64

DIN 7984

Hexagon socket head cap screw with low head

Chapter
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42

Standard thread M3.0 to M24.0

DIN EN ISO 4014/

Hexagon headed bolts with shank (formerly DIN 931 T1)

DIN EN 24014

Standard thread M1.6 to M64

DIN EN ISO 4017/

Hexagon headed bolt with thread to head (formerly DIN 933)

DIN EN 24017

Standard thread M1.6 to M64

DIN EN ISO 1207/

Slotted cheese head screw

DIN 84

Standard thread M1.0 to M10

DIN EN ISO 8765

Hexagon headed bolt with shank

Fine thread M8.0 to M64

DIN EN ISO 8676

Hexagon headed bolt without shank

Fine thread M8.0 to M64

DIN EN 1662

Hexagon headed bolt with flange, light series form F

Standard thread M5.0 to M16

DIN EN 1662

Hexagon headed bolt with flange, light series form U

Standard thread M5.0 to M16

DIN EN 1665

Hexagon headed bolt with flange, heavy series form F

Standard thread M5.0 to M20

DIN EN 1665

Hexagon headed bolt with flange, heavy series form U

Standard thread M5.0 to M20

ASME B18.2.1

Square bolts, UNC thread, 0.25 to 1.5 in

ASME B18.2.1

Hex bolts, UNC thread, 0.25 to 4 in

ASME B18.2.1

Heavy hex bolts, UNC thread, 0.5 to 3 in

ASME B18.2.1

Hex cap screws, UNC thread, 0.25 to 3 in

ASME B18.2.1

Heavy hex screws, UNC thread, 0.5 to 3 in

Reference diameter: You can either input your own value for the reference diameter or click the
button to calculate an approximate value after you input the operating data. This sizing function usually leads to bolt diameters that are
too large. We therefore recommend you input a value that is 1 or 2 standard sizes
less than the system's proposed value.
Bolt length: You can input any bolt length if you are inputting your own
bolt geometry. Otherwise, after you input the bolt length, the system sets it to the
next standard length.

Chapter
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42

Surface roughness of thread/bearing surface: The surface

roughnesses influence the amount of embedding and therefore also the preload loss
of the bolted joint.
Strength class: After the entry for standard strength classes you can click
the Define... button to define your own strength values. The shearing strength
ratios are set according to Table 5.5/2 in VDI 2230 Sheet 1 (2014), according to
strength class. The values can be overwritten.
Own definition of bolt geometry: To define your own bolt
geometry, you must set the Bolt type selection list to Own input. This
activates the Define... button, which you can click to input your own bolt
geometry values.

Figure 42.7: Dialog with three tabs for defining your own bolt geometry.

Chapter
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Bolts

42

Figure 42.8: Bolt geometry

General tab: If you are using a bolt with a bore, input the dimensions of the
bolt head as well as the bore diameter.
Thread tab: Data from the standard, the size of the thread, the lead, and the
thread length. This is where you define the factors used to calculate the flank
diameter d2 and the core diameter d3 (d2 = d - d2factor*P; d3 = d - d3factor*P).
Bolt shank tab: Data about the individual bolt cross sections. Click the
button to add a new cross section. Click the
button to remove the selected
cross section. Click the

button to delete all the cross sections.

Chapter
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42

42.2.3

Type of bolted joint

To define the type of bolting, enable either Nut or Blind hole. This
corresponds to the difference between through-bolt and single-bolted (tapped
thread) connections as defined in VDI. Click on the appropriate Define... button to open the corresponding input dialog for additional data about the nut or the
threaded part.

Figure 42.9: Input dialog for data about cut threads and nuts

Blind hole
For cut threads, the counter bore depth ts describes milling without thread that is
primarily used to extend the clamp length (see also Figure on page IV-966).
Nut
In the nut definition screen you can either select a standard for the geometry or
define one yourself.
For example, when calculating the length of engagement, you can either define the
hardness from the strength class (as specified in DIN EN ISO 898-2) or define the
shearing strength directly from the material.
The "Own Input" option is also available in both variants. However, when you input the strength class, you must also define the ratio of the shearing strength to
tensile strength (BM/Rm).

Chapter
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42

The system then converts the hardness value you enter here into tensile strength as
part of the hardness conversion process. The tensile strength Rm is then multiplied
by the ratio (BM/Rm) to calculate the shearing strength (BM).
The minimum hardness value for nuts with a standard thread (including UNC) is
taken from the strength class in Table 6 in DIN EN ISO 898-2. The minimum
hardness value for fine threaded nuts (including UNF) is taken from the strength
class in Table 7 of the same standard.
NOTE

If the dimension of the interface area DA is only slightly larger than the bearing
diameter of the bolt head dw, it must be calculated as a through-bolt connection
(note the deformation cone).
(DA to ~1.4*dw)

42.2.4

Washers

If this flag is set, a washer is inserted between the nut and the part and/or the head
and part.

Figure 42.10: Defining washers.

In the Calculation/Settings tab, if you select the "Determine specific

thermal expansion of washers" flag, you can also define the thermal expansion
coefficients that are used to calculate the difference in pretension force. You will
find a more detailed description in the "Settings" section.

Chapter
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42

42.2.5

Extension sleeves without external forces

You can specify the length of an individual extension sleeve in the extension
sleeves dialog. In a single-bolted (tapped thread) joint, a extension sleeve can be
used under the bolt head. In a through-bolt connection, an extension sleeve can be
used under the bolt head and under the nut.
No external forces are to act on the extension sleeves defined here. These sleeves
are to be used to create the spacing between the bolt head or nut and the part.
The extension sleeves are taken into account when sizing the length, calculating the
resilience, and in the length expansion at operating temperature.

42.2.6

Tightening technique

Uncertainties such as, for example, the scatter of the friction factors, tightening
techniques that differ in their precision, and instrument, operating and reading errors, result in variation in the achievable assembly pretension force. For this reason, oversizing the bolt is necessary, and is expressed by the tightening factor A =
FMmax/FMmin. If the required minimum preload Mmin remains constant, then an
increasing tightening factor aA means that the bolt must be sized for a larger maximum assembly preload FMmax (due to the greater scatter). Tightening technique and
associated tightening factors:
Tightening factor
A

Tightening technique

Adjusting technique

1.0

Yield point-determined
tightening mechanically or
manually

1.0

Angle of rotation-controlled
tightening mechanically or
manually

Experimental determination of
the preload moment and angle of
rotation

1.2 to 1.6

Hydraulic tightening

Adjustment by means of
measuring length or pressure

1.4 to 1.6

Torque-controlled tightening with

a torque wrench, torque
indicating wrench or a precision
torque wrench with dynamic
torque measurement

Experimental determination of
the required tightening torques on
the original bolting part, e.g. by
measuring the length of the bolt

1.6 to 1.8

ditto

Defining the nominal tightening

torque by estimating the friction
factor (surface and lubrication
ratios)

1.7 to 2.5

Torque-controlled tightening with

a bolt installation spindle

Torque wrench adjustment with a

tightening-up moment, set to the
required tightening moment (for
an estimated friction factor) plus

Chapter
IV-973

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42

a supplement.
2.5 to 4

Pulse controlled tightening with

an impact wrench

Torque wrench adjustment with

tightening-up moment as
described above

Chapter
IV-974

Bolts

42

42.3

Clamped parts inputs

The Clamped parts screen displays data about the materials and geometry of
the clamped parts, the distances involved for eccentric load/clamping, and data
about the load application factor.

Figure 42.11: Clamped parts inputs tab

42.3.1

Geometry of clamped parts

There are several basic types of clamped parts:

Plates
Cylinder
Prismatic body
Annulus segment

Chapter
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42

Figure 42.12: Clamped parts.

If you select Plates, it is assumed that the clamping deformation cone will be able
to expand sidewise freely. For all the other selection options, click the Geometry
button to enter the type of clamped part you want to use in the calculation.

Figure 42.13: Geometry inputs for the cylinder, prismatic body, and annulus segment.

Chapter
IV-976

Bolts

42

Click the Bore button to define a threadless through-bore in the part. You can also
define chamfers at the head and or nut here. These chamfers are then included
when the bearing areas are calculated. The chamfer reduces the outside radius of
the bearing area and therefore increases the surface pressure.

Figure 42.14: Defining through-bores and chamfers under head and nut.

You simply enter the different material situations in the list. The upper values for
permissible pressure, e-module and thermal expansion are material values that
apply to room temperature and, unless they are values you have entered, are always
shown with a gray background. If the "Calculate temperature dependent material
data automatically with estimation formulae" flag is set in
Calculations/Settings, the values for the operating temperature are
calculated empirically and displayed in the lower half of the particular material.
You cannot edit these values. If the flag is not set, you must input your own values.
Click the

buttons to call the particular empirical formulae so they can be app-

lied in the calculation. Click the

button to add a material and the

button to

delete the selected element. Click the

button to delete all the elements. The
calculated clamp length is displayed in the lk field.

Chapter
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42

42.3.2

Distances for eccentric cla mping/load

Figure 42.15: Possible load cases in the case of eccentric clamping.

As you can see in Figure 42.15, the axis of the center of gravity of the clamping
solid 0 - 0 determines the null point (origin) of the X-axis. The distance between
load line of action A - A and the center of gravity axis 0 - 0 is always positive. The
distance s between bolt axis S - S and center of gravity axis 0 - 0 is set as positive,
if the bolt axis S - S and the load line of action A - A lie on the same side as the
center of gravity axis 0 - 0. If not, this value is negative.
The dimension u defines the distance of the center of gravity axis 0 - 0 to the point
at which gaping first occurs. In Figure 42.15 this is the distance to the right-hand
side in cases I and III, but the distance to the left-hand side in case II. In cases I and
II, u must be positive, and in case II it must be negative. The guidelines governing
the use of prefixes specified in VDI 2230 Sheet 1 are applied here.

42.3.3

Load application

The VDI guideline issued in 2014 defines equations for calculating the load application factor. Here, you must select a configuration in accordance with Figure
42.13. The interface must lie within the range shown in gray. The length of the
clamped parts h, the distance to the connection piece akand the length of the
connected solid lA as shown in Figure 42.14 define the position of the application
of load point and therefore also the load application factor.

Chapter
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42

In single-bolted (tapped thread) connections, only configurations SV1, SV2 and

SV4 are available. You must use the height hESV up to the interface as the height h.

Figure 42.16: Configurations for defining the load application factor as shown in VDI 2230
(2014 edition).

Figure 42.17: Inputs for defining the load application factor as shown in VDI 36 (17 edition).

42.4

Constraints data

In this calculation, you can define the yield point, the maximum assembly preload
or both tightening torques as constraints. If you define the maximum and minimum
tightening torque as constraints, the tightening factor is then calculated from this
torque variation and the friction coefficient variation. You can also enter values for

Chapter
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42

the number of load cycles, embedding amount, preload loss and temperatures for
the screw connection in this window.

Figure 42.18: Preset values, ready for input.

Use of the yield point

In usual bolt layouts, the bolt is tightened to 90% of its yield point to calculate the
preload force. However, if you use yield point or angle-of-rotation controlled
tightening, you can increase this utilization value up to 100%.
Number of load cycles
If this number of load cycles is ND >= 2*106 the fatigue lives for final heat treated
and final rolled bolts are calculated in accordance with the formulae specified in
VDI (VDI 2230, 5.5/20 and 5.5/21). If smaller values are involved (ND < 2*106), a
limited life fatigue strength sizing is performed for the connection (5.5/22 and
5.5/23).
Amount of embedding
The amount of embedding is calculated according to which calculation method you
use. You can also input an extra amount of embedding value for flat seals. In addition, you can overwrite the calculated amount of embedding with your own value
or input the preload loss directly. If you input your own preload loss, the amount of
embedding is no longer taken into account.
Assembly and operating temperature
Now KISSsoft's bolt calculation function has been extended, it can be used for the
calculation guideline specified in VDI 2230, which also calculates bolted joints for

Chapter
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42

operating temperatures between -200 and +1000 degrees Celsius. You can specify
different temperatures for the bolt and the clamped parts. You can also take into
account the temperature-dependent changes in the Young's modulus, in the thermal
expansion coefficients, in the yield point and in the pressures permitted for the materials. You can either use empirical formulae to calculate these temperaturedependent values, or specify your own values. Since the empirical formulae for
steel have already been determined, you should check the values for hightemperature changes or, even better, enter your own values here.
All the criteria for the bolted joint are checked in the assembled state at ambient
temperature, and also in a stationary or non-stationary state at operating
temperature (according to VDI 2230: preload, bolt load, fatigue life, and surface
pressure).
KISSsoft automatically performs the calculation for assembly and operating
temperatures at the same time. This calculation should also be performed for a higher temperature difference between the bolt and the parts. The minimum
temperature difference between the parts or the bolt and the assembly temperature
must at least equal 30 C, so that results appear in the report.

42.4.1

Technical explanations

The critical influences of temperature on the operating properties of bolts are:

Change in pretension force due to thermal expansion
Change in pretension force due to relaxation (at high temperatures)
Brittleness (at high and low temperatures)
The lack of sufficient general data for materials (bolt materials and clamped parts)
means the number of calculation options is also limited. The change in pretension
force due to thermal expansion can be calculated very accurately because, as a first
approximation, the thermal expansion value can be viewed as linear (with the
temperature) (in a temperature range: from -100 to +500C). The other effects (relaxation and brittleness) can be minimized by selecting appropriate materials and
taking precautionary measures (see the relevant literature).
The calculation of the change in pretension force due to thermal expansion is
performed as specified by H. Wiegand in "Schraubenverbindungen, 4th Edition
1988, section 7.1.3.1" (with temperature-dependent thermal expansion value and
Young's modulus). All other calculations are based on the equations in VDI 2230
with the appropriate values at operating temperature.
KISSsoft suggests sensible values for much of the data you can input (Young's
modulus, thermal expansion value, yield point at operating temperature) which are
based on current technical literature (DIN standards, technical documentation from

Chapter
IV-981

Bolts

42

the company Bosshard, in Zug, Switzerland). These suggestions are based on the
Young's modulus for ambient temperature and, of course, also on the operating
temperature. When calculating the suggestion for the permissible pressure at operating temperature, the proportional change to the yield point was assumed. The suggestions are average values for "commonly used steels". They do not refer to one
specific material and must therefore be checked carefully in critical situations
because the influence of temperature also varies according to the type of material
involved. If you want to calculate material data automatically using empirical
formulae, simply click on the Calculation>Settings tab.

42.4.2

Coefficients of friction

In KISSsoft you can specify an interval for friction coefficients. The minimum value is used for calculation with FM, FMmax and the maximum value is used for
calculation with FMmin and FM/A. The maximum value therefore affects the scatter
of the tightening torques.

Figure 42.19: Friction coefficients in the thread.

Chapter
IV-982

Bolts

42

Figure 42.20: Friction coefficients in head bearing area and nut bearing area.

You can also use the sizing according to friction classes A to E as specified in VDI
2230 Sheet 1, Appendix to Table A5 to define the values for the coefficients of
friction. The minimum and maximum coefficients of friction for the thread, the
bearing surface and the nut support are then imported into KISSsoft.

42.4.3

Angle of rotation-controlled tightening

For angle of rotation-controlled tightening, the report displays a preload torque and
an angle of rotation split into a number of steps. Here you can enter the value for
this preload torque and the number of steps. The angle of rotation is then calculated
with the medium assembly preload force (FM + FM/A)/2. If the yield point
utilization is 100%, this force is applied up to the yield point. To calculate the
tightening angle of rotation you can also enter the required plastic strain of the
weakest cross section.

Chapter
IV-983

Bolts

42

42.5

Stripping strength

Click on the Length of engagement flag to calculate the length of engagement and check the stripping strength of the thread according to VDI 2230 section
5.5.5.

Figure 42.21: Entries for calculating the length of engagement and stripping strength

In this screen you can enter the data for the length of engagement. Use the sizing
buttons to set the individual defaults which were calculated from the entries in the
main screen.
The length of engagement meffmin is calculated from the (theoretical) tensile
strength Rm of the bolt material, the length of engagement meffmax is calculated
for the bolt and internal thread (with Rmmax, dmin or d2min and D2max or
D1max according to VDI 2230 Sheet 1, Equation 210/213). The more critical case
is then displayed in the results.
The default value for the Rmmax/Rm coefficient is 1.2. This is also stated as a
practice-related value in VDI 2230.
You can change the Rmmax/Rm coefficient in Calculation > Settings.
To calculate the worst case (VDI 2230, formula 210), you must also take the thread
tolerance into account. To define this influence, the minimum external diameter of
the bolt dmin, the maximum flank diameter of the internal thread D2max, the
minimum flank diameter of the bolt thread d2min and the maximum core diameter
of the internal thread D1max can be entered in this window.
The main report lists the stresses, the minimum length of engagement, and the
safety against shearing under load, with the maximum preload force for the connection.

Chapter
IV-984

Bolts

42

42.6

Settings

In Calculations > Settings you can enable additional settings:

Figure 42.22: Settings for bolts.

Chapter
IV-985

Bolts

42

Continue calculation if error messages appear

If you set this flag, the calculation will continue even if error messages are
displayed, for example to warn you that the yield point or the permitted pressure has been exceeded.
Calculate minimum preload force FM/A achieved
If this flag is set, the load FM/A is also calculated. The preload force FM/A is
the minimum preload force that must be present, if the entered preload force
FM is included. A is the tightening factor. It describes the scatter of the preload
force. If this option is set, the results overview in the main screen shows the results of the calculation with FM, otherwise the results with FMmax are displayed.
Do not increase required clamp load for eccentric clamping
KISSsoft increases the required clamp load to prevent gaping for eccentric
clamping. You can switch off this function here. You can then specify your
own required clamp load. Take care when using this option. The calculation assumes that gaping does not occur!
Use the resilience of the single-bolted connection for a through-bolt connection
If the diameter of the clamped part and the bolt head support is relatively small,
the connection can be calculated in the same way as a through-bolt connection.
In this case, the resiliences can still be defined as a "single-bolted connection"
(i.e. a single-bolted (tapped thread) joint).
Operating force only at operating temperature
Normally, KISSsoft calculates the minimum preload force based on the required clamp load and loading at ambient and operating temperatures. This flag
can be set when the operating force only occurs at operating temperature. In
this case, the minimum preload force is then only calculated at operating temperature. The mounting preload force FM in the working state is reduced by the
proportion (1-)*FA of the axial bolt load.
Calculate temperature dependent material data automatically with estimation formulae
KISSsoft can automatically calculate material data at operating temperature by
using empirical formulae. These empirical formulae do not take into account
the material data you entered: they use an average dependency for "commonly
used steels"! Delete this flag if you want to enter your own materials data at the
operating temperature.
Determine specific thermal expansion of washers
This opens the input field for thermal expansion values in the sub-window for
(flat) washers. If this flag is not set, the difference in preload force is calculated
using the average thermal expansion of the plates. In other words, the (flat)
washer has the same thermal expansion as the plates. This is why you have the

Chapter
IV-986

Bolts

42

option of inputting this value. If you do so, the difference in preload force is
calculated using the value you specified, but the resilience of the plates is still
used in this calculation. VDI 2230 does not specify that a special thermal expansion calculation is to be used for washers.
Calculate mounting and operating stress without torsion
Select this option if the connection is fully preloaded to the extent that torsional
stress no longer occurs. If you do this, the torsion is set to 0 when the system
calculates the equivalent stresses that occur during mounting and working.
Reduction coefficient
The reduction coefficient is used to calculate equivalent stress when the machinery is in its working state. In many cases, the torsional stress in elastically
preloaded connections reduces by 50%. This is why VDI 2230 recommends the
value 0.5 is used here.
Exceeding the yield point
Three selection options are available here: yield point cannot be exceeded,
yield point can only be exceeded during operations, or yield point can be exceeded during operation and mounting. This gives the user the opportunity to
select their preferred calculation variant.
Hardening coefficient
An additional hardening factor, kv, is used when calculating whether the yield
point has been exceeded during mounting and during operation. The default value for the hardening factor is 1.15. The VDI standard specifies that it should
lie between 1.1 and 1.2.
Additional torsional moment during operation
An additional torsional moment can be defined when calculating working
stress. This torsional moment is then used in the shearing load calculation. This
applies both if the yield point cannot be exceeded and in cases in which the
yield point can be exceeded.
Additional torsional moment during operation
An additional torsional moment can be defined when calculating working
stress. This torsional moment is then used in the shearing force calculation.
This applies in cases where the yield point is exceeded.
Endurance limit
Selection list for specifying the kind of bolt for which the endurance limit calculation is to be performed. In the case of high-strength friction-grip fasteners,
the sustainable fatigue life is reduced by 10% because of special geometrical
features. In the case of hot-galvanized high-strength friction-grip fasteners, the
sustainable fatigue life is reduced by 30%. (Comment in VDI 2230, chapter on
alternating stress)

Chapter
IV-987

Bolts

42

Tensile strength of bolt coefficient

This coefficient is used to calculate the minimum length of engagement required to achieve a practical value for Rm (as in VDI 2230). You will find a more
detailed description in the section on Stripping strength (see page IV-983).

Chapter
IV-988

Welded joints

43

43

Welded jo ints

Chapter 43
Welded joints
Underlying principles of calculation: DIN 18800, Part 1, Edition November 1990,
in particular section 8.4 "Joints with arc welding"

.
Figure 43.1: Basic data: Welded joints

Chapter
IV-989

Welded joints

43

43.1

Welded joints

You can apply the calculation method defined in DIN 18800 to these welded seam
types:

Butt seam through welded

Double HV welded seam counter welded

HV welded seam, cap position counter

welded

HV welded seam, root through welded

HY-seam with fillet weld, not through

welded
HY-seam, not through welded

Double-HY-seam with fillet weld, not

through welded

Double-HY-seam, not through welded

Chapter
IV-990

Welded joints

43

Double-I-seam, not through welded

Fillet weld, not through welded

Double-fillet weld, not through welded

Chapter
IV-991

Welded joints

43

43.2

Seam length

Table 20 in DIN 18800 shows various configurations that use welded seam length
l.

Chapter
IV-992

Welded joints

43

43.3

Welded seam equivalent stress

Use the following formula to calculate the equivalent stress for butt and filled
welded seams:

(43.1)

W,V : Equivalent stress [N/mm2]

r: Normal stress (vertical to the welded seam) [N/mm2]
r: Shear stress (vertical to the welded seam) [N/mm2]
p: Shear stress (parallel to the welded seam) [N/mm2]

Chapter
IV-993

Welded joints

43

43.4

Weld seam boundary stress

The weld seam boundary stress W,R,d is calculated with:

(43.2)

W,R,d: Weld seam boundary stress [N/mm2]

W : Weld seam boundary coefficient [-]
Rp: Yield point [N/mm2]
M: Part safety coefficient [-]

Chapter
IV-994

Welded joints

43

43.5

Part safety coefficient

The part safety coefficient m is usually 1.1 as specified in section 7.3 in DIN
18800. However, you can also use the value 1.0 to prove the suitability for use or
reduced stiffness.

Chapter
IV-995

Welded joints

43

43.6

Boundary safety coefficient

The weld seam boundary coefficient W is defined as specified in Table 21 of the

standard:
Weld
seam
type

Seam quality

Stress
type

St37-2 and
similar

St52-3 and
similar

1-4

all seam quality

Compressio
n

1.0

1.0

Proven seam quality

Tension

1.0

1.0

Unproven seam quality

Tension

0.95

0.85

5 - 15

All seam quality

Compressio
n, tension

0.95

0.85

1 - 15

All seam quality

Shear

0.95

0.85

Chapter
IV-996

Welded joints

43

43.7

Materials

Figure 43.2: Materials screen: Welded joints

The selection list contains materials from the DIN 18800 standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
IV-997

Glued and soldered joints

44

44

Glue d a nd sold ered jo in ts

Chapter 44
Glued and soldered joints
Calculation basis: [64]. The calculation is performed for glued and soldered joints
that are subject to shear.

Figure 44.1: Basic data: Glued and soldered Joints

Two different load cases are described:

Shear force: Transmission of shear force between two surfaces.
Torque: shaft-hub connection with a torque load.
The connection can be subject either to static or dynamic (usually pulsating) load.
The guide values for the static strength of soldered joints are taken from [64], Table 8/8 (average values of resistance to fracture due to shearing). Guide values for
glued joints are taken from Table 8/9. For the pulsating load on soldered joints,
50% of the static strength is assumed as the permitted limit (data not available: you
must check these connections to ascertain the endurance limit of the base material.

Chapter
IV-998

Glued and soldered joints

44

This may reduce the element safety of the soldered joint by approximately 80%).
For glued joints, 30% of the static strength is permitted (as defined in Table 8/9).
At present, the following materials can be used for glued joints:
cured at ambient temperature.
cured at higher temperature.
To calculate the shear strength value the program uses the mean value of the minimum and maximum value from the database. The value achieved by optimum
implementation as defined in Niemann is not used.
At present, the following materials can be used for soldered joints:
Soft solder LSn40, LSn60 for short-term loads
Soft solder LSn40 at continuous load
Brass solder: Steel NE heavy metals
New silver solder-copper: Steel
Silver solder: Steel NE heavy metals
There is no point calculating and sizing soldered joints with light Al-based metals
because the strength of the underlying material is usually less than that of the joint.
To calculate the shear strength value the program uses the mean value of the minimum and maximum value from the database.

Chapter
IV-999

Glued and soldered joints

44

44.1

Basic materials

These materials are only used to size the width, on the basis of the strength of the
base material.
At pr e s e nt , y o u ca n se l e ct t h e se ma t eri als :

Ck 45 N, Ck 60, CrNiMo, CrNi 4, CrNiMo, CrMo, St 37.3, St 52.3, St 60.2,

Ganevasit, PA 12, PA 66, POM, laminated wood.
You must then still decide which material will be the best for your joint. For
example, you should not select PA 12 if you are using a soldered joint.

Chapter
IV-1000

Glued and soldered joints

44

44.2

Settings

In this window you can view the required safety value and the shear strength to be
used in the sizing, you can change this value as required.

Figure 44.2: Settings: Glued and soldered joints

Chapter
IV-1001

Glued and soldered joints

44

44.3

Sizings

Sizing the width on the basis of the base material

Sizing the adhesion width (for shaft hub), or the adhesion length (for brackets),
on the basis on the strength of the base material. The tear resistance of the joint
is set so that it corresponds to the tear resistance of the underlying material or
the fatigue strength under pulsating stress of the shaft.
Sizing the width on the basis of stress
Sizing the adhesion width on the basis of stress. The tear resistance of the joint
is sized so that it can withstand the forces it is subjected to without compromising the required safety.

Chapter
IV-1002

Glued and soldered joints

44

44.4

Bracket connection

Calculating a glue or soldered joint with sheets or plates. You must specify the tension or compression force, the adhesion length, and the metal sheet or plate
thickness.

Chapter
IV-1003

Glued and soldered joints

44

44.5

Shaft connections

Calculating a glued or soldered joint for shaft-hub connections. You must specify
the transferring torque in Nm, the joint diameter and the length of the adhesion
point.

Chapter
IV-1004

Retaining rings (self-locking rings, Seeger rings)

45

45

Reta ini ng rin gs (self-lo cking ri ngs, See ger rings)

Chapter 45
Retaining rings (self-locking
rings, Seeger rings)
This module is used to perform calculations for shaft or hub retaining rings. The
calculations are carried out in accordance with the manual published by the company Seeger. To open the module, navigate to the module tree and double-click the
appropriate module (see Figure 45.1).

Figure 45.1 The Seeger ring calculation module

Chapter
IV-1005

Retaining rings (self-locking rings, Seeger rings)

45

45.1

Basic data

Input the following data in the Basic data tab:

"Geometry" group

Shaft/bore ring: specifies whether the calculation is to be performed for a

shaft or for a bore ring

Retaining ring/Circlip: specifies whether the calculation is to be performed

for a circlip or a retaining ring

d1: nominal length, the shaft diameter for a shaft ring, or the bore diameter
for a bore ring

d2: groove diameter

d3: inside diameter of the Seeger ring for shafts or external diameter of
Seeger ring for bores in the unstressed state

b: the maximum radial width of the Seeger ring

Measure l: see Figure 45.2

s: the thickness of the ring

: permissible dishing angle of the Seeger ring (see Figure 45.3)

sharp-cornered bearing area: Controls whether conditions with a chamfer,

the corner distance or the radius of g should be considered (see Figure
45.3)

g: the chamber or corner distance/radius

Chapter
IV-1006

Retaining rings (self-locking rings, Seeger rings)

45

Figure45.2 Geometry of shaft ring (a) and bore ring (b)

Figure 45.3 Definition of geometric values s, , g

"Operating data" group

q: the load factor, taking into consideration the effect of the shoulder length
ratio (see Figure 45.4)

the coefficient of friction between the ring surface and the shaft/bore
surface

"Materials" group

In this group you can define the material of the ring and shaft/bore. The
functionality is similar to the rest of the KISSsoft modules which are
located in the "Connections" module group.

Chapter
IV-1007

Retaining rings (self-locking rings, Seeger rings)

45

45.2

Automatic calculation of load factor q

If you click on the

button next to q, the system displays a window in which you
can calculate q, based on the ratio of the shoulder length n to the groove depth t
(see Figure 45.4). The groove depth is defined as:
t = (d1 - d2)/2 for shaft rings
t = (d2 - d1)/2 for bore rings

Figure 45.4 (a) Definition of load factor q, shoulder length n and groove depth t. (b) Sizing window for load factor q.

Chapter
IV-1008

Retaining rings (self-locking rings, Seeger rings)

45

45.3

Automatic calculation of the dishing an gle

Use Figure 45.5 to calculate automatically.

Figure 45.5 Calculation of , based on d1.

Chapter
IV-1009

Retaining rings (self-locking rings, Seeger rings)

45

45.4

Module specific settings

Here you can define the minimum required safety S.

Chapter
IV-1010

Answers to Frequently Asked Questions

46

46

Answers to Fr eque ntly Aske d Ques tio ns

Chapter 46
Answers to Frequently Asked
Questions

Chapter
IV-1011

Answers to Frequently Asked Questions

46

46.1

Adding new bolt types to the dat abase

The KISSsoft database includes the following bolt types:

Hexagon socket head cap screws EN ISO 4762
Hexagon headed bolts with shank (AB) EN ISO 4014
Hexagon headed bolts without shank (AB) EN ISO 4017
Slotted cheese head screw EN ISO 1207
Hexagon headed bolts with shank, metric fine thread (AB) EN ISO 8765
Hexagon headed bolts without shank, metric fine thread (AB) EN ISO 8676
Hexagon headed screws with flange, light series, shape F EN 1662
Hexagon headed screws with flange, light series, shape U EN 1662
Hexagon headed screws with flange, heavy series, shape F EN 1665
Hexagon headed screws with flange, heavy series, shape U EN 1665
Own definition of screw geometry
For each of these bolts types, a number of tables list the various bolts sizes (= bolts
series). You will find the name of the file that contains the bolts series data in the
database (see page I-124).
You enter a new size within an existing bolt type i.e. extend the bolt series (see
page IV-1011) or input a new bolt type (see page IV-1013).

46.1.1

Extending an existing bolt series

Example: Enter the data for M8 bolts with a length of 100 mm in the "hexagon
socket head cap screw EN ISO 4762" series.

Chapter
IV-1012

Answers to Frequently Asked Questions

46

Then start the database tool. Open the Screw Type M000.KDB, M040Typ
table. There, select the Hexagon socket head cap screw EN ISO
4762 data record. In the File name field you will see the name of the file
which contains the table with the bolt series data. Click the Edit button at the end
of the input line to open the file in the Editor:

To enter a new bolt:

Look for a similar bolt (M8, length 80mm).
You will see a line with all data for this bolt.

Copy this line. When you do so, note the exact sequence of the lines.

Chapter
IV-1013

Answers to Frequently Asked Questions

46

Change the data in accordance with Table 1 in EN ISO 4762 (length 100
instead of 80, length l1 72 instead of 52).

Save the file.

Document any changes for other users.

46.1.2

Creating a new bolt type

Before you can add a new bolt type you must already be familiar with the table
structure. You must know which value goes in which column (use the variable names from the descriptions in the table header).
Then, proceed as follows:
In the database, open the data record most similar to the new bolt type.
Copy this data record and rename it to suit the new bolt type.
Click the Edit button at the end of the input line for the file name. This opens
a file which still contains the "old" values.
Overwrite these values with the new values. Note the variables structure (i.e. a
specific variable is assigned to a number, depending on where the number appears) and the sorting of the lines.
Save the updated file with a new name and close the Editor.
Transfer the new file name to the database (to create the cross reference).
Then save the new data record.

V Sprin gs

Part

Springs

Chapter
V-1015

Compression springs

47

47

Com pressio n spr ings

Chapter 47
Compression springs
The calculation of compression springs is based on DIN EN 13906-1 (2002)[30].

Figure 47.1 Basic data for compression springs

Op e ra ti ng da ta

When you specify a load, you can use your own value as the spring force or travel.
You can also specify whether the spring is to be subject to static, quasistatic, or
dynamic, force.
Ge o m et ry

You can select the geometry data according to DIN 2098 Part 1 directly from this
table.
If you select Own input, you can either take selected values from the list or enter
your own values. Select Own input to specify your own spring length and the
diameter.
Instead of using the spring length in its non-stressed state L0 you can also use a
spring length in its stressed state L1 or select L2.
The choice of the End of spring and Manufacture affects the calculation
of the block length Lc.

Chapter
V-1016

Compression springs

47

Click the Update button to calculate the block lengths and the resulting values of
the current situation for individual springs and display them in a table.

47.1

Strength values

The material strengths are stored in different files, depending on diameter. The
transverse strength is either saved in the tables, as in DIN EN 13906-1 for thermoformed springs, or calculated from the predefined tensile strength as czul =
0.56Rm.
To calculate the endurance limit, use either the Goodman diagram as defined in EN
13906-1 or an approximation. The approximation assumes a dynamic strength of
0.25Rm and a gradient of the graph of the upper stress in the Goodman diagram of
0.75. For shot peened materials, the dynamic strength is increased by 20%. These
values roughly correspond to the diagrams in the DIN EN 13906-1 standard, but
you should regard the safeties more conservatively.

47.2

Shear stress values

The calculation of the highest shear stress also calculates the axial and shear spring
travel.

(47.1)

max: highest shear stress [N/mm2]

d: wire diameter [mm]
F: spring force [N]
D: average coil diameter [mm]
sQ: shear spring travel [mm]
FQ: shear spring force [N]
L: spring length [mm]
The highest corrected shear stress is calculated by:

(47.2)

kmax: highest corrected shear stress [N/mm2]

max: highest shear stress [N/mm2]

Chapter
V-1017

Compression springs

47

K: stress correction factor

(dependent on the ratio D/d)

47.3

Bearings coefficient

The Support you select defines the value of the support coefficient , as shown
in Figure 47.2.

Figure 47.2: Support with associated support coefficients for axially stressed compression
springs

The support coefficient is used for calculating the buckling spring travel sk. If the
buckling safety factor is not reached then the spring must be guided, otherwise it
will buckle.

47.4

Materials

Figure 47.3: Compression springs

Chapter
V-1018

Compression springs

47

The selection list includes materials from the DIN 17221, DIN 17223-1, DIN
10270-1, DIN 10270-1 and DIN 10270-3 standards.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

47.5

Tolerances

Figure 47.4: Additional wire diameter data for compression springs

When you select a spring from the table (in accordance with DIN 2098 part 1), the
tolerance of the diameter used here is specified in DIN 2076 C. To change the diameter tolerance, toggle to the Own input list to open the input fields. Here click
the

button next to the wire diameter field to open another screen. (see Figure)

In the Tolerances screen you can select wire diameters in accordance with DIN
2076 (1984), DIN 2077 (1979), EN 10270-1 (2001), EN 10270-2 (2001), EN
10270-3 (2001), or enter your Own input value.
If you select a wire diameter tolerance in accordance with the standard, the
tolerance will be inserted directly in the screen.
If you select Own input, you can define the value yourself.
Other tolerances are listed in accordance with the quality standard. In the
Tolerances list in the basic data you can choose one of the quality standards in
accordance with DIN 15800 (2009)[14] or DIN 2096 Part 1 (1981)[15].

Chapter
V-1019

Compression springs

47

47.6

Relaxation

The existing spring force can be located after a specific period of time by
calculating the relaxation. The compression spring settles to a particular value. Relaxation is also known as creep. The relaxation values are listed in the DIN EN
13906-1 standard, and shown in diagrams. The diagrams show curves at specific
diameters and temperatures, which are then recorded in a relaxation-stress diagram.
By noting the data from 2 different wire diameters temperatures, you can then infer
or extrapolate the relaxation value for a specified level of stress at operating
temperature and for a specific wire diameter.
In KISSsoft, the relaxation diagram for 48h can be displayed in relation to diameter, temperature and stress. Other graphics are also available that show the progress
of relaxation over time and the spring force. The results for the specified conditions
are then displayed in the relaxation report for 48h. The value of the spring force is
also calculated after 48h.
To extend the data for the materials relaxation curves, or add new data, add this
new information to the *.dat file for the appropriate spring material.
The relaxation curves in this file can be defined with 2 or 3 given measurement
points. The curves are then calculated from these points.

Figure 47.5: Relaxation for compression springs

Chapter
V-1020

Compression springs

47

47.7

Drawing data

To access the spring data required to create a drawing, click Drawing data. Use
the F10SPRING?.RPT file (for compression springs), or the F20SPRING?.RPT
file (for tension springs), etc. (? = d/e/f/i/s for the required language) to modify the
template to your own requirements.

47.8

Sizings

Figure 47.5: Sizing screen: Compression springs

If you selected Own input in the list under Geometry, you now see input fields
here instead of a table showing the values defined in the standard. Next to the
Wire diameter and the Effective coils, you can click the
size the following values.

button to

Using the predefined spring rate R = F/s, the number of turns n can also be
calculated if the wire diameter has been predefined. The number of turns is defined
by this value, but the strength and the geometric constraints are not checked. The
program also suggests a value for the minimum wire diameter and the associated
number of turns. The minimum wire diameter here is defined by the strength of the
material.

Chapter
V-1021

Tension springs

48

48

Tension spri ngs

Chapter 48
Tension springs
The tension spring calculation is described in the DIN EN 13906-2 (2013)[31]
standard.

Figure 48.1: Basic data: Tension springs

Op e ra ti ng da ta

When you specify a load, you can use your own value as the spring force or travel.
This force is defined as the initial preload force F0, which is required to
open the coils which lie one on top of the other. This force is only present if the
spring is pretensioned.
If the flag for Inner preload is not set, you can influence the number of
effective coils.
You can also specify whether the spring is to be subject to static, quasistatic, or
dynamic, stress.
Ge o m et ry

You can specify the spring length and the spring diameter directly in the main
screen.
Instead of using the spring length in its non-stressed state L0 you can also use a
spring length in its stressed state L1 or select L2.

Chapter
V-1022

Tension springs

48

For the wire diameter, you can either select the diameter values as defined in DIN
2098 supplement 1 from the list or enter your own value directly in the list.

Figure 48.2: Definitions used for tension springs

48.1

Strength values

Permissible shear stress is calculated from the tensile strength of cold formed tension springs. The tensile strength values are determined by diameter values stored
in various files. The shear stress is calculated using the formula zul = 0.45Rm.
Thermo-formed tension springs should not exceed the permissible shear stress of
zul = 600N/mm2. These values apply to static or quasi-static cases. Tension springs
as defined in DIN 2097 should not be subjected to dynamic stress if at all possible.
Shear stress is distributed very unevenly over the cross section of the wire or pin of
a tension spring. You can use an intensity factor k to approximate the highest
arithmetical stress. Additional stresses are present at the transitions to the eyes. As
they may be well above the permissible shear stress, no generally applicable
fatigue strength values can be given.

48.2

Shear stress values

The shear stress is calculated for the sizing of springs that are subject to static and
quasistatic stress:

Chapter
V-1023

Tension springs

48

(48.1)

Shear stress [N/mm2]

D: medium coil diameter [mm]
F: spring force [N]
d: wire diameter [mm]
Calculating shear stress for springs subjected to dynamic stress:

(48.2)

k: corrected shear stress [N/mm2]

: Shear stress [N/mm2]
k: stress correction factor
(dependent on the ratio D/d)

48.3

Manufacturing type

Thermo-formed tension springs cannot be produced with inner preload force

because the heat treatment creates an air gap between the coils. Cold shaped tension springs can be manufactured in two ways, either by winding on a coiling bench
or by winding on a spring winding machine. As defined in DIN EN 13906-2, a
formula is specified for each manufacturing method which gives the permissible
inner shear stress 0.

48.4

Eyes screen

Figure 48.3: Definitions used for eyes

Chapter
V-1024

Tension springs

48

Using the definitions of the Length of eye LH in each case, in this screen, you
can then determine the total length of the spring. In contrast, the Hook opening
m is a reported value that is not used in this calculation.
DIN 2097 defines 13 different eye shapes for tension springs. The program
suggests different eye lengths depending on the shape of the eye. The position of
both eyes is also handled separately in this DIN standard.

1/2 German loop

1/1 German loop

2/1 German loop

1/1 German loop at side

2/1 German loop at side

Hook

Extended side hook

English loop

Coiled-in hook

Screwed plug

Chapter
V-1025

Tension springs

48

Screwed-in screw cap

Screwed-in shackle

1/1 German loop inclined

48.5

Materials

Figure 48.4: Materials screen: Tension springs

The selection list includes materials from the DIN 17221, DIN 17223-1, DIN
10270-1, DIN 10270-1 and DIN 10270-3 standards.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
V-1026

Tension springs

48

48.6

Settings

Figure 48.5: Settings: Tension springs

If the Calculate length using coils flag is set, and the spring is
prestressed (Initial tension force flag set), the length of the spring is
calculated from the number of coils. You can no longer input the spring length in
the dialog.

48.7

Tolerances

Figure 48.6: Additional wire diameter data for tension springs

Click the
button next to the Wire diameter field to open the Tolerances screen.
In this screen you can select a wire diameter as defined in DIN 2076 (1984), DIN
2077 (1979), EN 10270-1 (2001), EN 10270-2 (2001), EN 10270-3 (2001) or input
your Own input to enter your own value.
If you select a wire diameter tolerance in accordance with the standard, the
tolerance will be inserted directly in the screen.
If you select Own input, you can define the value yourself.
Other tolerances are listed in accordance with the quality standard. In the
Tolerances list in the basic data you can choose one of the quality standards in
accordance with DIN 2097[16] or DIN 2096 Part 1 (1981)[15].

Chapter
V-1027

Tension springs

48

48.8

Relaxation

The existing spring force can be located after a specific period of time by
calculating the relaxation. The compression spring settles to a particular value. Relaxation is also known as creep. The relaxation values are listed in the DIN EN
13906-1 standard (the standard for compression springs), and shown in diagrams. It
was assumed that the same relaxation values can be used for both for tension
springs and compression springs. The diagrams show curves at specific diameters
and temperatures, which are then recorded in a relaxation-stress diagram. By
noting the data from 2 different wire diameters temperatures, you can then infer or
extrapolate the relaxation value for a specified level of stress at operating
temperature and for a specific wire diameter.
In KISSsoft, the relaxation diagram for 48h can be displayed in relation to diameter, temperature and stress. Other graphics are also available that show the progress
of relaxation over time and the spring force. The results for the specified conditions
are then displayed in the relaxation report for 48h. The value of the spring force is
also calculated after 48h.
To extend the data for the materials relaxation curves, or add new data, add this
new information to the *.dat file for the appropriate spring material.
The relaxation curves in this file can be defined with 2 or 3 given measurement
points. The curves are then calculated from these points.

Figure 48.5: Relaxation for tension springs

Chapter
V-1028

Tension springs

48

48.9

Drawing data

To access the spring data required to create a drawing, click Drawing data. Use
the F10SPRING?.RPT file (for compression springs), or the F20SPRING?.RPT
file (for tension springs), etc. (? = d/e/f/i/s for the required language) to modify the
template to your own requirements.

Chapter
V-1029

Tension springs

48

48.10

Sizings

Figure 48.7: Sizing screen: Tension springs

Click the
buttons next to the Wire diameter and Effective coils
fields to use the spring rate R = F/s to calculate the number of turns n for the
predefined wire diameter. The program also suggests a value for the minimum wire
diameter and the associated number of turns. The minimum wire diameter here is
defined by the strength of the material.

Chapter
V-1030

Leg springs

49

49

Leg spr ings

Chapter 49
Leg springs
The calculation used for leg springs is defined in DIN EN 13906-3 (2002) [32].

Figure 49.1: Basic data: Leg springs

Op e ra ti ng da ta

When you define a load you can either enter a value for the spring force, spring
angle, or spring torque.
To do this, you must first specify the torsion arm (R1,R2) on which the force is applied to the spring.
The value 0 is used to identify the starting angle. This is used together with the
direction of load (sense of winding) to calculate the maximum angle of the spring.
Depending on which value you select in the Guiding of spring list, the report will also include a reference value for the diameter of the working mandrel or
the working bush.
You can also specify whether the spring is to be subject to static, quasistatic, or
dynamic, stress.
Ge o m et ry

Chapter
V-1031

Leg springs

49

You can select the geometry data according to DIN 2098 Part 1 directly from this
table.
If you select Own input, you can either take selected values from the list or enter
your own values. If you select Own input you can select a value for the spring
diameter and enter it directly.
The winding clearance is the distance between the coils.

Figure 49.2: Definitions used for leg springs

49.1

Strength values

The permissible bending stress for cold formed leg springs is calculated from the
tensile strength. The tensile strength values are determined by diameter values
stored in various files. The bending stress is calculated using the formula zul =
0.7Rm. These values apply to static or quasi-static cases. The bending of the wire
or pin axis due to the load causes an asymmetrical distribution of the spring stresses. In order to approximate the arithmetical stress (dynamic case), you can use the
stress coefficient q in the calculation.

Chapter
V-1032

Leg springs

49

49.2

Bending stress values

The bending stress is calculated for the sizing of springs that are subject to static
and quasistatic stress:

(49.1)

shear stress [N/mm2]

T: spring torque [Nm]
d: wire diameter [mm]
Calculating the bending shear stress for springs subject to dynamic stress:

(49.2)

q: corrected bending shear stress [N/mm2]

: bending shear stress [N/mm2]
q: stress correction factor
(dependent on the ratio D/d)

49.3

Spring design

In order to prevent friction, the coils either do not touch each other or under only
slight stress. For the biggest achievable winding clearance the following applies:

Generally, leg springs are wound. There are two options for the leg design: they
can be either bent with offset (the radius must be specified) or tangential.

Chapter
V-1033

Leg springs

49

with tangential legs

49.4

with offset legs

Assumptions made for the calculation

The calculations apply only to leg springs with fixed or circular guided spring ends.
If the leg is not fixed, the spring must be guided by means of a pin or sleeve.

49.5

Materials

Figure 49.3: Materials screen: Leg springs

The selection list includes materials from the DIN 17221, DIN 17223-1, DIN
10270-1, DIN 10270-1 and DIN 10270-3 standards.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

Chapter
V-1034

Leg springs

49

49.6

Tolerances

Figure 49.4: Additional wire diameter data for leg springs

Click the
button next to the Wire diameter field to open the Tolerances
screen. In this screen you can select a wire diameter as defined in DIN 2076
(1984), DIN 2077 (1979), EN 10270-1 (2001), EN 10270-2 (2001), EN 10270-3
(2001) or input your Own input to enter your own value.
If you select a wire diameter tolerance in accordance with the standard, the
tolerance will be inserted directly in the screen.
If you select Own input, you can define the value yourself.
In the Tolerances list in the basic data you can choose one of the quality standards in accordance with DIN 2194 (2002)[17].

49.7

Drawing data

To access the spring data required to create a drawing, click Drawing data. Use
the F10SPRING?.RPT file (for compression springs), or the F20SPRING?.RPT
file (for tension springs), etc. (? = d/e/f/i/s for the required language) to modify the
template to your own requirements.

Chapter
V-1035

Leg springs

49

49.8

Sizings

Figure 49.5: Sizing: Leg springs

Click the
buttons next to the Wire diameter and Effective coils
fields to use the spring momentum rate RMR = M/ to calculate the number of
turns n for the predefined wire diameter. The program also suggests a value for the
minimum wire diameter and the associated number of turns. The minimum wire
diameter here is defined by the strength of the material.

Chapter
V-1036

Disc springs

50

50

Disc s prin gs

Chapter 50
Disc springs
The calculation for disc springs is described in DIN 2092 (2006) [12]. The mass
and quality requirements are handled according to DIN 2093 (2006)[13].

Figure 50.1: Basic data: Disc springs

Op e ra ti ng da ta

When you specify a load, you can use your own value as the spring force or travel.
You can also specify whether the spring is to be subject to static, quasistatic, or
dynamic, stress.
The calculations specified in DIN 2092 are for disc springs with or without bearing
areas for the ratios 16 < De/t < 40 and 1.8 < De/di <2.5 and materials specified in
DIN 2093.
Ge o m et ry

As specified in DIN 2093, disc springs are divided into 3 groups and 3 sequences.
Groups 1 and 2 contain the springs without a bearing area, whereas group 3 has the
springs with a bearing area. The disc thickness for group 1 is less than 1.25 mm, in
the group 2 it is between 1.25 and 6 mm and in group 3 it lies between 6 and 14
mm. The sequences differ according to spring hardness. Series A includes hard
springs, i.e. they can withstand larger forces, in a smaller travel of spring. Series A
includes hard springs, i.e. they can withstand larger forces in a smaller travel of

Chapter
V-1037

Disc springs

50

spring. This is followed by series B and series C which can withstand the least force in a larger travel of spring. If you select Own input, the input fields for
geometry data become active, and you can enter your own values in them. This
type of calculation only applies to springs without a support area, because the ratio
of the thicknesses t/t is not known, but it is still required for the calculation.

Figure 50.2: Dimensions of the disc springs

50.1

Strength values

In the case of springs that are subject to static or quasi-static load (N <= 104), the
maximum force on the spring is calculated. The formula is predefined in DIN
2092. This force then is compared to the effective force Fn of the spring (at s =
0.75h0) and the utilization of the spring force is calculated. If the required force is
greater than the spring's effective force, Fn, the deviation in the calculation is too
large. The DIN formula for calculating force only applies where the travel of the
spring is s = 0.8h0. The springs can be used in packages or columns to handle larger forces. The calculation used to ascertain the overall force of the system is then
represented in a force travel diagram. The calculation for disc springs is performed
without taking friction into account.
Furthermore, the stresses are calculated at edge points I to IV. Points I and IV are
subjected to compression, and points II and III are put under tension. Under dynamic load, the stress range is calculated using the maximum stress (either at point II
or III) with the relevant lower stress level. The permissible permanent stress range
is defined using a Goodman diagram. These values are then compared to give the
number of load cycles the spring should be able to withstand under load. DIN 2093
includes Goodman diagrams which are only valid for materials specified in DIN
17221 and 17222. If any other materials are involved, you must contact the spring
manufacturer.

50.2

Stress values

Stresses are calculated for edge points I to IV.

Point I:

Chapter
V-1038

Disc springs

50

(50.1)

Point II:
(50.2)

Point III:
(50.3)

Point IV:
(50.4)

I - IV : Stress at points I-IV [N/mm2]

E: Young's modulus [N/mm2]
: Poisson's ratio [-]
De: External diameter [mm]
s: Spring travel of an individual disc [mm]
t: Thickness of an individual disc [mm]
h0: Travel of spring until flat [mm]
: Diameter ratio (De/Di)
K1 - K4: Variables calculated from formulae (DIN 2092)

50.3

Materials

Figure 50.3: Materials screen: Disc springs

The selection list includes materials from the DIN 17221, DIN 17222, DIN 17224
and DIN 10270-3 standards.

Chapter
V-1039

Disc springs

50

If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

50.4

Calculate number

Figure 50.4: Sizing the number of packages/ columns

To estimate the number of discs or columns required, click the

button next to
the fields for number of springs per package or number of packages per column. In
this screen, you can define the maximum force and the maximum travel can be
defined. These values are then used to calculate and display the number of springs
per package or the number of packages per column.

Chapter
V-1040

Disc springs

50

50.5

Limit dimensions

For all disc springs, the external diameter De must lie in a tolerance field h12 and
the inside diameter Di must lie in a tolerance field H12.

Chapter
V-1041

Torsion-bar springs

51

51

Torsion-bar s prin gs

Chapter 51
Torsion-bar springs
The calculation of torsion-bar springs is described in DIN 2091 (1981)[11].

Figure 51.1: Main screen: Torsion-bar calculation

Op e ra ti ng da ta

When you specify the load, you can enter a value for either an angle of rotation or a
torsional moment.
If a torsion-bar is set as the default (Torsional bar preplaced flag) the
permitted shear stress of the torsion-bar, zul, is increased.

Ge o m et ry

Chapter
V-1042

Torsion-bar springs

51

Enter specific parameters to define the geometry of the spring.

For the toothed head form, you must also specify the number of teeth, although
this is purely for documentation and is not used for calculation. The standard
assumes shearing modulus G as a constant. However, the calculation is still
permitted even if this value is slightly different.

Figure 51.2: Defining a torsion-bar

Chapter
V-1043

Torsion-bar springs

51

51.1

Head forms

Torsion-bar springs as defined in DIN 2091 can have one of three different head
forms: rectangular, hexagonal and toothed. Toothed torsion-bar heads are usually
produced in accordance with DIN 5481 Part 1 or SAE J 498 b. However, they can
also be manufactured with special toothings. The body forms of the heads apply
only to bars that are loaded in the sense of rotation. Alternating loads require special design measures.

Figure 51.3: Forms of torsion-bar heads (rectangular, hexagonal, toothed)

51.2

Strength values

Definitions in DIN 2091:

Chapter
V-1044

Torsion-bar springs

51

DIN 2091 only applies to the materials defined in DIN 17221.

The permitted shear stresses:
For non-preloaded bars: zul = 700 N/mm2
For preloaded bars: zul = 1020 N/mm2
The heat treatment strength for these values is: Rm = 1600 - 1800 N/mm2
For the shearing modulus, G = 78500 N/mm2 is used as the default. Due to a
preload (above the yield point, deformed in the direction of working stress) after
the torsion-bar springs have been heat treated, there will be a better distribution of
the operating stresses, and a relief in the boundary zone will be achieved.

51.3

Shear stress

Calculating shear stress :

(51.1)

Shear stress [N/mm2]

T: Torsional moment [Nm]
d: Wire diameter [mm]

51.4

Limiting values

The following limit ratios for torsion-bar heads apply to torsion-bar springs:
rectangular, toothed: df/d > 1.3; hexagonal: df/d > 1.25
The strength values from the DIN standard apply to bar diameters 10 to 60 mm.
The guide value is a head length between 0.5 and 1.5d.
The Rh/d ratio should be between 1 and 50.

Chapter
V-1045

Torsion-bar springs

51

51.5

Sizings

Figure 51.4: Sizings screen: Torsion-bar springs

Click the
buttons next to the Wire diameter and the Shaft length
fields to open the screen described above. You can enter the torsional moment and
the angle of rotation in the sizing screen. These values are used to calculate the
torsional spring rate which is then used to size bar diameter d or shank length ls.
When sizing d and ls, you must first calculate d with the permitted shear stress value. You can then calculate the shank length ls from the bar diameter d. Various
values are assumed so that you can size the dimensions. (rectangular, toothed: df =
1.35d; hexagonal: df = 1.3d; da = df + df/7; Rh = (da-d)1.2)
These values are not transferred to the main screen.

VI Bel ts a nd chai n drives

Part

VI

Belts and chain drives

Chapter
VI-1047

V-belt

52

52

V-be lt

Chapter 52
V-belt
Preamble:
Follow the manufacturers instructions when sizing and verifying V-belt drives.
Most catalogs detail the entire calculation method. As the capacity of V-belts to
transfer power increases, due to improvements in their materials and flank shapes,
manufacturers' data provides the only really reliable values.
Fully automated calculation including standard V-belt lengths and standard
effective diameters. Determining transmittable power per belt taking into account
the speed, effective diameter, transmission speed ratio and belt length. All the data
is taken from manufacturers tables (for example, ContiTech). This also includes a
belt stress calculation module that uses data from belt-bending tests. This calculates
the end of rope force and axis load at standstill and in operation for the optimum
setting as well as for a setting in accordance with data in the catalogs.
As a variant, the calculation can also be performed with a third roller (tensioning
pulley). You define the X and Y coordinates of the tensioning pulley in the V-belt
tab. If you open the Configuration tab you can use the mouse to move the
tensioning pulley. In this case, the particular X and Y value is displayed in the status row. This roller can be positioned outside or inside as required.

Figure 52.1: Basic data: V-belt calculation

Chapter
VI-1048

V-belt

52

52.1

V-belts data

KISSsoft stores the tabular values (catalog data) in files which you can then edit.
You will find these file names in the KISSsoft database tool for the corresponding
belt types (for example, Z090-015.dat for XPA narrow V-belts).

52.2

V-belt standards

The following belt types are available:

XPA High-performance V-belts DIN7753/ISO4184 (CONTI-FO-Z)
XPB High-performance V-belts DIN7753/ISO4184 (CONTI-FO-Z)
XPC High-performance V-belts DIN7753/ISO4184 (CONTI-FO-Z)
XPZ High-performance V-belts DIN7753/ISO4184 (CONTI-FO-Z)
5/- High-performance V-belts DIN7753/ISO4184 (CONTI-FO-Z)
6/Y- High-performance V-belts DIN7753/ISO4184 (CONTI-FO-Z)
8/- High-performance V-belts DIN7753/ISO4184 (CONTI-FO-Z)
SPZ Narrow V-belt DIN7753/ISO4184 (CONTI-V)
SPA Narrow V-belt DIN7753/ISO4184 (CONTI-V)
SPB Narrow V-belt DIN7753/ISO4184 (CONTI-V)
SPC Narrow V-belt DIN7753/ISO4184 (CONTI-V)
8/- Multiflex V-belt DIN7753/ISO4184 (CONTI-V STANDARD)
10/Z Multiflex V-belt DIN7753/ISO4184 (CONTI-V STANDARD)
13/A Multiflex V-belt DIN7753/ISO4184 (CONTI-V STANDARD)
17/B Multiflex V-belt DIN7753/ISO4184 (CONTI-V STANDARD)
20/- Multiflex V-belt DIN7753/ISO4184 (CONTI-V STANDARD)
22/C Multiflex V-belt DIN7753/ISO4184 (CONTI-V STANDARD)
25/- Multiflex V-belt DIN7753/ISO4184 (CONTI-V STANDARD)
32/D Multiflex V-belt DIN7753/ISO4184 (CONTI-V STANDARD)
40/E Multiflex V-belt DIN7753/ISO4184 (CONTI-V STANDARD)
3V-9J Force-belts
5V-15J Force-belts
8V-25J Force-belts

Chapter
VI-1049

V-belt

52

3V-9N Narrow-V-belt USA standard

5V-15N Narrow-V-belt USA standard
8V-25N Narrow-V-belt USA standard

52.3

Configuring Tensioning Pulleys

Here you can select one of the following:

non-tensioning pulley
inside tensioning pulley
outside tensioning pulley
If you selected an inside/outside tensioning pulley, you can input the conical spring
washer diameter and the position (x/y) of the tensioning pulley. In the Configuration tab you can position the tensioning pulley interactively using the mouse
(the x and y values are displayed in the status row).

52.4

Application factor f1

You can enter this factor in the basic data screen. If you selected a configuration
with a tensioning pulley, you should increase factor f1 by 0.1. The table shown below is used to define the f1-factor (refer to the catalogs for more information):

Figure 52.2: Application factor V-belts

52.5

Center distance

The minimum center distance is calculated from the two belt sheave diameters.
You cannot enter a smaller value here. The sheaves must not touch each other
during operation.
The conversion processes uses a suggestion for new designs in accordance with the
ContiTech catalog. Here:
0.7*(d1+d2) <= a <= 2.0*(d1+d2)
In KISSsoft, the average coefficient for the suggested value is used in the
conversion.

Chapter
VI-1050

V-belt

52

a = 1.35*(d1+d2)

52.6

Belt length

You need to know the belt length before you can calculate a V-belt. If you have not
specified a length, or if you change to a configuration that involves a tensioning
pulley, you must ensure that the program recalculates the belt length.

52.7

Effective number of V-belts

The effective number of V-belts is calculated from the theoretical number by

rounding this value up to the next highest whole number.

52.8

Tensioning pulley diameter

The tensioning pulley diameter should be at least as big as the smallest belt sheave.
If at all possible, you should not use tensioning pulleys, in particular outside
tensioning pulleys. However, if you have to use a tensioning pulley, its diameter
should be at least 1.33d if it is an outside pulley or 1.0d if it is an inside pulley (d:
diameter of the smaller sheave).
Every manufacturer provides slightly different information about tensioning
pulleys.

Chapter
VI-1051

V-belt

52

52.9

Position of tensioning pulley (x/y)

When you configure the tensioning pulley, you can enter the position of the pulley
(in X/Y coordinates). Here, the axis of the small sheave is the origin of the
coordinates system. If you use the mouse to change the position in the Configuration tab you can only move the tensioning pulley within the valid area.

Chapter
VI-1052

V-belt

52

52.10

Inspecting V-belts

(belt bending test)

The actual axial stress of V-belt drives is calculated from data provided by the belt
bending test. Enthusiastic mechanics have a tendency to over-tension belt drives,
and therefore subject them to loads that are too high for their capabilities.

Chapter
VI-1053

Toothed belts

53

53

Tooth ed bel ts

Chapter 53
Toothed belts
Use this method to calculate and size all aspects of toothed belt drives, including
the tooth number and belt length, whilst taking into account standard numbers of
teeth. When you enter the required nominal ratio and/or the nominal distance of
axes, the program calculates the best possible positions. You can also calculate the
required belt width, taking into account the correction factors, the minimum tooth
numbers, and the number of meshing teeth. You can also print out assembly details
(belt bending test). The data for each type of belt is saved to self-describing text
files which can be edited as required.
You can also perform calculations for special stress-resistant toothed belts with
integrated steel ropes (e.g. AT5mm).
As a variant, the calculation can also be performed with a third roller (tensioning
pulley). You define the X and Y coordinates of the tensioning pulley in the
Toothed belts tab. If you open the Configuration tab you can use the mouse to
move the tensioning pulley. In this case, the particular X and Y value is displayed
in the status row. This roller can be positioned outside or inside as required.

Figure 53.1: Basic data: Toothed belt calculation

Chapter
VI-1054

Toothed belts

53

53.1

Technical notes (toothed belts)

Preamble:
Follow the manufacturers instructions to achieve the best results when sizing and
verifying toothed belt drives. Most catalogs detail the entire calculation method. As
the capacity of V-belts to transfer power increases, due to improvements in their
materials and flank shapes, manufacturers' data provides the only really reliable
values.
Elasticity:
As the manufacturers catalogs provide very little data on this subject, you must
treat the belt elasticity constraint values with caution. The elasticity (in N) is the
force required to lengthen the belt by 100%.
Weight:
As the details provided in manufacturers catalogs about this subject are not
complete, you must treat these values with caution.
Pretensioning the belt:
As the manufacturers catalogs provide very little data on this subject, you must
treat the constraint values with caution. The calculation method and the factors it
uses are stored in the Z091-0??.DAT files where they can be changed if required.
You can use one of the following procedures to calculate the required
pretensioning values for various types of belts. The data here is taken from the
catalogs:

Belt type:

Pretension:

Breco AT5, AT10, AT20

0.5

* Circumferential force

Synchroflex AT3, AT3 GIII, AT5 GIII,

AT10 GIII

0.5

* Circumferential force

Isoran XL, L, H, 8, 14

0.625

* Circumferential force

HTD 3, 5, 8, 14

0.25

* Max. permitted circumferential

force

8MGT, 14MGT Poly Chain GT2

0.5

* Circumferential force

RPP-HPR 8, 14

0.5

* Circumferential force

Table 53.1: Pretension

Forces in no load/load are calculated in accordance with [66], equation 27/23.

Chapter
VI-1055

Toothed belts

53

(53.1)

(53.2)

(53.3)

53.2

Toothed belt standard

You can select one of these standards:

XL-ISORAN RPP (FENNER)
L-ISORAN RPP (FENNER)
H-ISORAN RPP (FENNER)
8mm ISORAN RPP (FENNER)
14mm ISORAN RPP (FENNER)
8mm-ISORAN-RPP-GOLD (Megadyne)
14mm-ISORAN-RPP-GOLD (Megadyne)
8mm-ISORAN-RPP-SILVER (Megadyne)
14mm-ISORAN-RPP-SILVER (Megadyne)
RP8mm-Pirelli RPP-HPR
RP14mm-Pirelli RPP-HPR
PG3mm-Power Grip-HTD
PG5mm-Power Grip-HTD
PG8mm-Power Grip-HTD
PG14mm-Power Grip-HTD
8mm-DAYCO-RPP-(Panther)
8MGT-Poly-Chain-GT-Carbon (Gates)
14MGT-Poly-Chain-GT-Carbon (Gates)
8mm MGT-Poly Chain-GT2

Chapter
VI-1056

Toothed belts

53

14mm MGT-Poly Chain-GT2

AT3mm-SYNCHROFLEX
AT3mm GEN III-SYNCHROFLEX
AT5mm GEN III-SYNCHROFLEX
AT10mm GEN III-SYNCHROFLEX
AT5mm-BRECOflex
AT10mm-BRECOflex
AT20mm-BRECOflexAdditional standards on request.

53.3

Possible Sizings/Suggestions

The following sizings are possible if you select the different

Variable

Influencing/necessary variables

Belt profile

Power

buttons:

Speed (small disc)

Operating factor
Number of teeth on belt

Center distance
Number of teeth on sheave

Center distance

Number of teeth on belt

Number of teeth on sheave (all)

Ratio

Center distance
Nominal ratio
Speed (small disc)

Number of teeth on tensioning Number of teeth (small disc)

pulley
Table

Table 53.2: Possible sizings

53.4

Configuring Tensioning pulleys

Here you can select one of the following:

non-tensioning pulley
inside tensioning pulley
outside tensioning pulley

Chapter
VI-1057

Toothed belts

53

If you selected an inside/outside tensioning pulley , you can input the conical
spring washer diameter and the position (x/y) of the tensioning pulley. In the Configuration tab you can position the tensioning pulley interactively using the
mouse (the x and y values are displayed in the status row).

53.5

Application factor and summand for op erational behavior

You can either enter the application factor manually in the load factor interface, or
have the program define it from the operating parameters. If you selected a configuration with a tensioning pulley, you must increase the operating factor by 0.1.
Use the data in this table to define the factor (refer to the catalogs for more information):
Driven machine

Operating hours per day

0-10

10-16

16-24

Light drive

1.2

1.3

1.4

Medium-light drive

1.4

1.5

1.6

Medium-heavy drive

1.5

1.6

1.7

Heavy drive

1.7

1.8

1.9

Heavyweight drive

1.8

1.9

2.0

Table 53.3: Application factors

Summand for operational behavior

(This summand is added to the operating factor in the calculation)
Operational behavior:

Summand

continuous, 0-10 hr/day

continuous, 10-16 hr/day

+0.1

continuous, 16-24 hr/day

+0.2

intermittent or with alternating load

-0.1

Table 53.4: Summand

53.6

Center distance

The minimum center distance is calculated from the two belt sheave diameters.
You cannot enter a smaller value here. The sheaves must not touch each other
during operation.

Chapter
VI-1058

Toothed belts

53

53.7

Belt length and number of teeth on belt

In toothed belt drives the number of teeth on the belt is used to define the belt
length. You need this value when you perform the calculation for the belt. If you
did not specify the number of teeth on the belt or, if you switched to configuration
with a tensioning pulley, you must ensure that the program recalculates the value
for the number of teeth on the belt.

53.8

Effective belt width

The theoretical belt width (minimum width required to transmit the torque) can be
calculated from the data in the manufacturer catalogs. The effective belt width is
then taken as the next largest standard belt width.
As a general rule, the belt width should not be larger than 5*pitch. A warning message appears if you select a belt that is either too wide or too narrow. Although the
calculation continues, you use the data it provides at your own risk.
Defining the effective belt width/factor for the belt width:
To define the belt width, you will need the belt width factor (f_b). Use this formula
to calculate this factor:
(53.4)

The nominal power as specified in the catalog is a tabular value taken from the
manufacturers' catalogs and is dependent on the speed and number of teeth on the
smaller belt sheave.
With the calculated factor f_b you can then define the effective belt width from a
catalog table. However, if the value of f_b does not match a standard belt width, the
next biggest width will be used.
Remarks:
The theoretical belt width in the KISSsoft calculation reports corresponds to an
interpolated value, according to calculated factor f_b.
KISSsoft stores the tabular values (catalog data) in files which you can then edit.
Use the KISSsoft database tool to find the exact file name for a specific belt type
(e.g. Z091-001.DAT for XL-Isoran).

53.9

Tensioning pulley tooth number

The value you use for the number of teeth on a tensioning pulley should be at least
as large as the value given for the diameter of the smallest belt sheave.

Chapter
VI-1059

Toothed belts

53

Where possible, tensioning pulleys should be inside toothed lock washers.

However, if necessary, they can also be used as smooth sheaves from outside. The
diameter of the tensioning pulley should be at least 1.2 *d if positioned outside, or
1.0 *d if positioned inside (d: diameter of the smaller sheave). The data provided
by each belt manufacturer about tensioning pulleys varies greatly.

For Poly Chain GT:

An outside tensioning pulley reduces service life and should be avoided if
possible.
For AT belts:
AT5mm

AT10mm

AT20mm

with tensioning pulley

inside:

25 mm (z > 5)

with tensioning pulley

outside:

50 mm (z > 10)

with tensioning pulley

inside:

50 mm (z > 5)

with tensioning pulley

outside:

120 mm (z > 12)

with tensioning pulley

inside:

120 mm (z > 6)

with tensioning pulley

outside:

180 mm (z > 9)

Chapter
VI-1060

Toothed belts

53

53.10

Position of the tensioning pulley x/y

You must enter this value when you configure a tensioning pulley. Here, the axis of
the small sheave is the origin of the coordinates system. If you use the mouse to
change the position in the Configuration tab you can only move the
tensioning pulley within the valid area.

Chapter
VI-1061

Chain drives

54

54

Chai n drives

Chapter 54
Chain drives
Calculating chain drives with roller chains as defined in ISO 606 (with
standardized roller chain values taken from a database). The chain geometry (center distance, number of chain elements) for simple and multiple chains and the
transmissible power, axial forces, and variation in speed, are calculated by the
polygon effect, etc. Basis: DIN ISO 10823, [38] and [64].
During this calculation the program checks the highest permitted speed and displays a suggested value for the required lubrication.
As a variant, the calculation can also be performed with a third roller (tensioning
pulley). The X and Y coordinates of the tensioning pulley can be defined in the
Chain drives tab. If you open the Configuration tab you can use the mouse to
move the tensioning pulley. In this case, the particular X and Y value is displayed
in the status row. This roller can be positioned outside or inside as required.

Figure 54.1: Basic data: Chain calculation

54.1

Sizings

Using the drive data as a starting point, the program displays a list of suggested
values for suitable chain drives.

Chapter
VI-1062

Chain drives

54

Calculating the center distance from the chain length.

Calculating the chain length from the center distance.

54.2

Tensioning pulleys

You require tensioning pulleys if you need to limit the chain deflection or keep to a
minimum loop angle. You must arrange the tensioning pulleys under no load. They
must have at least three teeth.

54.3

Standard

Chain profile standard:

Roller chain ISO 606
The roller chain standard, ISO 606, includes chains as defined in the DIN 8154,
8187 and DIN 8188 standards. Roller chains are the most frequently used type of
chain because lubricated rollers reduce noise and wear. The chains defined in DIN
8187 correspond to the European type, and those defined in DIN 8188 correspond
to the American type. You should only install bush chains as defined in DIN 8154
in closed gear cases with sufficient lubrication.

54.4

Chain type

The data shown below depends on the type of chain:

Chain pitch
Maximum permitted speed of the small gear.
Nominal power at maximum permitted speed.
Tables in ISO 606 pages 8 to 10.

54.5

Number of strands

You can achieve high levels of power by using multiple chains. Chains are often
arranged in two or three strands (duplex, triplex). The values for duplex and triplex
chains are also given in the same standard.

Chapter
VI-1063

Chain drives

54

54.6

Application factor

Guide values in accordance with DIN ISO 10823, Table 2:

Figure 54.2: Application factor for chain calculation

54.7

Speed/number of teeth/transmission ratio

Range of ratio:
favorable

i = 1. . . 5,

good

i = 1. . . 7,

unfavorable

i = > 10.

Number of teeth:
Due to the polygon effect, we recommend a minimum number of teeth of between
17 and . . 25. Tooth numbers of less than 17 should only be used to produce low
levels of power. The preferred numbers of teeth for use in chain gears, as stated in
ISO 606, are: 17, 19, 21, 23, 25, 38, 57, 76, 95, 114.
You should use at least three teeth for tensioning pulleys.

54.8

Configuration

You can select one of these configurations:

without tensioning pulley
with tensioning pulley inside
with tensioning pulley outside
In a configuration involving tensioning pulleys, you must specify the number of
teeth and the position of the tensioning pulley (x/y). In the Configuration tab

Chapter
VI-1064

Chain drives

54

you can position the tensioning pulley interactively using the mouse (the x and y
values are displayed in the status row).

54.9

Center distance
Recommended center distance:

a = 30p. . . 50p (p: pitch)

You should avoid:

a < 20p and a > 80p

Click the

button to calculate the center distance from the number of chain links.

54.10

Polygon effect

When calculating chains, you must take the polygon effect into account both for
the reference circle and the center distance.
Formula for the reference circle:
(54.1)

(see also [66], equations 26/46)

Formula for the center distance:
The length of the loop on the chain wheel differs as follows from the formula
used for V-belts/toothed belts:
(54.2)

lUK: Length of loop for chains

lUR: Length of loop for V-belts

Chapter
VI-1065

Chain drives

54

54.11

Number of links

The number of links should usually be an even number.

Click the

button to calculate the number of links from the center distance.

Chapter
VI-1066

Chain drives

54

54.12

Geometry of chain sprockets

In KISSsoft, you can display and print out the geometry of chain sprockets as
defined in ISO 606 as a graphic. The graphics are created with a mean deviation.

Figure 54.3: Geometry of chain sprocket

You can also output other values for a sprocket wheel in a report. The figures in
this section show how specific information is represented in this report.

Figure 54.4: Chain sprocket width

VII Auto mo tive

Part

VII

Automotive

55

Synchron ization

Kapitel 55
Synchronization
Use this module to calculate the gear synchronization time and total time, based on
the specified geometry, forces and application data. Some additional calculations
for heat development, frictional power, and wear resistance, are also performed.
Calculations can be performed for common types of synchronizations for a given
number of cones (single, double or triple cone).

Figure55.1 Synchronization module tab

55.1

Geometry

Geometry data is needed for the synchronization ring, also called the cone. Additional data is needed for the spline shaft tip definition (the indexing) and ball block
angle. This is the external ball angle which holds the synchronizer at its position
(engaged or disengaged). Specific limit values have been defined for the angle input to ensure synchronization can be guaranteed.

Figure 55.2: (a) Description of main geometry: S = Sleeve, C = Ring/Conus, H = Hub, G =

Gear, (b) Spline shaft tip geometry

55.2

Operating data

The mechanical force is the force applied to the shifting handle. This force is
multiplied by the mechanical ratio and applied to the sleeve. The friction
coefficient at the beginning of the synchronization can be defined, for the conus
and the sleeve.
The gear inertia and the speed difference are required entries. Torque losses due to
mechanical friction, oil splashing, and other sources, can be defined. The defined
losses during the shifting will either help or hinder the process depending on the
shifting direction. If the synchronizer sleeve is subject to free movement before and
after the actual synchronization, the distances can be entered here to enable the total time to be calculated correctly (from another gear to the final end position of the
sleeve).
56

Friction clu tch es

Kapitel 55
Friction clutches
This module is used to calculate friction clutches and brakes in accordance with
VDI 2241 [90]. The results of this calculation can then be used to select a suitable
clutch or brake. The clutches are operated either mechanically, electromagnetically,
or by pressure (e.g. hydraulically), thereby either generating or removing pressing
force. The clutches can be designed to run either dry or with lubrication. This has a
significant effect on the coefficient of sliding friction and the coefficient of static
friction.

Figure 55.1: Basic data: Friction clutches

Figure 55.2: Display of a clutch

Force is stored in a spring. When the spring is released, the force returns the clutch
to its open state. Compression or disc springs are usually used here. Both types of
spring are pretensioned in their open state. In this example the compression is
created hydraulically, and therefore affects the piston. This additional definition of
storing force is not included in the VDI guideline. The guideline assumes that
frictional surface pressure is applied directly to the plate. As the dynamic
characteristics of the springs can also be non-linear, the force generated by the contact with the first plate is used in the calculation.
In KISSsoft, you can either define the spring forces or input the reference torque
MK and the load torque ML directly. As specified in VDI 2241, the work of
friction and the switching capacity are defined using an average sliding velocity
and an average coefficient of sliding friction. You can also specify the coefficient
of sliding friction as a dependency of 5 sliding velocities, because this coefficient
can vary greatly depending on which sliding velocity is present. However, this does
not take into account the aging of the oil, which would reduce the coefficient of
sliding friction.

Figure 55.3: Schematic display of a clutch

The dynamic moment of inertia JL can also be made up of a number of different

parameters. If there is a mass m at the distance r from the rotational axis, its moment of inertia can be calculated with JL2 = r2*m.
This can then be added to the existing moment of inertia JL1.
JL =JL1 + JL2.
Ratios can then reduce the moment of inertia on the clutch shaft J2red =
J2*(n2/n1)2. This reduced moment of inertia can then be added to the clutch shaft's
moment of inertia.
JL = JL1 + J2red

56.1

Calculation

Inputting the spring forces/defining the reference torque

If you decide to input the spring forces (Reference torque flag is set), the reference
torque is calculated as follows:

Fk (N): Piston force (FK = pK/AK)

pK (N/mm2): Compression on the piston
AK (mm2): Piston surface area
Fl (N): Spring force to plates contact
Fv (N): Pretension for spring force
F (N): Resulting force on the first plate (N)
The accelerating torque or the holding torque is then determined from this. Using
the different coefficients of sliding friction, if these have been defined, otherwise
using the mean coefficient of sliding friction:

MA (Nm): Accelerating torque

Fstat, Fdyn (N): Resulting force on the first plate
(-): Coefficient of sliding friction
rm (mm): average friction radius
zR (-): Number of friction surfaces (plates)
ML (Nm): Holding or load torque
0 (-): Coefficient of static friction
The reference torque is then defined from MA+ML. You can also define a torque
loss, which has a negative prefix for a clutch and a positive prefix for a brake.
However, if you define the reference torque directly, you cannot also define a
torque loss. This must then be taken into account with the reference torque.
The formulae specified in VDA 2241 [90] are used to define the sliding time t3.
For a clutch:

MK=MA, with a specified MK, with the influence of t12 (in this sequence):

For a brake:
with a specified MK, with the influence of t12 (in this sequence):

The engagement work of friction Q is then calculated with, or without, taking the
torque-rise time t12 into account, depending on whether or not this value has been
defined. The switching capacity on the total friction surface and the maximum
switching capacity are also calculated.
If you input curve points for the coefficient of sliding friction, the area below the
calculated curve in the torque diagram is calculated as the engagement work of
friction. The switching capacity is then derived from the time-based conclusion of
this calculation.
Each of these values must be input as specific values for the friction surface
because these are provided by the manufacturers in the relevant catalogs.
Furthermore, when you input the switching frequencies and the permitted engagement work of friction (one-time switching) the program calculates a utilization to
show whether the selected coupling will be adequate.

Qzul (kJ): permissible engagement work of friction

QE (kJ): permissible engagement work of friction (one-time switching)
Sh (1/h): Intersection-point switching-frequency
Sh (1/h): Switching frequency per time unit
The utilization AQ is then determined from this permitted value and the calculated
engagement work of friction:

When you select a clutch, you must take into account the reference torque, and
most importantly, the permissible engagement work of friction QE (one-time

switching) and the calculated permissible engagement work of friction (for higher
switching frequencies).

56.2

Definition of spring forces

Figure 55.4: Definition of spring forces

These additional inputs, Pretension for spring force Fv and Piston

force Fk, are used to determine the characteristic values required to calculate
the resulting spring force. The coefficient of sliding friction and the average radius
rm and the number of plates are then applied to determine the accelerating torque.
The coefficient of static friction from the Spring force to plates contact Fl is then used to define the holding torque.

56.3

Definition coefficients of sliding friction

and velocities

Figure 55.5: Definition coefficients of sliding friction and velocities

The coefficients of sliding friction are specified by the manufacturers in

accordance with the sliding velocities. The VDI 2241 standard assumes that a constant value is used. However, this may result in a large deviation in results. By inputting a maximum of 5 points you can create a poly line that connects these
points. From this line the program can then derive 10 values for the coefficients of
friction in the sliding velocity areas at the start and at the end. The 10 different
accelerating torques derived from this can then be used later on in the calculation.

56.4

Graphics

The graphics show the speed curve over sliding time t3, the torque diagram over
sliding time t3, and the coefficient of sliding friction curve for the sliding velocity,
of which a maximum of 5 points have been entered (if defined by the user).

56.5

Settings

If the Use radius to plates gravity center for the

calculation flag is set, the radius at the center of gravity for the plates is used
in the calculations instead of the mean radius of the plates rm. This radius is
calculated with:

VIII Various

Part

VIII

Various

Chapter
VIII-1080

Tolerance calculation

57

57

Toleranc e ca lcul ati on

Chapter 57
Tolerance calculation
In this module you enter the nominal lengths and their corresponding allowances
for various elements. These values are then used to calculate an overall tolerance.
This calculation uses a constant distribution (arithmetical sum) and the square root
of the tolerance squares (standard distribution) to define the maximum and minimum size of the measurement chains. You can also use the appropriate dimensions
to calculate the nominal length/expected value of the measurement chain. The
tolerance field specified in ISO is defined in accordance with ISO
286 in which the tolerances are defined up to a size of <= 3150 mm. In KISSsoft,
for tolerance classes H, h. JS and js, the values used in the standard are
extrapolated up to a value of 10000 mm.

Figure 57.1 Basic data

Chapter
VIII-1081

Strength verification with local stresses

58

58

Stren gth veri fica tio n wi th loca l s tresses

Chapter 58
Strength verification with local
stresses

Chapter
VIII-1082

Strength verification with local stresses

58

58.1

General

You can start this calculation in the Various section of the modules-tree.

58.1.1

Functionality of the software

The calculation program supplies a complete, written proof of integrity for static
and fatigue strength at the proof point W.
The strength verification is supplied in accordance with the local stress concept as
described in the FKM "Rechnerischer Festigkeitsnachweis fr Maschinenbauteile"
guideline. The idea behind the local stress concept is to estimate the service life on
the basis of the elastic-plastic, local stress at the critical point compared to the
Woehler line strain derived from an unnotched test beam. The local concept is
implemented as a stress-based variant within the framework of the FKM guideline.
Therefore, before it can be used, the material must be in an elastic state. In this
context, the concept used is not really a local concept like the elastic-plastic notch
root strain concept, but a concept close to the nominal stress concept, except that
the diameter quotient stands on the other side of the equation. It is a useful tool for
calculating static and high cycle fatigue proof in the high cycle range (N > 104).
Input: You can enter stress amplitudes and stress ratio at a proof point W and at a
neighboring point B. Alternatively, the stress ratio at the proof point and the support coefficient are estimated mathematically. Alternatively, the stress ratio at the
proof point and the support effect are estimated mathematically. You will also need
a number of parameters, such as surface roughness, part size etc. to calculate the
design coefficients. Additional load data, such as number of cycles, spectrum,
temperature etc. are also predefined.
Output: The calculation calculates the utilization factors for static cases and
fatigue. It creates a complete set of documents for this.

58.1.2

Areas of application for the FKM guideline

The software is based on FKM Guideline 183 "Rechnerischer Festigkeitsnachweis

fr Maschinenbauteile", chapters 3 and 4. The guideline applies to mechanical engineering and its associated industrial sectors. In real life scenarios, contractual
partners must agree how this guideline is to be implemented. For parts that are subject to mechanical stress, this guideline can be used to calculate the static and
fatigue strength either be for a finite or infinite working life. However, this
guideline does not cover other mathematical proofs such as brittle fracture stability,
stability or deformation under load, or experimental strength verification. Before
the guideline can be applied, it is assumed that the parts have been manufactured so
that all aspects of their design, material and operation are technically free of error

Chapter
VIII-1083

Strength verification with local stresses

58

and fit for purpose. The guideline is applicable for parts made of iron and
aluminum alloys, even at elevated temperatures, either by machining or welding,
and in particular for
parts with geometric notches
parts with welded joints
static stress
fatigue loads ranging from approximately (N > 104) cycles as an individual or
collective load
rolled and forged steel, including stainless, mix cast iron alloys as well as forged and cast aluminum alloys
different temperatures
a non-corrosive ambient media
Supplementary agreements must be drawn up if this guideline is to be used outside
the specified area of application. The guideline does not apply if a strength
verification is required using other standards, codes or guidelines, or if specific
calculation data, such as VDI 2230 for bolted joints, is applicable.
For simple rod-shaped and planiform elements, we recommend you use a
calculation method that involves nominal stresses. The calculation using local
stresses is to be used for volumetric parts or, in general, where stress is to be
calculated using the finite element method or the boundary element method, if no
specifically defined cross sections or simple cross section forms are present or if
the diameter quotients or notch effect values are unknown.

Chapter
VIII-1084

Strength verification with local stresses

58

58.2

Background

58.2.1

The FKM Guideline: Rechnerischer Festigkeit snachweis fr Maschinenbauteile

The idea for this guideline was proposed at a meeting of the DVM in Berlin, Germany, in May 1990, when experts from the then Federal Republic of Germany met
together with experts from the then German Democratic Republic. The objective
was to combine the standards from what was then two separate standards (VDI in
the Federal Republic of Germany and TGL in the German Democratic Republic) to
create a single new strength assessment guideline. The new guideline was to be
based, in particular, on the former TGL standards for strength calculation, VDI
guideline 2226, DIN 18800, Eurocode 3 and the recommendations of the IIW. It
was also to take into account the latest discoveries from research into the fatigue
strength of metallic parts. The FKM guideline is designed for use in mechanical
engineering and associated industrial sectors. The first edition of the FKM
guideline, "Rechnerischer Festigkeitsnachweis fr Maschinenbauteile" appeared in
1994, followed in 1998 by a third, completely reworked and extended edition
(characterized by its much more practical updates and a more user-friendly structure). A fourth edition, which was even more comprehensive, was published in 2002.
The main innovation of this edition was the inclusion of aluminum materials. An
English translation of this guideline appeared as the fifth edition. The sixth edition
of the guideline (2012) has, once again, been completely reworked and now
includes the results of new research, such as the data supplied by the tests in "Margin of safety static resistance" and "Improved FKM Guideline". In the meantime,
the FKM guideline has been widely accepted and is regarded as the best reflection
of the current state of technology.

58.2.2

Usefulness of the service life calculation

It is a well known and proven fact that the service life calculation is not sufficiently
accurate. In other words, factors in the range from 0.1 to 10, and in some cases
even greater, may occur between the calculation and the test, relating to the tolerable number of alternating cycles. However, a basic, if somewhat simplified, statement about the difficulties in achieving a reliable service life calculation has been
made: In this case the strength verification is based on a comparison of the stress
values and the stress itself. In a static strength verification, the occurring force can
be compared with the sustainable force. For a proof of service strength, the
characteristic functions, i.e. the stress spectrum and the Woehler line, are
compared. If the total damage, which is of central significance to the service life
calculation, is then understood as a quotient of the characteristic functions for
stress and sustainable stress, it is clear that this quotient is very sensitive to changes

Chapter
VIII-1085

Strength verification with local stresses

58

in these critical values. This means errors in determining the characteristic

functions will have a significant effect on the result. In addition, by influencing the
critical values, for example, by implementing specific measures when selecting
materials and at the production stage, the long-term sustainable service life can be
increased.
Three different concepts can be used to calculate the service life of components
that are subjected to cyclical stress. These are: the nominal stress concept, the local
concept and the fracture mechanics concept. These concepts have specific application areas. For many decades, the technical set of rules was based solely on the
nominal stress concept. However, nowadays the local concept and the fracture
mechanics concept are being used more and more frequently in this set of rules.
Whereas, in the nominal stress concept, the complex transfer function between
stress and service life contained in the total stress-strain event in critical material
volumes (notch bottom area) is given directly with the part Woehler line for nominal stresses, in the local concept this must be represented mathematically by a
number of relatively complex modules. This may be the reason for results
according to previous experience not being any more accurate than those achieved
with the nominal stress concept.
Possible sources of errors in calculating the local concept:
L oa d a ss u mp ti o n s

It must be emphasized that the load assumption must be as precise as possible to

ensure an accurate calculation of component service life. Any errors in load
assumption can have significant effects on the service life calculation results. The
effect may even be greater than those due to insufficient accuracy of the different
methods used for service life estimations. We recommend you check the load
assumptions carefully and test them if necessary. In this way, any uncertainties in
the load assumptions can be resolved by actual measurements performed at a later
date. This is particularly because this type of measurement can be performed nondestructively and can usually provide important information for subsequent designs.
L o cal str e s s

Local stresses can be determined either mathematically or by measurement. It is

essential that the part's geometry is entered exactly, in particular the splines and
wall thicknesses. A convergence check must also be performed to ensure the
effective stresses are not underestimated. However, a problem in productive operation still to be resolved is how to calculate the effective level of internal stresses in
a part cross section or in a surface layer so that this can be evaluated when
subjected to load stresses in a service life calculation.

Chapter
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Strength verification with local stresses

58

Co m bi n ed s tr es s

In the case of combined stress, a strength calculation should fulfill the instance of
the invariant (results independent of the selected coordinate system). However, as
Woehler lines (with different inclinations) are used for normal and shearing stresses, the resulting calculated service life/damage is no longer separate from, and
independent of, the selected coordinate system.
Ma t eri al pr op er ti e s

Since it is usually not possible to ascertain material properties by simply measuring

the finished part, we recommend you use standardized or, at least, welldocumented values. It is acknowledged that these values may be dispersed and not
always suitable. It is also not possible to determine reliable endurance limit values
from tensile strength Rm alone. The fatigue limit can be estimated using the proof
stress Rp02. The FKM guideline defines the values from Rm and also for the material type.
Cy cli cal d ef or ma ti o n c h arac t eri s tic

A check to see whether cyclical compaction or loss of cohesion is present must be

performed to see whether or not the sequence of load cycles plays a significant
role. This effect is not considered in the calculation program.
Su pp o rt e ff e ct

A number of different models can be used to determine the support effect. As many
comparisons between calculated results and test results have shown, a
mathematical estimate of the support effect is fraught with uncertainties.
Pro d uc ti o n pr oc e ss e s

When a local concept is applied, it is assumed that the volume element displays
cyclical material behavior. Influences encountered during the production process,
in particular surface layer properties, surface roughness, material state, and internal
stresses, must be taken into consideration. Currently used calculation methods also
have their limitations here.
Dam ag e par am e t ers

A number of damage parameters have been proposed to help determine the

influence of mean stress and the influence of multiple shafts. PSWT, the most wellknown damage parameter, corresponds to a mean stress sensitivity of M=0.41,
which is present in this order of magnitude for heat treatable steel, but assumes
entirely different values for low strength steels or wrought aluminum alloys. The
use of PSWT should be seen as a major source of errors. Also in question is the
extent to which the influence of internal stresses can be determined. In the latter
case, this is only known for exceptional cases in practice. Damage parameters are

Chapter
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Strength verification with local stresses

58

still widely used by researchers to determine multi-shaft behavior, excluding proportional stress. The influence of multi-shaft stress states on service life depends
greatly on which material is being used. This is because the material's resilience
determines which different damage mechanisms are present.
Dam ag e a c cu m ula ti o n

In practice, damage accumulation occurs almost exclusively in accordance with the

Palmgren-Miner linear hypothesis. Although the shortcomings of this hypothesis
were recognized early on, no significant advances that would lead to tolerable errors in the service life calculation have been made in this area despite decades of
intense international research. The only progress is that, by summarizing the
amplitudes below the endurance limit, various modifications have been proposed
which achieve much better results than the original Palmgren-Miner rule, and in
which no damage is caused to amplitudes below the endurance limit.
Even if the service life calculation methods for evaluating variants and analyzing
weak points are implemented correctly, it is not certain that the current level of
knowledge can achieve a reliable service life calculation for new parts. This
requires the use of strategies in which calculations are validated and calibrated by
specific experimental analyses. At the current level of knowledge it is only possible
to make relative forecasts about service life on a purely mathematical basis.

Chapter
VIII-1088

Strength verification with local stresses

58

58.3

Implementation in KISSsoft

58.3.1

Main screen

58.3.1.1
Selection of the part fo rm
Selection of the part form: you can choose between parts that are rod-shaped (1D),
shell-shaped (2D) or block-shaped (3D). They each have different stress components or stress types, and different indexing. If the local concept is applied, blockshaped (3D) parts are usually present. The selected part form influences the data
input for the stress components.

Figure 58.1: Main screen for the proof with local stresses

Rod-shaped parts: for rod-shaped parts - rod, beam, shaft - the following partrelated coordinates system applies: The X-axis lies in the rod axis, and the Y- and
Z-axes are the main axes of the cross section, and need to be specified in such a
way that Iy > Iz applies for the moment of inertia.
For planiform (flat) parts - disc, plate, shell, - the following part-related coordinates
system should apply in the proof point: the X- and Y-axes lie in the plane, and the
Z-axis is vertical to it in the direction of thickness. The normal stress and the shear
stresses in the direction of Z should be negligible.

Chapter
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Strength verification with local stresses

58

Block-shaped parts: volume-related coordinates systems apply. The primary stresses S1, S2 and S3 need to be calculated. In the proof point W on the free surface of
a 3D part, the primary stresses S1 and S2 should act in the direction of the surface
and the primary stress S3 points into the interior of the part, vertically to them. Generally, there is one stress gradient that runs vertically to the surface, and two stress
gradients in the direction of the surface, for all stresses. However, only the stress
gradients for S1 and S2, running vertically to the surface, can be taken into account
in the calculation, and not the stress gradients for S1 and S2 in both directions on
the interface and none of the stress gradients for S3.

58.3.1.2

Inputting the stress values on the proo f point and on the

neighboring point
If the support factor is determined according to the stress state on the neighboring
point, then the stresses on the proof point W and on the support point B, and also
the distance from point B to point W, will be entered. (Enter compressive stresses
as negative values):

Figure 58.2: Inputting the stress values on the proof point and on the neighboring point. Inputting the neighboring point distance.

Chapter
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Strength verification with local stresses

58

58.3.2

Load cases

In the endurance limit diagram, different assumptions are used to determine different levels for the maximum stress amplitude SAK. Assumptions where sm=const.
result in a larger SAK than for R=const. This is because the limit lines in the Smith
diagram rise by an angle < 45o (mean stress sensitivity). The most suitable
assumption depends on the expected change in stresses in the part when it is
subjected to permitted operational fatigue load. The overload case can therefore be
a decisive factor in whether or not a part is overloaded [62].
Load case
Type of overloading F1 (constant mean stress): at a constant mean stress the
stress amplitude increases as the decisive operating force increases
Type of overloading F2 (constant stress ratio): When the operating force increases, the ratio between the maximum stress and minimum stress remains the
same. This overload case usually returns conservative results (compared to
other overload cases) and should therefore be used in cases of doubt.
Type of overloading F3 (constant minimum stress): when the operating force
increases, the minimum load remains the same.
Type of overloading F4 (constant maximum stress): when the operating force
increases, the maximum load remains the same.

58.3.3

Woehler line

Miner elementary, Section 4.4.3.5.2 of the FKM guideline

If a stress collective is present instead of individual stress, the calculation should
usually be performed using the Miner elementary procedure.
Miner consistent, Section 4.4.3.5.2 of the FKM guideline
The Miner consistent procedure (derived from Haibach, see [94]) takes into
consideration the fact that the part endurance limit will reduce as damage increases.
The reduction applies from KD,=1*10e6.

58.3.4

Number of load cycles

Number of load cycles. If calculation in accordance with elementary Miner Rule is

selected, then inputs greater than ND result in constant use.

Chapter
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Strength verification with local stresses

58

58.3.5

Temperature

Inputting the temperature in degrees Celsius. The area of application of the FKM
Guideline is limited according to material, see section 1.2.1.7. The temperature
factor KT,D is defined on the basis of the temperature and the material type.

58.3.6

Temperature duration

Time period during which the part is subjected to the temperature.

58.3.7

Protective layer thickness, aluminum, chapter

4.3.4, Figure 4.3.4

Protective layer factor KS (which is defined via the protective layer thickness) takes
into account the influence of a protective layer on the fatigue strength of a part made of aluminum.

58.3.8

Stress ratios

The mean stress is recorded in the R-value. In comparison to the mean stress-free
case (cyclic loading, R=-1), the Woehler line is moved to higher sustainable stress
amplitudes in the case of trials with mean compression stresses, and in the case of
trials with mean tensile stresses the Woehler line is moved to lower sustainable
stress amplitudes. The sustainable stress amplitude's dependency on the mean
stress is material-specific, and is called the influence of the mean stress. This
usually increases along with the tensile strength of the material.
Here R is defined from -1 up to +1

Figure 58.3: Inputting the specific R-value

Chapter
VIII-1092

Strength verification with local stresses

58

Figure 58.4: Inputting your own R-value.

As the surface roughness increases, the Woehler line moves to lower stress
amplitudes, but the surface roughness alone is not the cause for this. The strength is
much more affected by the detailed properties of the surface. In addition, despite
similar surface properties and the same surface roughness, different processing
procedures can cause different material internal stress states, resulting in Woehler
lines differing from each other greatly.

Chapter
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Strength verification with local stresses

58

58.3.9

Spectra

You can select existing load spectra directly.

Figure 58.5: Selecting spectra

You can create a new load spectrum in the database tool (see section "Define load
spectrum" on page II-304).

58.3.10 Surface factor KV, section 4.3.3, Table 4.3.7

Case factor KV takes into account the influence of edge layer strengthening on the
fatigue strength.

Chapter
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Strength verification with local stresses

58

58.4

Materials

Figure 58.6: Materials screen: strength verification using local stresses

The selection list contains materials from the FKM Guideline.

If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can specify to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.

58.4.1

Surface roughness

The roughness factor takes into account the influence of the surface roughness on
the part's fatigue strength. Experiments are performed to derive it from the
endurance limits of unnotched test rods with and without surface roughness, and
shown in dependency of the material's total height Rz and tensile strength Rm. For
polished surfaces it has the value 1.0. For rolled, forged and gray cast scale, the
average roughness Rz=200m applies. The average roughness can also be defined
as your Own input.

Chapter
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Strength verification with local stresses

58

58.4.2

Settings

Figure 58.7: Settings

58.4.2.1
General settings
The references are to sections in the FKM guideline.
Co e ffi ci e n t K F ac c ord i n g t o e q ua ti o n 4. 3 .2 a n d 4 .3 .3 , s e c ti o n 4. 3 .1. 2

Notch effect coefficient as an estimated value to enable the effect of the roughness
coefficient to be determined, according to the nominal stress concept, when the
local stress concept is in use.
Flag set: Kf is defined according to formulae 4.3.2 and 4.3.3, described in section
4.3.1.2.
Flag not set: The KF coefficient is set as shown in Table 4.3.1.

Chapter
VIII-1096

Strength verification with local stresses

58

Cal cu la ti ng G w i t h ou t 2 / d eff , s e c ti o n 4. 3 .1. 3 .3

If the flag is not set in General data, Neighboring point data entry, then an approximation of the related stress gradient is calculated, using the calculation based on
the equations in 4.3.18. This contains terms for tension/compression, torsion, and
bending. If no bending is present, it is questionable whether the second term (2/d)
in the formulae makes any sense. The option programmed here is not provided in
the FKM Guideline!
Flag set: the stress gradient is defined without applying the second term in formula
4.3.18.
Flag not set: the stress gradient is defined while also applying the second term in
formula 4.3.18.

In p ut o f m e a n s tr e ss e s an d a mp lit u d es

If the flag is set, then the stresses are input in the main screen via the medium and
amplitude stress.

In p ut o f m e a n s tr e ss e s an d a mp lit u d es

Material values at reference diameter:

values are taken from database (at reference diameter) and multiplied by K1
Rm, Rp depending on value from database, sigW at reference diameter:
Rm, Rp are read from the database according to size (excluding K1), and the
fatigue strength is determined for the reference diameter entered in the database, and then it is multiplied by K1
Rm, Rp depending on value from database, sigW constant:
Fatigue strength not multiplied by K1, correct value must be in database
Rm, Rp depending on value from database, sigW calculated from Rm:
Fatigue strength is calculated from Rm. Rm is in database according to size,
conversion according to FKM

Ne ig h b ori ng p oi n t d a ta e n try , s e c ti o n 4. 3 .1. 3 .3, Fo rm ul a 4. 3 .1 7

Flag set: Notch sensitivity factor-related stress slope is defined in the neighboring
point via the stress state. To do this, the stress values and the distance between the
proof point and neighboring point must be entered in the main screen.
Flag not set: Notch sensitivity factor-related stress gradient is not determined from
the values at a neighboring point. The related stress gradient at the point of maximum stress is estimated using formula 4.3.18. To do this, two radii (Radius 1 and

Chapter
VIII-1097

Strength verification with local stresses

58

Radius 2) must be defined (for the two directions on the surface), and also a typical
part dimension d. See also: module specific settings, Calculation of G without
2/deff, above.

Dir ec ti o n of lo ad as s pe cifi e d, s ec ti o n s 4.1 . 0, 4 . 6.2

Flag set: the calculation is carried out for synchronous stresses.

Flag not set: the calculation is performed for asynchronous stresses (4.6.2.2). It can
safely be assumed that this method of approach is a cautious one.

Us e t h e m ec h an ic al m at eri al s u pp o rt c o ef fici e n t, s ec ti o ns 4 . 3.1 , 4 .3 .1 .3 . 2

If this flag is selected, the mechanical material support coefficient is used for the
calculation, otherwise the Stieler support coefficient is used. If sharp notches are
present, the mechanical material support coefficient takes into account the strength
reserves and contains the static size coefficient. The mechanical material support
number (nwm) is made up of three parts: the static support number (nst), the
mechanical deformation support number (nvm) and fracture mechanical support
number (nbm). Assumption: nst = 1 is applied to the "Smooth shaft" and "Own Input" notch types.

Se le c ti ng ma t eri als da t a, s e ct i on 3 .2 .1

The part standard values Rm and Rp must be calculated from the semi-finished
product or test piece standard values Rm,N and Rp,N or from the part drawing value
Rm,Z. In exceptional situations, the part actual values Rm,I and Rp,I can be applied.
Refer to section 3.2.1.2.

Chapter
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Strength verification with local stresses

58

58.4.2.2
Required safet ies
The FKM Guideline is one of the few calculation guidelines that lists the required
safeties according to the consequences of failure etc. In combination with safe load
assumptions and an average probability of survival of the strength variables
P=97.5%, they apply for both welded and non welded parts. Safety factor are
defined on the basis of the selected material and the defined consequences of
failure, probability of occurrence of the load, and also inspection and test. It
differentiates between steel, cast iron (ductile or non ductile), and also aluminum
(ductile or non ductile), i.e. five different classes. Alternatively you can also set the
safety factors manually.

Figure 58.8: Selecting the safeties according to material and load properties

jmt

Safety margin against creep strength depending

on time

jp

Safety margin against yield point

jpt

Safety margin against creep limit

jF*jG

Safety against the endurance limit

Chapter
VIII-1099
58

Strength verification with local stresses

Chapter
VIII-1100

Hertzian pressure

59

59

Hertz ian pressur e

Chapter 59
Hertzian pressure
In this module, the Hertzian pressure of two bodies is calculated. In the case of a
load on a rolling pair that is applied vertically to the contact surface, elliptical
flattening occurs for point contact, and rectangular flattening occurs in the case of
linear contact. The Hertzian equations are used to help calculate the maximum
pressure (Hertzian pressure) and also the proximity of the two bodies (ball,
cylinder, ellipsoid, plane; convex or concave). The calculation formulae have been
taken from "Advanced Mechanics of Materials, 6th Edition [78]. The underlying
principle for calculation for point contact is that the diameter of the bodies is
defined on two principal planes, from which an equivalent diameter is then defined.
In the case of linear contact, the calculation is performed in one main plane, so
there is only one equivalent diameter. In addition the location and value of the maximum primary shearing stress in the interior of the body are determined.
An approximation of the cylinder/cylinder configuration has been calculated using
the dissertation from Weber/Banaschek [69]. The formula (55) from Norden's book
[89] is used to calculate the approximation of the cylinder area.

Figure 59.1: Main window for Hertzian pressure

The main window for Hertzian pressure (see Figure 59.1) is where you define the
normal force, the configuration, and the diameter (in addition to the supporting

Chapter
VIII-1101

Hertzian pressure

59

length for linear contact), and the materials used in the body.
You can select one of these configurations:
Ball - ball
Ball - cylinder
Ball - ellipsoid
Ball - plane
Ellipsoid - ellipsoid
Ellipsoid - cylinder
Ellipsoid - plane
Cylinder - cylinder
Cylinder - plane
On the right, in the main screen, an image of the current configuration is displayed
to help you input the values more easily.
For normal force, there is also a sizing option. If you click the sizing buttons next
to the normal force, you can enter the required Hertzian pressure, and the system
will then calculate the normal force from it.
If the bearing area has a concave bend then you must enter the diameter as a negative value. Negative diameters are only possible in the case of Body 2.

Chapter
VIII-1102

Hertzian pressure

59

59.1

Settings

Use the Depth display factor to define the depth display in the graphic.
The depth of the point max is multiplied by this coefficient. The resulting depth is
then displayed in the graphic. The default setting of this coefficient is 6.

Chapter
VIII-1103

Hardness conversion

60

60

Hardn ess co nversio n

Chapter 60
Hardness conversion
You access the Hardness conversion module in the Extras > Hardness
conversion menu. The hardness conversion is also present in the materials
screens as a sizing function, where, for example, the tensile strength can be defined
by means of a hardness value.
This module contains the hardness conversion calculation as specified in DIN EN
ISO 18265, Edition 2/2014. During the conversion, select Extras > Hardness
conversion to display a selection list in which you can select the required material. The other conversions (for the materials) use the table for unalloyed and lowalloy steels and steel casting. As required in each particular case, the stored tables
can be used to convert the value of the tensile strength into Vickers, Brinell or
Rockwell hardness, and vice versa. Due to possible variations, the received values
should only be used if the default testing process cannot be applied. The interim
values of the value conversion table will be interpolated from the neighboring values.

Figure 60.1: Hardness conversion input screen

Integrated conversions of the steels and steel groups according to DIN EN ISO
18625:

Kapitel
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60

Unalloyed and low-alloy steels and steel casting (Table AA1)

Heat treatable steel in heat treated state (Table B.2)

Heat treatable steel in untreated, soft-annealed or normally annealed state

(Table B.3)

Heat treatable steel in hardened state (Table B.4)

Cold-working steels (Table C.2)

High-speed steels (X80WMo6.5, X82WMo6.5, X90WMo6.5,

X97WMo3.3, X100WMo6.5, X85WMoCo6.5.5, X105WMoCo6.5.5 and
X79WCo18.5) (Table D.2)
The range of validity for unalloyed and low-alloy steels and steel casting (with the
conversion in the material screens applied) is limited as follows:
Tensile strength Rm: 255 to 2180 N/mm2
Vickers hardness HV: 80 to 940 HV
Brinell hardness HB: 76 to 618 HB
Rockwell hardness HRB: 41 to 105 HRB
Rockwell hardness HRF: 82.6 to 115.1 HRF
Rockwell hardness HRC: 20.3 to 68 HRC
Rockwell hardness HRA: 60.7 to 85.6 HRA
Rockwell hardness HRD: 40.3 to 76.9 HRD
Rockwell hardness HR 15N: 69.6 to 93.2 HR 15N
Rockwell hardness HR 30N: 41.7 to 84.4 HR 30N
Rockwell hardness HR 45N: 19.9 to 75.4 HR 45N
61

Linear drive tra in

Kapitel 60
Linear drive train
Use this calculation module to calculate drive screws. Drive screws are used to
convert rotational movement into longitudinal movement or to generate great
forces.

Kapitel
VIII-1105

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60

Although trapezoidal screws are almost exclusively used as drive screws, some
rough operations also use buttress threads.

Figure 60.1: Basic data: Linear drive train

Figure 60.2: Dimensions of trapezoidal screws

Kapitel
VIII-1106

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60

There are two different configurations of linear drive train that can be calculated:
Load case 1
Stress on the spindle in a spindle press
Load case 2
Stress on the spindle in a gate valve

Figure 60.2: Load cases Linear drive train

The information provided in Roloff Matek [62] is used to calculate linear drive
trains (drive screws).

Kapitel
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61.1

Calculation

Short and long linear drive trains subjected to pressure are handled separately in
the calculation process.
Short pressure stressed drive screws
Short pressure stressed drive screws are not at risk of buckling and therefore are
not tested for this.
The required cross section of the thread can therefore be defined using the formula:

d(z)zul: under static load: Rp/1.5; under pulsating load zdSch/2.0; under
alternating load: zdW/2.0;
Long pressure stressed drive screws
The formula for calculating the necessary core diameter of the thread is taken from
the Euler equation:

d3

64 F S lk

E
3

S: Safety (S6 to 8)
lk: mathematical buckling length, lk 0.7*l (Euler buckling case 3 used for general, guided spindles)

Calculation of the strength:

Load case 1:
The upper part of this configuration is subject to torsion and the lower part is subject to compression and therefore buckling.

Kapitel
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Torsional stress:

tzul

Wp

Wp: polar moment of resistance Wp0.2*d3^3

tzul: permissible torsional stress; static load tF/1.5; pulsating load tsch/2.0;
alternating load tW/2.0;
Compressive (tensile) stress:

d ( z)

d ( z ) zul

A3

A3: Thread minor diameter cross section

d(z)zul: permissible compressive (tensile) stress:
Load case 2:
The upper part of this configuration is subject to torsion and the lower part is subject to compression, infrequent tension and torque.
Formula for the part to be checked:

d ( z ) 3 1 t d ( z ) zul
2

The required torque corresponds to the thread moment, if not subject to any moments of friction.

T F d 2 / 2 tan( ' )

Kapitel
VIII-1109

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60

d2: Flank diameter of the thread

Lead angle of the thread (for single thread trapezoidal screws 3 to 5.5)
': Thread friction angle

Figure 60.3: Values for the friction angle

The + in the formula stands for "tightening the spindle", and - stands for "loosening
the spindle". The KISSsoft procedure calculates both situations and outputs the
results in a report.

Calculation for buckling (only for long spindles):

First of all, calculate the slenderness ratio.

lk

lk

lk

d3 4
4

I / A3

64 d 3
2

Slenderness ratio of the spindle

lk: mathematical buckling length
i: Gyration radius

lk 4
d3

Kapitel
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Only 3 different materials can be used for the spindle so that the slenderness ratio
can be defined correctly.
Elastic buckling is present if >=0 = 105 for S235; >=89 for E295 and E335.

The non-elastic area as defined by Tetmajer and <105 for S235.

K 310 1 . 14
For <89 and for E295 and E335:

K 335 0 . 62
For a non-elastic case, the Johnson parabola equation can also be used for the
calculation. (also for other materials)

K dS ( dS

dP )

The safety can then be calculated as follows:

K
vorh

S erf

The required safety for elastic buckling is Serf3 to 6. For non-elastic buckling it is
Serf4 to 2.
Buckling no longer needs to be calculated for a slenderness ratio < 20.

Analysis of the nut:

Kapitel
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60

The surface pressure of the nut is calculated from the nut length:

F P
l1 d 2 H 1

p zul

P: Pitch of thread
l1: Length of the nut thread
d2: Flank diameter of the thread
H1: Flank engagement of the thread
pzul: permissible surface pressure
Due to the uneven distribution of surface pressure, the nut length should be no
greater than 2.5*d. During sizing, the length is limited to 2.5* d even if a longer
one is input.

Efficiency and self-locking:

The efficiency of the conversion from rotational movement into longitudinal movement:

tan
tan( ' )

The conversion of movement is only possible for non self-locking threads, because
the limiting value in this case is, if = ', the efficiency is 0.5.
If >' the thread is no longer self-locking.
Each of the permissible values are listed in the Roloff Matek tables.

Kapitel
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61.2

Sizings

This calculation module can calculate the core diameter d3 of a long spindle that is
subject to pressure, when you select "Own Input".
In addition, it can also define the nut length on the basis of permissible surface
pressure and the required safety.

61.3

Settings

Figure 60.4: Settings input window

Coefficient of permissible surface pressure; this factor is used to define the ratio to Rm, in other words pzul = fpzul*Rm
Required safeties for diameter, shearing, stress, surface pressure and buckling:
for the calculation and the sizings

Kapitel
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61.4

Materials

Figure 60.5: Nut materials input window.

In the selection list, you can select materials in accordance with the standard.
If you have set the Own Input flag, a new dialog appears here. This displays the
material data used in the calculation which you can define to suit your own
purposes. You can also define your own materials directly in the database (see page
I-124) so that these can also be used in future calculations.
You can only select these different materials for nuts. For the spindle material you
can choose E295 (St 50.2), E335 (St 60.2) and S235 (37.3) materials, because the
calculation of buckling is only designed for use with these materials.
The strength values for the 3 materials have been fixed:
E295 (St 50.2): Rp02 = 295 N/mm2; zdSch = 295 N/mm2; zdW = 195
N/mm2; 0 = 89; tSch = 205 N/mm2; tW = 145 N/mm2
E335 (St 60.2): Rp02 = 335 N/mm2; zdSch = 335 N/mm2; zdW = 235
N/mm2; 0 = 89; tSch = 230 N/mm2; tW = 180 N/mm2
S235 (St 37.3): Rp02 = 235 N/mm2; zdSch = 225 N/mm2; zdW = 140
N/mm2; 0 = 105; tSch = 160 N/mm2; tW = 105 N/mm2

Kapitel
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Linear drive train

IX KISSsys

Part

IX

KISSsys

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62

KISSsys: Calc ula tio n Systems

Chapter 62
KISSsys: Calculation Systems

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62.1

General

KISSsys is an extension to the KISSsoft calculation program. With KISSsoft, you

can arrange, optimize, and recalculate, individual shafts, gears, or shaft-hub connections. In contrast, KISSsys is suitable for administering machine element systems.
Some special links between different calculations are already present in KISSsoft.
For example, bearing forces can be transferred from the shaft calculation and gears
can be placed onto a shaft. However, in the case of larger systems, such as a multilevel gearbox with several shafts and gears, separate performance data and speed
must be entered for each individual stage. load has to be updated berechnet werden,
must be jeder Calculation the Rating has to be updated.
In contrast with KISSsoft, where the individual calculation takes center stage,
KISSsys provides a way to observation a system as a whole. However, KISSsys
has not been designed to replace KISSsoft. Instead it is an extension that uses the
existing, tried and tested calculation modules. You could say that KISSsys
administers the relationships between individual elements but leaves the
calculation of the individual elements to KISSsoft.

62.1.1

Structure of KISSsys

KISSsys is based on an object management system called Classcad. Classcad

manages the administration of KISSsys elements, evaluates the expressions for variables and provides an interpreter with which the user can also generate functions
for special purposes.
This forms the basis for a user interface and a link with KISSsoft. The functionality
of the user interface is different for administrators, who generate new systems or
change the systems' structure, and for normal users who, while using the same
structure, merely want to change data, recalculate, and observe results. It takes more effort, and a better understanding of the program structure, to generate new systems than to use an existing system, which is easy to do.

62.1.2

Ways in which KISSsys can be used

At the most basic level, KISSsys provides a way for grouping calculations. All
calculations belonging to a system can be called up from one interface. In addition,
you can get an overview of the most important results of all calculations. This
makes it immediately obvious which particular gear pair or shaft is critical.
Even just this view of all the calculations that are of interest makes work
considerably easier.

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KISSsys then offers a way for you to specify relationships between variables. For
example, you can calculate the speeds in a gearbox from the initial speeds and the
transmission ratios. Moreover, KISSsys can also describe the power flow.
Consequently, in KISSsys you only need to enter the load for the calculations in a
few places. This enables you to quickly recalculate a complex system for varying
load cases.
KISSsys enables you to store tables for loading cases or even variants. In this way,
you do not have to constantly reenter the load data. KISSsys can also store the data
for variants of a construction. With one click of a button you can then perform all
the calculations for a selected load or variant.
For example, imagine a shaft with a radial force of unknown direction (e.g. via a
belt drive/ belt force, whose direction is only determined when the equipment is
installed). If it is necessary to define the worst case scenario, you could use
KISSsys to rotate this force in steps of up to 360o.
KISSsys is not only of great benefit during construction, it is also useful in the sales environment. With KISSsys you can for example store a standard gearbox in
your computer. If the client later requests different loads on a gearbox of this kind,
instead of the ones originally used for its construction, KISSsys lets you quickly
check whether the gearbox will meet the new load requirements.
Different example applications are illustrated on the KISSsoft CD or website.

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62.2

The user interface

The user interface provides several views of the administered data. There are table
views, which are primarily designed to provide you with a good overview of the
calculations. Another view, which has a tree structure, represents the hierarchy of
an assembly structure, while the two-dimensional power flow diagram is primarily
designed to display the kinematic coupling of the system. In addition, you can
produce a three-dimensional display of the entire system or of subsystems.
This section details the options for using the KISSsys system without administrator
rights.

Figure 62.1: The KISSsys user interface with tree view, diagram view, 3D view, tables and 2D
diagram

62.2.1

Tree view

The tree view (on the left in Figure on page IX-1119) lists all elements present
in the system, hierarchically. This provides a way to display an assembly structure.
Beside the name of the element there is a bitmap that identifies the type of the element. Bitmaps in blue represent KISSsoft calculations, and bitmaps in red
represent KISSsys elements. You can identify variables such as numbers, functions

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or character strings. With a click with the right-hand mouse button you can open a
separate context menu which provides functions for an element.
Each element has a Properties dialog which you can display here. The Properties dialog contains an overview of the available data elements or variables.
However, these can only be changed by the administrator.
In the case of the KISSsoft calculations you can select kSoftInterface in the
context menu to start the appropriate KISSsoft module. The calculation data can
then be changed or evaluated in KISSsoft. Select kSoftReport to display the
calculation report and select Calculate to perform the calculation in the
background without a user interface. Data is only exchanged with KISSsoft via the
KISSsys calculation elements.

62.2.2

Diagram view

Diagram view (on the right in Figure on page IX-1119) shows the kinematic
coupling of the elements. To start with, the element structure has nothing to do
with the calculations. The calculations only use the data that relates to the shafts,
gears and connections, and they can be added or deleted as you wish.
The structure consists of shafts and their sub-elements: gears, forces, couplings and
bearings. The kinematic coupling and the power flow between the shafts is
achieved via connections. The connection has the calculation standard to transfer the speed to the next element (usually simply the transmission ratio) and it
transfers a torque, also with loss of efficiency.
The externally supplied torque and a speed are defined with speed/torque elements.
In each case you can specify whether the speed or the torque are known or whether
they should be calculated by KISSsys. The number of predefined values must
correspond with the number of degrees of freedom.
The elements in the diagram view can be moved with the left-hand mouse button.
Click with the right-hand mouse button to display a context menu like the one in
tree view. You can change the zoom factor by pressing the '+' or '-' keys, or in the
context menu which you access by right-clicking.

62.2.3

Table view

To display the tables, select Show in the context menu in tree or diagram view.
The contents of the tables are defined during system set-up. The values displayed
in black cannot be changed, but the red numbers or strings can be edited. A special
table for user interfaces contains fields with a gray background. These are
functions and you can start them by double-clicking on them with the left-hand
mouse button.

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You can print the contents of the table, or press Ctrl-C to copy it and, for
example, paste it into a spreadsheet.

62.2.4

3D view

To display the windows for the 3D view, select Show in the context menu in tree
view. You can rotate the view with the left-hand mouse button, enlarge or reduce it
with the right-hand one, and move it with the center mouse button. One of the main
views can be selected via the menu or the Tool bars.
In 3D view you can export the 3D geometry into the CAD system (via the context
menu). If you want to display graphical elements (see System.kSys3DElements), you can export the elements from that file if you have the appropriate license. If a 3D kernel is present and you want to generate solid
elements, a CAD file will be generated directly.

62.2.5

Message output

In the lower part of the program window (see Figure on page IX-1119) there is
an output window for messages. Error messages and warnings from KISSsoft
calculations will be displayed under Messages. Calls by KISSsoft are reported
under KISSsoft, so this view is usually not required.
In the lower program window, as in KISSsoft, you will see an information tab. If
information about a particular function is present, it is displayed in this tab.

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62.2.6

Menus, context menus and the Tool Bar

In the File menu you can open, store and save models, open and close projects, and
close KISSsys. You can also open or close KISSsys templates.
Each individual docking window in the user interface can be hidden or displayed in
the View main menu. You can also refresh all views.
In the System main menu you can generate the KISSsoft report and perform
kinematics and KISSsoft calculations. You can also select a load spectrum for the
model from the KISSsoft database or define your own in KISSsys. Use these
functions to call the characteristics of the element and variable overviews.
In the Insert menu, the Assistant will guide you through the steps required to create
a simple gear unit or a single stage planetary gear unit. The Elements Box operates
like the Assistant in that it lets you add elements, but without any structural limitations. Default templates are used to add pre-defined models or templates to an
existing model.
In the Extras menu you will find the administrator settings, the license tool, the
configuration tool and the language setting. Select Extras > Settings to change general program settings such as the names of individual elements or table settings.
As in Windows, at the end of the menu bar you will see the Help entry which you
can use to navigate in the KISSsoft manual and in the KISSsys program. Click
on Help > Info to find information on the program version and on the support
provided by KISSsoft.
In the Window main menu you will find actions for organizing the opened subwindows such as tables and 3D views. The printing action is only enabled if a table
is open.
In addition to the main menu, KISSsoft uses context menus in many places. Use
context menus to access actions for a particular area or model element. Context
menus are normally called up by clicking the right-hand mouse button.
Select the Tool bar for rapid access to the menu actions that you need to use most
often. Also note the tool tips: they display information about the actions in the Tool
bar and also the more detailed explanations in the status bar.

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62.3

Creating Models in KISSsys

This chapter is intended for KISSsys users.

There are four ways for you to create new models in KISSsys. They are described
in the next four sections.

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62.3.1

Classic method

If you enable the Administrator in KISSsys Extras -> Administrator,

the system displays, in the Template tab, all elements that are required for creating
a model. You create a model by copying the particular elements from the template
and inserting them in the navigation tree. It is also possible to create the elements
by moving them from the template to the navigation tree. All possible models can
be created with the classic method.

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62.3.2

Element Assistant

The Insert > Elements wizard is based on the classic method. If you use this
wizard, you no longer have to drag and drop or cut and paste data. To insert an
element, click on it, and the system automatically inserts it in the current structure
in the navigation tree. Using the Element Assistant you can create all possible
kinds of variants.

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62.3.3

System Assistant

Under Insert > System of Shafts KISSsys provides an Assistant with

which you can create cylindrical gear stages. This Assistant leads you through the
model step by step when you are creating it. You use it in the same way as the Assistant. Use this function to create a cylindrical gearbox.
Use the KISSsys Assistants to create parallel shafts with the following
combinations of gears:
Cylindrical gear
Bevel gear
Worm wheel
Face gear
Use the Planetary gear Assistant to create a single stage planetary gear unit.
This Assistant leads you through the model step by step when you are creating it.
You use it in the same way as the Assistant.

62.3.4

Setup with icon

The default setting is that all the elements are listed on the left-hand side of the
screen as icons, so you can construct a model from the very beginning.

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62.3.5

Creating and modifying tables

To create your own tables in KISSsys Model you can use a predefined table called
"UserInterface", which is stored in the template in "Tables". You use this "UserInterface" table to add all the parameters from the elements and your own texts.
You can select the table's name to suit your needs.
For each cell, no matter what it contains, you can right-click with the mouse to select Format in the context menu. There you can set the font, color, background color, and position, of the text for that cell.

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62.3.6

Adding variables in tables

One way of inserting variables in the "UserInterface" table is to select a variable

from the "Properties" dialog and then click on the corresponding icon in the "Tool
bar" menu. You can then insert the variables either as text (Name), as a reference,
or as an expression.
Text
You can also input texts directly in the cell. Alternatively, you can use the Text
icon to help you. Select the parameter you want to insert from an element's property and preselect a cell in the table. Then click on the Text icon. This transfers the
required value to the cell. You can also hold down the left-hand mouse button and
drag and drop the required parameter to insert it directly. The default setting is for
text to be inserted. Click on Extras > Settings > Tables tab to
define the default setting as a text, reference or expression

Reference
Referenced data is displayed in red. These values are referenced with a parameter
in the element property. You can modify the value both in the table and in the property.

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You can add referenced values to cells in the same way as you add texts. Select the
parameter you want to insert from an element's property and preselect a cell in the
table. Then click on the Reference icon. This transfers the required value to the
cell. Alternatively, you can hold down the right-hand mouse button and insert the
parameter in the appropriate cell. A selection window appears in which you can
select a text, reference or expression, as required.

Expression
The expression is merely shown as a value and cannot be modified in the table.
You can insert an expression into a cell in the same way as a reference.

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62.3.7

Individual names for elements

Individual names can be used for all KISSsys elements. The individual name is
assigned to the element automatically when it is assigned to the model. This
behavior can be set individually for each element (Extras->Settings>Elements).
Use the <autoInc> and <localInc> tags to add an index to the individual name at
the insertion position. The first of these tags increments the index globally. This
means that no other element in the model can have the same name. The second of
these tags increments the index locally (in the same folder). Use the <parentName>
tag to add the name of the hierarchically superior item.
The "Automatically/Ask" option is set to suppress or display the dialog that
prompts the user to define the name for the new element for the model. Click on
"Reset" to select the KISSsys default name. You can use the "All questions", "All
automatic" and "Reset all" functions to modify all the elements at the click of a
button.

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62.4

Extended functionality for developers

In addition to the functionality already described, more functions are available for
developers.
To open a template file, click on File>Open Templates. Alternatively, click on
Insert > Default templates to load the template file. It is displayed as a tree under Templates.
To add new elements in tree view, you can "Copy" and "Paste" them. The new
elements are added as copies from a template file.
You can rename and delete elements via context menu functions.
The data in the Properties dialog can be edited. New variables can be added and deleted
Hidden variables will be displayed and all functions can be performed.
Hide messages by selecting Extras>Suppress messages.

62.4.1

Properties dialog

In tree view, or in the diagram for an element, you can open the KISSsys Properties dialog via the context menu. In it you can add new variables or change
existing ones. Only one Properties dialog is available. A second one will not
be displayed.

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Figure 62.2: The KISSsys Properties dialog

<Figure 51>.2 shows the Properties dialog. On the left you see a tree view in
which you can select data elements or variables, and on the right you see a dialog
for the selected variable. The following fields are available for the variables:
Type: Display the Variable type (see section "Variables" on page IX-1134).
Name: The name of the variable. You can change the name here. However, if a
variable has to be used in formulas or references, you must also change the
name there, as otherwise the variable cannot be found.
Reference: Enter the reference target here for reference elements. A name
must be entered in quotation marks. An alternative would be the name of a
string variable (see page IX-1135). In the case of Variants (see page IX-1135)
the index must be entered here in an array. Here, an invalid reference will be
marked in red.
Value: The current value of the variable.
Expression: An Expression used for calculating the variable (see page IX1141). The value will be calculated on the basis of the expression, if an expression is present.
"KISSsoft KISSsys" flag. The variable can be transferred from KISSsoft to
KISSsys.
Flag "KISSsys KISSsoft" flag. The variable can be transferred from KISSsys to KISSsoft.
Click the Reference and Variant buttons to convert the variable into a reference or variant variable and back.

62.4.2

Table view

The format of the tables is defined in the hidden definition variable. There are
different types:
Table for calculations: This table is best suited for displaying the data for several elements of the same type. The definition format is:
[[type,rows,columns],['variable1','variable2',..],
[element1,element2,..]]

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In the case of type 1, you can edit each displayed value, in the case of type 2
you can edit all values that have no expression, and in the case of type 3 you
can edit all values for which the KISSsys KISSsoft flag has been set. The
Number of Rows or Columns is not used.
Table for arrays or variants: In this table, the arrays or variant variables are
displayed in separate columns. The definition format is:
[[type,rows,columns],['variable1','variable2',..]]
In the case of type 21, you can edit each displayed value, in the case of type 22
you can edit all values that have no expression, and in the case of type 23 you
can edit all values for which the KISSsys KISSsoft flag has been set. The
Number of Columns is not used.
Table for user interface: You can configure this table to suit your needs. The
definition is [[type,rows,columns],[[A1,B1],[A2,B2]]]. The
contents can be inserted via a context menu in the table, and should not be
changed in the definition. Since the definition is changed interactively, you
must not set an expression here. The number of rows or columns should also
only be changed via a dialog, as otherwise information on reference elements
will be lost.

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62.5

The existing elements

62.5.1

Variables

The following variables can be used:

Real: A numerical value.
String: A character string. Input in quotation marks e.g. "Text".
Point: A coordinate or vector with 3 components. Input in {1,2,3} format.
Array: A one-dimensional or multidimensional field. Input e.g. as
["Text",1.23,{1,2,3},[1,2]].
Function: An executable function. Input best entered via the special input
screen.
ElementID: The ID of a Classcad object. Output as $31, input as name of the
object with no quotation marks.
List: Displayed as selection list and acts as a number in the Interpreter (index
of the list beginning with 0). The selection list is defined as an array via the
Edit list menu item, e.g. ["one","two","three"].
Database List: The name from the KISSsoft database is displayed in a selection list. In the Interpreter, this type also acts as a number according to the database ID. The database assignment is defined as an array via the Edit list
menu item: ["database","table"]
Each of the variables has a name, a value, an expression and different flags. If an
expression is present, the value of the variables is defined via this expression. The
expression is therefore particularly suited for the input of formulas. If, in contrast, a
formula is entered in place of the value, this formula will be evaluated and the
result will be assigned. The actual formula will be lost. The KISSsoft>KISSsys and KISSsys->KISSsoft flags determine how data is
exchanged between the two programs. Only variables with the appropriate flag
activated will be exchanged.
In the case of functions, the function is placed in the expression, and the value has
no meaning.
For the Real, String, Point, List and Database List data types there
are additional reference elements and variant elements.

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62.5.1.1
Refe rences
A reference element behaves like any other variable, with the difference that
another variable fetches the data. A valid variable name must be entered as the target for the reference element. The reference target must be entered as a character
string. This will be either an actual name in quotation marks or an expression
resulting in a character string, e.g. a concatenation of character strings (e.g.
gear1+'.z' with the string variables gear1 or 'gearwheel1.z'). The
system marks an invalid reference in red.

62.5.1.2
Variant s
Internally, the variant elements administer a field of variables, whereas externally
they behave like a normal variable. As additional data, the variant is assigned an
index variable, which indexes the field. The index variable must be entered as an
array of variables (e.g.[system.index]). With these data types you can store
load spectra or system variants and the results can be displayed in tables.

62.5.2

Calculation elements

All the elements for KISSsoft calculations are derived from classes which begin
with the name kSoft. In tree view they have a bitmap with a blue background.
The calculation elements have a series of functions:
Calculate: performs a KISSsoft calculation in the background.
kSoftInterface: starts KISSsoft interactively
kSoftReport: performs the calculation and displays the report.
SetFlags: Sets the flags for data exchange between KISSsoft and KISSsys to
suit the required storage location.

Save in KISSsys: The data will be passed on in both directions.

Save in KISSsoft: Data with a stored expression will be transferred from

KISSsys to KISSsoft, and all other data will only be transferred in the other
direction.

This function sets the flags only once when selected. It therefore has no effect
on later changes.
kSoftModul: This hidden function displays the KISSsoft module descriptor.
getTranslationTable: This hidden function shows the translation table for variable names from KISSsys to KISSsoft. In the calculation element, the translation table can be extended via the TranslationTable array: For example,

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an entry of
[['eps_a_min','ZP[0].Eps.aEffI'],['eps_a_max','ZP[0].
Eps.aEffE'] adds a link between the variables eps_a_min and
eps_a_max and the corresponding KISSsoft variables. Until now the names
of the KISSsoft variables could only be taken from the report templates,
*.rpt.
getUtilization: This function returns the utilization, and the required safety/safety ratio.
In the fileName variable you can specify a KISSsoft calculation file which will
automatically be loaded at the start of the calculation, before any other variables
are transmitted. You can use the savingMode variable to specify whether this
KISSsoft calculation file should be saved automatically:
Don't ask and don't save When KISSsoft is shut down you will not be asked
if the file should be saved after changes have been made to it.
Ask for saving When KISSsoft is shut down you will be asked if the file
should be saved. (KISSsoft default response)
Save automatically When KISSsoft is shut down, the calculation file will be
saved automatically without a user confirmation prompt.
Save file in KISSsys No file name will be entered in fileName. Instead, the
entire calculation file will be saved in the KISSsys element.
The shaft calculation contains the special method UpdateShaftElements. This must
be called up if an element of force is to be added/deleted on a shaft. It evaluates the
type and number of elements of forces on the shaft and transfers them into the
'forces' array in the shaft calculation. This array is a defining factor for the forces in
the shaft calculation.

62.5.2.1
Relat ionsh ip of calculations wi th element s
Templates are provided which automatically link the calculation with the shafts
and gears. To do this, use the Dialog function. In the case of fundamental
changes, i.e. when more elements of forces are added to the shaft, this dialog must
be called up again to update the relationships.

62.5.2.2
Storage strategie s fo r calculation s
There are different options for saving the calculation data:

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1. All data is to be saved in the KISSsys file and the calculations can only be
accessed via KISSsys: Select Save file in KISSsys in savingMode. It is best to set the flags bidirectionally.
2. All data is to be saved in a KISSsoft file and the file can also be changed
outside of KISSsys: Select Ask for saving, or Save automatically in savingMode. Use SetFlags to set the mode to Save in
KISSsoft. Note here that the calculation data will only be loaded from
the KISSsoft file when the calculation is called up for the first time. After
the KISSsys file is opened, you should therefore call up kSoftCalculate occasionally.

62.5.2.3
Importing exi sting KISSsoft calculat ions
If there are already KISSsoft calculations present for elements of a new KISSsys
system, you can simply load the files into the KISSsoft window. However, you
should note a few points:

The file name under fileName in the KISSsys calculation element will be
changed. The name must either be deleted or modified.
During the shaft calculation the elements of forces and the bearings are overwritten. For this reason, you need to call up the dialog or the UpdateShaftElements function after importing the calculation. The elements of forces
and bearings cannot be imported, and neither can the positions. This data must
be entered in KISSsys.
In the case of gears you must ensure that the sequence of the gears matches up.

62.5.3

Elements for shafts

Different elements can be placed onto shafts. They will also be transferred into the
KISSsoft shaft calculation. The position on the shaft is defined with the position variable.
kSysHelicalGear: A cylindrical gear.
kSysBevelGear: A bevel gear. The position of the peak is defined by the direction variable.
kSysWorm: A worm.
kSysWormGear: A worm wheel.
kSysCoupling: A coupling. Diameter d and Width b can be entered for the 3D
display.

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kSysBearing: A normal type of bearing. Losses can be recorded in Tloss.

The direction of the loss torque should be defined with a sign (speed) in
the expression.
kSysRollerBearing: A rolling element bearing. The bearing geometry will be
loaded from the KISSsoft bearings database during each refresh. Losses can be
recorded in Tloss. The direction of the loss torque should be defined with a
sign (speed) in the expression.
kSysCentricalLoad: A centrical load. KISSsys will always prompt with a torque (Ty) but no power. This torque will also be included in the kinematics calculation.
kSysMass: An additional mass on the shaft.
kSysRopeSheave: A rope sheave. Unlike the torque, the belt force will not be
calculated via the connection. It is up to the user to ensure that the belt force
matches up in two belt pulleys.
kFaceGear: A face gear.

62.5.4

Connection elements

kSysGearPairConstraint: a connection between two cylindrical or bevel

gears.
kSysPlanetaryGearPairConstraint: a connection between a gear and a planet. You can select the type of pairing: sun-planet, planet-internal gear or planet-planet. Both gears must also be entered in this sequence. In addition, a planet carrier must be selected. The number of planets needs to be defined in the
NofPlanets variable in the planet carrier coupling.
kSysPlanetaryBevelGearConstraint: a connection between a bevel gear and
a rotating bevel gear for bevel gear differentials. As in the case of the planetary
connection, the sequence of the bevel gears and the number of planets must be
defined. An efficiency cannot be specified here.
kSysWormGearConstraint: a connection between a worm and wormwheel.
Optionally, you can define two efficiencies (eta1 and eta2) for the driving
worm or driving gear.
kSysCouplingConstraint: a connection with transmission ratio 1 between two
couplings. The kinematic force of the coupling can be activated or deactivated.
Additionally, it is possible to specify a slip, e.g. for flake graphite couplings or
synchronizations. The torque in the connection will usually be calculated, but it
can also be specified.

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kSysBeltConstraint: a connection between belt sheaves. The transmission

ratio is calculated from the diameter ratio. A slip and an efficiency can be specified. When you are inputting the slip, take into account the transmission ratio
and the sign. The calculation is performed in accordance with: n1 - d2/d1 . n2 =
slip
kSysConnectionBearing: A connection between two shafts
kSysConnectionRollerBearing: A connection between two shafts
kSysSynchronizer: A shaft synchronizer
Using the setConfig(slipConstraint_r/[slipConstraint_r,
slip_r], torqueConstraint_r/[torqueConstraint_r,
torque_r]) function you can activate or deactivate the connection:
1. Closed, without slip: setConfig([TRUE, 0], FALSE),
2. Open, without torque: setConfig(FALSE, FALSE),
3. Open, with torque: setConfig(FALSE, [TRUE, 20])

kSysSpeedOrForce: An element for specifying speed or torque. Both values

can either be specified, otherwise they will be calculated. For the torque, you
can also preset the power as an alternative.
Using the setConfig(speedConstraint_r,
torqueConstraint_r/[torqueConstraint_r, type_r,
torque_r]) function you can change the presets. If you specify a load type,
the values below have these meanings: 0..torque with sign, 1..torque driving,
2..torque driven, 3..power driving, 4..power driven. Examples:
1. Speed and torque specified: setConfig(TRUE, TRUE),
2. Speed and torque with value specified: setConfig(TRUE,
[TRUE, 0, 20]),
3. Only driving power specified: setConfig(FALSE, [TRUE, 3,
20])

62.5.5

Displaying elements in 3D graphics

Each element has an OnRefresh3DView function which generates the 3D display. If necessary, this function can be overwritten. You can set the color of an
element in the range from 0 to 255, with the kSys_3DColor variable, and set the
transparency with the kSys_3DTransparency variable. These two variables
must be created if necessary.

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62.5.6

System settings

You can make use of a series of setting options in the System element:
kSoftAcceptChanges: The default setting yes means the changes will be
transferred from KISSsoft. If the setting is no, nothing will be transferred. The
setting asked means you are prompted to confirm whether the changes should
be transferred when KISSsoft is shut down.
kSysKinematicFunc: During the kinematics calculation you can call up the
OnCalcTorque function. The standard implementation of this function calls
up the calculation of the bearing actions for all shafts.
kSysKinematicMode: The calculation of the kinematics can either be iterative
or not. Iterations for the torque must be activated if the efficiency needs to be
included. Iterations for speeds are only necessary if formulas for speeds have
been entered.
kSys3DElements: You can optionally display graphical elements or solid elements (3D kernel required). Graphical elements will be generated faster,
although solid elements are more detailed, and it is for example possible to also
display a loaded housing.
project_name: The project name will be displayed in the KISSsoft calculation
reports.
project_contract: The commission number will be displayed in the KISSsoft
calculation reports.

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62.6

Programming in the Interpreter

There are programming options in the expressions used in variables and in

functions.

62.6.1

Expressions in variables

The programming options in expressions are restricted. No local variables may be

used.
Between the data types, the operators are defined in accordance with Table 62.1. A
series of mathematical functions is also available. They are listed in table 62.2.
Data type

Operations

Description

Real

+,-

Addition and subtraction

*,/

Multiplication and division

<,>=,=,!=,>=,>

Relational operators

!,AND,OR

Logical operators

+,LEN

Concatenation and length operators

<,>=,=,!=,>=,>,!

Relational operators

+,-

Addition and subtraction

*,**

Scalar and vector multiplication

:x,:y,:z

Access to components

LEN

Vector length

[],+,LEN

Indexing, concatenation and length operator

String
Point

Array

Table 62.1: Permitted operators for data types

abs(x)

Supplies the value of x

sign(x)

Supplies the sign of x (+1, -1 or 0 if x=0)

min(a,b,...)

Supplies the smallest value of the arguments

max(a,b,...)

System supplies the largest value of the arguments

a_r(x)

System converts from degrees to radian measure

r_a(x)

System converts from curve to degrees

sin(x)

System calculates sin of x in the radian measure

sinh(x)

System calculates sinh of x

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asin(x)

System calculates arcsin of x

cos(x)

System calculates cos of x in the radian measure

cosh(x)

System calculates cosh of x

acos(x)

System calculates arccos of x

tan(x)

System calculates tan of x in the radian measure

tanh(x)

System calculates tanh of x

atan(x)

System calculates arctan of x

atan(y,x)

System calculates arctan of y/x

exp(x)

System calculates e to the power of x

ln(x)

System calculates the natural logarithm of x

log(x)

System calculates the decadic logarithm of x calculates

sqrt(x)

System calculates square root of x

pow(x,y)

System calculates x to the power of y

fmod(x,y)

System calculates x modulo y

Table 62.2: Predefined mathematical functions

A variable's expression can contain the specified operations and any function calls.
If limited expressions are to be used, the expression must begin with # and the
result has to be returned with RETURN:
#
IF a>b THEN
RETURN a;
ELSE
RETURN b;
ENDIF

62.6.2

Functions

The different options for programming in functions are best described with the help
of examples. A function's header looks like this:
// Transferred variables from calling program
PAR Parameter1, Parameter2;
// Declaration of constants
CONST PI=3.1415926, E=2.71828;

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// Declaration of local variables

VAR a,b,c,d;

Here, the lines that begin with // are comments. Each of these three lines may
only occur once, and the declared variables must be separated with a comma. A
non-initialized parameter or variable is VOID. This can be checked with
ISVOID(variable).
Limited statements have two variants: IF or SWITCH statements:
// IF statement with optional ELSIF and ELSE Block
IF Parameter1 > 5 THEN
a = sin(PI*Parameter1);
ELSIF Parameter1 < 0 THEN
a = Parameter1;
ELSE
a = 0;
ENDIF
// SWITCH Statement with selection of figures or texts
SWITCH Parameter2
CASE 'Zero': b = 0;
CASE 'one': b = 1;
DEFAULT: b = 5;
ENDSWITCH

For loops, there are four program variants:

// FOR Loop with optional intervals
FOR a = 1 TO 8 STEP 2 DO
b = b + a;
IF b>100 THEN
BREAK;
// Ends the Loop
ENDIF
NEXT
// WHILE Loop
WHILE b<100 DO
b = b*10;
WHEND
// DO Loop
DO
b = b*10;
UNTIL b>100;
// FORALL Loop is executed for all elements of an array
c = [1,2,3,4,5,6,7,8,9];
a = 0;
FORALL c d DO
// d receives each of the values of an element from c
a = a + d;
NEXT

There is a special syntax for calling up functions that belong to objects. The standard method is to specify the object name followed by a point and the name of the

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function. However, the name of an object can also be contained in a local variable.
This allows you to change the object for the function call at runtime.
// The OBJ_GetMember function is called for Object1
Object1.OBJ_GetMember('variablenname');
// a is a local variable of Type String with the
a = 'Object1';

name of an object

// This calls a Service function for the object with the name a
b = a.OBJ_GetMember('variablenname');
// calls a function created by the user for Object1.
a.Userfunction();
// the function created by the user is called
// for the current object.
Userfunction();
// the function created by the user is called
// for the hierarchically superior object.
^.UserFunction();

The system searches for variable names relative to the current object. If
object.z is used in an expression, the system will first of all attempt to find this
variable below the current object. If it is not present, the search will continue in the
hierarchically superior object (in accordance with ^.object.z) and so on.

62.6.3

Important service functions

OBJ_GetChildren()

Supplies an array with all child objects.

OBJ_GetName()

Supplies the name of the object.

OBJ_GetId()

Supplies the ID of the object.

OBJ_GetId()

Supplies the ID of the object.

OBJ_HasMember()

Tests whether a variable is present

OBJ_GetMember()

Supplies the variable of the current object.

OBJ_FindMember()

Supplies the variable of the current or hierarchically superior object.

Table 62.3: Important service functions

62.6.4

Variable dialogs

In interpreter functions, variable dialogs can be generated for the input of variables.
The call is:

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res = CADH_VarDialog([Title, Width, Height, Pitch],

[Dialogelement1], [Dialogelement2], ...);
The title will be displayed in the title line of the dialog, and width and height show
the dialog's dimensions in pixels. The pitch (between 0 and 1) describes the
relationship between the width of the field description and the dialog width (default
value 0,4). This definition of the dialog size can be followed by any number of arrays with the definition of the individual dialog elements.
The return value is an array. Its first value is res[0] =1 if the dialog ends with
OK, otherwise it will be zero. The other elements of the returned array supply the
results of the input fields.
Below, the following convention is used to define the type of a variable:
_str=String, _n=Int, _r=Real, _b=Bool. For example, in the case of Caption_str,
this means that the variable Caption is of the type String.

62.6.4.1
Dialog elements for the variable dialog
The following dialog elements are available for the variable dialogs:
H oriz o n ta l gr o u pi ng:

The horizontal grouping provides a framework in which the individual dialog elements are lined up beside each other. Their position must always be defined by a
vertical group, which means that all dialog elements contained within a horizontal
grouping must be defined in a vertical group. A horizontal group is defined as
follows:
[C:VDGL_HORZ,Caption_str,DistAbove_n,DistAfter_n,[Dialogelem]]
C:VDGL_HORZ: Type definition for horizontal grouping.
Caption: Caption of the horizontal grouping. If "Caption" is not an empty
string, a frame will be drawn around the horizontal group.
DistAbove: distance above the horizontal group to the next dialog element.
DistAfter: distance behind the horizontal group to the next dialog element.
"DistAfter" and "DistAbove" are specified in pixels.
[Dialogelem]: Element array for the definition of the dialog elements located in
the horizontal grouping. This array may only contain elements of the type
VDGL_Vert.
Ve r ti cal gr o upi n g:

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The vertical grouping provides a framework in which the individual dialog elements will be lined up below each other. The width of the dialog elements is
defined by the vertical group. A vertical group is defined as follows:
[C:VDGL_Vert,Caption_str,[XStart_r,XEnd_r],XPart_r,[Diag],Marg_n]
C:VDGL_Vert: Type definition for vertical grouping
Caption: Caption of the vertical grouping. The vertical grouping always has a
frame drawn around it.
[XStart,XEnd]: XStart and XEnd define a factor (between 0 and 1) for the
width of the vertical group with reference to the width of the hierarchically superior dialog. Additionally, they define the X-position of the vertical group.
XPart: Factor between 0 and 1 that defines the ratio between the prompted value and the input value for the dialog fields (the text assigned to an input field
is called the "prompt"). If XPart=-1 the prompt will be positioned above the dialog element.
[Diag]: Element array used to define the dialog elements located in the vertical
grouping.
Marg (margin): An optional parameter defining the displacement of the dialog
elements in relation to the edge of the vertical group, which means that the dialog elements contain the distance "Marg" (margin) both from the left-hand and
from the right-hand edge of the vertical group.
Rea l Edi t F eld :

Provides an edit box in which the user can input a floating comma number.
[C:VDGL_Real,Prompt_str,Preset_r,res,res,Places_n]
C:VDGL_Real: Type definition of RealEditFeld.
Prompt: Text assigned to the input field.
Preset: preset value.
res: Here, a space is reserved for two optional parameters which are not in use
at present. However, these spaces must not be left empty in the definition (e.g.
[C:VDGL_Real,Prompt,Preset,0,0,Places] would be a correct solution but not
[C:VDGL_Real,Prompt,Preset,,,Places]).
Places: This is an optional parameter defining the number of decimal places of
the input field.
ReturnVal: (return value). The return value is the input string.
In t E dit F el d:

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Provides an edit box in which the user can input a whole number.
[C:VDGL_Int,Promt_str,Vorgabe_n]
C:VDGL_Int: Type definition of IntEdit field.
Prompt: Text assigned to the input field.
Preset: preset value.
ReturnVal: (return value). The return value is the input string.
Stri n g E dit F el d:

Provides an EditBox in which you can input text.

[C:VDGL_Str,Promt_str,Vorgabe_str]
C:VDGL_Str: Type definition of the StringEdit field.
Prompt: Text assigned to the input field.
Preset: Preset value.
ReturnVal (return value): The return value is the input string.
T ex t dis pla y:

The system generates a text display. If an empty string is entered instead of text,
the text field can also be used to define a distance.
[C:VDGL_Prompt,Prompt_str,Fieldheight_n]
C:VDGL_Prompt: Type definition of text display.
Prompt: Field text.
Fieldheight: Height at which the text is displayed.
In tC o m b oB ox :

Provides a combo box in which the user can input a whole number.
[C:VDGL_IntCom,Prompt_str,[Entr_n],Sign_n/[Ind_n],0,0,AsVal_b]
C:VDGL_IntCom: Type definition of IntComboBox.
Prompt: Text assigned to the combo box.
[Entr]: Element array of the available list items (in the case of an IntComboBox the components must be whole numbers).
Sign/[Ind]: Here you have the option of using "Sign" to either set a constraint
value, which is contained in the list, directly, or using "Ind" to select a value in
a particular list position as a constraint value (the first element in the list is located at position 0)."Sign" or "[Ind]" are optional parameters.

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AsVal: If the optional parameter "AsVal" has been set and is not 0, the return
value becomes the input. Otherwise the return value is the index of the selected
entry.
In t E dit C om b oB o x:

Provides a editable combo box in which the user can input a whole number. Please
note that the values entered here are whole numbers.
[C:VDGL_IntComE,Prompt_str,[Entr_n],Sign_n/[Ind_n]]
see IntComboBox
ReturnVal: (return value). The return value is the input string.
Rea lC o mb o B ox:

Provides a combo box in which the user can input a floating comma number.
[C:VDGL_RealCom,Prompt_str,[Entr_r],Sign_r/[Ind_n],0,0,AsVal_b]
see IntComboBox
Rea l Edi t C om b oB ox :

Provides a editable combo box in which the user can input a floating comma number.
[C:VDGL_RealComE,Prompt_str,[Entr_r],Sign_r/[Ind_n]]
see IntComboBox
ReturnVal: (return value). The return value is the input string.
Stri n gC o m b oB ox:

Provides a combo box in which the user can input a string.

[C:VDGL_StrCom,Prompt_str,[Entr_str],Sign_str/[Ind_n],AsPos_n]
see IntComboBox
AsPos: Contrary to the IntComboBox, the return value here represents the index of the selected field, if the optional parameter "AsPos" has been set and is
not 0. Otherwise the return value is the input.
Stri n g E dit C om b oB o x:

Provides a editable combo box in which the user can input a string input.
[C:VDGL_StrCom,Prompt_str,[Entr_str],Sign_str/[Ind_n]]
see IntComboBox
ReturnVal (return value): The return value is the input string.

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Co d e b ut t o n:
Se rvi c e bu t t o n:

62.6.4.2

Example application o f a variable dial og

Figure 62.3: Example of a variable dialog

The section below uses the example of the program code for the variables dialog
shown in Figure 62.3, in which the greatest possible number of elements are used:
//

VARIABLES DECLARATION

VAR res,result1,result2,result3,result4,result5,fullResult;
// DIALOG AND INPUT DATA
res = CADH_VarDialog(["Example of Variable Dialog",500,400,0.4],
[C:VDLG_StrCom,"StrCOMBOBOX1:",["Gear1","Gear2","Gear3"],[2],0],

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[C:VDLG_Prompt,"TEXT1:",30],
[C:VDLG_IntCom,"IntCOMBOBOX1:",[12,17,19],17,0,0,1],
// HORIZONTAL GROUP

WITH

ONE

VERTICALGROUP

[C:VDLG_HORZ,"HORIZONTAL UNIT1",20,10,
[

// Warning: remember brackets!

[C:VDLG_VERT,"VERTICAL UNIT1",[0.3,0.9],-1,
[
[C:VDLG_Str,"StringFld:","Test Program"],
[C:VDLG_RealComE,"RealCOMBOBOX1",[5.3,7.1,9.1],[2]]
],
20
]

// Warning: remember brackets!

],
// HORIZONTAL GROUP

WITH

TWO

VERTICAL UNITS GROUPS

[C:VDLG_HORZ,"HORIZONTAL UNIT2",10,10,
[
[C:VDLG_VERT,"VERTICAL UNIT2",[0.01,0.35],-1,
[
[C:VDLG_Int,"IntFld:",6],
[C:VDLG_StrComE,"StrCOMBOBOX2:",["Gear1","Gear2"],[0]]
],
10
],
[C:VDLG_VERT,"VERTICAL UNIT3",[0.4,1],-1,
[
[C:VDLG_Real,"RealFld:",5.6,0,0,3,3],
[C:VDLG_IntComE,"IntCOMBOBOX2:",[5,7,9],7]
]

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]
]
]
);
// res [0] contains 1 if

OK was pressed , or

else

IF res[0] THEN
// READ RESULTS FROM DIALOG:
result1 = res[1];

//res [1]= Gear3

result2 = res[2];

//res[2]= TEXT1:

result3 = res[3];

//res[3]= 17

result4 = res[4];

//res [4]= [["Test Program",9.1]]

result5 = res[5];

//res[5]= [[6,"Gear1"],[5.6,7]]

fullResult=res;
//res=["Gear3","TEXT1:",17,[[''Test Program",9.1]],[[6,"Gear1"],[5.6,7]]]
CADH_Message(fullResult);
ENDIF

62.6.4.3
Interactions wit h variable dialogs
It is possible to interact with variable dialogs. Selections in lists, changes in input
fields and selections in lists can trigger callbacks to a user-defined function. Then,
it is also possible to change dialog elements from this callback routine.

You set a local function as a callback via the title input in the variable dialog:
res = CADH_VarDialog([[Title,PROC(Callback)], Width,
Height, Pitch], [Dialogelement1], [Dialogelement2],
...);
The local callback function will now be called up if there are changes in the dialog.
The function is declared as follows:
PAR res;
PROC Callback
PAR handle, elemNo, event, eventPar;
IF TYP(elemNo)=STRING THEN
IF elemNo='@combo' AND event=C:CBN_SELCHANGE THEN
IF eventPar=0 THEN // own input, enable input
CADH_VarDialogAccess(handle,[['@input1',C:VDLG_ENABLE,TRUE]]);

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ELSE // disable input, set value to zero

CADH_VarDialogAccess(handle,[['@input1',C:VDLG_ENABLE,FALSE],
['@input1',c:VDLG_ASSIGN,0]]);
ENDIF
ENDIF
ENDIF
ENDPROC
res = CADH_VarDialog([['Title',PROC(Callback)], 400, 400 0.4],
[[C:VDLG_Real,'@input1'],'Input1:',2],
[[C:VDLG_StrCom,'@combo'],'Selection:',
['own input','calculate'],[0],TRUE]);

A handle is transferred to the dialog as a code parameter, plus an element identifier,

the event, and additional parameters. The possible events are:
Element type

Event

Parameter

Dialog

Initialization

none

WM_INITDIALOG
Combobox

Selection

Current value

CBN_SELCHANGE
Input field

Leave field

Current value

WM_KILLFOCUS

Button

activated

none

BN_CLICKED
Either the number of the element according to the index in the results array is
transferred as the element number, or the name of the element is transferred. Like
in the example, a name can be defined by transferring an array, with a type and
name, into the array's first element for the dialog element.
Access from the callback routine to the dialog is via this function:
CADH_VarDialogAccess(handle, [[elemNo, action,
param],[elemNo, action, param],...]
Here, the following actions are permitted:
Action

Description

Parameter

DLG_ASSIGN

Assignment to input field

New value

VDLG_SELECT

Selection in combo box

[position]/value

VDLG_ENABLE

Activate or deactivate

TRUE/FALSE

VDLG_SETFOCUS

Focus on new element

Element's ID

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If no action is specified, the value in the input field will be returned. The return
takes the form of an array with as many elements as code parameters.

62.6.5

Defining 2D graphics

In KISSsys you can generate two-dimensional graphics for displaying results

which are present in arrays. You can store the definition of the graphic in the data
variable expression of the kSys2DPlot graphical element. Beam and line graphics can be displayed in parallel. The definition of the graphic consists of three
parts:
Axis system (1 or 2 axis systems can be defined)
XY-line graphics
Beam graphic
Below, each of these parts is described in more detail.

62.6.5.1
The definition o f the axis system (af)
At least one axis system must be defined. The second one is optional. The definition for the axis system is as follows:
[ | Xaxisname_str , | min_x_r , | max_x_r ] , [ | Yaxisname_str , | min_y_r
, | max_y_r ] , [ axiscolor_str/array , | axiscross_x_r , axiscross_y_r ] ,
[ | scaleinterval_x_r , | scaleinterval_y_r , [ | exponential_x_n , | exponential_y_n ]

where :
XAxisname: Name of the X-axis.
YAxisname: Name of the Y-axis.
min : Minimum value of the axis (optional).
max : Maximum value of the axis (optional).
axiscolour : Color of the axis defined in a string (red ,green, blue, yellow, white, gray, cyan, brown, magenta, purple, black) or as an array [ r_n , g_n , b)_n
](where r, g, b represent the red, green and blue color values from 0 to 255 (optional).
axiscross : The intersection point of the axes (optional).
scaleinterval : Increment of the axis scaling.
exponential : If 1 is input, the axis will be logarithmically subdivided.

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62.6.5.2
The definition o f an XY - line graphic (dg_l)
For an XY-line graphic the following information is required:
grouptype_n , [ dataarray_x_r ] , [ dataarray_y_r ] , [ | linename_str , |
|linecolour_str/array , | linestyle_n ] , | assignaxis_n

where :
grouptype : = 1 (for lines graphic).
dataarray : Contains the X or Y coordinates of the data.
linename : Name of the element.
linecolour : Line color.
linestyle : Line type (0- solid, 1- interrupted, 2- dashed, 3- semicolon, 4- dash
dot dot)
assignaxis : Number 1 or 2 of the coordinates system

62.6.5.3
The definition o f a beam chart (dg_b)
For a beam chart, a group of data is defined as follows:
grouptype_n , [ dataarray_1_r , ... , |dataarray_n_r ] , [ barcolour_str/array ] , | bargroupname_1_str , [ | barelementlabel_1_str , ... ,
barelementlabel_1_str ] , | barclass_n

where :
grouptype := 2 (for beam chart).
dataarray : Contains the data for the group.
barcolour : Color of the group's beams.
bargroupname : Name of the group.
barelementlabel : Names for individual elements.
barclass : Display as group (=0) or sorted by elements (=1).

62.6.5.4
The entire defi nition
The entire definition must begin with the definition of the axis system. After this,
you can list any number of definitions for line and beam charts. Each part definition must be enclosed in square brackets, just like the entire definition:
[ [af_1] , | [ af_2] , | [dg_l_1] , ..., | [ dg_l_ n1 ] , | [ dg_b_ 1 ] ,
..., [ dg_b_ n2 ]]

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If lines and beams are to be used simultaneously, a second coordinates system will
automatically be applied. This can, however, be changed by the definition of a second coordinates system. An example of the available options is listed as follows:
[
[['x-AXIS'],['y-axis',0],[[40,250,150],[-1000,-10]],[30,20,0,0]],
[['x-AXIS 2'],['y-axis 2',0],['blue',[0,0]],[30,20,0,0]],
[1,[-1000,-500,0,500,1000],[5,20,40,55,71],['LINE1','red',0]],
[1,[-1000,-500,0,500,1000],[2,20,46,60,83],['LINE2',[200,5,150],3]],
[2,[5,25,16,10,4],['red',3],'group 1'],
[2,[40,35,25,20,12],['red',3],'group 2']

The example shows two lines and two groups of beams in two separate coordinate
systems.

62.6.5.5
Displaying the graphic
After the graphic has been defined in the data variable you can display the graphic with the graphical element's Show function. Later you can update it with the
Refresh function in the menu or the graphics window.

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62.7

Specific functionalities

Some specific calculations are integrated in KISSsys.

62.7.1

Load Spectrum Calculation

With KISSsys the user can generate an entire gearbox or drive train in a single file.
Calculations can be then performed easily for the whole system using KISSsoft
modules. In several load cases are present (load spectrum or load cycle), KISSsys
can be used to analyze a complete system using this load spectrum.
The user is then able to define load cases for the whole system and perform the
calculation for all the components. Lifetime calculations with a load spectrum can
be used with the same components as in KISSsoft.
The safety factors and service lives of different gears and bearings can be
calculated. Shaft fatigue and static safeties can also be calculated using this load
spectrum. The remaining components (which cannot be used to perform a
calculation with a load spectrum) are regarded merely as a test for the "weakest"
part.
The load spectrum functionality can be used for the following types of calculation:

Calculation of a gearbox with a user defined load

Calculation of a gearbox with a single load level taken from the load spectrum.
Calculation of a gearbox with a predefined load spectrum (similar to the ones
defined in KISSsoft)
It is also possible to extend the spectrum by adding extra additional values or settings, for example to consider different shift speeds for each bin, which is itself
defined by a frequency, torque or power, and a speed.
To perform the calculations, the following KISSsoft modules are also required to
perform at least one strength calculation for the elements that need to be calculated:
Gear service life and safety factors with load spectrum
ZZ1 (load spectra) including modules Z16, Z16a, Z18 and Z18a
Shaft calculation with load spectrum
WA8 (load spectra) including modules W01s and W06s
Full version of KISSsys for template implementation and setup
K11c SYS module

Chapter
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62.7.2

Efficiency Calculation

You can use the efficiency calculation in KISSsys to calculate the heat level in a
particular gearbox. Several different methods are implemented to enable you to
select how the calculation is to be performed, according to the ISO/TR 14179 standard, Part 1 and Part 2.
A thermal analysis can be defined in two sections: power loss and heat dissipation.
An external cooler can also be taken into account. The power losses and heat dissipation can be divided up into several sections to enable the effect of all the individual gearbox components to be taken into consideration.
There are two main types of power loss: load-dependent losses and non-loaddependent losses. Both types of loss are usually present when a gear unit is operating. Power loss can also be sub-divided into gear unit elements, such as gears,
bearings and seals. Meshing and churning losses are taken into account for gears,
whereas rolling, sliding, seal and drag friction are taken into account for bearings,
and seal friction for seals. In some cases, the results must be treated with caution
because the calculation methods used may not fully support the type of geometry.
Heat dissipation can be divided into heat dissipation through the housing, base, and
rotating parts (input/output shafts and couplings) and cooling oil flow.
You can then simply calculate the total efficiency and the total heat dissipation
capacity of a gear unit for a given lubricant temperature, cooler power and input
power. You can also specify two of these three entries and calculate the optimum
value for the third parameter, which is the value with which you achieve the best
heat level for the gear unit. In other words, the value where the heat dissipated
equals the heat generated through the power losses.
The difference between Part 1 and Part 2 of the standard is the way in which the
different values are entered for the calculations. The main benefit of Part 1 is that it
enables you to enter your own heat transfer coefficient for the heat dissipated
through the housing (if it has a very specific shape), whereas, in Part 2, this
coefficient is calculated using an approximation of the shape of the housing. The
main benefit of this part is that it also takes fins, bases and rotating parts into
consideration when calculating the amount of heat that is dissipated.

Chapter
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62.7.3

Taking into account housing deformation in st atic KISSsys calculations

62.7.3.1
Introduction
The inclusion of housing deformation in KISSsys calculations is based on the use
of a reduced stiffness matrix for the housing, as calculated by the Finite Element
Method (FEM). This reduced stiffness matrix should include the nodes that refer to
the center position of the bearings that connect the shafts of the gearbox to the
housing.

62.7.3.2
Main calculat ion steps
The calculation steps that must be followed to perform this kind of analysis are
summarized next. Please note that the process to generate the reduced stiffness
matrix is not described, since it is different for each FEM computer program used.
For more information on this, please refer to your FEM program manuals.

Step 1: Import the stiffness matrix and the FEM nodes coordinates

The first step is to read the stiffness matrix and the FEM nodes coordinates. This is
achieved by calling the relevant function in the housing element, in the KISSsys
model (right-click, select ImportStiffnessMatrix). Both the stiffness matrix and the
nodes coordinates should be positioned in the same file, together with some information on the system of units used. An example of such a file (that can now be
handled by KISSsys) is given next:

Chapter
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*******

Step 2: Position the housing correctly in the KISSsys model

Since the FEM model and the KISSsys model may not have a matching coordinate system (CS), you should then position the housing correctly in the
KISSsys model. To do so, right-click on the housing element again, and select
the ResetPosition function. In the next dialog, you can either input the origin
and orientation of the housing CS directly, or use the ThreePointPositioning
function. To do so, select three points (e.g. bearings) in the KISSsys model
from a drop-down list, and then enter the coordinates of the same three points
in the housing CS. Make sure that these three points are not collinear. This procedure returns the housing CS with respect to the KISSsys CS. A visual check
of the correct positioning can be also done by reading a simplified step file of
the housing (e.g. only wireframe) and showing it in the KISSsys 3D viewer. To
import a step file in the housing, the user can right mouse click on it and select
Dialog. We recommend you use a simplified version to avoid overloading the
KISSsys model. Finally, the user can also choose to show the FEM nodes on
the KISSsys model, by right mouse clicking on the housing element and selecting ShowNodes. Every time the orientation of the housing is changed, the user
has to select ShowNodes again, in order to update the nodes view in KISSsys.

Step 3: Perform
Click the housing calculation button to start the analysis. The first step in the
calculation is the mapping of the FEM nodes on KISSsys bearings. The pro-

Chapter
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62

gram gives a message of any nodes that could be mapped and their distance to
the closest bearing. At this point the user must know if in reality the rejected
nodes correspond to bearings or not and hence select to continue or cancel the
calculation. One possible reason for not mapping bearings of interest to nodes,
is the wrong positioning of the housing in the KISSsys CS. If this is the case,
then the previous step must be repeated. If this is not the case, and the difference between FEM nodes and bearings (as reported in the mapping message) is
not that big, then the user can change the tolerance that is used in the mapping
process. This can happen for example in the case that the FEM node is not positioned in the middle of a bearing, but at its edges. The tolerance used in the
mapping can be changed from the housing properties in KISSsys (right mouse
click on the housing and select Properties window). There, the tolerance is given in millimeters.
If you continue the calculation, the program reduces the stiffness matrix to the
part that corresponds to the mapped nodes. Nodes that have not been not mapped to bearings are ignored. The calculation also ignores any predefined offsets
and tilting values given previously in the bearings and sets them to zero. The
algorithm performs all KISSsoft calculations and derives the forces on the bearings. From these forces the program calculated the offsets and tilting on the
bearings (using the FEM stiffness matrix). Then, using the resulting offsets, the
KISSsoft calculations are run again, resulting possibly on new bearing forces
and offset values. This procedure is continued iteratively until there is convergence between successive forces and offset calculations. There may be cases
where due to a housing with small stiffness, the maximum number of iterations
is reached. In such a case the user will be informed on the percentage difference between the two last iterations and the results of the last iteration will be
kept. After the calculation has completed, the user can perform a range of other
investigations, for example analyzing the gearing contact to determine the effect of housing stiffness on the parameters used to size the gear unit.
The user can even use more than one housing, each with a different stiffness
matrix, in the KISSsys model. In such a case and at the beginning of the calculation, the program asks the user which housing it should use. This can be very
useful if they want to compare the effect of different housing designs on the
gear unit design.

Chapter
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62.7.4

Modal analysis of shaft systems

62.7.4.1
Introduction
Users can use the modal analysis of shaft systems function in KISSsys to calculate
the eigenfrequencies and eigenmodes of a complete shaft system, including the
effect of the gear connection between shafts. Performing a modal analysis for individual shafts is not realistic. It must be performed for the entire topology of the
shaft system. The necessary calculation steps, together with important restrictions
are given next.

62.7.4.2
Calculation p rocedure
In order to calculate the system dynamics, the user must import a ShaftSystem
KISSsys calculation in the model. Right-click, and select Modal analysis from the
context menu, to open a dialog in which you can set various parameters for the
calculation. The user must define the number of eigenfrequencies that must be
calculated, if only torsional or all vibration types will be included and the
calculation method of gear mesh stiffness. For this last option, the following
selections are available:

According to ISO 6336, where the tooth contact stiffness as described in this
standard is used.

Using the KISSsoft Contact Analysis (CA) algorithm, where a full contact analysis is performed in the gear connections. If KISSsoft does not have a CA calculation for a particular gear pair type, or the gear pair transfers no power, the
ISO 6336 method is used for that specific pair.

Infinite, where the gear mesh stiffness is assumed infinite. This option can be
selected if the user wants to check limiting conditions.
Ignore, where the gear mesh stiffness is assumed zero and hence there is no
connection between the vibrating shafts (each one vibrating independently).

Chapter
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All the above properties of the dynamic calculation are also available in the properties window of the calculation (right click on calculation and select Properties
window).

62.7.4.3
Result s
After the calculation is finished, a new tab opens, in which a 3D animation of the
vibrating system can be displayed. There, the user can select the eigenfrequency to
view and also define the animation speed and the scaling of the deformations. The
eigenfrequency values and gear mesh stiffness used for each gear pair are also
displayed in the system dynamics report. To display this report, right-hand click on
the ShaftSystem calculation and then select ShowDynamicsReport. In this report
the gear mesh stiffness is shown as zero, when the user has selected to either use
infinite or ignore the gear mesh stiffness. It should be noted here that in the animation window only gears that belong to a shaft calculation file are shown.
Nevertheless, all the gears are taken into account in the modal analysis.

Finally, also note that, if a modal analysis is performed for a planetary system, this
does not take into account the effect of the rotating planets' position on the system
bending stiffness. This is in agreement with the quasi-static calculation procedure
followed normally in eigenfrequencies analysis.

X Bibl iogr aphy and Inde x

Part

Bibliography and Index

63

Bibl iogr aphy

[1] A.G.M.A.: Fundamental Rating Factors and Calculation Methods for Involute
Spur and Helical Gear Teeth. Norm 2001-B88, 1988.
[2] Akahori, H., Sato, Y., Nishida, T., Kubo, A.: Prove di durata di Face Gear
(Testing the durability of face gears). Organi di trasmissione, 2002, No. 12 or
MTP2001-Fukuoka, The JSME Int. Conference, Japan, 2001.
[3] Basstein, G., Sijtstra, A.: Neue Entwicklung bei Auslegungen und Fertigung
von Kronenrdern. Antriebstechnik, 32 (1993), No. 11.
[4] Bock G., Nocj R., Steiner O.: Zahndickenmessung an Getriebeschnecken nach
der Dreidrahtmethode. Physikalisch-Technische Bundesanstalt, Braunschweig,
1974.
[5] Decker, K.H.: Maschinenelemente. Carl Hanser Verlag Mnchen, 10th Edition, 1990.
[6] Dietrich G., Stahl H.: Matrizen und Determinanten in der Technik. VEB Verlag Leipzig, 5th Edition, approx. 1960.
[7] DIN ISO 15312: Wlzlager - Thermisch zulssige Betriebsdrehzahl - Berechnung und Beiwerte, October 2004.
[8] DIN 732: Wlzlager - Thermische Bezugsdrehzahl - Berechnung und Beiwerte, May 2010.
[9] DIN 743: Tragfhigkeitsberechnung von Wellen und Achsen, December 2012.
[10] DIN 867: Bezugsprofile fr Evolventenverzahnungen an Stirnrdern (Zylinderrdern) fr den allgemeinen Maschinenbau und den Schwermaschinenbau,
February 1986 Issue.
[11] DIN 2091: Drehstabfedern mit rundem Querschnitt: Calculation and Design.
DIN Taschenbuch 29, Beuth Verlag Berlin, 2011.
[12] DIN 2092: Tellerfedern: Berechnung. DIN Taschenbuch 29, Beuth Verlag
Berlin, 2011.
[13] DIN 2093: Tellerfedern: Masse, Qualittsanforderungen. DIN Taschenbuch
29, Beuth Verlag Berlin, 2011.
[14] DIN EN 15800: Zylindrische Schraubenfedern aus runden Drhten: Quality
specifications for cold coiled compression springs. DIN Taschenbuch 29, Beuth
Verlag Berlin, 2011.
[15] DIN 2096: Zylindrische Schraubenfedern aus runden Drhten und Stben:
Gtevorschrift fr warmgeformte Druckfedern. DIN Taschenbuch 29, Beuth Verlag Berlin, 2011.

[16] DIN 2097: Zylindrische Schraubenfedern aus runden Drhten: Gtevorschriften fr kaltgeformte Zugfedern. DIN Taschenbuch 29, Beuth Verlag Berlin,
2011.
[17] DIN 2194: Zylindrische Schraubenfedern aus runden Drhten und Stben:
Kaltgeformte Drehfedern (Schenkelfedern), Gtenorm. DIN Taschenbuch 29,
Beuth Verlag Berlin, 2011.
[18] DIN 3960: Begriffe und Bestimmungsgrssen fr Stirnrder und Stirnradpaare mit Evolventenverzahnung. December 1987 Issue.
[19] DIN 3961: Toleranzen fr Stirnradverzahnungen, Grundlagen, 1978.
[20] DIN 3967: Flankenspiel, Zahndickenabmasse, Zahndickentoleranzen, 1978.
[21] DIN 3971: Begriffe und Bestimmungsgrssen fr Kegelrder und Kegelradpaare, July 1980 Issue.
[22] DIN 3975: Begriffe und Bestimmungsgrssen fr Zylinderschneckengetriebe
mit Achsenwinkel 90 Grad, July 1976 Issue.
[23] DIN 3990: Tragfhigkeitsberechnung von Stirnrdern. Parts 1, 2, 3, 4, 5, 11
and 21. December 1987 Issue.
[24] DIN 3991: Tragfhigkeitsberechnungen von Kegelrdern, 1990.
[25] DIN 5480: Zahnwellen-Verbindungen mit Evolventenflanken. Parts 1 to 15.
March 1986.
[26] DIN 6885: Passfedern. Sheets 1-3, 1968.
[27] DIN 6892: Passfedern - Berechnung und Gestaltung, 2012.
[28] DIN 7151: ISO Grundtoleranzen fr Lngenmasse bis 500 mm, 1964.
[29] DIN 7190: Berechnung und Anwendung von Pressverbnden. February
2001.
[30] DIN EN 13906-1: Compression springs: Calculation and Design. DIN Taschenbuch 29, Beuth Verlag Berlin, 2011.
[31] DIN EN 13906-2: Tension springs: Calculation and Design. Beuth Verlag
Berlin, 2013.
[32] DIN EN 13906-3: Turnsprings: Calculation and Design. DIN Taschenbuch
29, Beuth Verlag Berlin, 2011.
[33] ISO 7902: Hydrodynamic plain journal bearings under steady-state
conditions. Part 1, 2013, Part 2 and 3, 1998.
[34] DIN 31653: Hydrodynamische Axial-Gleitlager im stationren Bereich. DIN
Taschenbuch 198, Beuth Verlag Berlin, 1991.

[35] DIN 31654: Hydrodynamische Axial-Gleitlager im stationren Bereich. DIN

Taschenbuch 198, Beuth Verlag Berlin, 1991.
[36] DIN 58400: Bezugsprofil fr Evolventenverzahnungen an Stirnrdern in der
Feinwerktechnik. June 1984 Issue.
[37] DIN 58405: Abmasse fr die Feinwerktechnik, Part 2.
[38] Dubbel, H.: Taschenbuch fr den Maschinenbau. Springer Verlag Berlin,
15th Edition, 1986.
[39] Eschmann, P.: Die Wlzlagerpraxis. R.Oldenburg Verlag Munich, 1978.
[40] FAG: Standard program. Catalog WL 41510, 3rd Edition 1995.
[41] FKM Guideline: Rechnerischer Festigkeitsnachweis fr Maschinenbauteile.
VDMA Verlag Frankfurt, 6th Edition, 2012.
[42] Hnchen, R., Decker, K.H.: Neue Festigkeitslehre fr den Maschinenbau.
Carl Hanser Verlag Munich, 3rd Edition, 1967.
[43] Hirn, H.: Computergesttzte Zahnradoptimierung. Fink GmbH, Druck und
Verlag Pfullingen, 1999.
[44] ISO 6336: Calculation of load capacity of spur and helical gears. Parts 1, 2,
3, 4, 5. 2006 Edition.
[45] ISO/DIS 10300: Calculation of load capacity of bevel gears. Parts 1, 2, 3.
ISO 10300 2001 Edition, ISO/DIS 10300 Draft 2011.
[46] Kissling, U.: KISSsoft - eine praxisgerechte Maschinenelemente-Software.
Antriebstechnik 27, 1988, No. 12, pp. 34-40.
[47] Kissling, U.: Auslegung von Maschinenelementen. CIM Management 11 4,
1995.
[48] Kissling, U.: Technische Berechnungen auf Personal Computern. VDI-Z
130, 1988, No. 5, pp. 45-52.
[49] Kissling, U.: Sicher dimensioniert. Antriebstechnik 6, 2007. Pp. 64-68.
[50] Kissling, U., Beermann, S., Hirn, T.: Kronenrder: Geometrie und Festigkeit,
Antriebstechnik 10, 2003.
[51] Klingelnberg in-house standard 3028: Auslegung eines Kegelradgetriebes
ohne Achsversatz. Issue No. 2.
[52] Klingelnberg in-house standard 3029: Auslegung eines Kegelradgetriebes
mit Achsversatz. Issue No. 2.
[53] Klingelnberg in-house standard 3030: Tragfhigkeits-Berechnung fr Spiralkegelrder. Issue No. 1.

[54] Klotter, K.: Technische Schwingungslehre, Volume 2. Springer Verlag Berlin, 2nd Edition, 1960.
[55] Kollmann, F.: Welle-Nabe-Verbindungen. Springer Verlag Berlin, 1984.
[56] Lachenmaier, S.: Auslegung von evolventischen Sonderverzahnungen fr
schwingungs- und geruscharmen Lauf von Getrieben. VDI Verlag Dsseldorf,
WZL Range 11 No. 54, 1983.
[57] Lang, O., Steinhilper R.: Gleitlager. Konstruktionsbcher Volume 31, Springer Verlag Berlin, 1978.
[58] Linke, H.: Stirnradverzahnung. Carl Hanser Verlag Munich, 1996.
[59] MAAG: Pocket Book. 2nd Extended Edition, Zrich, 1985.
[60] Massa, E.: Costruzione di macchine. Editori Masson Italia, Milan, 1981.
[61] Matek, W., Muks D., Wittel H.: Roloff/Matek Maschinenelemente. Vieweg
Verlag Braunschweig, 11th Edition, 1987.
[62] Matek W., Muks D., Wittel H., Becker M., Jannasch D.: Roloff/Matek Maschinenelemente. Vieweg Verlag Braunschweig, 15th Edition, 2001.
[63] Matthias, K.: Schraubenkrfte in einer Flanschverbindung. Maschinenbau,
Berlin 34 (1985) 11, p. 517.
[64] Niemann G.: Maschinenelemente, Volume 1. Springer Verlag Berlin, 2005.
[65] Niemann G.: Maschinenelemente, Volume 2. Springer Verlag Berlin, 1983.
[66] Niemann G.: Maschinenelemente, Volume 3. Springer Verlag Berlin, 1985.
[67] NIHS 20-25: Uhrenindustrie, Schweizer Norm SN 282 025, October 1993.
[68] Obsieger: Tooth form factors used for external and internal teeth Zeitschrift
Konstruktion 32 (1980), p. 443-447.
[69] Weber C., Banaschek K.: FVA-Bericht 129 und 134, Elastische Formnderung der Zhne und der anschliessenden Teile der Radkrper von Zahnradgetrieben, FVA 1955.
[70] Rules for The Classification of Naval Ships (FREMM 3.1), Bureau Veritas,
March 2004.
[71] SKF: Main Catalog 4000 T. 1989 Edition.
[72] Spinnler, Prof.: Manual de calcul dorganes des machines. EPFL Lausanne,
1990.
[73] VDI 2226: Festigkeitsberechnung metallischer Bauteile.
[74] VDI 2227: Festigkeitsberechnung.

[75] VDI 2230: Systematische Berechnung hochbeanspruchter Schraubenverbindungen, Sheet 1. December 2014.
[76] VDI 2545: Zahnrder aus thermoplastischen Kunststoffen. 1981 Edition.
[77] KISSsoft: Klassische Anleitungen zu den Berechnungsmodulen:
KISSsoft Gear Pump Analysis, Hombrechtikon, 2005.
[78] Boresi, A.P., Schmidt R.J.: Advanced Mechanics of Materials, 6th. Edition,
John Wiley and Sons, Inc., 2002.
[79] Roth, K.: Zahnradtechnik - Evolventen-Sonderverzahnungen zur Getriebeverbesserung, Springer DE, 1998.
[80] Hoechst, High Chem: Technische Kunststoffe - Berechnen, Gestalten, Anwenden, B.2.2, Hoechst AG, 1992.
[81] Theissen, J.: Berechnung der Sicherheit gegen Graufleckigkeit von Industriegetrieben auf der Grundlage des neuen Rechenverfahrens nach FVA 259.
Dresdner Maschinenkolloquium, TU Dresden, Sept. 2003. Tagungsband pp. 195212.
[82] FVA-Informationsblatt Nr. 54/7: Testverfahren zur Untersuchung des
Schmierstoffeinflusses auf die Entstehung von Graufleckigkeit bei Zahnrdern,
FVA Vereinigung, Frankfurt, 1999.
[83] Feulner, R.: Verschleiss trocken laufender Kunststoffgetriebe, Lehrstuhl
Kunststofftechnik, Erlangen, 2008.
[84] DIN 32711: Welle-Nabe-Verbindung - Polygonprofil P3G. March 2009
Issue.
[85] DIN 32712: Welle-Nabe-Verbindung - Polygonprofil P4C. March 2009
Issue.
[86] Decker, K.-H.: Maschinenelemente, Funktion, Gestaltung und Berechnung,
Hanser Verlag Munich, 2001.
[87] Klingelnberg, J.: Kegelrder Grundlagen, Anwendungen, Springer Verlag
Berlin Heidelberg, 2008.
[88] Norden, N.: On the compression of a Cylinder in Contact with a Plane
Surface, National Bureau of Standards, 1973.
[89] Annast, R.: Kegelrad-Flankenbruch, Technical University Munich, 2002.
[90] VDI 2241: Schaltbare fremdbettigte Reibkupplungen und -bremsen, Sheet
1: 1982; Sheet 2: 1984.
[91] Burdick, R.: Manufacturing Single-Enveloping Worm Gear Sets, Gear Solutions, April 2003.

[92] Harris, T., Rumbarger, J.H., Butterfield, C.P.: Wind Turbine Design
Guideline DG03: Yaw and Pitch Rolling Bearing Life. 63 pp.; NREL Report No.
TP-500-42362, 2009.
[93] DET NORSKE VERITAS: Calculation of gear rating for marine transmissions, Norway, 2003.
[94] Haibach, E.: Betriebsfestigkeit, Verfahren und Daten zur Bauteilberechnung,
2nd Edition, Springer Verlag 2002.
[95] Winter, H., Podlesnik B.: Zahnfedersteifigkeit von Stirnradgetrieben, Parts 1
to 3, Antriebstechnik 22 1983.
[96] Harris, T.: Rolling Bearing Analysis, 4th Edition, John Wiley & Sons Inc.,
2001.
[97] Schlecht, B: Maschinenelemente 2, Getriebe - Verzahnungen - Lagerungen,
Pearson Studium 2010.
[98] Tsai, S.-J., Wu, S.-H.: Geometrical Design of Conical Gear Drives with Profile-shifted Transmission; 12th IFToMM World Congress, 2007.
[99] Tsai, S.-J., Wu, S.-H.: Designing Skew Conical Gear Drives in Approximate
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JSME International Conference on Motion and Power Transmission, 2009.

Chapter
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XI Inde x

1
12. Calculating the required amount of lubricating oil - II-277

2
2D geometry - II-615

3
3D export - II-649
3D geometry - I-190, II-625
3D interface to ASCON Kompas - I-250
3D interface to Autodesk Inventor - I-211
3D interface to CATIA - I-242
3D interface to CoCreate - I-245
3D interface to Creo Parametric (ProEngineer) - I-229
3D interface to Solid Edge - I-203
3D interface to Solid Works - I-195
3D interface to ThinkDesign - I-247
3D interface to Unigraphics NX - I-217
3D interfaces - I-184
3D view - IX-1121

A
Abbreviations used in gear calculation - II-676
Accuracy grade bevel gears - II-514
Accuracy of the tooth form - II-599
Activate offset of load center point - III-728
Add your own texts in the results window - I-107, I-256
Addendum angle and root angle - II-475, II-477
Addendum angle gear 2, dedendum angle gear 2 - II-502
Addendum coefficient gear 1 (middle), addendum coefficient gear 2 (middle) - II-502
Addendum reduction - II-531, II-537
Add-in (menu items in CAD) - I-212, I-218
Add-in functions (calls) - I-200, I-209, I-215, I-228
Adding additional tabs and dialogs - I-101
Adding and deleting files - I-95
Adding manufacturing data - I-195, I-200, I-203, I-209, I-211, I-215
Adding manufacturing data on the drawing - I-224
Adding new bolt types to the database - IV-1011
Adding tip chamfer - II-385
Adding tip rounding - II-384

Chapter
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62

Adding variables in tables - IX-1128

Additional inputs for DIN 6892 Method B - IV-869
Additional strength calculation of all variants - II-438
Adhesives - I-142
AGMA 6101-E08/AGMA 6001-E08 - III-750
AGMA 925 - II-420, II-614
Allow large profile shift - II-446
Allow simplified calculation in accordance with DIN 3990/ISO 6336 - II-448
Allowances for racks - II-661
Alternating bending factor - II-305, II-310, II-493
Ambient density - III-693
Amplitude of contact stiffness - II-641
Amplitude of transmission error - II-639
Analog to DIN 3991, Method B - II-534
Analog to ISO 10300, Method B - II-533, II-534
Angle error - II-598
Angle modifications - II-478
Angle of flank normal - II-622
Angle of rotation-controlled tightening - IV-982
ANSI 92.1 and ISO4156/ANSI 92.2M - IV-917
Answers concerning geometry calculation - II-653
Answers to Frequently Asked Questions - I-251, II-652, III-833, IV-1010
Answers to questions about strength calculation - II-662
Application factor - II-280, II-287, II-495, II-534, II-553, II-574, IV-854, IV-871, IV881, IV-893, IV-910, IV-924, IV-936, VI-1063
Application factor and summand for operational behavior - VI-1057
Application factor f1 - VI-1049
Arc-like end relief I and II - II-367
Arc-like profile modification - II-362
Areas of application for the FKM guideline - VIII-1082
Assembly - II-622
Assumptions made for the calculation - V-1033
Automatic calculation of load factor q - IV-1007
Automatic calculation of the dishing angle - IV-1008
Automatic change of reference profiles - II-657
Automatically - II-379
Automotive - VII-1067
Average surface pressure - III-819
Axial clearance - III-730
Axial offset - II-528
Axial spanning with nut - IV-855
Axial/transverse module - II-545
Axis alignment - II-611, II-637

B
Background - VIII-1084
Ball/pin diameter shaft/hub - IV-918
Base size - III-694

Chapter
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62

Basic data - II-262, II-411, II-470, II-525, II-545, II-566, II-585, III-716, IV-905, IV1005
Materials - I-149
Basic data inputs - IV-955
Basic installation - I-42, I-44, I-254
Basic material Glued and Soldered joints - I-141
Basic materials - IV-999
Beam profiles - I-149
Bearing - III-687, III-689, III-710
Bearing application factor - II-518, II-536
Bearing calculation General - III-722, III-775
Bearing calculation with inner geometry - III-785, III-806
Bearing data - III-806
Bearing data tab - III-804
Bearing force curve and direction of the bearing forces - II-641
Bearing manufacturer - III-733
Bearing power loss - II-555
Bearing ring deformations - III-807
Bearing width - III-824
Bearings coefficient - V-1017
Bearings with radial and/or axial force - III-798
Belt length - VI-1050
Belt length and number of teeth on belt - VI-1058
Belts and chain drives - VI-1046
Bending critical speed - III-743
Bending stress values - V-1032
Bevel and Hypoid gears - II-466
Bevel gear - generating a 3D model - I-193
Bevel gear factor at flank and root - II-519
Bevel gears
Determine permitted overloads - II-670
Bevel gears with cyclo-palloid gear teeth - II-510
Bevel gears with Palloid toothing - II-512
Beveloid gears - II-583
Bibliography - X-1164
Bibliography and Index - X-1163
Bolt data - IV-966, IV-970
Bolted joint under axial and shearing force - IV-956
Bolted joint under axial load - IV-957
Bolts - IV-952
Bore - I-146
Coefficients of friction classes - I-147
Nuts - I-148
Nuts strength class - I-147
Strength class - I-146
Thread type - I-147
Tightening factor - I-146
Type - I-148
Washer - I-148
Bolts and pins - IV-945

Chapter
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62

Bolts/pins - I-144
Boundary safety coefficient - IV-995
Bracket connection - IV-1002
Buckling - III-717, III-744

C
Calculate flank safety with 0.85*b (ISO 10300) - II-494
Calculate form diameter from tooth form - II-453, II-654
Calculate lubrication factor with oil temperature - II-456
Calculate moment of inertia from tooth form - II-455
Calculate number - V-1039
Calculate scuffing - II-306
Calculate the internal temperature and the flash temperature - II-307
Calculating a pinion type cutter - II-390
Calculating and generating a report - I-91, I-108
Calculating axial forces on bearings in face-to-face or back-to-back arrangements - III799
Calculating cylindrical gears manufactured using tools specified in DIN 3972 - II-655
Calculating force on bearings with a contact angle - III-739
Calculating planet carrier deformation with FEM - II-329
Calculating Shafts - III-715, III-735
Calculating the displacement volume of gear pumps - II-455
Calculating the reference profile - II-390
Calculating the Safeties - III-758
Calculating the thermal nominal speed - III-787
Calculating the thermally permissible operating speed limit - III-789
Calculation - III-829, IV-853, VII-1072, VIII-1107
Calculation according to AGMA 421.06 (High Speed Gears) - II-672
Calculation according to Klingelnberg, Gleason and Oerlikon - II-468, II-487
Calculation according to SKF Catalog 2004 - III-790
Calculation elements - IX-1135
Calculation in accordance with SKF Catalog 1994 - III-792
Calculation method - III-746
Calculation method for friction - III-732
Calculation methods - II-279, II-360, II-488, II-532, II-673, III-816
Calculation of flank safety - II-448, II-449
Calculation of KH with manufacturing errors - II-324
Calculation of size coefficients for small gears - II-457
Calculation of spline connections as described in DIN 5480 with diameter centering IV-903
Calculation of the wear coefficient kw for steel - II-276, II-646
Calculation of volume-specific heat - III-831
Calculation procedure - IX-1161
Calculation reports - I-108
Calculation using Methods B or C (DIN 3990, 3991) - II-663
Calculation using your own Woehler line - II-454
Calculation variables - I-116
Calculation with enhanced formulae (differs from standard) - II-562

Chapter
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62

Calculation with experimental data - III-756

Calculation with normal module instead of axial module - II-545, II-561
Calculation with operating center distance and profile shift according to manufacture II-455
Calculations - II-344, II-345, II-346, II-347, II-453, II-516, II-561
Calculations - IV-863
Campbell diagram - III-773
Center distance - II-263, II-265, II-546, II-567, VI-1049, VI-1057
Center distance - VI-1064
Center distance tolerances - II-355
Center distance tolerances - I-140
Chain drives - VI-1061
Chain profiles ISO606 - I-142
Chain type - VI-1062
Change the output of angles in reports - I-252
Changes of the parameters for generation - I-203
Changing base settings in the interface - I-232, I-240
Characteristic number - II-514
Check changes in safeties if the center distance changes - II-674
Check if mounting of planets is possible - II-450
Checking the contact pattern - II-582, II-617
Checking the meshing - II-598
Circular pitched teeth - II-388
Clamped connections - IV-862
Clamped parts inputs - IV-974
Classic method - IX-1124
Classification of bearings - III-776
Coefficient for minimum tip clearance - II-447
Coefficient for minimum tooth thickness at tip - II-447
Coefficient of friction for hypoid gears - II-516
Coefficient of thermal expansion for housing - II-417
Coefficients of friction - IV-843, IV-852
Coefficients of friction - IV-981
Coefficients used to determine fatigue strength - III-757
Columns - I-104
COM Interface - I-175
Comment field - I-80
Comments - I-105, I-115
Comparing types - III-781
Comparison of a FEM calculation with spiral-toothed gear wheel calculation - II-673
Compression springs - V-1015
Compression springs standard - I-140
Condition query IF ELSE END - I-89, I-119
Conditions for using shaft calculation files - II-335
Conditions I - II-428, II-501
Conditions I/II - II-442
Conditions II - II-426, II-430, II-502
Conditions III - II-503
Cone angle - II-586
Configuration - II-342

Chapter
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62

Configuration - VI-1063
Configuration tool - I-61
Configuring Tensioning pulleys - VI-1056
Configuring Tensioning Pulleys - VI-1049
Conical interference fit - IV-851
Conicity - IV-858
Connecting roller bearing - III-714
Connection elements - III-713, IX-1138
Connection, general - III-714
Connections - IV-838
Consider gyroscopic effect - III-725
Consider weight - III-725
Constraints data - IV-978
Constraints on various bearings - III-711
Constructed involute - II-349
Contact Analysis - II-376, II-401, II-459, II-497, II-520, II-637, II-655
Contact analysis/Face load factor - II-459
Contact line (face gear) - II-633
Contact lines on tooth flank - II-639
Contact spring stiffness - II-515
Context menu - I-77, I-80, II-378
Convert external pressure with multiple interference fit - IV-846
Converting or inputting Gleason toothing data - II-483
Coupling - III-708
Creating a new bolt type - IV-1011, IV-1013
Creating and modifying tables - IX-1127
Creating Models in KISSsys - IX-1123
Creating, opening and closing projects - I-94
Cross sections - III-687, III-689, III-715, III-761, III-769
Crossed helical gears and precision mechanics worms - II-560, II-564
Cross-section types - III-701, III-763, III-834
Crowning - II-369, II-375
Custom roller profile - III-806
Cutter radius - II-487
Cutter/Tool
Hobbing cutter - II-343, II-379
Pinion type cutter - II-345
Cutting teeth on an existing shaft - I-232, I-237
Cycloid - II-388
Cylindrical gear pairs - II-316
Cylindrical gears - II-260, II-491
Cylindrical interference fit - IV-839

D
Database Tool and External Tables - I-124, II-286, II-347, II-569, III-746, IV-847, IV859, IV-865, IV-876, IV-887, IV-899, IV-905, IV-915, IV-929, IV-942, IV-948,
IV-996, IV-1011, V-1018, V-1025, V-1033, V-1039, VIII-1094, VIII-1113
Deep toothing or cylindrical gears with a high transverse contact ratio - II-451, II-653

Chapter
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62

Default values for addendum coefficients - II-496

Default values for tip base clearance - II-496
Define details of geometry - II-568
Define details of strength - IV-910, IV-912
Define grinding wheel for gear n dialog window - II-357
Define load spectrum - II-287, II-304, II-492, II-573, II-574, II-607, III-753, VIII-1093
Define misalignment for individual elements - II-325
Defining 2D graphics - IX-1153
Defining input and output - I-169
Defining Shafts - III-684
Defining sub elements - III-689, III-698
Defining the scoring load level (oil specification) - II-665
Defining your own default files - I-51, I-72, I-94, I-170
Definition coefficients of sliding friction and velocities - VII-1076
Definition in [COCREATE] - I-60
Definition of spring forces - VII-1075
Definitions and dimensions of standard cutters for palloid toothing - II-513
Definitions in [CADEXPORT] - I-57
Definitions in [CATIA] - I-59
Definitions in [GRAPHICS] - I-56
Definitions in [HICAD] - I-60
Definitions in [INTERFACES] - I-57
Definitions in [INVENTOR] - I-58
Definitions in [LICENSE] - I-56, I-70
Definitions in [PATH] - I-42, I-46, I-48, I-51, I-52, I-53, I-69, I-97, I-108, I-113
Definitions in [PROENGINEER] - I-59, I-231
Definitions in [REPORT] - I-56, I-110
Definitions in [SETUP] - I-44, I-45, I-46, I-49, I-50, I-54
Definitions in [SOLIDEDGE] - I-58, I-203
Definitions in [SOLIDWORKS] - I-58, I-187
Definitions in [THINK3] - I-60
Deflection and Bearing Forces, Distribution and Force of Torque - III-737
Deleting a database entry - I-130
Description of database tables - I-140
Description of the public interface - I-165
Determine the equivalent torque (for load spectra) - II-674
Diagram view - IX-1120
Diagrams - II-461
Dialog elements for the variable dialog - IX-1145
Difference between cylindrical gear calculation following ISO 6336 or DIN 3990 - II662
Differences between different gear calculation programs - II-662
Differential gears - II-516
Dimension of the integral worm shaft - II-556
Dimensioning - II-540, II-590
DIN 3967 - II-353
DIN 5480 - IV-917
DIN 58405 - II-353
DIN 743 (2012) - III-749
Directory structure - I-48

Chapter
XI-1178

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62

Disc spring standard - I-148

Disc springs - V-1036
Disconnect license from the network - I-70
Discretized model - II-406
Display critical bearing - III-731
Displaying elements in 3D graphics - IX-1139
Displaying the graphic - IX-1155
Dissipated Heat Flows - III-787
Distances for eccentric clamping/load - IV-977
Do not cancel if geometry errors occur - II-355, II-446
Docking window - I-72, I-74, I-77
Documentation point - III-715
Downloading a license file - I-43, I-44, I-45, I-46
Drawing - II-622
Drawing data - I-72, I-109, II-604
Drawing data - V-1020
Drawing data - V-1028
Drawing data - V-1034
Drawing number - III-692
Dynamic factor - II-308, II-519
Dynamic load capacity - III-784
Dynamic user Interface - I-99

E
Eccentric crowning - II-370
Eccentric profile crowning - II-365
Editing the control file - II-622
Effect of partial load - II-337
Effect of profile modifications - II-659
Effect of torsion on the body of the gear - II-336
Effective belt width - VI-1058
Effective number of V-belts - VI-1050
Effective/Actual - IV-917
Efficiency Calculation - IX-1157
Efficient interfaces - I-166
EHL lubricant film thickness and spin to roll ratio. - III-802
Eigenfrequency - III-717, III-742
Element Assistant - IX-1125
Element overview - III-692
Elements - I-103
Elements editor - III-687, III-691, III-692, III-834
Elements for shafts - IX-1137
Elements list - III-687, III-690
Elements of the KISSsoft User Interface - I-71
Elements tree - III-687, III-689, III-692
Elliptical deformation - II-397
Elliptical root modification - II-387
Enhanced service life calculation in accordance with ISO 281 - III-809

Chapter
XI-1179

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62

Enter safeties - III-755

Entry curve as specified by Hirn - II-386
Equivalent stress for sizings - III-734
Estimate the strength of asymmetrical spur gear toothings - II-673
Evaluation - II-627
Example
Interference fit calculation - I-134, I-168, I-172
Example application of a variable dialog - IX-1149
Example of a call from Excel - I-178
Explicitly reading (importing) and generating data - I-171
Export individual teeth - II-600
Export shaft geometry - III-690, III-704
Expressions in variables - IX-1132, IX-1141
Extended functionality for developers - IX-1131
Extended service life calculation in accordance with Supplement to DIN ISO 281
(2007) - III-795, III-806
Extending an existing bolt series - IV-1011
Extension sleeves without external forces - IV-972
External diameter and throat radius - II-550
External tables - I-124, I-132, I-140, I-141, I-142, I-144, I-146, I-147, I-148, I-149, I150, I-152, I-153, I-154, I-162, I-163, II-272, II-352, II-355, II-531
Eyes screen - V-1023

F
f0r and f1r coefficients - III-787
Face gear - 3D geometry - I-191
Face gears - II-521
Face load factor - II-305, II-313, II-459, II-536
Face width ratio - II-498
Facewidth - II-264, II-475, II-547, II-567
Factors - II-308, II-518, II-536, II-589
Failure probability - III-731, III-798
Fatigue Limits for New Materials - III-836
File interface - III-804
Fine Sizing - II-427, II-500
FKM-Richtlinie, Edition 2012 - III-750
Flange connection with torque and forces - IV-957
Flank breaking - II-399
Flank curvature radii - II-621
Flash temperature - II-628, II-643
FOR loop - I-116, I-121
Forces - III-687, III-704
Form factors - II-304
Formatting - I-103, I-108, I-113, I-114
Formula entry and angle input - I-89
Fp-Tolerance as specified in tables in DIN3962 - II-446
Free cross section - III-715, III-834
Frequency of load - III-753

Chapter
XI-1180

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62

Friction clutches - VII-1069

Friction coefficients f0 and f1 - III-788, III-793
Functionality of the software - VIII-1082
Functions - IX-1142
Functions tables - I-133

G
Gear pump - II-411, II-648
Gear teeth in the case of an existing basic solid - I-195, I-203
Gear teeth in the case of existing shaft data - I-211
Gear teeth when existing shaft data is present - I-217, I-222, II-353
Gear tool - II-616
Gear tooth forms - II-292, II-615
Gears - III-721, III-743
General - I-40, I-110, II-445, II-467, II-537, II-538, II-559, II-622, IV-903, VIII-1082,
IX-1117
General bearing - III-710
General calculation procedure for KHbeta as specified in ISO 6336-1, Appendix E. II-341
General entries - III-769
General settings - VIII-1095
Generate - II-594
Generate a cylindrical gear with a pinion type cutter - II-381
Generate a cylindrical gear with an imported hobbing cutter - II-381
Generate a cylindrical gear with an imported pinion type cutter - II-383
Generate a rack with a hobbing cutter - II-391
Generate a rack with imported hobbing cutter data - II-391
Generate a SA worm - II-393
Generate cylindrical gear with hobbing cutter - II-379
Generate rack with a pinion type cutter - II-391
Generate rack with imported pinion type cutter - II-392
Generate with the other gear in the pair - II-390
Generating 3D shafts - I-188, I-195, I-203, I-211, I-217, I-250
Generating a database entry - I-129
Generating a face gear with a pinion type cutter - II-390
Generation of 3D gears - I-186, I-195, I-200, I-203, I-209, I-211, I-215, I-217, I-222, I230, I-242, I-246, I-248, I-250
Generation of 3D model - II-462
Geometry - II-593, VII-1068
Geometry data - I-174
Geometry details - II-271, II-479, II-530, II-549, IV-909
Geometry of chain sprockets - VI-1066
Geometry of clamped parts - IV-974
Geometry standards - IV-905
Geometry-Fine Sizing for 3 gears - II-438
Global settings - KISS.ini - I-52, I-53, I-69, I-70, I-108, I-113
Glued and soldered joints - IV-997
GOST-21354-87 - II-281, II-283

Chapter
XI-1181

KISSsys: Calculation Systems

62

Graphics - II-437, II-443, II-509, III-811, IV-932, VII-1077

Graphics list - II-651
Graphics menu - II-610
Graphics window - I-72, I-77
Grinding notch - II-299
Groups - I-104

H
Hnchen & Decker - III-746, III-760
Hand of gear for gear teeth - II-262
Handling bending and torsion using the results for the shaft - II-338
Hardening depth - II-629
Hardening depth, known by its abbreviation - II-302, II-579
Hardness conversion - VIII-1103
Head forms - V-1043
Header and footer - I-110
Heat development - II-642
Heat transfer coefficient - III-823
Heat transfer surface - III-823
Height of face gear - II-531
Helix angle - II-472, II-585
Helix angle at reference circle - II-262, II-263, II-527
Helix angle modification - II-368, II-369, II-371
Helix angle modification, parallel - II-462
Helix angle reference circle gear 1 - II-566
Helpful information about the Generation of 3D model tab - II-517
Helptext viewer - I-76, I-85
Hertzian pressure - VIII-1100
Housing material - III-725
How can I test the software? - I-254
How to use KISSsoft - II-598
Hydrodynamic plain radial bearing - III-815
Hydrodynamic plain thrust bearing - III-826
Hypoid gears with cyclo-palloid gear teeth - II-510

I
Implementation in KISSsoft - VIII-1088
Import and export data with the database tool - I-131
Important service functions - IX-1144
Importing existing KISSsoft calculations - IX-1137
Importing the shaft geometry - III-690, III-702
Improve tooth form - II-599
Impurity - III-725
Individual names for elements - IX-1130
Influence factors - IV-947
Initial parameters - I-69

Chapter
XI-1182

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62

Inner contour - III-687, III-689, III-704

Input data - II-593
Input different load cycles for bending and torsion (for finite life calculations) - III-730
Input elements - I-89
Input file - I-170
Input format for data in imported files - II-595
Input materials for gear calculations in the database - I-253
Input normal diametral pitch instead of normal module - II-446
Input of number of teeth with decimal places - II-264, II-446
Input quality - II-445
Input window - III-687, III-762
Inputting the stress values on the proof point and on the neighboring point - VIII-1089
Inputting Tolerances - IV-842
Inside diameter - II-531, II-569
Inspecting V-belts - VI-1052
Installation on the server - I-45
Installing KISSsoft - I-41
Insufficient scuffing safety - II-664
Integrating the KISSsoft Add-in - I-212, I-218, I-232, I-249
Integrating the KISSsoft Add-in (menu options in CAD) - I-197, I-205
Interactions with variable dialogs - IX-1151
Interfaces between calculation programs and CAD - Overview - I-166
Internal teeth - differences in the reference profile if you select different configurations
- II-658
Intersecting notch effects - III-769, III-834
Introduction - II-259, IX-1158, IX-1161
ISO 1328 - II-353
Iterative calculation of load distribution - III-730

J
Joint - III-714

K
Key - IV-866
Key standard - I-144
Kinematics - II-642
KISSsoft Calculation Modules - I-72, I-87
KISSsys - IX-1115
Calculation Systems - IX-1116

L
Language settings - I-49, I-72
Lead angle at reference circle - II-545
Leg springs - V-1030
Length factor - IV-884, IV-896, IV-939

Chapter
XI-1183

KISSsys: Calculation Systems

62

Licensing - I-42, I-44

Licensing the KISSsoft system. - I-46
Lifetime factors - II-303
Lifetime factors as defined in ISO 6336 - II-290, II-493, II-576
Limit dimensions - V-1040
Limited cross section - III-715
Limiting the number of teeth - II-429
Limiting the root diameter - II-429
Limiting the tip diameter - II-428
Limiting values - V-1044
Limiting values in the calculation - III-832
Linear drive train - VIII-1104
Linear end relief I and II - II-367, II-368, II-375
Linear profile modification - II-385
Linear tip and root relief - II-361, II-366
Linear tip and root relief with transition radii - II-364
Linking the individual slices - II-409
List of key words used - I-136, I-138
List tables - I-136
Load - II-279, II-488, II-532, II-552, II-570, III-809
Load application - IV-977
Load capacity of roller bearings - III-784
Load case - III-756
Load cases - VIII-1090
Load distribution - III-811
Load distribution coefficient - II-305, II-309
Load factor - IV-873
Load factor for endurance calculation - III-760
Load factor for static analysis - III-760
Load spectra - III-720
Load spectra - I-142
Load spectra with negative elements - II-306, II-494, II-556, II-579
Load Spectrum Calculation - IX-1156
Load spectrum with changing torque - II-312, II-666
Load spectrum with negative bins - III-720
Load tab - III-809
Lubricant temperature - III-720
Lubricants - I-144
Lubrication - II-277, III-725
Lubrication arrangement - III-819
Lubrication coefficient - II-296

M
Machining allowance for cylindrical gear - I-140
Magnetic tension - III-709
Main calculation steps - IX-1158
Main input area - I-84
Main screen - IV-868, IV-869, VIII-1088

Chapter
XI-1184

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62

Main settings - II-334

Maintain root circle when changing profile shift - II-447
Managing database entries - I-126, I-129
Manual and Search - I-76
Manufacture - II-487
Manufacturing a gear - II-616
Manufacturing Data and Working Data - II-591
Manufacturing drawing - II-622
Manufacturing process - II-476, II-480
Manufacturing process for bevel and hypoid gears - I-141
Manufacturing tolerances - II-605
Manufacturing type - V-1023
Mass - III-709
Master gear - II-418
Material - III-694
Material and lubrication - II-272, II-531, II-550, II-552, II-569, II-586
Material Disc spring calculation - I-152
Material Interference fit - I-151
Material of bolts - I-151
Material of enveloping worm wheels - I-151
Material of gears - I-153
Material of plain bearings - I-151
Material of shaft-hub connection - I-152
Material pairing factor (strengthening an unhardened gear) - II-665
Material properties - III-695
Material Shaft calculation - I-152
Material Spring calculation - I-150
Material Welded joints - I-152
Materials - I-253, II-272, IV-847, IV-859, IV-876, IV-887, IV-899, IV-915, IV-929,
IV-942, IV-948, IV-996, VIII-1094, VIII-1113
Materials - I-149
Materials - IV-865
Materials - V-1017
Materials - V-1025
Materials - V-1033
Materials - V-1038
Maximal no of solutions - II-429, II-501
Maximum deflection for sizings - III-734
Maximum service life coefficient - III-731
Maximum Speeds - III-794
Measurement grid - II-439
Menus, context menus and the Tool bar - I-72, I-74, I-75, I-94, I-95, I-98
Menus, context menus and the Tool Bar - IX-1122
Meshing - II-582, II-616
Message output - IX-1121
Messages - I-92
Method Crown Gear (DIN 3990) - II-533
Method ISO 6336-B/Literature - II-532, II-533
Methods used for strength calculation - II-466, II-472, II-488, II-532, II-570
Minimum distance between 2 planets - II-450

Chapter
XI-1185

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62

Minimum safeties - II-514

Modal analysis of shaft systems - IX-1161
Model and results viewer - II-332
Modification for mold making - II-395
Modification for pinion type cutter - II-396
Modification for wire erosion - II-396
Modification of S-N curve (Woehler line) in the range of endurance limit - II-290
Modifications - I-142, II-289, II-300, II-347, II-350, II-356, II-372, II-387, II-537,
II-575, II-588
Modifications sizing - II-442
Modified rating life according ISO 281 - III-724
Modified tabs and dialogs supplied with the system - I-100
Modifying the selected 3D model - I-231, I-236
Modifying the teeth on an existing shaft - I-239
Module ratio - II-475, II-499
Module specific settings - III-727, IV-1009
Module-specific inputs - III-817
Moment of friction - III-732, III-733, III-790
Moment of friction, seals - III-733
Multi-bolted joint with any bolt position - IV-959
Multi-Spline standard - I-149

N
Necessary entries in the input window - II-428, II-501
Network version with dongle (protection key) - I-45
Network version with the license code - I-46
Node density - III-729
Non circular gears - II-592
Non-identical (mirrored symmetry) tooth flanks - II-657
Non-linear shaft - III-727
Normal force curve - II-639
Normal force distribution - II-640
Normal module - II-262, II-525, II-566, II-585, IV-906
Normal module (middle) - II-470
Normal module (middle), reference diameter, length of reference cone - II-501
Normal module ranges for Klingelnberg machines (cyclo-palloid) - II-511
Notch effects on hollow shafts - III-835
Notch factors - III-753
Notches on the inner contour - III-835
Notches on the outer contour - III-835
Notes - II-582
Notes about profile modification - II-376
Notes on calculations in accordance with the Klingelnberg standard - II-510
Notes on face gear calculation - II-540
Number of blade groups, tool - II-487
Number of buckling cases - III-717
Number of eigenfrequencies - III-717
Number of links - VI-1065

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62

Number of load cycles - II-298, II-493, II-577, VIII-1090

Number of load peaks - IV-914
Number of radial sealing rings, worm shaft - II-555
Number of strands - VI-1062
Number of teeth - II-264, II-474, II-546, II-586, IV-907
Number of teeth with common multiples - II-660

O
Occurring flank pressure - IV-883, IV-895, IV-926, IV-938
Offset (Center dist.) - II-474
Oil level - III-732
Oil level and Lubrication type - III-792, III-801
Oil temperatures - III-823
Oil viscosity, depending on temperature - II-631
Only geometry calculation - II-532
Only take solutions into account if the following conditions are fulfilled - II-506
Open interfaces concept in KISSsoft - I-167
Opening the calculation file - I-227
Opening the calculation file for the created gear - I-201, I-210, I-216
Operating backlash - II-414
Operating data - IV-955, VII-1069
Operations - II-378, II-379
Optimal tip relief - II-302, II-579
Outer contour - III-687, III-689, III-697
Output file - I-170
Overview of the available CAD interfaces and their functionality - I-185, I-190
Overview of the bevel gear manufacturing process and the terminology used in it - II467
Own data for Woehler line (S-N curve) - III-696
Own Input - II-354, III-714
Own inputs - IV-874

P
Page layout - I-110
Pair/gear data - II-297
Pairing an external gear to an inside gear that has a slightly different number of teeth II-654
Parasolid Export of 3D Shafts - I-191
Part safety coefficient - IV-994
Permissible decrease in quality - II-553
Permissible mass decrease - II-555
Permissible maximum wear of tooth thickness - II-449
Permissible pressure - IV-875, IV-886, IV-898, IV-928, IV-941
Permissible static stress - III-784
Permissible thickness of lubrication film - III-825
Permissible tooth thickness decrease - II-555

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62

Permitted values - IV-950

Pinion - Face gear with Z1 > Z2 - II-541
Plain bearing - III-776
Planetary stages - II-320
Planets - II-450
Plastic - II-447
Plastic according to VDI 2545 (YF Method B) - II-282, II-285
Polygon - IV-922
Polygon effect - VI-1064
Polygon standard - I-144
Position - III-693
Position of shaft axis in space - III-705, III-706, III-716, III-718, III-725
Position of tensioning pulley (x/y) - VI-1051
Position of the tensioning pulley x/y - VI-1060
Possible Sizings/Suggestions - VI-1056
Power loss - II-642
Power, torque and speed - II-288, II-492, II-534, II-554, II-574
Power-on time - II-456, II-559
Preamble - I-169
Precision mechanics - II-653
Preliminary treatment and grinding allowance - II-348, II-349, II-357
Pressure angle at normal section - II-263, II-471, II-527, II-545, II-566, II-585
Pressure angle at normal section an - IV-906
Pressure angle driving/driven flank
Hypoid gears - II-471
Pressure angle modification - II-366, II-371
Pressure curve - III-811
Pressure curve for each rolling body - III-814
Pretension - II-301
Procedure for toothing creation - I-195, I-203, I-211
Process for calculating thermally permitted operating speed (DIN 732-2) - III-788
Profile and tooth trace diagram - II-617
Profile crowning (barreling) - II-365
Profile modification - II-289, II-372, II-493, II-575
Profile modifications - II-358, II-361
Profile shift coefficient - II-265, II-382, II-475, II-529, II-547, II-567, II-627, IV-907
Profile shift coefficient (center) - II-586
Profile shift coefficient (on the pinion) - II-528
Programming in the Interpreter - IX-1141
Progressive profile modification - II-363, II-385
Project Management - I-51, I-72, I-75, I-93
Project properties - I-95, I-98
Properties - I-77, I-79, I-80, I-83, III-776
Properties dialog - IX-1131
Properties of the most important bearing types - III-779
Proposal for the hardening depth EHT - II-609
Protective layer thickness, Aluminum - III-755
Protective layer thickness, aluminum, chapter 4.3.4, Figure 4.3.4 - VIII-1091
Pure thrust bearing - III-713

Chapter
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62

Q
Quality - II-268, II-446, II-476, II-529, II-548, II-567, II-586, IV-908

R
Range tables - I-135
Ratio facewidth to center distance - II-452
Ratio facewidth to normal module - II-451, II-506
Ratio facewidth to reference circle, gear 1 - II-452
Ratio of length of reference cone to facewidth - II-505
Reading (importing) a cylindrical gear - II-384
Reading (importing) a worm into the axial section - II-394
Reading (importing) the rack - II-393
Reduced stiffness on the side edges - II-408
Reference cone apexes on the outside/inside of the unworked part - II-480
Reference diameter gear 2 - II-470
Reference gearing - II-560
Reference profile - II-342, II-347, II-496, II-587, II-596
Reference profiles - I-140
Reference temperature - II-416, III-693, III-718
References - IX-1132, IX-1135
Registering the interface - I-242
Registering the server - I-175
Relationship of calculations with elements - IX-1136
Relative water absorption during swelling - II-416
Relative welding factor (scuffing) - II-297, II-375, II-493, II-576
Relaxation - V-1019, V-1027
Report - II-443, II-601
Report menu - II-603
Report settings - I-110
Report templates - I-78, I-108, I-113, I-171, I-252
Report Viewer - I-72, I-84, I-108
Required safeties - II-288, II-423, II-458, II-492, II-534, II-554, II-562, II-574, VIII1098
Required safeties for cylindrical gears - II-653, II-663
Required service life - II-492, III-731
Required transverse contact ratio - II-451
Requirements placed on the third party program - I-170
Restore previous stages of the calculation - I-257
Restoring a database entry - I-130
Resulting shearing force - IV-911
Results - II-426, II-435, II-442, II-461, II-508, IX-1162
Results and Reports - I-101, I-106
Results from FEM calculation - IV-963
Results of a calculation - I-107
Retain tip circle when modifying profile shift - II-446
Retaining rings (self-locking rings, Seeger rings) - IV-1004
Rights - I-52

Chapter
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62

Roller bearing - III-776, III-778, III-803

Roller bearing - I-154
Roller bearing basis data - I-155
Roller bearing Internal geometry - I-157, III-785
Roller bearing tolerance - I-162
Roller bearing Tolerance classes - I-162
Roller Bearings (Inner Geometry) - III-785, III-803
Rolling bearings - III-710, III-721, III-803
Root diameter allowances - II-354
Root radius - II-388
Root rounding, ground - II-302
Rough sizing - II-422, II-436, II-498
Rules - I-65
Running KISSsoft via an add-in - I-200, I-209, I-215, I-221

S
Safety against deformation/fracture - III-754
Safety against fatigue/deformation - III-757
Safety against micropitting - II-643
Safety factor curves - II-631
Safety factor for the calculation of the shear stress at EHT - II-457, II-609
Scope of a report - I-108, I-110, I-114
Scuffing and sliding velocity (face gear) - II-635
Seam length - IV-991
Selecting the type of roller bearing - III-779
Selection of hobbing cutters - I-141
Selection of pinion type cutters - I-148
Selection of the part form - VIII-1088
Sense of rotation - III-694, III-705, III-718
Server functionality - I-175
Service life - II-287, II-534, II-553, II-573, II-607, III-753, III-795
Service life calculation with load spectra - III-796
Service life of files - I-171
Setting Up KISSsoft - I-47
Settings - II-355, II-445, II-516, II-538, II-559, II-581, II-649, II-650, IV-848, IV-860,
IV-877, IV-888, IV-900, IV-930, IV-943, IV-949, IV-984, IV-1000, VII-1078,
VIII-1095, VIII-1102
Settings - IV-864
Settings - V-1026
Settings - VIII-1112
Setup with icon - IX-1126
Shaft angle - II-473, II-530, II-560, II-569, II-585
Shaft connections - IV-1003
Shaft editor - III-687, III-692
Shafts and Bearings - III-683
Shape of flank - II-549
Share factor - IV-885, IV-897, IV-940
Shear stress - V-1044

Chapter
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62

Shear stress values - V-1016, V-1022

Show automatic dimensioning - III-733
Show coordinate system - III-733
Simplified view of the gears - I-201
Single contact stiffness - II-640
Single normal pitch deviation - II-515
Single user version with dongle (protection key) - I-44
Single user version with license code - I-45
Sizing - III-763
Sizing modifications - II-372
Sizing of gear geometry - II-452
Sizing of torque - II-608
Sizing the bearing clearance - III-823
Sizings - II-423, II-424, II-451, II-528, II-539, III-830, IV-850, IV-861, IV-878, IV889, IV-901, IV-931, IV-944, IV-951, IV-1001, V-1029, V-1035, V-1045, VI1061, VIII-1112
Sizings - IV-864
Sizings - V-1020
Small no. of pittings permissible - II-296, II-493
Smoothing the tooth form curvature to calculate Hertzian pressure in the contact
analysis - II-406
Solders - I-143
Sommerfeld number - III-824
Special features in KISSsoft - IV-954
Special toothing - II-655
Specific functionalities - IX-1156
Specific sliding - II-627, II-642
Spectra - VIII-1093
Speed - III-693, III-694, III-717
Speed/number of teeth/transmission ratio - VI-1063
Spline (geometry and strength) - IV-890, IV-902
Spline (strength) - IV-890, IV-913
Spline shaft - IV-879
Spline Standard - I-142
Spring design - V-1032
Springs - V-1014
Standard - VI-1062
Standard and special tabs - I-88, I-91, I-108, II-262, II-279, II-308, II-379
Standard profiles - IV-880, IV-891, IV-923, IV-934
Standard radius at shoulder - III-729
Start and end block - I-111
Starting KISSsoft - I-68
State during heat treatment - III-694
Static calculation - II-279, II-283, II-572
Static calculation on shearing - II-572
Static strength - II-532
Stiff connection - III-714
Stiffness curve - II-640, III-813
Storage locations - I-97
Storage locations and descriptions - I-113

Chapter
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62

Storage strategies for calculations - IX-1136

Straight line flank - II-389
Strength - III-745
Strength calculation as defined in VDI 2736 - II-572
Strength calculation in acc. with Hirn - II-570
Strength calculation in acc. with Hoechst - II-571
Strength calculation in acc. with ISO 6336/Niemann - II-570, II-571
Strength calculation method - IV-910
Strength calculation methods - II-552
Strength calculation using mean position in tolerance field (of tooth form) - II-456
Strength calculation with several geometries on one gear - II-668
Strength details - II-288, II-493, II-554, II-575
Strength details (AGMA) - II-280, II-288, II-303
Strength parameter according to AGMA - III-757
Strength parameters in accordance with DIN - III-756
Strength parameters in accordance with FKM - III-754
Strength parameters in accordance with Hnchen and Decker - III-753
Strength values - V-1016, V-1022, V-1031, V-1037, V-1043
Strength verification with local stresses - VIII-1081
Stress - III-759
Stress curve - II-642
Stress curve (face gear) - II-634
Stress ratio - III-759
Stress ratio R - IV-915
Stress ratios - VIII-1091
Stress values - V-1037
Stripping strength - IV-983, IV-987
Structure of KISSsys - IX-1117
Student version - I-44
Summary - II-461, II-606
Support of gearing - II-555
Surface factor - III-694
Surface factor KV, section 4.3.3, Table 4.3.7 - VIII-1093
Surface roughness - III-763, VIII-1094
Surface roughness at tooth root - II-514
Surface roughness of housing - III-732
Surface roughness of shafts and shaft-hub connections - I-144
Synchronization - VII-1067
System Assistant - IX-1126
System data - II-289
System of units - I-50, I-72
System settings - IX-1140

T
Table view - IX-1120, IX-1132
Tables - I-90
Tabs - I-105

Chapter
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62

Take into account deformation due to shearing and shear correction coefficient - III728
Take into account user specific additions - II-456
Take protuberance into account - II-456
Take shot peening data into account in calculating the strength of toothed gears - II-671
Taking double helical gearing into account in the shaft calculation - III-837
Taking into account housing deformation in static KISSsys calculations - IX-1158
Taking into account shaft bending (face load factor and contact analysis) - II-314, II333
Taking the results into account in the report - III-696
Technical explanations - IV-980
Technical notes (toothed belts) - VI-1054
Temperature - III-693, VIII-1091
Temperature duration - III-754, VIII-1091
Temperature of housing - III-693, III-719
Templates - IV-919
Temporary files - II-601
Tension springs - V-1021
Tensioning pulley diameter - VI-1050
Tensioning pulley tooth number - VI-1058
Tensioning pulleys - VI-1062
Test version - I-44, I-254
Text formatting features - I-115
The active working project - I-48, I-51, I-75, I-94, I-96, I-97
The definition of a beam chart (dg_b) - IX-1154
The definition of an XY-line graphic (dg_l) - IX-1154
The definition of the axis system (af) - IX-1153
The entire definition - IX-1154
The existing elements - IX-1134
The FKM Guideline
Rechnerischer Festigkeitsnachweis fr Maschinenbauteile - VIII-1084
The influence of the face load factor KH for tooth trace deviation fma is due to a
manufacturing error. - II-665
The info window - I-75, I-89
The Messages window - I-75, I-92
The module tree - I-74
The project tree - I-51, I-72, I-75, I-93
The Results window - I-75, I-88, I-107
The Shaft element - III-692
The user interface - IX-1119, IX-1120, IX-1121
Theoretical contact stiffness - II-632
Theoretical involute/form grinding - II-388
Theory of Contact Analysis - II-402
Thermal expansion coefficients - III-818
Thermal reference speed - III-786
Thermally permissible service speed - III-786
Thickness factors from the shaft diameter - III-769
Thickness modification coefficient - II-475
Thickness of lubrication film and specific oil film thickness - II-614
Tightening technique - IV-972

Chapter
XI-1193

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62

Tip alteration - II-351

Tip diameter allowances - II-354
Tolerance calculation - VIII-1080
Tolerance field - III-722
Tolerances - II-352, II-558, II-596, IV-916
Tolerances - V-1018
Tolerances - V-1026
Tolerances - V-1034
Tolerances standard - I-149
Tool bar and context menu - I-77, I-78
Tooltips and status bar - I-73, I-86, I-90, I-91, I-107
Tooth contact stiffness - II-294, II-372
Tooth form - II-377, II-626, IV-921
Tooth form factors - II-292, II-643
Tooth system - II-626
Tooth thickness - II-465
Tooth thickness at tip - II-655
Tooth thickness modification factor - II-548
Tooth thickness tolerance - II-352, IV-916
Tooth thickness tolerances - I-162
Tooth trace modification - II-315, II-375, III-770
Tooth trace modifications - II-358, II-366
Toothed belt standard - I-163, VI-1055
Toothed belts - VI-1053
Toothing - I-82, II-258
Topological modification - II-371
Torque curve - II-640
Torque curve/Frequency of change of load direction - IV-882, IV-894, IV-925, IV-937
Torsion critical speed - III-743
Torsion-bar springs - V-1041
Transmission accuracy level number - II-304
Transmission error - II-637
Transmission error acceleration - II-638
Transverse coefficient - II-308
Tree view - IX-1119
Triangular end relief I and II - II-370
Twist - II-371
Type - II-468, II-481
Type of bolted joint - IV-970
Type of calculation - III-750, III-751
Type of load spectrum - II-305
Type of loading/Frequency of change of load direction - IV-913
Type of modification - II-358, II-537
Type of oil lubrication - III-733

U
Undercut or insufficient effective involute - II-654

Chapter
XI-1194

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62

Underlying principles of calculation - II-359, II-467, II-522, II-543, II-565, II-584, IV903
Unit switch - I-90
Use 2013 solver - III-729
Use alternative algorithms for the tooth form calculation - II-447
Used files - I-170
Usefulness of the service life calculation - VIII-1084
User-defined settings - I-61

V
Value input fields - I-50, I-75, I-89, I-90
Values on the x-axis of diagrams - II-461
Variable dialogs - IX-1144
Variable external diameter of the hub - IV-857
Variable hub external diameter - IV-845
Variables - IX-1132, IX-1134
Variants - IX-1132, IX-1135
Variations in rolling as defined in DIN 58405 - II-656
Various - VIII-1079
Varying qualities - II-446
V-belt - VI-1047
V-belt Standard - I-141
V-belt standards - VI-1048
V-belts data - VI-1048
VDI 2737
Calculation of gear rim - II-272, II-457
Viewer with neutral format interface - I-190
Viewing database entries - I-126, I-129

W
Warning
Washers - IV-971
Ways in which KISSsys can be used - IX-1117
Wear - II-645
Wear iteration - II-409
Weld seam boundary stress - IV-993
Welded joints - IV-988, IV-989
Welded seam equivalent stress - IV-992
What licenses are available? - I-255
Width - II-586
Width and circumferential factor - IV-915
Woehler line - VIII-1090
Woehler line for material - II-630
Woodruff Key - IV-933
Woodruff Key standard - I-144
Worm wheel - generating a 3D model - I-194

Chapter
XI-1195

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62

Worms with enveloping worm wheels - II-542

Z
Z-Y coefficients and the technology factor - II-338