Low Node Density

KISSsoft Release 03/2016 F
Team-SolidSQUAD
File
Name : INPUT_FINAL
Changed by: Personnel on: 23.03.2018 at: 10:16:05
Important hint: At least one warning has occurred during the calculation:
1-> Shaft 'input':

the sum of torques is not zero.
ΔT = -180.000 Nm
2-> For shaft with internal diameter the notch factors are not available.
None of the known calculation methods produces reliable data. It is proposed to
use the data for the full shaft and to judge the results conservatively.
3-> Static calculation:

The required safety is not reached!
Analysis of shafts, axle and beams
Input data
Coordinate system shaft: see picture W-002
Label input
Drawing
Initial position (mm) 0.000
Length (mm) 241.800
Speed (1/min) 2400.00
Sense of rotation: clockwise
Material 20 MnCr 5
Young's modulus (N/mm²) 206000.000
Poisson's ratio nu 0.300
Density (kg/m³) 7830.000
Coefficient of thermal expansion (10^-6/K) 11.500
Temperature (°C) 20.000
Weight of shaft (kg) 0.935
(Notice: Weight stands for the shaft only without considering the gears)
Weight of shaft, including additional masses (kg) 1.020
Mass moment of inertia (kg*mm²) 222.103
Momentum of mass GD2 (Nm²) 0.009
Label Shaft 2
Drawing
Initial position (mm) 213.300
Length (mm) 20.000
Speed (1/min) 2400.00
Sense of rotation: clockwise
1/22
Material C45 (1)
Young's modulus (N/mm²) 206000.000
Poisson's ratio nu 0.300
Density (kg/m³) 7830.000
Coefficient of thermal expansion (10^-6/K) 11.500
Temperature (°C) 20.000
Weight of shaft (kg) 0.077
(Notice: Weight stands for the shaft only without considering the gears)
Weight of shaft, including additional masses (kg) 0.077
Mass moment of inertia (kg*mm²) 6.006
Momentum of mass GD2 (Nm²) 0.000
Position in space (°) 0.000

Regard gears as masses
Consider deformations due to shearing
Shear correction coefficient 1.100
Contact angle of rolling bearings is considered
Tolerance field: Mean value
Reference temperature (°C) 20.000
Figure: Load applications
Shaft definition (input)
Outer contour
Cylinder (Cylinder) 0.000mm ... 17.400mm

Diameter (mm) [d] 16.0000
Length (mm) [l] 17.4000
2/22
Surface roughness (µm) [Rz] 8.0000

Length (mm) [l] 1.6000
Radius right (Radius right)

r=1.50 (mm), Rz=8.0, Turned (Ra=3.2μm/125μin)
Radius left (Radius left)

Taper (Cone) 19.000mm ... 24.500mm

Diameter left (mm) [dl] 15.0000
Diameter right (mm) [dr] 22.0000

Length (mm) [l] 40.0000

Length (mm) [l] 105.3000



Taper (Cone) 177.800mm ... 180.800mm


3/22


Taper (Cone) 186.800mm ... 188.800mm


Length (mm) [l] 12.8000
Taper (Cone) 201.600mm ... 202.600mm






Length (mm) [l] 21.6500
4/22
Taper (Cone) 229.450mm ... 230.450mm

Taper (Cone) 231.450mm ... 233.450mm


Chamfer right (Chamfer right)

l=1.00 (mm), alpha=30.00 (°)
Inner contour
Cylinder inside (Cylindrical bore) 0.000mm ... 177.800mm

Length (mm) [l] 177.8000

Length (mm) [l] 17.0000

Length (mm) [l] 18.5000

Length (mm) [l] 28.5000
Forces
Type of force element Cylindrical gear

Label in the model Cylindrical gear
Position on shaft (mm) [ylocal] 218.5000
5/22
Position in global system (mm) [yglobal] 218.5000
Operating pitch diameter (mm) 56.0000
Helix angle (°) 29.9274 left
Working pressure angle at normal section (°) 18.9103
Position of contact (°) 20.0000
Length of load application (mm) 21.6500
Power (kW) 45.2389 driving (Output)
Torque (Nm) -180.0000
Axial force (N) -3700.6875
Shearing force X (N) -4586.5802
Shearing force Z (N) 5171.7642
Bending moment X (Nm) 35.4399
Bending moment Z (Nm) -97.3702
Bearing
Label in the model 1

Bearing type Own Input
Bearing position (mm) [ylokal] 5.000
Bearing position (mm) [yglobal] 5.000
Degrees of freedom
X: fixedY: fixedZ: fixed
Rx: freeRy: freeRz: free
Shaft definition (Shaft 2)
Outer contour

Length (mm) [l] 20.0000
Bearing
Label in the model Support

Bearing type Own Input
Bearing position (mm) [ylokal] 15.000
Bearing position (mm) [yglobal] 228.300
Degrees of freedom
Rx: freeRy: freeRz: free
CONNECTIONS
(Joint, general) 220.000mm

Degrees of freedom
Rx: fixedRy: fixedRz: fixed
----------------------------------------
Shaft 'input': The mass of the following element is taken into account (y= 207.7375 (mm)): Cylindrical gear 'Cylindrical gear'
m (yS= 207.7375 (mm)): 0.0011 (kg)
Jp: 0.0000 (kg*m²), Jxx: 0.0000 (kg*m²), Jzz: 0.0000 (kg*m²)
6/22
-----------------------------------------
m (yS= 210.5500 (mm)): 0.0215 (kg)
-----------------------------------------
m (yS= 221.3125 (mm)): 0.0627 (kg)
Results
Shaft
Maximum deflection 135.655 (μm) (input pos = 125.000 mm)
Mass center of gravity

input (mm) 145.064
Shaft 2 (mm) 10.000
Total axial load

input (N) -3700.688
Shaft 2 (N) 0.000
Torsion under torque

input (°) -1.234
Shaft 2 (°) 0.000
Bearing
Rolling bearings, classical calculation (contact angle considered)
Shaft 'input' Bearing '1'

Position (Y-coordinate) [y] 5.00 mm
Bearing reaction force [Fx] 0.637 kN
Bearing reaction force [Fy] 0.134 kN
Bearing reaction force [Fz] -0.065 kN
Bearing reaction force [Fr] 0.640 kN (-5.8°)
Displacement of bearing [ux] 0.000 µm
Displacement of bearing [uy] 0.000 µm
Displacement of bearing [uz] 0.000 µm
Displacement of bearing [ur] 0.000 µm
Misalignment of bearing [rx] 0.192 mrad (0.66')
Misalignment of bearing [ry] -1.766 mrad (-6.07')
Misalignment of bearing [rz] 1.787 mrad (6.14')
Misalignment of bearing [rr] 1.797 mrad (6.18')
7/22
Shaft 'Shaft 2' Bearing 'Support'
Misalignment of bearing [rx] -0.245 mrad (-0.84')
Misalignment of bearing [ry] -21.534 mrad (-74.03')
Misalignment of bearing [rz] -2.004 mrad (-6.89')
Misalignment of bearing [rr] 2.019 mrad (6.94')
Bearing 'Joint, general'

Bearing reaction moment [Mx] -42.30 Nm
Bearing reaction moment [My] -0.00 Nm
Bearing reaction moment [Mz] -32.77 Nm
Bearing reaction moment [Mr] 53.51 Nm (-142.24°)
Misalignment of bearing [rx] 0.000 mrad (0')
Misalignment of bearing [ry] 0.000 mrad (0')
Misalignment of bearing [rz] 0.000 mrad (0')
Misalignment of bearing [rr] 0.000 mrad (0')
Note: Utilization = (Lreq/Lh)^(1/k)

Ball bearing: k = 3, roller bearing: k = 10/3
8/22
Figure: Deformation (bending etc.) (Arbitrary plane 173.7051626 120)
Nominal stresses, without taking into account stress concentrations

GEH(von Mises): sigV = ((sigB+sigZ,D)^2 + 3*(tauT+tauS)^2)^1/2
SSH(Tresca): sigV = ((sigB-sigZ,D)^2 + 4*(tauT+tauS)^2)^1/2
Figure: Equivalent stress
9/22
10/22
Strength calculation according to DIN 743:2012
Summary
input
Material 20 MnCr 5
Material type Case-carburized steel
Material treatment case-hardened
Surface treatment No
Calculation of endurance limit and the static strength
Calculation for load case 2 (σav/σmv = const)

Cross section Position (Y-Coord) (mm)
A-A 10.00 Smooth shaft
B-B 50.00 Smooth shaft
C-C 100.00 Smooth shaft
D-D 150.00 Smooth shaft
E-E 180.00 Smooth shaft
F-F 200.00 Smooth shaft
G-G 220.00 Smooth shaft
Results:
Cross section Kfb Kfs K2d SD SS SA
A-A 1.00 0.87 0.95 1.20 1.01 5.64
B-B 1.00 0.87 0.93 2.87 2.57 12.73
C-C 1.00 0.87 0.93 2.95 2.79 12.24
D-D 1.00 0.87 0.93 2.50 2.57 10.39
E-E 1.00 0.87 0.90 5.65 6.07 23.65
F-F 1.00 0.87 0.90 4.47 4.89 18.69
G-G 1.00 0.87 0.87 35.39 37.57 133.81
Required safeties: 1.20 1.20 1.20
Abbreviations:
Kfb: Notch factor bending
Kfσ: Surface factor
K2d: size factor bending
SD: Safety endurance limit
SS: Safety against yield point
SA: Safety against incipient crack
Utilization (%) [Smin/S]
Cross section static endurance

A-A 119.277 100.267
B-B 46.632 41.862
C-C 43.062 40.746
D-D 46.686 47.920
11/22
E-E 19.781 21.224
F-F 24.542 26.829
G-G 3.194 3.390
Maximum utilization of shafts (%)

[A]
input: 119.277
12/22
Utilization = Smin/S (%)
Figure: Strength
Calculation details
General statements
Label input
Drawing
Speed (1/min) [n] 2400.00
Material 20 MnCr 5
Material type Case-carburized steel
Material treatment case-hardened
Surface treatment No
Tension/Compression Bending Torsion Shearing

Load factor static calculation 1.700 1.700 1.700 1.700
Load factor endurance limit 1.000 1.000 1.000 1.000
Reference diameter material (mm) [dB] 16.00

σB according to DIN 743 (at dB) (N/mm²) [σB] 1200.00
σS according to DIN 743 (at dB) (N/mm²) [σS] 850.00
[σzdW] (bei dB) (N/mm²) 480.00
[σbW] (bei dB) (N/mm²) 600.00
[τtW] (bei dB) (N/mm²) 360.00
Thickness of raw material (mm) [dWerkst] 55.00
13/22
Material data calculated according DIN743/3 with K1(d)
Material strength calculated from size of raw material
Geometric size factor K1d calculated from raw material diameter
[σBeff] (N/mm²) 936.17
[σSeff] (N/mm²) 663.12
[σbF] (N/mm²) 663.12
[τtF] (N/mm²) 382.85
[σBRand] (N/mm²) 2180.00
[σzdW] (N/mm²) 374.47

[σbW] (N/mm²) 468.08
[τtW] (N/mm²) 280.85
Endurance limit for single stage use
Calculation for load case 2 (σ.av/σ.mv = const)
Cross section 'A-A' Smooth shaft

Comment
Position (Y-Coordinate) (mm) [y] 10.000
External diameter (mm) [da] 16.000
Inner diameter (mm) [di] 0.000
Notch effect Smooth shaft
Mean roughness (µm) [Rz] 8.000

Load: (N) (Nm)
Mean value [Fzdm, Mbm, Tm, Fqm] -66.800 0.000 90.000 0.000
Amplitude [Fzda, Mba, Ta, Fqa] 66.800 3.175 90.000 640.724
Maximum value [Fzdmax, Mbmax, Tmax, Fqmax] -227.122 5.398 306.000 1089.230
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 201.062 402.124 804.248 201.062
Stresses: (N/mm²)
[σzdm, σbm, τm, τqm] (N/mm²) -0.332 0.000 111.906 0.000
[σzda, σba, τa, τqa] (N/mm²) 0.332 7.897 111.906 4.249
[σzdmax,σbmax,τmax,τqmax] (N/mm²) -1.130 13.424 380.480 7.223
Technological size influence [K1(σB)] 0.780

[K1(σS)] 0.780
Tension/Compression Bending Torsion
Notch effect coefficient [ß] 1.000 1.000 1.000

Geometrical size influence [K2(d)] 1.000 0.949 0.949
Influence coefficient surface roughness [KF] 0.867 0.867 0.923
Influence coefficient surface strengthening [KV] 1.000 1.000 1.000
Total influence coefficient [K] 1.154 1.207 1.136
Present safety for endurance limit:

Equivalent mean stress (N/mm²) [σmV] 193.826
Equivalent mean stress (N/mm²) [τmV] 111.906
Fatigue limit of part (N/mm²) [σWK] 324.596 387.833 247.182
14/22
Influence coefficient of mean stress sensitivity.
[ψσK] 0.210 0.261 0.152
Permissible amplitude (N/mm²) [σADK] 1.135 25.959 191.426
Safety against fatigue [S] 1.197
Required safety against fatigue [Smin] 1.200
Result (%) [S/Smin] 99.7
Present safety
for proof against exceed of yield point:
Static notch sensitivity factor [K2F] 1.000 1.000 1.000
Increase coefficient [γF] 1.000 1.000 1.000
Yield stress of part (N/mm²) [σFK] 663.119 663.119 382.852
Safety yield stress [S] 1.006
Required safety [Smin] 1.200
Present safety
for proof of avoiding incipient crack on hard surface layers:
Safety against incipient crack [S] 5.638
Cross section 'B-B' Smooth shaft

Comment

Load: (N) (Nm)
[A, Wb, Wt, A] 380.133 1045.365 2090.730 380.133
Stresses: (N/mm²)

[K1(σS)] 0.780

15/22


[ψσK] 0.210 0.255 0.148
Present safety
Present safety
Cross section 'C-C' Smooth shaft

Comment

Load: (N) (Nm)
[A, Wb, Wt, A] 415.476 1194.492 2388.985 415.476
Stresses: (N/mm²)

[K1(σS)] 0.780
16/22



[ψσK] 0.210 0.254 0.148
Present safety
Present safety
Cross section 'D-D' Smooth shaft

Comment

Load: (N) (Nm)
[A, Wb, Wt, A] 415.476 1194.492 2388.985 415.476
Stresses: (N/mm²)
17/22

[K1(σS)] 0.780



[ψσK] 0.210 0.254 0.148
Present safety
Present safety
Cross section 'E-E' Smooth shaft

Comment

Load: (N) (Nm)
18/22
[A, Wb, Wt, A] 614.2 2980.6 5961.2 614.2
Stresses: (N/mm²)

[K1(σS)] 0.780



[ψσK] 0.210 0.247 0.144
Present safety
Present safety
Cross section 'F-F' Smooth shaft

Comment
19/22

Load: (N) (Nm)
[A, Wb, Wt, A] 424.115 2498.302 4996.605 424.115
Stresses: (N/mm²)

[K1(σS)] 0.780



[ψσK] 0.210 0.247 0.144
Present safety
Present safety
20/22
Cross section 'G-G' Smooth shaft
Comment

Load: (N) (Nm)
Mean value [Fzdm, Mbm, Tm, Fqm] 986.6 0.0 38.8 0.0
Maximum value [Fzdmax, Mbmax, Tmax, Fqmax] 3354.3 114.9 131.8 5923.1
[A, Wb, Wt, A] 1199.0 10411.3 20822.5 1199.0
Stresses: (N/mm²)
[σzdm, σbm, τm, τqm] (N/mm²) 0.823 0.000 1.862 0.000
[σzdmax,σbmax,τmax,τqmax] (N/mm²) 2.798 11.035 6.330 9.545

[K1(σS)] 0.780



[ψσK] 0.210 0.238 0.139
Present safety
21/22
Present safety
Remarks:
- The shearing force is not considered in the analysis specified in DIN 743.
- Cross section with interference fit:
The notching factor for the light fit case is no longer defined in DIN 743.
The values are imported from the FKM-Guideline..
End of Report lines: 971
22/22

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KISSsoft Release 03/2016 F

1-> Shaft 'input':

3-> Static calculation:

Analysis of shafts, axle and beams

Coordinate system shaft: see picture W-002

Position in space (°) 0.000

Figure: Load applications

Shaft definition (input)

Cylinder (Cylinder) 0.000mm ... 17.400mm

Cylinder (Cylinder) 17.400mm ... 19.000mm

Radius right (Radius right)

Radius left (Radius left)

Taper (Cone) 19.000mm ... 24.500mm

Cylinder (Cylinder) 24.500mm ... 64.500mm

Cylinder (Cylinder) 64.500mm ... 169.800mm

Radius right (Radius right)

Cylinder (Cylinder) 169.800mm ... 177.800mm

Radius right (Radius right)

Taper (Cone) 177.800mm ... 180.800mm

Cylinder (Cylinder) 180.800mm ... 183.800mm

Radius left (Radius left)

Radius right (Radius right)

Taper (Cone) 186.800mm ... 188.800mm

Cylinder (Cylinder) 188.800mm ... 201.600mm

Taper (Cone) 201.600mm ... 202.600mm

Cylinder (Cylinder) 202.600mm ... 206.600mm

Radius right (Radius right)

Radius left (Radius left)

Cylinder (Cylinder) 206.600mm ... 207.800mm

Cylinder (Cylinder) 207.800mm ... 229.450mm

Cylinder (Cylinder) 230.450mm ... 231.450mm

Taper (Cone) 231.450mm ... 233.450mm

Cylinder (Cylinder) 233.450mm ... 241.800mm

Chamfer right (Chamfer right)

Cylinder inside (Cylindrical bore) 0.000mm ... 177.800mm

Cylinder inside (Cylindrical bore) 177.800mm ... 194.800mm

Cylinder inside (Cylindrical bore) 194.800mm ... 213.300mm

Cylinder inside (Cylindrical bore) 213.300mm ... 241.800mm

Type of force element Cylindrical gear

Label in the model 1

Shaft definition (Shaft 2)

Cylinder (Cylinder) 0.000mm ... 20.000mm

Label in the model Support

(Joint, general) 220.000mm

Maximum deflection 135.655 (μm) (input pos = 125.000 mm)

Mass center of gravity

Total axial load

Torsion under torque

Rolling bearings, classical calculation (contact angle considered)

Shaft 'input' Bearing '1'

Bearing 'Joint, general'

Note: Utilization = (Lreq/Lh)^(1/k)

Nominal stresses, without taking into account stress concentrations

Figure: Equivalent stress

Calculation of endurance limit and the static strength

Calculation for load case 2 (σav/σmv = const)

Required safeties: 1.20 1.20 1.20

Utilization (%) [Smin/S]

Cross section static endurance