Helical3D User's Manual: Advanced Numerical Solutions
Helical3D User's Manual: Advanced Numerical Solutions
Helical3D User's Manual: Advanced Numerical Solutions
Advanced
c Numerical Solutions
Hilliard OH
Preface xiii
2 Software Architecture 13
3 Preliminaries 17
3.1 System of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Reference frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Getting Started 25
4.1 Installing Helical3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Starting Helical3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 The main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Building a Model 39
7.1 System level data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.2 Pinion and gear menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.3 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4 Tooth numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.5 Spacing errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.6 Tooth profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.7 Surface modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.8 Modeling the rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.9 Modeling the shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
8 Running an Analysis 97
8.1 Surface gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8.2 Finite element probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.3 Load sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8.4 Specifying a contact grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
8.5 The setup menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8.6 Other output files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.12 The tooth data menu for the pinion or an external gear. . . . . . . . . . . . . . . 50
7.13 The tooth data menu for an internal gear. . . . . . . . . . . . . . . . . . . . . . . 50
7.14 The tooth modification menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.15 Linear tip modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.16 Linear root modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.17 Quadratic tip modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.18 Quadratic root modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.19 Crown modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.20 Flat Crown modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.21 The tabular profile modifications menu. . . . . . . . . . . . . . . . . . . . . . . . 61
7.22 Tabular tip modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.23 The tabular lead modifications menu. . . . . . . . . . . . . . . . . . . . . . . . . 63
7.24 Tabular lead modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.25 The topographical modifications menu. . . . . . . . . . . . . . . . . . . . . . . . . 65
7.26 The menu for specifying rim data. . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.27 The menu for a simple rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.28 An external pinion or gear with a simple rim . . . . . . . . . . . . . . . . . . . . 69
7.29 An internal gear with a simple rim . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.30 The menu for a webbed rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.31 An external pinion or gear with a webbed rim, showing segment i located ahead
of segment i − 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.32 An external pinion or gear with a webbed rim, showing segment i located behind
segment i − 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.33 An external pinion or gear with a webbed rim, showing segment i located inside
segment i − 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.34 An external pinion or gear with a webbed rim, showing segment i located outside
segment i − 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.35 An internal gear with a webbed rim, showing segment i located ahead of segment
i−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.36 An internal gear with a webbed rim, showing segment i located behind segment
i−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.37 An internal gear with a webbed rim, showing segment i located inside segment i − 1 79
7.38 An internal gear with a webbed rim, showing segment i located outside segment
i−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.39 An example of a pinion or an external gear with a webbed rim. . . . . . . . . . . 81
7.40 An example of an internal gear with a webbed rim. . . . . . . . . . . . . . . . . . 82
7.41 The menu for a splined rim on an external gear. . . . . . . . . . . . . . . . . . . 83
7.42 The menu for a splined rim on an internal gear. . . . . . . . . . . . . . . . . . . . 84
7.43 An external pinion or gear with an externally splined rim. . . . . . . . . . . . . . 86
7.44 An external pinion or gear with an internally splined rim. . . . . . . . . . . . . . 87
7.45 An internal gear with an externally splined rim. . . . . . . . . . . . . . . . . . . . 88
7.46 An internal gear with an internally splined rim. . . . . . . . . . . . . . . . . . . . 89
7.47 An example of an external gear with internal splines. . . . . . . . . . . . . . . . . 90
7.48 An example of an external gear with external splines. . . . . . . . . . . . . . . . 91
7.49 An example of an internal gear with internal splines. . . . . . . . . . . . . . . . . 92
7.50 An example of an internal gear with external splines. . . . . . . . . . . . . . . . . 93
7.51 The menu for specifying shaft data. . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.52 The shaft model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.53 The dimensions of the outer surface of a shaft segment. . . . . . . . . . . . . . . 96
7.54 The dimensions of the outer surface of a shaft segment. . . . . . . . . . . . . . . 96
9.35 The graph of root stress vs. face, generated by the SEARCHSTRESS menu. . . . 141
9.36 The POINTSTRESS menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9.37 The graph of root stress vs. face, generated by the POINTSTRESS menu. . . . . 143
9.38 The PATTERN menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
9.39 The contact pattern generated by the PATTERN menu. . . . . . . . . . . . . . . 145
9.40 The AUDIT menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
9.41 The BODYDEFLECTION menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
9.42 The graph generated by the BODYDEFLECTION menu. . . . . . . . . . . . . . 149
9.43 The BODYREACTION menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
9.44 The graph generated by the BODYREACTION menu. . . . . . . . . . . . . . . . 151
9.45 The BRGDEFORMN menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
9.46 The graph generated by the BRGDEFORMN menu. . . . . . . . . . . . . . . . . 153
9.47 The BRGREACTION menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9.48 The graph generated by the BRGREACTION menu. . . . . . . . . . . . . . . . . 155
We are pleased to release the Helical3D software for use by the gearing community. We have
received active support and encouragement from many people. We would especially like to thank
Timothy Krantz of the Army Research Laboratory at the NASA Glenn Research Center for his
support and encouragement. The Small Business Innovation and Research (SBIR) program of
the U.S. Army Research Laboratory has funded the development of much of the technology in
Helical3D.
Sandeep Vijayakar
Samir Abad
Hilliard OH
xiv Preface
Chapter 1
np N p
ng = (1.1)
Ng
where,
1.2 Pitch
Pitch is generally defined as the distance between equally spaced points or surfaces on a given
line or curve. On a cylindrical gear it is the arclength between similar points on successive teeth
and is known as circular pitch p. In Figure 1.1 the teeth are shown as helical, or at an angle to
the axis of the gear cylinder. If the teeth are parallel to the axes then they are called straight
or spur teeth. Then the normal circular pitch and the transverse circular pitch are equal. The
axial pitch is infinite for spur gear teeth.
One of the most important pitch classifications in an involute gear is the base pitch, shown
in Figure 1.2. Primarily, it is the circular pitch on the perimeter of the base circle, but by
definition of the involute curve the arc distance becomes the linear normal distance between
corresponding sides of adjacent teeth when raised to position as part of taut line. In spur gears
there is only one base pitch to consider. In helical gears, base pitch can be defined in the section
normal to the helix angle (normal base pitch), parallel to the gear axis (axial base pitch) and
perpendicular to the gear axis (transverse base pitch). Since gear teeth are equally spaced it
becomes apparent that in order to roll together properly, two gears must have the same base
pitch. More specifically, two mating involute gears must have the same normal base pitch.
With the number of teeth N and the circular pitch p given, the circumference of the circle
and consequently the pitch diameter Dp can be calculated from
N ×p
D= (1.2)
π
Diametral pitch P is the ratio of teeth to the pitch diameter in inches.
N
P = (1.3)
Dp
An industry practice is to not display the units of Diametral pitch, and assume that the units
are inch−1 . This practice leads to much confusion when the unit of length being used is not
inches. We encourage users to always track the units of the diametral pitch. The module m is
the inverse of the diametral pitch:
D
m= (1.4)
N
Again, industry practice is to not display the units of the module m, but to assume that it is
millimeters. We encourage users to explicitly keep track of the units of this parameter, especially
when millimeter is not the user’s unit of length.
The diametral pitch and module regulate the proportions or the size of the gear teeth. There-
fore, for a known load to be transmitted, the pitch is chosen which in turn determines the number
of teeth to suit the desired ratio and size of the gear. The number of teeth divided by the di-
ametral pitch produces the diameter of the gear pitch circle. The part of the tooth above the
pitch circle is called the addendum and the lower part is the dedendum.
The diametral pitch referred to is usually the pitch of the tool producing the gear teeth and
is known as the generating diametral pitch. The strength required of the gear teeth, the number
of teeth required to provide the given ratio, and size of the pitch circles to satisfy center distance
or space requirements are controlled by the diametral pitch. The load to be transmitted by the
gear teeth controls the tooth thickness which is also regulated by the diametral pitch.
TRANSVERSE CIRCULAR
PITCH
AXIS
AXIAL PITCH
NORMAL
CIRCULAR
PITCH
BASE PITCH
CIRCULAR PITCH
BASE PITCH
PITCH CIRCLE
BASE CIRCLE
An involute curve is evolved from origin point A on a base circle shown in Figure 1.3. The point
P on a taut line containing point B describes the curve. The taut line is tangent to the base
circle at point B, and normal to the involute curve at P. This line segment BP is the radius of
curvature ρc of the involute curve at point P and is equal in length to the arc AB. The angle
θ subtended by the arc AB is the Involute roll angle of the involute to the point P. The angle
between OP (radius r) and OB (base radius rb ) is the pressure angle φ at point P.
When two involute curves are brought together as profiles of gear teeth and are made tangent
at a point P, the pressure angle φ is equal on both members (Figure 1.4). The line BB’ is the
common normal passing through the point of contact P and is tangent to both the base circles.
All contact and tooth action will take place along the common normal. If one member is rotated,
the involute curves will slide together and drive the other member in the opposite direction. The
pressure angle through the point of contact of a pair of involute curves depends on the distance
between the centers of their respective base circles. A gear does not really have a pressure
angle until its involute curved profile is brought in to contact with a mating curve as shown in
Figure 1.4. At that time the pressure angle φ becomes the operating or rolling pressure angle
between the mating gears. For an operating center distance C, and base circle radii rbp and
rbg of the pinion and gear respectively, the operating pressure angle φop is determined by the
expression.
rbp + rbg
cosφop = (1.5)
C
In helical gears, pressure angles are defined in three planes. The transverse pressure angle is
defined in the plane normal to the gear axis or parallel to the gear face. Normal pressure angle
is in the plane or section which is normal or perpendicular to the helix.
The pressure angle at any radius r greater than the base radius rb is given by:
rb
cosφ = (1.6)
r
N
Pitch Diameter, Dp =
P
A
Addendum, a =
P
Outer Diameter, Dout = Dp + 2a
Base Diameter, Db = Dp cos φ
π
Circular Pitch, p =
P
1.4 Spur gear calculations 5
A r
c
PRESSURE
BASE CIRCLE
ANGLE
r
a B
f
q rb
O ROLL ANGLE
Og
r
bg f
Bg
GEAR
PINION
Bp
f rbp
Op
Figure 1.4: Pressure angles of pinion and gear at the contact point.
1.4 Spur gear calculations 7
Pitch Diameter, Dp = mN
Addendum, a = mA
Outer Diameter, Dout = Dp + 2m
Base Diameter, Db = Dp cos φ
Circular Pitch, p = πm
(1.7)
Of all the above dimensions, the base radius rb and the number of teeth N are the only absolute
properties of the spur gear. The diametral pitch P (or module m), the pressure angle φ and the
thickness t depend on the particular pitch circle that they are measured on. Unless otherwise
specified, P , m, φ and t refer to the generating diametral pitch, generating module, generating
pressure angle, and the generating thickness, respectively and are measured on the generating
pitch circle. If these are are measured on the operating pitch circle, then they are called the
operating diametral pitch Pop , operating module mop , operating pressure angle φop , operating
tooth thickness top , respectively.
To convert the operating pressure angle φop to φ first compute the base diameter Db :
N
Db = cos φop
Pop
N
Db = cos φ
P
D 2
θ= ( ) −1
Db
In terms of the radius r at an arbitrary point and the base radius rb , Involute angle θ is given
by
r
θ = ( )2 − 1
rb
8 Introduction to gear geometry
t1 t2
+ (θ1 − tan−1 (θ1 )) = + (θ2 − tan−1 (θ2 ))
2r1 2r2
t1 t2
− (θ1 − tan−1 (θ1 )) = − (θ2 − tan−1 (θ2 ))
2r1 2r2
(1.8)
This formula can be used to convert thicknesses from the generating circle to the operating
circle, and vice-versa.
πD
ψ = tan−1 (1.9)
L
The relationship between the helix angle at the generating and operating diameter is there-
fore:
Dop Dg
= (1.10)
tan ψop tan ψg
At any diameter, the diametral pitch (or module), pressure angle and tooth thickness may be
measured either in the transverse plane or in the normal plane. The normal diametral pitch Pn
(normal module mn ), the normal pressure angle φn and the normal tooth thickness tn are related
to the transverse diametral pitch Pt (transverse module mt ), the transverse pressure angle φt
1.5 Helical gear calculations 9
Item Description
np Revolutions per minute (RPM) of the pinion
ng Revolutions per minute (RPM) of the gear
C Operating center distance
N Number of teeth
Np Number of teeth on the pinion
Ng Number of teeth on the gear
θ Involute roll angle at a point on the involute
r Radius at a point on the involute
ρc Radius of curvature at a point on the involute
p Circular pitch
P Diametral pitch
m Module
φ Pressure angle at a point on the involute
t Tooth thickness measured at a point on the involute
Pop Operating diametral pitch
mop Operating module
φop Pressure angle at the operating pitch point
top Tooth thickness measured at the operating pitch point
rb Base radius of the involute
A Addendum constant
a Addendum
Dp Pitch Diameter
Dout Outer diameter
Db Base diameter
10 Introduction to gear geometry
N
Pitch Diameter, Dp =
Pt
A
Addendum, a =
Pn
Outer Diameter, Dout = Dp + 2a
Base Diameter, Db = Dp cos φt
π
Normal Circular Pitch, pn =
Pn
π
Axial Pitch, px =
Pn sin ψ
π
Transverse Circular Pitch, pt =
Pt
Transverse Circular Pitch on Base Circle, pbt = pt cos φt
The normal diametral pitch Pn , the normal pressure angle φn and the normal tooth thickness
tn are the parameters that are preferred for describing a helical gear. This is because these normal
parameters are directly related to the normal parameters of the hob that is used to cut the helical
gears.
φn = φnhob
Pn = Pnhob
mn = mnhob
tn = wn
where wn is the normal space width of the hob.
Software Architecture
The Helical3D package consists of a group of programs for the analysis of external and internal
helical gear pairs. Figure 2.1 shows the program modules in this package, and how they interact.
Calyx is a powerful contact analysis code capable of analyzing a variety of contact problems,
including 2D and 3D static and dynamic analysis of systems such as gears, compressors, and
brakes. Because Calyx is designed to be capable of handling a variety of problems, it commu-
nicates with the outside world through a programming language. The programming language
interface of Calyx brings flexibility at the expense of ease of use. Such an interaction is appro-
priate for an advanced Calyx user, but not for a gear design engineer.
In order to address this issue, the program Multyx is used. Multyx is capable of communicat-
ing with the user through an easy to use menu-based interface or a command line interface. It
translates the user’s commands into the appropriate programming language statements and sends
them on to Calyx. A typical user need not even know that Calyx is running in the background.
In addition to the user interface, Multyx also has built-in model generators. The internal
and external helical gear tooth models, the web, and spline models described in this manual
are all generated by Multyx. It also has post-processing and data extraction code, to help the
user extract the results of analysis from Calyx. In Helical3D, Multyx is customized with model
generators needed for spur and helical gear applications.
Multyx and Calyx are designed as portable code, and can run on any system that supports
standard C++. In order to keep it portable, Multyx ’s menu system is command line based,
and does not use any of the GUI features such as buttons, windows or mouse interaction. The
following dialog shows a sample of command line interface of Multyx.
E:>multyx
MultyX v.1.06, Copyright Advanced Numerical Solutions Dec 21 2000
MultyX>post ok patt
MultyX.PostProc.1/11.Pattern>HELP
MENU Show menu
? Show menu
HELP Show menu
EXIT Return to main menu.
QUIT Return to main menu.
START Draw the contact pattern.
CLEAR Clear the graphics page.
SURFACEPAIR Surface pair (Currently=PINION_SURFACE1_GEAR_SURFACE1)
MEMBER Member (Currently=GEAR)
TOOTHBEGIN 80 Tooth no. or instance no. of surface.
TOOTHEND 2 Tooth no. or instance no. of surface.
14 Software Architecture
Guide is a program that provides a Graphical User Interface (GUI) to Multyx. Guide trans-
lates each of Multyx ’s dialogs and presents them to the user in a graphical form. The command
line menu described above is presented to the user as shown in Figure 2.2.
In addition, Guide provides the user with convenient ways of viewing the graphics, and helps
the user convert the graphics into Microsoft formats and into Encapsulated PostScript (EPS)
files. These formats can be used in documentation. In Helical3D, Guide is customized for spur
and helical gear applications.
Although Guide enhances the friendliness of Multyx, it is not required. All the features of
Multyx can be accessed without Guide. The connection between Guide and Multyx is based on
the TCP/IP telnet protocol when they are running on different computers. When running on
the same computer, they communicate through named pipes. Guide is a heavy user of advanced
operating system features including GUI support, multi-threading support, and inter-process
communication support. Guide now runs on Windows 95/98/NT/2000/XP systems only.
This manual describes the various features of the Helical3D package.
15
Preliminaries
The previous chapter gave an overview of the software architecture. This chapter provides some
information to help you get up and running with the program.
3.2 Bodies
In multi-body contact analysis, the term ‘body’ is used to refer to an object that is capable of rigid
body motion, and interacts with other bodies through surface contact and bearing connections
(Figure 3.1).
There is a special body called the ‘fixed body’ which refers to ground.
In Helical3D, the pinion and gear are treated as separate bodies. In addition, if splined
supports are used for the pinion, an additional body called the pinion shaft body is created. The
pinion body and pinion shaft body interact through contact at the splines. Similarly, if splines
are used to support the gear, an additional body called the gear shaft body is created. This gear
shaft body interacts with the gear body through contact at the splines.
Thus Helical3D creates 2, 3 or 4 bodies depending on the boundary conditions applied to
the pinion and gear.
18 Preliminaries
X2
Y3 Y2
X3
Body 2
Body 3
X1
Y1
Body 1
Yo
Xo
Ground
In addition to the body reference frames, there is a special reference frame called the fixed
reference frame that is considered as ‘ground’, and does not move. It is used as the reference for
defining the locations of all other reference frames.
Figures 3.3 and 3.4 show how Helical3D sets up the pinion and gear reference frames relative
to the fixed reference frame in an external and internal gear set, respectively. The fixed frame is
located with its origin at the operating pitch point. Its Z axis is parallel to the axes of rotation
of the pinion and gear. Its Y axis is along the center distance direction. The pinion and gear
reference frames have their origins at their centers of rotation, with the Z axis being the axis of
rotation. At time t = 0, the pinion and gear X, Y and Z axes are parallel to the corresponding
axes of the fixed reference frame.
Manufacturing and assembly errors applied to the system might perturb the location of these
reference frames slightly from their nominal location.
20 Preliminaries
Ygear
Xgear
Zgear
Yfixed
rpitch,gear
Ypinion
Zfixed
Xfixed
rpitch,pinion
Zpinion
Xpinion
Figure 3.3: The reference frames set up for a pair of external helical gears
3.3 Reference frames 21
Yfixed
Xfixed
Zfixed Ypinion
rpitch,pinion
Ygear
Xpinion
Zpinion
rpitch,gear
Xgear
Zgear
Figure 3.4: The reference frames set up for an internal helical gear and external pinion.
22 Preliminaries
Bearing 3
Body 2
Body 3
Body 1 Bearing 2
Bearing 1
Ground
3.4 Bearings
In a multi-body system, bodies can also interact through bearings (Figure 3.5).
Bearings are treated as a stiffness connection between two bearing ‘races’ (Figure 3.6). Each
race has an attached reference frame. The race is treated as a rigid body, and the six degrees of
freedom of the first bearing race and the six degrees of freedom of the second bearing race are
inter-related through a stiffness matrix.
The six degrees of freedom are the three translation degrees of freedom Ux , Uy and Uz , and
three rotation degrees of freedom θx , θx and and θz (Figure 3.7). The degrees of freedom represent
the motion of race 1 relative to race 2. The components are measured in the reference frame
attached to race 2.
The bearing may also generate internal reaction forces and moments. The six components of
bearing reaction consist of three forces Fx , Fy and Fz , and the three moments Mx , My and Mz .
Again, these reactions are those exerted by race 1 on race 2. The components are computed in
the reference frame of race 2.
Depending on the user’s inputs, Helical3D can generate a bearing for the pinion and one for
the gear. For the pinion bearing, race 1 is attached to the pinion and race 2 is attached to the
fixed body. The gear is treated similarly.
Since Helical3D attaches race 2 of both bearings to ground, the bearing rigid body deforma-
tion and reaction components can be interpreted as the forces and moments acting parallel to
the axes of the fixed reference frame.
3.4 Bearings 23
Y1 X2
Y2
X1
Race 1
Race 2
X2
Uy
Y2
Ux
Race 1
Race 2
X2
Y2
Fy Fx
Race 2
Getting Started
The PREPROC command allows the user to graphically inspect the latest model. If the user
has changed some parameters after the last GENERATE action, then the PREPROC command
detects this and calls the GENERATE command itself.
The SETUP command is used to set up an analysis, and the FEPROBES, SURFGAGES,
and LOADSENSORS commands are used to control the data created by the analysis.
The POSTPROC command is used to graphically inspect the results of the analysis.
30 Getting Started
Chapter 5
Helical3D’s user interface is presented by Guide in graphical form, as shown in Figure 5.1.
Helical3D also sends out a stream of informational, error and warning messages to the user.
These messages are separated by Guide, and presented in separate windows as shown. The
user activates these message windows by clicking the appropriate “Error”, “Information” or
“Warning” tab. Graphical information sent by Helical3D is directed to a graphics window.
Integer data items are entered through a dialog box of the kind shown in Figure 5.2. The
current value appears in a box in the dialog box. If the value of the data item is undefined, then
the box appears blank.
Floating point data is entered through the dialog box shown in Figure 5.3.
Boolean data items are those that can only take a YES/NO or TRUE/FALSE type of value.
Their value is set by checking or clearing the box as shown in Figure 5.4.
The last kind of data item is of the ‘switch’ type. The value of a switch menu item can be
selected from a fixed set of valid choices. The choice is made through a drop down list as shown
in Figure 5.6.
5.8 Graphics
Guide directs the graphical output from Helical3D to a graphics window. The graphics are
stored as separate pages. a new page is started when Helical3D clears the graphics screen. The
user can move between screens using the buttons on the toolbar.
Double clicking anywhere in the graphics window with the left mouse button or dragging the
mouse in the graphics window with the left button depressed lets you zoom in. To zoom out,
double-click with the right mouse button. The buttons on the toolbar can also be
used to zoom in, zoom out and to return to the original view.
By default, the graphics are refreshed automatically when necessary. However, this behaviour
can be undesirable if the graphics are very complex. This auto-refresh behavior can be toggled
using the View|EnableAutoRefresh and View|DisableAutoRefresh commands. If auto-refresh is
disabled, then the user can refresh the graphics using the button.
It is possible to save a sequence of graphics pages in a metafile (a .MET file) using the
File|SaveReplayFile command. This file can later be replayed in Guide using the File|ReplayGraphicsFile
command.
The graphics currently displayed can be saved in Windows Metafile format (a .WMF file)
by using the File|SaveWindowsMetafile command. This .WMF file can subsequently be loaded
by another application such a word processor. An encapsulated PostScript file (a .EPS file)
can be created by using the File|CreateEPSFile command. This command creates an .EPS file
containing only the visible part of the current graphics page. Parts of the page that are not
visible because of the zoom level will be cropped from the .EPS file.
The Edit|Copy command will copy the graphics in Windows Metafile format onto the clip-
board.
Graphics pages can be printed by using the File|Print command on Guide’s main menu.
Chapter 6
Sometimes it is convenient to run Helical3D without the interactive graphical user interface.
This is useful if a batch file is needed to run several jobs in a batch queue.
\progra~1\ansol\Helical3D\multyx helicalpair3dcr.sdf
The main menu of Helical3D comes up in the command line mode. The names of the
commands and data items is the same as when running under Guide. You may type ? or HELP
for options at any prompt.
MultyX v.2.01, Copyright Advanced Numerical Solutions Jun 24 2004
Computer ID: 0020E065BC754C535A6E
Read data from session file:
multyx.ses
MultyX>EDIT PINION
MultyX.Edit.Pinion>TOOTH
MultyX.Edit.Pinion.Tooth>?
MENU Show menu
? Show menu
HELP Show menu
EXIT Accept changes and return.
QUIT Return after discarding changes in this menu and all sub-menus.
MODFN Surface modifications
NTEETH 20 The number of teeth on pinion
NFACEELEMS 4 The number elements across face
COORDORDER 10 limit on order of coord axodes
38 Running Helical3D without the Graphical User Interface
Building a Model
All data describing the model is entered in sub-menus of the EDIT menu. Figure 7.1 shows the
EDIT menu. In this menu, and in all sub-menus under it, the QUIT command takes the user
back to the parent menu after discarding all changes made in the sub-menu and all sub-menus
under it. The EXIT command takes the user back to the parent after saving the changes.
There are three sub-menus under this EDIT menu. The SYSTEM command leads to a menu
for entering system level data. The PINION and GEAR commands lead to separate sub-menus
for entering data specific to the pinion and gear, respectively.
Depending on the features licensed at a particular site, an aditional item MESHTYPE may
also be visible in this EDIT menu. This allows a user to select the kind of model to be generated.
Choices are CAPP and CALYX3D. CAPP is an older analysis and post-processing package.
Unless otherwise stated, it will be assumed that the user has selected CALYX3D.
If the flag USEMODULE is checked, then the user can use the gear module instead of
diametral pitch. Users in countries where module is preferred should check this item. In the rest
of this manual, we will assume that this flag is not checked.
The SYSTEM command in the EDIT menu of Figure 7.1 leads to the SYSTEM menu shown in
Figure 7.2. The parameters in this menu are summarized in Table 7.1.
If the MESHTYPE option in the main menu was set to CAPP, then the name of a configu-
ration file can be specified in the CONFIGFILE item.
CENTERDIST is the operating center distance. This should always be a positive value.
OFFSET (Figure 7.3) is the axial offset of the gear with respect to the pinion. When this value
is zero, the mid face cross-sections of the pinion and gear coincide. When it is positive, the gear
is shifted by this amount in the +Z direction.
ROTX and ROTY (Figure 7.4) are the angular misalignment values in Degrees for the pinion
about the X and Y axes, respectively. The Z axis is the axis of rotation, the Y axis is along the
center distance direction, pointing from the pinion to the gear. The X axis is perpendicular to
these two. The three axes form a right handed system. The right hand rule is used to determine
the sign of this angle. The misalignment values are in Degrees.
The INPUT switch selects whether the PINION or the GEAR acts as the input for power.
The torque and angular speed directions of the input member are the same. They are opposite
7.1 System level data 41
Item Description
CONFIGFILE String, Configuration file for CAPP (if
MESHTYPE=CAPP)
CENTERDIST Float, The operating center distance
OFFSET Float, The axial offset of the gear wrt. the
pinion
ROTX Float, The radial misalignment (Deg) of
the pinion.
ROTY Float, The tangential misalignment (Deg)
of the pinion.
INPUT Switch, Which body is the power input
choices available are PINION and GEAR
SPECIFY Switch, Whether INPUTTORQUE or
OUTPUTTORQUE is known.
TORQUEINPUT Float, The torque at the input member
IF(SPECIFY=INPUTTORQUE)
TORQUEOUTPUT Float, The torque at the input member
IF(SPECIFY=OUTPUTTORQUE)
RPMINPUT Float, Input speed in RPM
MU Float, The coefficient of Coulomb friction
MAGRUNOUTGEAR Float, Magnitude of high point of runout
error
ANGRUNOUTGEAR Float, Orientation angle (Deg) high point
of runout error
MAGRUNOUTPINION Float, Magnitude of high point of runout
error
ANGRUNOUTPINION Float, Orientation angle (Deg) high point
of runout error
BACKSIDECONTACT Boolean, Check for back side contact
RADIALCONSTRAINT Boolean, Check to constrain radial motion
IF(BACKSIDECONTACT)
RADIALLOAD Float, The operating center distance
IF(BACKSIDECONTACT AND
¬(RADIALCONSTRAINT))
42 Building a Model
Gear
mid-face
OFFSET
Pinion
mid-face
GEAR
Y Y
Z Z
ROTX
ROTY
PINION
Item Description
LUMPMASS Float, Lumped mass at pin-
ion/gear center
LUMPMOMINERTIA Float, Lumped polar moment of
inertia Jz about the pinion or
gear axis of rotation
LUMPALPHA Float, The damping constant for
the lumped mass and moment of
inertia
7.3 Bearings
The BEARING commands in Figures 7.6 and 7.7 lead to the bearing data menu shown in
Figure 7.8. Table 7.3 describes the parameters.
If the RIGIDRACE box is checked, then the inner diameter of the pinion or external gear
(or the outer diameter in the case of an internal gear) is treated as a rigid body. Otherwise,
its deformation is expressed using a Fourier series expansion in the circular direction, and a
7.3 Bearings 45
polynomial series in the axial direction. The order of this series expansion can be specified in
the CIRCORDER and AXIALORDER boxes.
The RIGIDRACE box appears only when the pinion or gear model has no rim model, or if
the rim model is of the SIMPLE type described later. If the rim is of the WEBBED type, the
the bearing race is treated as rigid. If the rim is of the EXTSPLINED or INTSPLINED type,
the splines are attached to a flexible surface on the pinion or gear, and the bearing race is a rigid
cylinder attached to the spline supports.
In addition to the deformation of the race, the rigid body type motion of the inner diameter of
the pinion/gear may be constrained by leaving the BEARING box unchecked. If the BEARING
box is checked, then stiffness and damping matrices can be assigned to the rigid body motions.
The stiffness and damping matrices of the bearing are read in from a existing input data file.
The name of the file should be entered into the BRGFILE box.
The contents of a sample bearing file are shown below.
0 0 0 0 0 0
1.0e7 0 0 0 0 0
0 1.0e7 0 0 0 0
0 0 0 0 0 0
0 0 0 0.0e9 0 0
0 0 0 0 0.0e9 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
0 0 0 0 0 0
46 Building a Model
Inside the bearing file, the first line in this file must always have 6 zeroes. This line is assigned
for future use. The next 12 lines contain the 6x6 stiffness and 6x6 damping matrices. The last
line contains a zero. This is a flag intended for future use. The 6x6 matrices correspond to
the 6 degrees of freedom of bearing race 1 relative to bearing race 2, as measured in the race 2
reference frame.
The six degrees of freedom are the three translations in the X, Y and Z directions and the
three rotations about the X, Y and Z directions. The X axis points from the gear center to the
pinion center. The Z axis is along the axis of rotation.
7.3 Bearings 47
Figure 7.9: The tooth and side numbering scheme for the pinion or an external gear
Figure 7.10: The tooth and side numbering scheme for an internal gear
7.5 Spacing errors 49
Figure 7.12: The tooth data menu for the pinion or an external gear.
Item Description
LINEARTIPMOD Boolean, Whether to apply the
linear tip modfn.
ROLLLINEARTIPMOD Float, Roll angle at start of the
linear tip modfn.
MAGLINEARTIPMOD Float, Magnitude of the linear tip
modfn.
Item Description
LINEARROOTMOD Boolean, Whether to apply the
linear flank modfn.
ROLLSTARTLINEARROOTMOD Float, Roll angle at start of the
linear flank modfn.
ROLLENDLINEARROOTMOD Float, Roll angle at the end of the
linear flank modfn.
MAGLINEARROOTMOD Float, Magnitude of the linear
flank modfn.
The PROFILETABLE command in the tooth modification menu of Figure 7.14 leads to the
menu shown in Figure 7.21. This menu is used to specify an arbitrary profile modification in
tabular form. Table 7.13 and Figure 7.22 show the meaning of the parameters in this menu. The
modification is specified at an arbitrary number of roll angle values. In between these roll angle
values, the profile modification is linearly interpolated.
Similarly, an arbitrary lead modification can be specified in tabular form. The LEADTABLE
command in the tooth modification menu of Figure 7.14 leads to the menu shown in Figure 7.23.
Table 7.14 and Figure 7.24 show the meaning of the parameters in this menu. The modification
is specified at an arbitrary number of ζ values. The surface coordinate ζ varies from −1 to +1
along the face width of the tooth. In between these ζ values, the lead modification is linearly
interpolated.
Finally, a surface modification that is an arbitrary function of both the roll angle and ζ can
be specified using the topographic modification option. The TOPOMOD command in the tooth
modification menu of Figure 7.14 leads to the menu shown in Figure 7.25. Table 7.15 shows the
meaning of the parameters in this menu. The modification is specified at an arbitrary number
of ζ and roll angle values. The magnitude is specified for each pair of these values. Bilinear
interpolation is used between them.
7.7 Surface modifications 55
Modification
MAGLINEARTIPMOD
Roll Angle
Root Tip
TIP
ROLLLINEARTIPMOD
Item Description
QUADTIPMOD Boolean, Whether to apply the
quadratic tip modfn.
ROLLQUADTIPMOD Float, Roll angle at start of the
quadratic tip modfn.
MAGQUADTIPMOD Float, Magnitude of the
quadratic tip modfn.
56 Building a Model
Modification
MAGLINEARROOTMOD
Roll Angle
Root Tip
ROLLSTARTLINEARROOTMOD
TIP
ROLLENDLINEARROOTMOD
Item Description
QUADROOTMOD Boolean, Whether to apply the
quadratic flank modfn.
ROLLSTARTQUADROOTMOD Float, Roll angle at start of the
quadratic flank modfn.
ROLLENDQUADROOTMOD Float, Roll angle at the end of the
quadratic flank modfn.
MAGQUADROOTMOD Float, Magnitude of the
quadratic root modfn.
7.7 Surface modifications 57
Modification
MAGQUADTIPMOD
Roll Angle
Root Tip
TIP
ROLLQUADTIPMOD
Item Description
LEADCROWN Boolean, Whether to apply the
lead crowning.
MAGLEADCROWN Float, Magnitude of the lead
crown.
58 Building a Model
Modification
MAGQUADROOTMOD
Roll Angle
Root Tip
ROLLSTARTQUADROOTMOD
TIP
ROLLENDQUADROOTMOD
Item Description
FLATLEADCROWN Boolean, Whether to apply the
lead crowning.
MAG1FLATLEADCROWN Float, Magnitude of the lead
crown at the ζ = −1.0 end.
ZETA1FLATLEADCROWN Float, Start ζ at the ζ = −1.0
end.
MAG2FLATLEADCROWN Float, Magnitude of the lead
crown at the ζ = +1.0 end.
ZETA2FLATLEADCROWN Float, Start ζ at the ζ = +1.0
end.
7.7 Surface modifications 59
Modification
MAGLEADCROWN
Zeta
Zeta=-1.0 Zeta=+1.0
Modification
MAG1LEADCROWN
Zeta
Item Description
TABLEPROFMOD Boolean, Whether to use a profile
modfn table.
NROLLS Integer, The number roll angles
used in the profile modfn. table
IROLL Integer, The roll angle number in
the profile modfn. table
ROLLANGLE Float, Vector, indexed by IROLL,
Roll angle in the profile modfn.
table
MAGNITUDE Float, Vector, indexed by IROLL,
Magnitude of modification in the
profile modfn. table
62 Building a Model
Modification
MAGNITUDE
Roll Angle
Root Tip
ROLLANGLE
Item Description
TABLELEADMOD Boolean, Whether to use a lead
modfn table.
NZETAS Integer, The number zetas used
in the lead modfn. table
IZETA Integer, The zeta number in the
lead modfn. table
ZETA Float, Vector indexed by IZETA,
Zeta value in the lead modfn. ta-
ble
MAGNITUDE Float, Vector indexed by IZETA,
Magnitude of modification in the
lead modfn. table
64 Building a Model
Modification
MAGNITUDE
Zeta
Zeta=-1.0 Zeta=+1.0
ZETA
Item Description
TOPOMOD Boolean, Whether to use topo-
graphic modfns.
NZETAS Integer, The number of zetas used
in the topographic modfn. table
IZETA Integer, The zeta number in the
topo modfn. table
ZETA Float, Vector indexed by Zeta
value in the topo. modfn. table
NROLLS Integer, The number of roll angles
used in the topo. modfn. table
IROLL Integer, The roll angle number in
the topo. modfn. table
ROLL Float, Vector indexed by IROLL,
Roll angle in the topo. modfn.
table
MAGNITUDE Float, Array indexed by IZETA
and IROLL, Magnitude of modi-
fication in the lead modfn.
7.7 Surface modifications 65
Figure 7.27 shows the menus as they appear for the SIMPLE rim, for external and internal
gears, respectively. Table 7.16 and Figures 7.28 and 7.29 explain the meaning of the input
parameters.
Figure 7.30 shows the menus as they appear for the WEBBED rim, for external and internal
gears, respectively. Table 7.17 explains the meaning of the input parameters. The WEBBED
rim is composed of an arbitrary number of ‘segments’. The position of the first segment cannot
be changed. Each of the remaining segments can be placed in four different positions relative to
the previous segment, as shown in Figures 7.31 through 7.38
Figure 7.39 shows an example of an external gear with a webbed rim. Refer to the session file-
externalwebbed.ses in the WORKING directory for rim details. Figure 7.40 shows an internal
gear with a webbed rim. Refer to the session file- internalwebbed.ses in the WORKING directory
for rim details.
Figures 7.41 and 7.42 show the menus as they appear for the EXTSPLINED and INTSPLINED
rims, for external and internal gears, respectively. Table 7.18 explains the meaning of the input
parameters. The EXTSPLINED option refers to external splines, and the INTSPLINED option
refers to internal splines. Either of these can be used with external and internal gears. These
four combinations, and the parameters required are depicted in Table 7.18 and Figures 7.43
through 7.46.
Examples of external and internal gears with external and internal splines are shown in
Figures 7.47 through 7.50.
7.8 Modeling the rim 67
RIM WIDTH
Front Back
OUTERDIA
ROOTDIA
TOOTH
RIM
RIMDIA
INNERDIA
RIM OFFSET
RIM WIDTH
Front Back
RIM
OUTERDIA
RIMDIA ROOTDIA
TOOTH
Item Description
RIMDIA Float, Rim diameter of the gear
NTHETA Integer, Number of elements in
the circular direction
ELEMTYPE Switch, Type of finite element.
Available options are LINEAR,
QUADRATIC and CUBIC
AXIALORDER Integer, Polynomial order in the
face direction
CIRCORDER Integer, Fourier series order in the
circular direction
NSEGS Integer, Number of segments
used to define the rim
ISEG Integer, Segment number for
which data is being displayed
RA Float, Vector indexed by ISEG,
Radial coordinate at side A.
RB Float, Vector indexed by ISEG,
Radial coordinate at side B.
ZA Float, Vector indexed by ISEG, Z
coordinate at side A.
ZB Float, Vector indexed by ISEG, Z
coordinate at side B.
POSITION Switch, Vector indexed by ISEG,
Relative position of the rim seg-
ment.
NETA Integer, Vector indexed by ISEG,
Number of elements in the η di-
rection direction
NZETA Integer, Vector indexed by ISEG,
Number of elements in the ζ di-
rection direction
7.8 Modeling the rim 73
TOOTH
ζ B
Seg. 1
A
Seg. I
Seg. 2
R
η
Seg. I-1
Figure 7.31: An external pinion or gear with a webbed rim, showing segment i located ahead of
segment i − 1
74 Building a Model
TOOTH
Seg. 1
Seg. 2
R
Seg. I-1
ζ
B
Z Seg. I
Figure 7.32: An external pinion or gear with a webbed rim, showing segment i located behind
segment i − 1
7.8 Modeling the rim 75
TOOTH
Seg. 1
Seg. 2
R
ζ
Seg. I-1
B
Seg. I
Z
η A
Figure 7.33: An external pinion or gear with a webbed rim, showing segment i located inside
segment i − 1
76 Building a Model
B TOOTH
ζ
A
Seg. I
Seg. I-1 Seg. 1
η
Seg. 2
R
Figure 7.34: An external pinion or gear with a webbed rim, showing segment i located outside
segment i − 1
7.8 Modeling the rim 77
Seg. I-1
Seg. I Seg. 2
B
η
Seg. 1
ζ
A
R
TOOTH
Figure 7.35: An internal gear with a webbed rim, showing segment i located ahead of segment
i−1
78 Building a Model
Seg. I
A
ζ
η
Seg. I-1
Seg. 2
Seg. 1
TOOTH
Figure 7.36: An internal gear with a webbed rim, showing segment i located behind segment
i−1
7.8 Modeling the rim 79
Seg. 2
Seg. I-1
Seg. 1
Seg. I
ζ R
A
η
B TOOTH
Figure 7.37: An internal gear with a webbed rim, showing segment i located inside segment i − 1
80 Building a Model
Seg. I
B
ζ η
Seg. I-1
Seg. 2
Seg. 1
TOOTH
Figure 7.38: An internal gear with a webbed rim, showing segment i located outside segment
i−1
7.8 Modeling the rim 81
SPLINE LENGTH
Front Back
OUTERDIA
ROOTDIA
TOOTH
RIM
RIMDIA
INNERDIA
RIM OFFSET
SPLINE WIDTH
SPLINE OFFSET
Y
Y
ANGPOSN
X
Z
SPLINE LENGTH
Front Back
7.8 Modeling the rim
OUTERDIA
ROOTDIA
SPLINE WIDTH TOOTH
RIM
RIMDIA
INNERDIA
RIM OFFSET
SPLINE OFFSET
Y
Y
PRESSANGLE
ANGPOSN
X
Z
SPLINE LENGTH
Front Back
RIM
OUTERDIA
RIMDIA ROOTDIA
TOOTH
SPLINE OFFSET
Y
Y
ANGPOSN
X
Z
SPLINE LENGTH
Front Back
7.8 Modeling the rim
SPLINE WIDTH
RIM
OUTERDIA
RIMDIA ROOTDIA
SPLINE OFFSET
Y
Y
PRESSANGLE
ANGPOSN
X
Z
Running an Analysis
The NUMSPROF parameter controls how many search points should be used over this range.
The face parameter T varies from −1.0 to +1.0 over the face of the tooth. The face width
range parameters TFACEBEGIN, control TFACEEND range over which the search is carried
out, and NUMTFACE controls the number of search points within this range.
The DEPTHBEGIN, DEPTHEND and NUMDEPTH parameters extend the search range to
a number NUMDEPTH of points ranging in depth from DEPTHBEGIN to DEPTHEND below
the surface. This is an expensive computation, and should not be used unless necessary. The
surface gage will measure the stress at the critical depth. The depth is in physical length units.
Because finite element stresses computed very close to the highly concentrated contact loads
can have a large amount of error, we need a way to screen out points that are too close. The
parameter DISTMIN is the minimum allowed distance of a stress calculation point from a contact
point. Stresses will not be calculated at any point whose distance from a contact point is less
than this value. This distance is in physical length units.
During the analysis, all the surface gage readings are written to a file called GAGES.DAT.
Each row in this file corresponds to a time instant. The first column in the file contains the
value of the time. The remaining columns contain the readings of the surface gages. There are
four columns of data for each gage. The first column for a gage contains the critical maximum
principal normal stress (s1 ) over its search range. The second column contains the value of the
critical minimum principal normal stress (s3 ). The third column contains the critical maximum
shear stress (τmax ), and the fourth column contains the critical Von Mises’ shear stress (svm ).
The columns are separated by tabs.
cell will end up carrying all the load (Figure 8.5). If the grid is too narrow, then the contact zone
will get truncated, causing artificially high contact pressures at the edges of the grid (Figure 8.6).
If the grid size is correct, a variation of contact pressure similar to that in Figure 8.7 should be
obtained.
Figure 8.8 shows an example of a contact grid set up on a pair of contacting teeth.
Figure 8.5: Contact pressure distribution across the width of contact obtained when the contact
grid is too wide.
Figure 8.6: Contact pressure distribution across the width of contact obtained when the contact
grid is too narrow.
8.5 The setup menu 105
Figure 8.7: Contact pressure distribution across the width of contact obtained when the contact
grid is correct.
The PREPROC command in the main menu leads to the pre-processing menu shown in Fig-
ure 9.1. The POSTPROC command leads to the dialog box shown in Figure 9.2, where Multyx
asks for the name of the post-processing data file created in the analysis step. When a valid
name is entered, the post-processing menu shown in Figure 9.3 comes up.
The pre-processing menu and the post-processing menu are used to make drawings of the sys-
tem and its components. The CLEAR command clears the graphics screen. The DRAWBODIES
draws all the selected bodies using the current view settings. The DRAWBODIES command
does not clear the screen before it makes the drawing. In the post-processing menu, the FIRST-
POSN, PREVPOSN, NEXTPOSN, and LASTPOSN commands allow the user to move from
one time step saved in the post-processing file to another. Entering a position number directly
in the GOTOPOSN box takes the user directly to that time step.
Figure 9.5: The view menu in pre-processing mode with the LOADS option disabled.
9.2 View parameters 111
Figure 9.7: The view menu in post-processing mode with the LOADS option enabled.
9.3 The DRAWBODIES command 113
2 1
3
20
4
19
18
Figure 9.11: Tooth numbering superimposed on a pinion drawing, using the NUMBER command.
9.5 The TOOTHLOAD command 117
1200.000000
1000.000000
800.000000
600.000000
400.000000
200.000000
0.000000
Figure 9.13: The tooth load vs. time graph generated by the TOOTHLOAD menu.
-0.600000 -0.400000 -0.200000 -0.000000 0.200000 0.400000 0.600000
Time
Pre- and Post-processing
9.6 The CONTACT command 119
500000.000000
400000.000000
300000.000000
200000.000000
100000.000000
0.000000
Time
Figure 9.15: The tooth contact pressure vs. time graph generated by the CONTACT menu.
Pre- and Post-processing
1.923510E+005: Tooth 20 of PINION at time=-4.000000E-001, SPROF=3.863336E+001, TFACE= -2.5806
2.932673E+005: Tooth 1 of PINION at time=-2.000000E-001, SPROF=2.468407E+001, TFACE= -4.44089
Contact Pressure on surface pair: PINION_SURFACE1_GEAR_SURFACE1
2.261298E+005: Tooth 2 of PINION at time=6.000000E-001, SPROF=2.407096E+001, TFACE= 6.451613
300000.000000
9.6 The CONTACT command
200000.000000
0.000000
Time
Figure 9.16: The tooth contact pressure vs. time graph generated by the CONTACT menu with
121
122 Pre- and Post-processing
700.0
600.0
9.8 The SUBSURFACE command
500.0
400.0
300.0
200.0
100.0
0.0
5 10 15 20
Tooth No.
Figure 9.18: The tooth load histogram generated by the TOOTHLDHIST menu.
123
124 Pre- and Post-processing
principal normal stress s3 ), MAXSHEAR (the maximum shear stress τmax ) and VONMISES
(the Von Mises’ octahedral shear stress svm ).
Figure 9.20 shows an example of a graph of sub-surface stress vs. depth.
5.528799E+004: Tooth 20 at depth=4.400000E-003, s=4.019923E+001, t=4.019923E+001 (contact pressure=1.825415E+005)
5.922931E+004: Tooth 1 at depth=3.425000E-003, s=2.299332E+001, t=2.299332E+001 (contact pressure=1.964007E+005)
Max Shear (s3-s1)/2
0.000000E+000: Tooth 2 at depth=0.000000E+000, s=0.000000E+000, t=0.000000E+000 (contact pressure=0.000000E+000)
60000.000000
50000.000000
40000.000000
9.8 The SUBSURFACE command
30000.000000
20000.000000
10000.000000
0.000000
0.000000 0.002000 0.004000 0.006000 0.008000 0.010000 0.012000 0.014000 0.016000 0.018000 0.020000 0.022000
Figure 9.20: The sub-surface shear graph generated by the SUBSURFACE menu.
Depth
125
126 Pre- and Post-processing
Figure 9.22: The grid load histogram generated by the GRIDLDHIST menu.
Tooth 20 Tooth 1 Tooth 2
127
128 Pre- and Post-processing
Figure 9.24: The grid pressure histogram generated by the GRIDPRHIST menu.
Tooth 20 Tooth 1 Tooth 2
129
130 Pre- and Post-processing
Tooth 1
Contact Pressure at Time = -4.000000E-001, Range=[0.000000E+000,8.292303E+004]. Each Div.=1.000000E+004
Figure 9.25: The grid pressure histogram generated by the GRIDPRHIST menu for DSPROF=
0.02 (too wide contact grid).
9.10 The GRIDPRHIST command 131
Tooth 1
Contact Pressure at Time = -4.000000E-001, Range=[0.000000E+000,2.822320E+006]. Each Div.=1.000000E+006
Figure 9.26: The grid pressure histogram generated by the GRIDPRHIST menu for DSPROF=
0.0001 (too narrow contact grid).
132 Pre- and Post-processing
Tooth 1
Contact Pressure at Time = -4.000000E-001, Range=[0.000000E+000,2.008247E+005]. Each Div.=1.000000E+005
Figure 9.27: The grid pressure histogram generated by the GRIDPRHIST menu for DSPROF=
0.0015 (correct contact grid).
9.11 The SEPBEFHIST command 133
menu.
Tooth 20 Tooth 1 Tooth 2
Pre- and Post-processing
Figure 9.29: The histogram of grid separation before contact, generated by the SEPBEFHIST
9.12 The SEPAFTHIST command 135
menu.
Tooth 20 Tooth 1 Tooth 2
Figure 9.31: The histogram of grid separation after contact, generated by the SEPAFTHIST
Pre- and Post-processing
9.13 The SEARCHSTRESS command 137
100000.000000
90000.000000
80000.000000
70000.000000
60000.000000
9.13 The SEARCHSTRESS command
50000.000000
40000.000000
30000.000000
20000.000000
10000.000000
0.000000
Figure 9.33: The graph of root stress vs. time, generated by the SEARCHSTRESS menu.
Time
139
s1=5.146283E+004, tth=20, time=-4.000000E-001, s=9.920000E+000, t=-2.400000E-001, dpth=5.000000E
s1=9.591633E+004, tth=1, time=3.000000E-001, s=9.920000E+000, t=-1.200000E-001, dpth=5.000000E-0
Max Ppl normal stress (s1) on PINION at FILLET1
140
100000.000000
90000.000000
80000.000000
70000.000000
60000.000000
50000.000000
40000.000000
30000.000000
20000.000000
10000.000000
0.000000
0.000000 2.000000 4.000000 6.000000 8.000000 10.000000 12.000000 14.000000 16.000000 18.000000
s_Prof
Figure 9.34: The graph of root stress vs. profile, generated by the SEARCHSTRESS menu.
Pre- and Post-processing
s1=5.146283E+004, tth=20, time=-4.000000E-001, s=9.920000E+000, t=-2.400000E-001, dpth=5.000000E
s1=9.591633E+004, tth=1, time=3.000000E-001, s=9.920000E+000, t=-1.200000E-001, dpth=5.000000E-0
Max Ppl normal stress (s1) on PINION at FILLET1
s1=5.128844E+004, tth=2, time=6.000000E-001, s=9.920000E+000, t=0.000000E+000, dpth=5.000000E-00
100000.000000
90000.000000
80000.000000
70000.000000
60000.000000
9.13 The SEARCHSTRESS command
50000.000000
40000.000000
30000.000000
20000.000000
10000.000000
0.000000
Figure 9.35: The graph of root stress vs. face, generated by the SEARCHSTRESS menu.
t_Face
141
142 Pre- and Post-processing
100000.000000
80000.000000
60000.000000
9.14 The POINTSTRESS command
40000.000000
20000.000000
0.000000
-20000.000000
Figure 9.37: The graph of root stress vs. face, generated by the POINTSTRESS menu.
Time
143
144 Pre- and Post-processing
Contact Pressure
4.200E+005
3.150E+005
2.100E+005
1.575E+005
R
1.050E+005
7.875E+004
5.250E+004
Z 2.625E+004
Time=-0.4
Body no.2:PINIONSHAFT (Origin at:[0,-1,0])
==================================================================
Contact forces:
Exerted by:PINION
Total :f [-974.3496506,-360.2120942,-1.704639161e-012],
mo[310.218819,-837.6780654,1000]
m [310.218819,-837.6780654,25.65034942]
Total contact force=f [-974.3496506,-360.2120942,-1.704639161e-012]
mo[310.218819,-837.6780654,1000]
m [310.218819,-837.6780654,25.65034942]
Bearing forces:
Total bearing force=f [0,0,0],
mo[0,0,0]
m [0,0,0]
The forces (and moments) are broken down into contact forces, bearing forces, internal forces,
mass and damping forces and reaction forces. The reaction forces are the forces exerted by the
reference frame constraints.
Two values for the moments are displayed. In the above example, mo refers to the moments
computed about the origin of the pinion shaft body. m stands for the moment computed about
the origin of the fixed reference frame. The moments about the fixed reference frame are more
useful in comparing the action and reaction acting on different bodies.
Regardless of the origin about which the moments are computed, the X Y and Z components
of each force and moment always refer to the fixed reference frame.
9.16 The AUDIT command 147
-0.030700
-0.030800
-0.030900
9.18 The BODYREACTION command
-0.031000
-0.031100
Time
149
150 Pre- and Post-processing
4007.000000
4006.000000
4005.000000
4004.000000
9.18 The BODYREACTION command
4003.000000
4002.000000
4001.000000
4000.000000
Time
151
152 Pre- and Post-processing
0.010030
0.010020
9.20 The BRGREACTION command
0.010010
0.010000
Time
153
154 Pre- and Post-processing
1003.000000
1002.000000
9.20 The BRGREACTION command
1001.000000
1000.000000
Time
155
156 Pre- and Post-processing
Chapter 10
IglassViewer is a very powerful tool for pre and postprocessing gear models and results. Sev-
eral features have been added to the Multyx program so as to enhance the compatability with
IglassViewer. Thus it can be considered as a program which enables the user to view pre and
postprocessing files generated by an external code. Note that the IglassViewer graphics window
is independent of the guide graphics window. The advantage of using IglassViewer over guide
program for pre and postprocessing is that it is more faster, efficient and more simple to operate.
Also, you can visualise the models in their dynamic mode which is not possible using the Guide
program. Following sections gives a detailed explanation of the procedure for creating the pre
and postprocessing iglass files and also the various functions associated with the iglass program.
Button Purpose
Zoom In
Zoom Out
Move the model upwards (If Spin
is turned OFF)
Move the model downwards (If
Spin is turned OFF)
Move the model towards right (If
Spin is turned OFF)
Move the model towards left (If
Spin is turned OFF)
Rotate the model upwards (If
Spin is turned ON)
Rotate the model downwards (If
Spin is turned ON)
Rotate the model towards right
(If Spin is turned ON)
Rotate the model towards left (If
Spin is turned ON)
Rotate the model clockwise (If
Spin is turned ON)
Rotate the model counterclock-
wise (If Spin is turned ON)
View the model in an isometric
view
View the model in the Y − Z
plane
View the model in the X − Z
plane
View the model in the X − Y
plane
162 Pre and Post processing using IglassViewer
Figure 10.10: The generate iglass file menu for post processing.
Figure 10.19: Finite element mesh so as to find the stress at a nodal point
168 Pre and Post processing using IglassViewer
The colors for minimum and maximum stress contours can be controlled using the palette
mode menu shown in Figure 10.18. A POSITIVE mode will align the scale from 0 (minimum
stress) to a maximum positive value (maximum stress). A NEGATIVE mode will align the
scale from 0 to a negative value. The BOTH type mode will align the scale from the maximum
negative value (minimum stress) to a maximum positive value (maximum stress). So as to find
the stress at a node, double click on the gear body. The finite element nodes are now visible as
shown in figure 10.19. Clicking once on the node will show the stress at that nodal point in the
‘pick’ item of the Palette menu.
Double clicking on the ‘Background’ button will popup the ‘Color’ window shown in Fig-
ure 10.20 using which you can change the background color of the iglass graphics window.
The Contact pattern menu shown in Figure 10.21 is used to view the contact pressure pattern
on the contacting surfaces. Figure 10.22 shows an example of a contact pattern on the gear tooth.
The EXIT button will take you out of the iglass post processing window.
10.5 Features specific to iglass post processing 169
The finite element meshes in the Helical3D package are created with very little input from the
user. The user does not need to provide any of the node numbering and element connectivity
information to the model generator. This information is read by the program from pre-existing
files called ‘template’ files.
Figures A.1 through A.4 show the element connectivity and element numbering scheme used
in the four standard templates. The orientation of the element coordinate system is indicated
by the notch in one of the corners of each element. The range of the surface profile coordinate
s for the two contact surfaces is also shown. The ζ direction is pointing outside the page.
The element orientation for the rim sector is shown in Figure A.5.
172 Tooth Mesh Templates
[1] Planetary Gear Train Ring Gear and Support Structure Investigation, Mark Valco, Ph.D.
Dissertation, Cleveland State University, 1992.
[2] Gear Tooth Stress Measurements of Two Helicopter Planetary Stages, Krantz, T. L., NASA
Technical Memorandum 105651, AVSCOM Technical Report 91-C-038, 1992.
[3] A combined surface integral and finite element solution for a three-dimensional contact
problem, S. Vijayakar, International Journal for Numerical Methods in Engineering, vol.31,
pp. 525-545, 1991.
[4] Nonlinear and dynamic programming, G. Hadley, Addison Wesley Publishing company,
1964.
[6] Linear and Combinatorial Programming, Katta G. Murty, John Wiley, 1976 ISBN: 0-471-
57370-1.
[8] Natural Frequency Spectra and Vibration Modes of Planetary Gears, Jian Lin and Robert
Parker, 1998 ASME Design Engineering Technical Conference, September 1998, Atlanta
Georgia.
[10] Gear Dynamics Experiments, Part II: Effect of Involute Contact Ratio, Blankenship and
Kahraman, ASME 7th International Power Transmissions and Gearing Conference, San
Diego, October 1996.
[11] Gear Dynamics Experiments, Part III: Effect of Involute Tip Relief, Blankenship and Kahra-
man, ASME 7th International Power Transmissions and Gearing Conference, San Diego,
October 1996.
[12] The use of boundary elements for the determination of the geometry factor, Vijayakar and
Houser, 1986 AGMA Fall Technical Meeting, Paper no. 86-FTM-10.
[13] Finite element analysis of quasi-prismatic structures, S. Vijayakar, H. Busby and D. Houser,
International Journal for Numerical Methods in Engineering, vol. 24, pp. 1461-1477, 1987.
[14] Edge effects in gear tooth contact, S. Vijayakar, ASME 7th International Power Transmis-
sions and Gearing Conference, San Diego, October 1996.
178 BIBLIOGRAPHY