KISSsoft 2023 – Tutorial 8

Calculation of a cylindrical gear pair

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Contents

1 Task ....................................................................................................................................... 3
1.1 Input data................................................................................................................................................. 3
1.1.1 Power data .......................................................................................................................................... 3
1.1.2 Geometry ............................................................................................................................................. 3
1.1.3 Reference profile ................................................................................................................................. 3
1.1.4 Additional data..................................................................................................................................... 3

2 Solution .................................................................................................................................. 5
2.1 Starting the software................................................................................................................................ 5
2.2 Selecting a calculation ............................................................................................................................. 5
2.3 Gear Pair Geometry ................................................................................................................................ 6
2.4 Defining the power data and calculation method..................................................................................... 7
2.5 Material and lubrication ........................................................................................................................... 9
2.6 Reference profile ..................................................................................................................................... 9
2.7 Tolerances ............................................................................................................................................. 10
2.8 Lubrication ............................................................................................................................................. 11
2.9 Calculate................................................................................................................................................ 11
2.10 Report .................................................................................................................................................... 12

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1 Task
This tutorial explains how to input data you already know for cylindrical gear pairs in KISSsoft.
You must perform the following steps:

▪ Input the necessary data in KISSsoft

▪ Calculate it according to ISO 6336
▪ Document the results

1.1 Input data

The data below are to input in KISSsoft while the explanation for entering the data is described from section 2 in this
tutorial:

1.1.1 Power data

Power [P] 3.5 kW
Speed [n] at drive 2500 1/min (Gear1 driving)
Application factor [KA] 1.35
Service life [H] 750 h

1.1.2 Geometry
Normal module [mn] 1.5 mm
Helix angle at reference circle [ß] 25 °
Hand of helix of Gear 1 Right hand
Pressure angle at normal section [n] 20 °
Number of teeth [z] Gear1/Gear2 16 / 43
Face width [b] Gear1/Gear2 14 / 14.5 mm
Center distance [a] 48.9 ±0.03 mm
Profile shift coefficient [x] Gear 1 (pinion) 0.3215

1.1.3 Reference profile

Dedendum coefficient [h*FP] Root radius coefficient [*fP] Addendum coefficient [h*aP]
Gear 1 (pinion) 1.25 0.3 1.0
Gear 2 1.25 0.3 1.0

1.1.4 Additional data

Material:

Material Hardness data Flim Hlim

2
Gear 1 (pinion) 15 CrNi 6 case-hardened HRC 60 430 N/mm 1500 N/mm2
Gear 2 15 CrNi 6 case-hardened HRC 60 430 N/mm2 1500 N/mm2

Lubrication:

Grease lubrication Microlube GB 00 80 °C

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Base tangent length allowances:

No. of teeth spanned [k] Max. base tangent length [Wkmax] Min. base tangent length [Wkmin]
Gear 1 (pinion) 3 11.782 mm 11.758 mm
Gear 2 6 25.214 mm 25.183 mm

Quality [Q] (ISO 1328:2013) 8/8

Tooth trace modification End relief
Contact pattern not verified or inappropriate
Type of pinion shaft

Load case for the pinion shaft

ISO 6336 Figure 13a; l = 53 mm; s = 5.9 mm; dsh = 14 mm

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

Figure 1. Starting KISSsoft, initial window

2.2 Selecting a calculation

In the Modules tree window, select the «Modules» tab to call the calculation for cylindrical gear pairs:

Figure 2. Calling the cylindrical gear calculation

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The KISSsoft input window then opens:

Figure 3. KISSsoft Cylindrical gear calculation input window

The following sections describe how to input parameters for the gear pair.

2.3 Gear Pair Geometry

Input the normal module (1.5 mm), pressure angle (20°), helix angle (25°), center distance (48.9 mm), number of teeth
(16/43), facewidths (14/14.5 mm), profile shift coefficient (0.3215/...) and the quality (8/8) in the input window in the
«Basic data» tab; «Geometry» group. You cannot input a value for the profile shift of gear 2 directly because this value
is calculated from the center distance and profile shift of the first gear. You can click the Sizing button to size the
value to match your requirements.

The quality can be set to match the standard for the calculation method for strength.

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 Figure 4. Quality settings, Quality does not depend on the calculation method.

General hints

A click on the Convert button behind the input fields allows the conversion based on other data to the respective
values.

With the sizing button , input values can be inserted automatically.

The settings button allows additional settings related with the input field.

If an angle input is required, a right click in the input field opens another window, which allows the input of angle,
minute and second.

2.4 Defining the power data and calculation method

Now, go to the «Rating» tab, group «Strength» and input the kinematics, the required service life (750 h). In this
example, the torque is defined by inputting the power (3.5 kW) and speed (2500 1/min). However, in a different
example, if you want to input the torque and calculate the power, simply set the radio button to the right of the input
field from torque to power.

You must also set the reference gear correctly (first gear - gear 1) for the load.
Set the “Factors, root, flank” to ISO 6336:2019 from the group “Calculation method”.

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 Figure 5. Input window – « Strength» tab

In the input window in the «Factors» tab, group “Face load factor”, you can input the application factor and the face
load factor. The face load factor can be defined directly (by the drop-down list “Own Input”) or by clicking the plus
button next to the input field.

You must select the “Position of contact pattern” to “not verified or inappropriate”, and the "Flank line modification” to
“End relief”.

Figure 6. Define the face load factor

The possible shaft configurations are displayed by clicking on the Info button next to the "Type of pinion shaft" field.
The present case corresponds to Fig. 13A. The distances l and s can be entered in the "Define face load factor"
window (Figure 6).

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 Figure 7. Define face load factor

Note:
You need the shaft configuration to calculate face load factor KHß. ISO 6336 (or DIN 3990) provides 5 different
configurations from which you can select the one you require. These examples are listed A to E in the figure at the top,
on the right.

2.5 Material and lubrication

In the «Basic data» tab, «Material and lubrication» group input window you select the gear materials from a drop-down
list. 15 Cr Ni 6, case-carburized steel is used in this example.

You can also select the lubrication as well as the lubrication type. Click the Plus button to define the lubricant
temperature.

Figure 8. Input window – «Basic data» tab, «Material and Lubrication» group

2.6 Reference profile

In the «Reference profile» tab you can now input further data, such as the reference profile, the dedendum coefficient,
the root radius factor and the addendum coefficient for Gear 1 and Gear 2.

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 Figure 9. Input window – «Reference profile» tab

2.7 Tolerances
You can input the center distance tolerances either by selecting them from the drop-down list or by inputting your own
values as shown in the example.

You can also define the tooth thickness allowances in the «Tolerances» tab. It is often the case that only the
tolerances of base tangent length and the number of teeth spanned are specified. If you input these values, the
KISSsoft system will then calculate the correct tooth thickness tolerances for the tooth form.

To enter the base tangent lengths, click the «Tolerances» tab, «Allowances» group, and then click the Convert button
next to the tooth thickness allowance input window.

Figure 10. Input window – «Tolerances» tab

You can now input the number of teeth spanned and the base tangent length (min/max). Then click Calculate. Then
click «Accept» to transfer the values to the main screen.

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Attention: You cannot input a deviation until profile shifts have been specified for both gears. Otherwise you will receive
incorrect values and you must repeat the sizing process.

Note: You can change the number of teeth spanned between steps 2 and 3. To do this, set the flag in the checkbox
next to the «Number of teeth spanned» field in the input window in the «Allowances» group in the «Tolerances» tab
and then change the Number of teeth spanned either in the «Allowances» group or in the calculation screen.

Figure 11. Input window «Tolerances» tab, «Allowances» group

2.8 Lubrication
The input window in the «Material and lubrication» group in the «Basic data» tab accepts the input value for lubricant
temperature for the various types of lubricant. You can select other lubrication types and grease types in the
corresponding dropdown list.

The «Lubricant temperature» input field for oil or grease lubrication defines the basic temperature of the gear body.
Note that the «Lubricant temperature» is important for calculating the effective lubricant viscosity.

The «Ambient temperature» field only defines the base temperature for dry run. In this case, the temperature of the
gear body does influence the calculation.

Exceptions:
▪ Worm gears: the «Ambient temperature» is an input value used to calculate the temperature safety factor.
▪ Plastic gears: as the strength values of plastic gears depend greatly on the temperature of the gear body, you
must input the corresponding temperatures here.

Figure 12. Inputting the temperature for a dry run

2.9 Calculate

Click in the tool bar or press «F5» to calculate the strength. An information about a high KHβ value appears due to
the contact pattern assumed to be unfavorable.

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 Figure 13. Information window after «Calculation»

This means that the value of KHß may be unreasonably high. When you test the contact pattern in the workshop, you
can see whether this assumption was conservative or realistic.

If you have worked through this tutorial correctly, the safety factors should match with Figure 14 (Note that there might
be a difference according to the possible change of the calculation):

Figure 14. Result of the example

2.10 Report

By clicking on the button or alternatively by using the keyboard shortcut [F6], the (main) calculation protocol with
all inputs and results can be opened:

Figure 15. Main report

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