GEAR DESIGN SOLUTIONS

Release 5.1 2014

Dontyne Offices HQ,

Newcastle, England

Gearbox system model

Gear Design
Analysis AND Optimization
Software Tools
Training AND Support

The lead times and accuracy

made possible by the introduction
of the Optimal calculation would
simply not have been possible
without the software.
Gaudlitz GmbH

The gear metrology expertise

from Dontyne and the applications
experience of Renishaw was an
ideal combination to produce
software that offers a high level
of functionality and exploits
the benefits of Renishaws coordinate measuring machine
(CMM) scanning systems.

Dontynes software brought us a

huge improvement in productivity:
reducing hours of work to seconds.
The visual representations make
the software very intuitive to use
and understand, and the results
are quite accurate. The endeavour
was so successful that more
collaboration is inevitable.

Renishaw plc

Eaton Corporation

For a list of references and technical papers associated

with Dontyne Systems products and personnel refer to
our website www.dontynesystems.com

WHATS NEW
UK Technology Industry Reception Given By The Queen
and The Duke of Edinburgh At Buckingham Palace - June 9, 2014
Dontyne Systems and
several other North East
entrepreneurs were invited to
a special reception in honour
of the UK Technology Industry
given by Her Majesty the
Queen and His Royal Highness
the Duke of Edinburgh at
Buckingham Palace.

New Office Space for Growing Workforce

Dontyne Systems continues to
expand its customer base across
the world and has secured contracts
for development of customer
specific software as well as for the
Gear Production Suite program.
This expansion necessitates a move
to larger office space. Dontyne has
secured an outstanding facility with
views over the quayside, providing

an ideal environment to host

Software Engineers, Transmission
Designers, and Technical Sales
personnel. The increased personnel
will dramatically improve our
development speed and support.
The office also provides a suitable
venue for customer specific training
for groups of 4-8.

GEarbox
Designer
Gearbox Concept tool
Drag and drop concept level layout of
gearbox system for rapid development of
transmissions to determine speed, torque,
clutching, and power to analyse efficiency
with live test for valid connections.
This is a specialist module to help in the
very earliest stages of gear box design.
It allows a transmission layout to be
constructed in several minutes, with no
need to create a spreadsheet specific
arrangement. A system model can then
be constructed from the concept layout.

8 Speed Lepelletier Automatic

Static Deflection Model

3D graphical interface

This tool can create a gear box layout and

uses a fully coupled matrix to determine
the deformation through the gear, shaft,
bearing and housing. It is possible to import
a stiffness matrix from 3rd party software.
Controls exist to indicate power through the
system and emphasise The Advanced level
of the tool links directly to detailed design
and analysis tools within the Suite.

Gearbox view of motor sport transmission

Gearbox contains spur and spiral bevel gears

Standard Features include :-

Spur, Helical and Bevel gears

Shaft Assembly
Designer

Shaft Deflections

The shaft sections,

gear positions and
supports are input

Misalignments in Line of Action

Forces
Shaft Stresses
Fully Coupled Housing Stiffness
Matrix
3D Gearbox Graphics
Deflected Plots
Concept or Detailed Gears

Power flow plot

Shaft calculations for gear misalignment

Gear design PRO

Spur aNd Helical
Design

Features include :Involute internal and external spur

and helical gear geometry
ISO 6336 rating (inc. 2008
updates)
AGMA 2001 D 04 rating
Tolerances to ISO 1328
Tolerances to AGMA 2015
Standardized tooth proportions
or calculate for maximum contact
ratio
Plots of gears in 2D and 3D
DXF output of transverse tooth
profile
Co-ordinates output of tooth
profile
Measurement over balls and
chordal span including contact
height
Metric or Imperial(English) units
Gear sizing
Flash temperature calculations
Graphical plot of specific sliding
Plot of theoretical path of contact
Material database (user defined)
SN fatigue curve plots
Comprehensive micro-pitting
model originally developed by
Dave Barnett based on results of a
British Gear Association research
program.

Rating

Inspection

Experimentally validated model of micro pitting

The wear due to progressive mircopitting can be viewed in

3D at any stage.

PLANETARY
Features include :Involute spur and helical gear
geometry
Assembly check for equal spacing
Single or double planet
arrangement
Interference checks for outer
diameters
Speed and torque of all
components
ISO 6336 rating (inc. 2008
updates)
Tolerances to ISO 1328
Cumulative damage and safety factor
Standardized tooth proportions or
calculate for maximum contact
ratio
Plots of gears in 2D and 3D
DXF output of transverse tooth
profile
Co-ordinates output of tooth
profile
Measurement over balls and
chordal pan including contact
height
Metric or Imperial(English) units
Material database (user defined)
Phasing calculation

Single Stage Layout

Gear design PRO

ISO/AGMA 23509-A08 BEVEL

Generic BEVEL

Straight Bevel

Spiral Bevel

Zerol Bevel

The Generic bevel gear

Generic bevel refers to the fact that the geometry is not specific to a machine process but is the true theoretical form of the gear
with full line conjugation between components without any virtual back plane approximations. The spiral types can be defined as
straight, logarithmic (equal angle), circular, or involute.
In addition, typical modifications such as profile crowning, face crowning, and slope can be applied to modify the load bearing
pattern shape and position. If there is a requirement for small batch then these forms can be produced on modern 5-Axis CNC
milling machines. Face milling or face hobbing gear generating machines are not required.

Generic BEVEL ANALYSIS

Features include :Straight bevel

3 spiral types
Micro modifications
Conjugation check
90 or non-90 degree design

Define Conjugate Surface

Contact
lines shown

Apply Micro-Geometry

Create a small
interference

Export Surface to machine centre

and inspection equipment
DXF 3D line grid
IGES Bspline surface
ASCII X,Y,Z Co-ordinates

connections
Splines
Produce spline designs to ISO 4156,
DIN 5480 and ANSI B92.1 1970 with an
ANSI rating system. The side, inner and
outer variants are considered. The root
rounding can be arbitrarily adjusted to user
preference. All profiles can be exported as
DXF to wire erosion machines.

Features include :ISO 4156 Splines

DIN 5480 Splines
ANSI B92.1 1970 Splines
Calculation of load distribution in
the bearing
Consideration of centrifugal forces
for high speed ball bearings
Subsurface stresses for large
bearings with surface hardening
Calculation for bearing sets like
multiple angular contact bearings
Load spectra
Extension of contact ellipsis and
contact angle under load
Calculation with elastic outer ring
for track rollers
Full integration of bearing analysis
including non-linear bearing
stiffness in shaft tool
Calculation of natural frequencies
with gyroscopic effect
Combined calculation of multiple
coupled coaxial shafts
Axial and shear deformations are
taken into account

Variable tooth forms including

helical thread

Rolling Bearing
Calculation Software

Rolling bearing calculation

according ISO/TS 16281
The bearing life calculation
according ISO/TS 16281 (2008) is
the latest standardized version of a
bearing life calculation. The bearing
life is calculated using the load
distribution on each rolling element
and is therefore not limited to an
external force but can also consider
tilting moments and the influence of
clearance or pretension. For each of
the five degrees of freedom either a
load or a displacement/rotation can
be specified.

As in the calculation according ISO

281 (2007) the influence of the
lubricant can be considered. Either
the ratio or the specific film thickness
can be used. The life with and without
consideration of the lubricant will be
provided as a result.
MESYS Shaft Calculation
The shaft calculation allows the
calculation of displacements,
forces and strength according to
DIN 743 and bearing life for several
connected coaxial shafts. The

MESYS Rolling Bearing Calculation

according ISO/TS 16281 is included
in the software and the nonlinear
stiffness of rolling bearings in
considered.
Because of the nonlinear bearing
stiffness shafts with more than two
bearings can be calculated with
accurate bearing forces as result.
Pretension of bearings can be
considered. Combinations of angular
contact bearings can be easily
considered as bearing set:

LOAD ANALYSIS MODEL

The load analysis program calculates
the deformation of gear tooth
components and their consequences
on properties such as stress and
transmission error (accuracy
of ratio) under load. Versatile
graphics and reporting features
offer a quick interpretation of the
resulting analysis and formatting

for customer reports. Links to

metrology and manufacturing
equipment enable evaluation of
existing gear components as well
as newly designed components.
The Advanced level of this module
incorporates the FE calculation
GATES originally developed and
experimentally validated at The

GATES , Gear Analysis for Transmission Error and Stress

Design Unit, Newcastle-Upon-Tyne,

England. Already implemented by
some of the most trusted gear design
and manufacturing institutions in the
UK, the program has been used in the
development of an extensive range
of marine, industrial and automotive
applications.

Specific film thickness calculation and ISO

TR- 15144 micro-pitting method A

Features include :Surface definition, (profile and

flank line modification)
Contact stress
Root bending stress
3D FE model of tooth stiffness
Power loss and efficiency
Surface topological modification
definition
Multiple load cases
Double helical gears
Effect of gear misalignment
Various graphical interfaces
Import of measured gear surface

Gear contact stress

Bearing load pattern

Power loss and efficiency

Micro-geometry definition

Surface modifications defined by :Normal pressure angle change

Linear / parabolic profile
modification
4th degree polynomial
Simulated bias
A user model exported to GPS
format
Measured data compatible to
common manufacturing systems

Surface modification can be applied

to minimise transmissions error (and
hence noise and vibration effects) at
a specific load

Nominal 3D surface modification / 3D surface with simulated or measured bias

ADVANCED LOAD ANALYSIS MODEL

micro geometry optimisation
Up to 20,000 micro geometry variations can be defined for each batch run
Up to 10 increments for
each parameter
Pinion and wheel can
be linked so that steps
change together

Available surface
Modifications

Up to 9 load cases for

each modification
User selects results for optimum modification parameters

Tooth surface stress

Transmission Error (TE)

Non Involute LTCA

Involute

User Defined

Loaded Tooth Contact

Analysis for user defined
tooth profiles for Spur
and Helical gears. Profiles
can be imported from user
data files or embedded
geometry routine under
licence (e.g. Convoloid
overlear). Other modules
can define tooling for
machining and inspection to
create a control system for
production.

Bevel Gear LTCA

Loaded Tooth Contact
Analysis for bevel gears
showing marking pattern
stress concentrations, and
transmission error

Apply crowning to profile

and lead.
Apply bias weighted to
heel or toe.

ADVANCED LOAD ANALYSIS MODEL

Dontyne Systems has completed several

projects to develop customer specific
applications or integrate functionality into the
Gear Production Suite under licence.
One example is an exclusive agreement on
Convoloid gearing from Genesis Partners (US).
Convoloid technology has the potential to
dramatically improve performance in helical
systems, while gear components can be
produced using common machine tools
and production methods.

Improvements in power density Involute/

Convoloid up to 40% for same ratio and
face width (example shown 20%)

Improvement over involute for same ratio

and face width
Reduced stress enables more power
Low tooth numbers and optimized root
forms (no undercut)
Increase life potential
Reduced weight
Reduced centre distance

Carrier Comparison between existing 750KW Gearbox and Convoloid Enhanced Gearbox
Parameter Existing 750KW

Existing 750KW Gearbox

Convoloid Enhanced Gearbox

Planet Speed

34.12 rpm

34.12 rpm

Planet Torque

34.9 kN-M

34.9 kN-m

Bearing Type

Spherical Roller (2)

Cylindrical Roller (4)

Bearing Configuration

Under Planet

Straddle Mount

Bearing Loads

367.2 kN

360.9 kN

Bearing L10 life

129,900 hr

124,900 hr

Planet Carrier Weight

775 kg

646 kg (-16.7%)

Planet/Brg Assembly

225 kg

218 kg (-3.1%)

Ring

503 kg

456 kg (-9.3%)
With projected cost savings at 24,431/MW
Annual Production Projected Total Savings

2,000MW

48,862,000

4,000MW

97,724,000

8,000MW

195,448,000

10,000MW

244,310,000

Based on data from 20% Wind Energy by 2030,

US Department of Energy

Analysis of Involute/Convoloid Parameters

Optimized Involute and Convoloid designs
including tip relief

Analysis shows typical

10-30% reduction in
stress and improved
loading condition.

Improved Convoloid Centre relief

Relief applied to
the transition zone
to improve contact
conditions further.

Centre distance tolerance

+0.075 mm

-0.075 mm

Analysis used to
establish envelope
of operation where
advantage is maintained.

machine centre
TOOL DESIGN
Gear hobbing generated
profile to check tool design

Features include :Tool design

Tool database
Simulation of profile generation
and micro geometry
Analysis of max/min tolerances on
generated profile
Protuberance and short lead
hobbing techniques on profile
Use tool generated profile in
bending stress calculation for
accurate rating

Tool Database

Define new tool

Search and select tool

Machine Simulations

Features include :Calculate resulting gear profile

using existing tooling and machine
settings
Model various machines and
processes (Hob, Grind, Dress,
Shape, Shave, Wire Erosion,
Injection Mould, Forge)
Import/export of co-ordinate files
to machine tools
Improved gear quality
Reduced costs and resources
Shorter lead times
More efficient production
Balancing contact forces
for shaving

Thread grinding

Cavity (Injection Moulding)

Creating 3D models
for formed gears
produced by injection
moulding or forging

Dressing and grinding

Profile error calculated from existing tooling

Inspection
Centre
Co-ordinate Evaluation Direct from Gear Inspection
and CMM Equipment
Features include :Interfacing to gear measuring
machines and co-ordinate
measuring machines
Evaluation of linear errors
Profile/flank/pitch to common
standards (ISO, DIN, AGMA)
2D scan for full form inspection
in root
3D Surface inspection
Simulation of physical
inspection(measurement over
balls, tooth span)
Simulation of contact testing
Statistical analysis of production
Definition of master surface
Diagnostics and optimization of
tool and machining process by
compensation of errors

Standard parameter evaluation

Virtual testing tooth span,

measurement over balls,
transmission error

Advanced Analysis Functions

Statistical evaluation of multiple

measurements and creating a
master surface

Simulating dynamic tests such as

contact marking with virtual master
or other measured component

The Gear Production Suite can

interface to a variety of measuring
devices for a range of geared
tooth components. The adjacent
picture shows an Equator using 3D
models from Dontyne Systems Gear
Production Suite demonstrating
the comparison of:
Bevel gears
Internal spline
10 tooth Convoloid gear

OPTIMAL
Each module is a powerful tool in its own right and can be individually licensed, but there is additional benefit to
utilising all modules together. Data gathered at the machining and inspection stage can be compared to the design
specification and the contact models by networking in-house or even via Internet using the Gear Production
Suite as a process control platform. The data can be used for many purposes other than direct design such as
correct tooling or machining errors (see opposite). The software can be used to optimise both product quality and
performance giving direct return on investment.

GEAR PRODUCTION SUITE

(Key)
Gear Design Pro
Design and rate gear
components using common
standards
Load Analysis Model
Simulate operating
characteristics of gear pairs
Inspection Centre
Define component quality and
simulate testing procedure
Machine Centre
Calculation of component form
based on machine and tool
settings
Optimal
Calculate optimum machine
and tool settings

Tool corrected by mapping error to previous tool surface for higher accuracy tool in a 2D plain
Old tool
New tool
surface

Error vectors
mapping theoretical
and measured
surface

Before Calculation

After Calculation

The theoretical surface (black) and tool

surface (blue) can be designed in Gear
Production Suite or imported from
CAD, measured data imported from
measuring equipment

The error between theoretical and

measured surface is mapped by a
vector (green) and used to create
modified tool surface

The calculation can be applied to multiple layers or a complete surface model for corrections to a 3D volume

Distorted gear due to shrinkage

Invert errors on mould

Improved quality gear

Gearbox system model

Gear Design
Analysis AND Optimization
Software Tools
Training AND Support

www.dontynesystems.com
UK
Email : [email protected]
Telephone : +44 191 206 4021
Dontyne Systems Limited is a company registered in England and Wales with company
number 05973058
Registered office: rotterdam house, 116 quayside, newcastle upon tyne NE1 3dy
VAT Registration Number: 902 9027 45