smt masta training manual - 캐드앤그래픽스 of masta.pdf · gear iso6336 safety factors input...

©SMT 2006

Slide 1

MASTA

MASTA

Th

e M

ost

Po

werf

ul S

oft

ware

fo

r T

he M

ost

Po

werf

ul S

oft

ware

fo

r

Tra

nsm

issio

n

Tra

nsm

issio

n

Desig

n/D

evelo

pm

en

t/M

an

ufa

ctu

rin

gD

esig

n/D

evelo

pm

en

t/M

an

ufa

ctu

rin

g

©SMT 2006

Slide 2Mission of MASTA System

Mission of MASTA System

Mission of MASTA System

1.1.able to identify and fix Design W

eakness as

able to identify and fix Design W

eakness as

early as possible

early as possible

2.2.able to reduce Development Tests as much

able to reduce Development Tests as much

as possible

as possible

3.3.able to identify design inherited

able to identify design inherited

Manufacturing Problems at design stage

Manufacturing Problems at design stage

4.4.able to fix Production Problems quickly

able to fix Production Problems quickly

5.5.easy to use and no need for full time user

easy to use and no need for full time user

Maximise Perform

ance at Minimum Cost & Time

©SMT 2006

Slide 3

Versions

Versions

Versions

��Automotive Version:

Automotive Version:

��Complete System from Drive Line Compatibility to Gear

Complete System from Drive Line Compatibility to Gear

Manufacturing

Manufacturing

��From Passenger Car application to Heavy Duty

From Passenger Car application to Heavy Duty

Application

Application

��Aerospace Version

Aerospace Version

��From Design to Gear Manufacturing

From Design to Gear Manufacturing

��Industrial Version

Industrial Version

��From High Speed Application to Low Speed Application

From High Speed Application to Low Speed Application

��Design for Ultra

Design for Ultra-- low Noise Application

low Noise Application

©SMT 2006

Slide 4

DLC M

odule

(Drive Line Compatibility)

Use existing transmission & axle due

to compatibility (Automotive version only)

Decide gear ratios to meet VP, cost &

fuel consumption (Automotive version only)

MASTA

MASTA

Modules of MASTA

Modules of MASTA

Modules of MASTA

VPS M

odule

(Vehicle Perform

ance Sim

ulation)

Design &

Analysis Modules

Modify existing transmission & axle

to achieve compatibility

Design new transmission & axle to

maximise the perform

ance at

minimum cost and time

NVH Modules

Gear Manufacturing

Modules

FMA ---Failure Mode Analysis for

major components

Achieve good gear quality at low

cost

©SMT 2006

Slide 5

Technologies of MASTA



System Technology

System Technology

��Complete System Static Analysis (Non

Complete System Static Analysis (Non-- Liner)

Liner)

��System Dynamics

System Dynamics

Component Technology

Component Technology

��Leading gear technology

Leading gear technology

��Advanced shaft technology

Advanced shaft technology

��FEA based casing technology

FEA based casing technology

��Latest bearing technology

Latest bearing technology

Unique Gear Manufacturing Technology

Unique Gear Manufacturing Technology

��For

For Hobbing

Hobbing/Shaping/Shaving process

/Shaping/Shaving process

��For

For Hobbing

Hobbing/Shaping/Grinding process

/Shaping/Grinding process

��For Spiral bevel and Hypoid gear manufacturing

For Spiral bevel and Hypoid gear manufacturing

©SMT 2006

Slide 6

Capability of MASTA

Capability of MASTA

Capability of MASTA

1.1.

Vehicle Perform

ance Simulation & Drive Line

Vehicle Perform

ance Simulation & Drive Line

Compatibility Check (for Automotive version only)

Compatibility Check (for Automotive version only)

2.2.

Transmission Design

Transmission Design

3.3.

Transmission Analysis and Optimisation

Transmission Analysis and Optimisation

4.4.

Gear Design for Manufacturing

Gear Design for Manufacturing

5.5.

Hobbing

Hobbing, Shaping, Shaving Cutter and Grinding Wheel

, Shaping, Shaving Cutter and Grinding Wheel

Design for Cylindrical Gears

Design for Cylindrical Gears

6.6.

Cutter Design and Machine Setting for Bevel/Hypoid

Cutter Design and Machine Setting for Bevel/Hypoid

Gears

Gears

7.7.

Simulation for Gear

Simulation for Gear Manufactruing

ManufactruingProcess

Process

Hobbing

Hobbing/Shaping/Shaving and

/Shaping/Shaving and

Hobbing

Hobbing/Shaping/Grinding Process

/Shaping/Grinding Process

©SMT 2006

Slide 7

VPS & DLC

VPS & DLC

VPS & DLC

©SMT 2006

Slide 8

ECE R 101 - urban and extra urban cycles

0

20

40

60

80

100

120

140

0200

400

600

800

1000

1200

Tim

e (s)

Speed (km/h)

engine

clutch

gearbox

final drive

fuel economy

vehicle

drive cycle

drive cycle

%

gradient

Predicted Acceleration From Rest

0

25

50

75

100

125

150

010

20

Tim

e (s)

Vehicle Speed (km/h)

Gearbox A

Gearbox B

Gearbox C

vehicle acceleration

vehicle acceleration

wheel

Model Structure

Model Structure

Model Structure

©SMT 2006

Slide 9

Inputs

Inputs

Inputs

��Evaluation of different options

Evaluation of different options

Driveline Ratios

0

2468

10

12

14

16

1st

2nd

3rd

4th

5th

Driveline Ratio

Gearbox A

Gearbox B

Gearbox C

©SMT 2006

Slide 10

Traction Diagram

Traction Diagram

Traction Diagram

Case Study Engine (2 litre) Curves

0

20

40

60

80

100

120

140

160

180

200

01000

2000

3000

4000

5000

6000

7000

Engine Speed (rpm)

Torque (Nm)

010

20

30

40

50

60

70

80

90

100

Power (kW)

Torque

PowerVehicle tractive effort and resistance

02468

10

050

100

150

200


Tractive Force (kN)

1st

2nd

3rd

4th

5th

Grade (0%)

Grade (5%)

Grade (10%)

Grade (15%)

Grade (20%)

Grade (25%)

Outputs

Outputs

Outputs

©SMT 2006

Slide 11

��Option C excluded as top speed too low

Option C excluded as top speed too low

Predicted Acceleration From Rest

0

25

50

75

100

125

150

175

010

20

30

40

50

60

Tim

e (s)


Gearbox A

Gearbox B

Gearbox C

Outputs

Outputs

Outputs

©SMT 2006

Slide 12

Drive Cycle Simulation



Outputs

Outputs

Outputs

©SMT 2006

Slide 13

Engine Map

Engine Map

Engine Map

Outputs

Outputs

Outputs

©SMT 2006

Slide 14

Fuel Economy

Fuel Economy

Fuel Economy

Fuel Economy over ECE R 101 Urban Drive Cycle

05

10

15

20

25

30

Land Rover, Discovery, (4.0)

Mazda M

PV (3.0)

Jaguar XJ6 (3.0)

Toyota Camry (2.4)

Ford Focus (1.6)

Peugeot 206 (1.6)

Peugeot 206 (1.4)

Ford Fiesta (1.4)

Toyota Prius (hy.)

Honda Insight (hy.)

Fuel Economy (km/litre)

Outputs

Outputs

Outputs

©SMT 2006

Slide 15

Acceleration

Acceleration

Acceleration

Acceleration & Elasticity Performances

02468

10

12

14

0-50

0-100

80-120,

5th

60-100,

5th

60-100,

4th

50-80, 4th

50-80,

3rd

Speeds km/h

Time (s)

Gearbox A

Gearbox B

Outputs

Outputs

Outputs

©SMT 2006

Slide 16

Model for AMT shift quality

Model for AMT shift quality

Outputs

Outputs

Outputs

©SMT 2006

Slide 17

Shift Simulation

Shift Simulation

Outputs

Outputs

Outputs

©SMT 2006

Slide 18

Transmission Design

Transmission Design

For any Arrangement

For any Arrangement

©SMT 2006

Slide 19

Truck Applications

Truck Applications

Truck Applications

Track Transmission with

Planetary Range Change

©SMT 2006

Slide 20

Truck Application

Truck Application

Truck Application

Track Transmission

with Range Change

©SMT 2006

Slide 21

Passenger Car Applications



Front Drive Transmission

©SMT 2006

Slide 22




Front Drive Transmission

©SMT 2006

Slide 23

Complex Automatic Transmission



©SMT 2006

Slide 24

Aerospace Applications

Aerospace

Aerospace Applications

Applications

Simplified demonstration models, client

confidentiality maintained

©SMT 2006

Slide 25

Track Applications

Track Applications

Track Applications

©SMT 2006

Slide 26

Marine Applications

Marine Applications

Marine Applications

Very wide and big helix angle gear

©SMT 2006

Slide 27

Analysis

Analysis

For any Arrangement

For any Arrangement

©SMT 2006

Slide 28

Analysis based on Actual Duty Cycle



©SMT 2006

Slide 29

�Component Stiffness and Masses

Underlying Analysis Model


•Shafts –classic finite element beam model (or

derived from full FE model for complex 3-D shape,

e.g. to capture gear blank deflection)

•Bearings –stiffness derived from non-linear load-

deflection models (use Herztiancontact theory &

bearing internal geometry, ref T. Harris)

•Gears –mesh stiffness and line of action derived

from gear geometry

•Housing & complex shafts –reduced stiffness and

mass derived from full FE models

©SMT 2006

Slide 30



•Specialised Interface allows rapid

modelling of geared systems

•Component libraries and databases

•Fully integrated analysis & results display

©SMT 2006

Slide 31

�Powerflowanalysis to calculate all component speeds,

powers, torques

�System Finite Element Model created from Design Geometry



�System model retains all degrees of freedom, laterals, axial,

tilt, torsional

©SMT 2006

Slide 32

Validation MASTA vsMSC.NASTRAN

Shaft Deflection

Shaft Deflection

Shaft Deflection

Nominal X Bending Stress

05

10

15

20

25

30

35

050

100

150

200

250

300

Offset (mm)

Bending Stress (MPa)

MASTA X Bending Stress

Nastran |pt2 Bend Stress|

Nastran |pt4 Bend Stress|

Transaxle Input Shaft Deflection (x)

-250

-200

-150

-100

-500

50

100

150

050

100

150

200

250

300

350

Offset (m

m)

Displacement (um)

MSC-N

astran, spring m

odel

MASTA, full m

odel

MSC-N

astran, pinned

MASTA, pinned

©SMT 2006

Slide 33

Shaft Analysis

Shaft Analysis

Shaft Analysis

MASTA Shaft Forces and Fatigue Analysis

MASTA Shaft Forces and Fatigue Analysis

Qualitative Behaviour of Stresses in A Rotating

Shaft

Time

Stress

Bending Stress

Axial + Torsional S

tress

Total S

tress

Qualitative Behaviour of Stresses in A Rotating

Shaft

Tim

e

Stress

Equivalent Fully Reversing Stress

Goodman Diagram

vs Curves

Mean Stress

Alternating Stress

Yield Line (Langer)

Soderberg Line

Goodman Line

Gerber Curve

ASME Elliptic Curve

Bagci Curve

©SMT 2006

Slide 34

Fatigue/Lives/Scoring



•Various rating and lifingmethods

•Bearings, ISO + supplier

•Gears, ISO/AGMA +

experience/references/database

•Shafts, classic beam model fatigue

or use full FE

Gear ISO6336 Safety Factors

Input

Idler i/p

Idler o/p

PTO1

PTO2

Gen.

Pump.

Contact

Bending

Bearing Duty Cycle % Damages

Hyd

. Pum

p Le

ft

Hyd

. Pum

p Rig

ht

Gen

. Lef

t

Gen

. Right

Id

ler L

eft

Idler R

ight

Inpu

t Right

In

put L

eft

Upp

er P

TO1

Left

Upp

er P

TO1

Right

Upp

er P

TO2

Left

Upp

er P

TO2

Right

Description

Symbol

Wheel 2

Pinion

Description

Symbol

Wheel 2

Pinion

Torque (Nm)

T739.9309

265.2582

Speed (rpm)

n4301.8868

12000

Power (kW)

P333.3333

333.3333

Duration (hr)

100

100

Number of Cycles

NL

25811320.75

72000000

Description

Symbol

Wheel 2

Pinion

Percentage Damage

0%

0%

Factor Of Safety For Pitting

SH

1.36

1.26

Calculated Contact Stress (MPa)

σH

1187.5

1207.9

Nominal Contact Stress (MPa)

σH0

Description

Symbol

Wheel 2

Pinion

Percentage Damage

0%

0%

Factor Of Safety For Bending

SF

2.66

2.57

Tooth Root Stress (MPa)

σF

352.2

356.4

Nominal Tooth-Root Stress (MPa)

σF0

188.8

191.1

Bending Durability Results (ISO 6336-3)

Contact Durability Results (ISO 6336-2)

847.2461

Load Conditions & Inputs

Input Gear Train\W

heel to Pinion: ISO 6336 Rating Report

Load Case: Full Power In New Design State

©SMT 2006

Slide 35

�System Deflection

System Static Analysis

System Static Analysis

Calculation:

•Apply Input Torque

•Derived Gear Loads

•Calculate System Deflection

(non-linear force/load balance)

Results:

•Shaft loads and deflection

•Bearing loads,

misalignments & life

•Gear misalignment & life

Static deflection, zero to full load

©SMT 2006

Slide 36

System Deflections

System Deflections

System Deflections

•For lightweight aerospace transmission

it is important to include effects of

housing/support flexibility on internals

Gear Mesh Misalignment, FBetaX

Idler/I

nput

Inpu

t/PTO

1

PTO

1/PT

O2

IdlerO

utpu

t/Gen

. Gen

./Hyd

. Pum

p

Bearing Misalignment (mRad)

Hyd

. Pum

p Le

ft

Hyd

. Pum

p Rig

ht

Gen

. Lef

t

Gen

. Rig

ht

Idle

r Lef

t Id

ler R

ight

Inpu

t Right

In

put L

eft

Upp

er P

TO1

Left

Upp

er P

TO1

Rig

ht

Upp

er P

TO2

Left

Upp

er P

TO2

Rig

ht

•MASTA allows

inclusion of

housing flexibility

via reduced

stiffness imported

from housing FE

model

©SMT 2006

Slide 37

System Dynamics

System Dynamics

System Dynamics

Calculation:

•Static load condition provides

system stiffness

•Add mass to give dynamic model

•Solve multi-shaft system modes (or

single shaft if required)

•Forced excitation

Results:

•Modal Map, Mode shapes, Forced Response to Excitation,

Critical Speed Maps, Campbell Diagrams etc

System Dynamic Mode, full load condition

©SMT 2006

Slide 38

System Dynamics

System Dynamics

System Dynamics

Mode 2: torsionaldriveline

Mode 4: shaft bending mode

Fully Coupled Gearbox Modal Frequencies for

Cruise Condition

0

0.51

1.52

2.53

12

34

56

78

91011121314151617181920

Mode #

Frequency

Fully Coupled Gearbox Model Critical Speed

Map

00.5

11.5

22.5

3

1.0E+06

1.0E+07

1.0E+08

1.0E+09

1.0E+10

1.0E+11

Brg/Support Stiffness

Frequency

Mode1

Mode 2

Mode 3

Mode 4

Mode 5

Mode 6

Mode 7

Mode 8

•MASTA can run full coupled gearbox or

shafts in isolation

•Check excitations from shaft and gear

rotation speeds do not coincide with

modal frequencies

©SMT 2006

Slide 39

Advanced System Deflection



•Example showing use of MASTA

& FE for complex shaft shapes. A

truck planet carrier shaft.

•Complex geometry done in industry

standard CAD tools

©SMT 2006

Slide 40




•Example showing use of MASTA

& FE for complex shaft shapes. A

truck planet carrier shaft.

•Complex FEA done in industry standard

tools, e.g. NASTRAN or ANSYS

©SMT 2006

Slide 41




•MASTA interface to NASTRAN & ANSYSFE

©SMT 2006

Slide 42




•MASTA interface to NASTRAN & ANSYS FE

©SMT 2006

Slide 43

Gear Optimisation for High Perform

ance and Low Cost


ance and Low Cost


ance and Low Cost

©SMT 2006

Slide 44

Very Accurate Gear Rating for Life



Internal dynamic factor: method B & C

Face load factor: Method A & B

Nominal tooth-root stress: Method B & C

All other factors: Method B

©SMT 2006

Slide 45

Gear Rating to Scuffing



©SMT 2006

Slide 47




Transmission Error & Contact Pattern (Predicted)

T.E. for all Load Case

C.P. @ 100% Load

C.P. @ 50% Load

C.P. @ 10% Load

©SMT 2006

Slide 48LTCA for Ultra-low Noise Gear

LTCA for Ultra

LTCA for Ultra-- low Noise Gear

low Noise Gear

High contact ratio: Industrial Gear

High contact ratio: Industrial Gear --set

set

©SMT 2006

Slide 50

Failure Mode Analysis for Major Components



Sort the major components by design lives to guide the investm

en

Sort the major components by design lives to guide the investm

ent of

t of

manufacturing process

manufacturing process

©SMT 2006

Slide 53

HobbingCutter Simulation

Hobbing

HobbingCutter Simulation

Cutter Simulation

Gear rating based on the actual gear fillet

generated by the hobs

©SMT 2006

Slide 55

Shaping/HobbingProcess

Shaping/

Shaping/ Hobbing

HobbingProcess

Process

Rapidly identify root causes and solutions to poor

Shaping/Hobbingquality

Profile

Lead

Pitch

©SMT 2006

Slide 56

Plunge Shaving Dynamics Simulation



To

fin

d o

ut

if t

he

ge

ar

is d

iffi

cu

lt t

o s

ha

ve

an

d a

lso

pro

vid

e

so

luti

on

if

the

re is

dif

fic

ult

y a

t g

ear

de

sig

n s

tag

e

Go

od

dy

na

mic

s:

no

dif

ficu

lty

in

sh

avin

g

©SMT 2006

Slide 57




Ve

ry b

ad

dyn

am

ics

, h

en

ce

very

po

or

sh

av

ing

qu

ality

To

fin

d o

ut

if t

he

ge

ar

is d

iffi

cu

lt t

o s

ha

ve

an

d a

lso

pro

vid

e

so

luti

on

if

the

re is

dif

fic

ult

y a

t g

ear

de

sig

n s

tag

e

©SMT 2006

Slide 58

Shaving cutter micro modification



A p

ow

erf

ul to

ol fo

r g

ea

r m

icro

mo

dif

ica

tio

n a

nd

he

at

tre

atm

en

t

dis

tort

ion

co

mp

en

sati

on

Profile

Lead

©SMT 2006

Slide 59

Spiral/Hypoid Gear Contact pattern



Contact pattern after assembly

Contact pattern in-service

Predict the contact pattern for given machine setting

©SMT 2006

Slide 61

Spiral/Hypoid Pinion Finish Stock Distribution

Spiral/Hypoid Pinion Finish Stock Distribution

Even finish stock distribution makes cutter life longer,

connection between rough/finish fillet smoother, and …

…

©SMT 2006

Slide 62

Heat Treatment Distortion compensation

Heat Treatment Distortion compensation

Pinion flank is designed based on heat treated wheel

©SMT 2006

Slide 63

3D Simulation of Pinion cutting

3D Simulation of Pinion cutting

Connection

between rough

root and finish

filet

Check the gears

before starting any

machining

©SMT 2006

Slide 64

Summary

Summary

Summary

��Maximise/Upgrade the ratio=load/volume of transmission at minimu

Maximise/Upgrade the ratio=load/volume of transmission at minimum

m

cost and time cycle

cost and time cycle

��Improve Gear Contact Pattern and System Response to Improve

Improve Gear Contact Pattern and System Response to Improve

Noise/Vibration

Noise/Vibration

��Optimise Major Component Design to Maximise Life and Perform

ance

Optimise Major Component Design to Maximise Life and Perform

ance

��Minimise Manufacturing Cost

Minimise Manufacturing Cost

��Design gears using existing hobs and Shapers

Design gears using existing hobs and Shapers

��Predict failure modes of the major components at design stage

Predict failure modes of the major components at design stage

��Predict and fix potential gear manufacturing problems at design

Predict and fix potential gear manufacturing problems at design stage

stage

��Optimise gear cutter design at design stage (for cylindrical and

Optimise gear cutter design at design stage (for cylindrical and

bevel/hypoid gears)

bevel/hypoid gears)

��Simulate Manufacturing Process to identify and fix the root cau

Simulate Manufacturing Process to identify and fix the root causes of Gear

ses of Gear

quality in no time (for cylindrical and bevel/hypoid gears)

quality in no time (for cylindrical and bevel/hypoid gears)

MASTA has been used to

©SMT 2006

Slide 65

How to contact us?

How to contact us?

EE-- mails:

mails: [email protected]

[email protected]

Website:

Website: www.smartmt.com

www.smartmt.com

SMT Limited

SMT Limited

14 Regent Street

14 Regent Street

Nottingham

Nottingham

NG1 5BQ

NG1 5BQ

Tel: +44 (0) 115 941 9839

Tel: +44 (0) 115 941 9839

Fax: +44 (0) 115 950 9278

Fax: +44 (0) 115 950 9278

smt masta training manual - 캐드앤그래픽스 of masta.pdf · gear iso6336 safety factors input...

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