EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

Romax Technology European User Forum 2015

Paris, September30th 2015

Frank SeibickeKlingelnberg GmbH

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

Paris, September 30th 2015

Frank SeibickeKlingelnberg GmbH

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

1. Klingelnberg Group2. ClosedLoop Manufacturing of Bevel Gears3. Bevel Gear Design with KIMoS4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer6. Azimuth Thruster: Design example

Agenda

September 2015 Page 3

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

1. Klingelnberg Group2. ClosedLoop Manufacturing of Bevel Gears3. Bevel Gear Design with KIMoS4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer6. Azimuth Thruster: Design example

Agenda

September 2015 Page 4

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

Leading international company in gear technology

Founded in 1863 Family business In the 7th generation, owner-management More than 1,300 staff in the

KLINGELNBERG Group Equity capital approx. 50 % Turnover of KLINGELNBERG Group

approx. 280 Mio €

Klingelnberg Group

Page 5September 2015

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAEKlingelnberg Group:Production Sites in Zurich, Hueckeswagen, Ettlingen, Gyoer (HU); Corporate Headquarters are located in Zurich

September 2015 Page 6

KLINGELNBERG GmbH, EttlingenKLINGELNBERG GmbH, HueckeswagenKLINGELNBERG AG, Zurich

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

1. Klingelnberg Group2. ClosedLoop Manufacturing of Bevel Gears3. Bevel Gear Design with KIMoS4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer6. Azimuth Thruster: Design example

Agenda

September 2015 Page 7

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

Operating in ClosedLoop is the basis to get manufactured what is designed!

KIMoS is a design suite for all types of spiral bevel gears The KIMoS results are stored as Neutral Data in a manufacturing

database These data are the basis for: Tool preparation: Blade grinding and Cutter set-up Manufacturing of spiral bevel gears in soft and hard stage in ClosedLoop

independent form manufacturing method Topography and spacing measurement Roll test for Bevel Gear Set

ClosedLoop Manufacturing of Bevel Gears

Page 8September 2015

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAEClosedLoop Manufacturing of Bevel Gears

Page 9September 2015

KOMET corr.settings

Cutting

3D checking

KIMoS

Theoretical nominals

Carburizing

Lapping

Blade grinding

METEORIT corr. settings

Grinding(also ClosedLoop)

Cutter setting

3D checking

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

1. Klingelnberg Group2. ClosedLoop Manufacturing of Bevel Gears3. Bevel Gear Design with KIMoS4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer6. Azimuth Thruster: Design example

Agenda

September 2015 Page 10

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

KIMoS is the basis for ClosedLoop manufacturing KIMoS as an engineering tool covers the whole design process starting

from the definition of Macro geometry until the Micro Geometry of a gear set is released for manufacturing

KIMoS also assists the manufacturing process with a lot of functions in several modules, for example: Complete data for tool preparation Calculation for deburring process Calculation for arbor length

The KIMoS program package consists of several different modules what allows to customize the package for each individual application

Bevel Gear Design with KIMoS

Page 11September 2015

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A New Challenge in CAEProcess Flow in Bevel Gear Design with KIMoS

Page 12September 2015

Standards

Dimensioning

Contact Pattern

Development

Stress Analysis

Database

N E U T R A L D A T A

ProductionDatabase

Import InterfaceGLEASON cage: spa-fileOerlikon CDS Previous KIMoS versions

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

1. Klingelnberg Group2. ClosedLoop Manufacturing of Bevel Gears3. Bevel Gear Design with KIMoS4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer6. Azimuth Thruster: Design example

Agenda

September 2015 Page 13

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A New Challenge in CAESystem Based Limitations

September 2015 Page 14

tooth is described by an elastic model

manufacturing deviations can be considered

load is calculated for each individual contact line

multiple mesh is taken into consideration

Hertzian pressure is calculated in steps for each individual contact line

tooth root stress is calculated in steps for each individual contact line

tooth pair 1tooth pair 2

tooth pair 3

Limitation: Gear body and it’s environment is assumed as infinite stiff!

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

1. Klingelnberg Group2. ClosedLoop Manufacturing of Bevel Gears3. Bevel Gear Design with KIMoS4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer6. Azimuth Thruster: Design example

Agenda

September 2015 Page 15

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAEConsideration of whole gear box by interaction with Romax Designer

Page 16September 2015

RomaxDESIGNER

KIMoS LTCAwith BECAL

5Designing

the Gear Pair

1

Powertrain Simulation

3

ImportLoad Cases from

RomaxDESIGNERvia Load Spectra Editor

4Export

Results toRomaxDESIGNER

6Export

Gear Dimensions toRomaxDESIGNER

2

Dynamic analysis

7

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAEConsideration of whole gear box by interaction with Romax Designer

Page 17September 2015

Input Rotation

Output rotation

RomaxDesigner Model

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAEConsideration of whole gear box by interaction with Romax Designer

Page 18September 2015

RomaxDesigner Model / KIMoS interface

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

A New Challenge in CAE

1. Klingelnberg Group2. ClosedLoop Manufacturing of Bevel Gears3. Bevel Gear Design with KIMoS4. System Based Limitations 5. Consideration of whole gear box by interaction with Romax Designer6. Azimuth Thruster: Design example

Agenda

September 2015 Page 19

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Azimuth Thruster: Design exampleRomaxDesigner model of Azimuth Thruster

CAD model RomaxDesigner model

Gears, shafts, bearings, housings

A New Challenge in CAE

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Desired:Thrust (x direction)Torque (roll direction)

UndesiredSide forces (y direction)Pitching moments (pitch direction)Yawing moments (yaw direction)

Azimuth Thruster: Design example6 DOF Forces

A New Challenge in CAE

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Static deflections, based on load conditions

Gear and Bearing ratings, including system deflections

Gear and Bearing static assessment (e.g. bearing and gear contact stress under crash-back condition)

System vibration predictions System modes Vibration response to prop excitation (torque fluctuation) Vibration response to gear transmission error

Azimuth Thruster: Design exampleSystem Analysis

A New Challenge in CAE

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For each prop speed considered

Apply torque, thrust

(can apply full 6DOF forces and moments if desired)

Loads must be calculated externally

Azimuth Thruster: Design exampleModel setup

A New Challenge in CAE

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

Deflections and gear/bearing ratings

Azimuth Thruster: Design exampleStatic Assessment

A New Challenge in CAE

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140 KN Thrust, 30KNm torque

Deflections can affect durability and sealing

Azimuth Thruster: Design exampleSystem deflections – Torque and Thrust

A New Challenge in CAE

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

Azimuth Thruster: Design exampleGear / Bearing Analysis – under loads and deflections

A New Challenge in CAE

EXPERT PRECISIONUnrivaled products and services –the tradition of KLINGELNBERG

Zero misalignment With system deflections

Target: Bevel Gear EaseOff specified such that patch centralises under true misalignment

Azimuth Thruster: Design exampleBevel gear contact patch analysis

A New Challenge in CAE

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With system deflections(nominal load)

With system deflections(over-speed load)

Azimuth Thruster: Design exampleBevel gear contact patch analysis

A New Challenge in CAE

Target: Bevel Gear EaseOff specified such that patch centralises under true misalignment

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Example: ISO bearing ratings

(Loads on propeller calculated externally and prescribed in RomaxDesigner)

Azimuth Thruster: Design exampleGear / Bearing Duty Cycle Analysis

A New Challenge in CAE

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Peak loads during crash-back Nominal

Azimuth Thruster: Design exampleExtreme static load assessment – e.g. crash-back

A New Challenge in CAE

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Peak loads during crash-back

Azimuth Thruster: Design exampleExtreme static loads – crash-back

Pinion shaft lower bearing stress contours

A New Challenge in CAE

Nominal

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Modes and vibration response

Azimuth Thruster: Design exampleDynamic Assessment

A New Challenge in CAE

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13 Hz 60 Hz

Global Local

1023 Hz

Azimuth Thruster: Design exampleSystem modes

A New Challenge in CAE

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1023 Hz (external view)

1023 Hz mode - coupled mode of housing of shaft system

1023 Hz (internal view)

Azimuth Thruster: Design exampleSystem modes

A New Challenge in CAE

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Response from all modes

Response from 12 Hz only

(Modal damping – dry response)

Azimuth Thruster: Design exampleVibrational system response to bending excitation at propeller (5KNm)

A New Challenge in CAE

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Response to torsional prop excitation 5KNm magnitude at 200 rpm

Azimuth Thruster: Design exampleOperating deflected shape

A New Challenge in CAE

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Fast (much faster than classical FE) predictions of static deflections Analytical bearing contact models Multi-fidelity component representations (1D/3D)

Combined gear and bearing analysis using system misalignments Gear life ratings /static strength Bearing life ratings / static strength

Modal and vibration analysis of system Integration with KIMoS bevel gear analysis Load spectra’s are taken over from ROMAX Designer Optimization of EaseOff under consideration of calculated deflections easy data exchange between booth systems

Summary: RomaxDesigner/KIMoS analysisA New Challenge in CAE