Presentation

Klingelnberg GmbH · Peterstrasse 45 · D-42499 Hueckeswagen · Klingelnberg AG · Binzmuehlestrasse 171 · CH-8050 Zurich 

Page 1 

New Dimensions in Bevel Gear Production 

Dynamic Positioning Conference - October 11-12, 2011 - Houston, Texas 

Dipl.-Ing. Rudolf Houben - Head of Calculation and Design - Bevel Gear Division


1. Introduction 

2. Gear Design 

3. Gear Production 

4. Summary & Outlook 


Page 2 




1. Introduction Thrusters – Then and Now 

source: Schottel 


Page 3 










Page 4 




2. Gear Design Input Data and Design Considerations 

IInput t Data: D t u gear ratio ti 

Ʃ shaft angle 

T torque 

n rotational speed 

K A 

… 

application pp factor 

… 

Design Considerations: 

F 

� definition of gearing system 

� input of basic data 

� computer aided design by proposals 

for missing gear parameters 

�� review and optimization of the actual design 

based on characteristic values 

� load induced stress levels 

within the teeth 

mtv � F � �YFa 

�YSa 

�Y� 

�YK 

�YLS 

� K A � Kv 

� K F� 

� K F� 

b� 

mmn 


Page 5 

source: Rolls-Royce 




2. Gear Design Material Strength and Rating 

� 

FP 

� F limY 

� 

S 

ST 

F min 

NT 

�relT 

RrelT 


Y 

Y 

Y 

Y 

X 

Page 6 

� 

� F � 

S 

FP 

F 

� 

� H � 

S 

to avoid tooth breakage to avoid pitting 



Dipl.-Ing. Rudolf Houben - Head of Calculation and Design - Bevel Gear Division 

HP 

H

2. Gear Design Results of Macro Design 

� BBasic i parameters t of f the th toothing t thi 

� Blank dimensions 

� EaseOff (crowning data) 

�� Contact pattern without load 

� Transmission error 

� Machine settings 

�� Tooling information 


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2. Gear Design Bevel Gear Set and Surrounding Components 

shaft design g of ppinion 

bearing stiffness 

shape of ring gear 

bearing flanges 

housing 

Relative position of pinion and gear is influenced by: 

� tolerances in manufacturing and assembly 

� ddeflections fl ti under d lload d 

� bearing clearances 

� thermal expansions 

� … 


Page 8 




2. Gear Design System Boundaries of Software Tools 

� flexible teeth 

Gear Calculation Tool Static Static Analysis Tool 

� teeth of infinite stiffness 

� gear bodies b di of f infinite i fi it stiffness tiff 

� flexible fl ibl gear bodies b di and d surrounding 

di 


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2. Gear Design Relative Position of Pinion and Ring Gear 

M 

D 

O 

P 

i 

n 

i 

o 

n 

H+ V+ 

f 

f 

s 

e 

t 

S 

h 

a 

f 

t 

A 

n 

g 

l 

e 

Σ+ 


Page 10 

J+ 




M 

D 

R 

i 

n 

g 

G 

e 

a 

r

2. Gear Design Closed Loop of Gear Design 

Gear Optimization p 

V, H, J, Ʃ 

Static Analysis 


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F i = f(φ) 




2. Gear Design Product Development Processes in Comparison 

S 

T 

A 

N 

D 

A 

R 

D 

A 

D 

V 

A 

N 

C 

E 

D 

Gear Design g Production Testing g Optimization p 

Production Testing g Operation p 

Gear Design Optimization Production Testing Operation 


Page 12 










Page 13 




3. Gear Production New Gear Cutting Machine C300 

� Double spindle for cutting pinions in one clamping 

� Dry processing for soft cutting 

� Max. diameter d e2 = 3000 mm 

� Max. mean normal module m mn = 50 mm 


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3. Gear Production Tooling System 


� Modular system 

�� Cutter heads with radii r = 350 350, 450 450, 550 and 650 mm 

� No. of starts of all cutter heads z 0 = 7 

� Universal blades clustered by nominal module 14 ≤ m 0 ≤ 46 mm 

�� Coated carbide inserts for soft cutting 

Page 15 




3. Gear Production Heat Treatment 

�� high surface hardness 

� ductile core material 


tooth 

normal 

force 

Page 16 

α φmax 

n 

axial runout 




φ 

permissibble 

axial 

runout deeviation 

φmaax

3. Gear Production Closed Loop Production 

� networking: g 

no more manual input of 

summaries and 

corrective settings 

� appropriate flank form 

modifications already 

defined during gear design 


database 

Page 17 




3. Gear Production Quality Record 

1 2 3 4 5 6 7 8 9 10 

forging 

blank 

machining 

soft 

cutting 

heat 

treatment 

pre- premachining 

measure- measurement 

hard 

cutting 

measure- measurement 

final 

machining 

final 

inspection 

6 

8 

� material certificates 

� tooling setup reports 

� hardness profile 

� gear measurement reports 

� photos of contact pattern 

� … 


3 7 

6 8 8 

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4







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5. Summary 

�� As a precondition to apply appropriate flank form modifications to a bevel 

gear set, deflections affecting the relative position of pinion and ring gear 

need to be known. 

� KIMoS and RomaxDesigner in combination represent a powerful software 

package for analysis and optimization of the bevel gear set and the 

surrounding components. 

� Closed loop production ensures precise gear manufacturing according to 

the design. design 

� Heat treatment significantly influences the quality of a bevel gear set. 

� Quality record of the overall process chain is most important to guarantee 

reliable power transmission. 

transmission 


Page 20 




5. Outlook Simulation of the Overall Drive System 

Static Analysis of Drive System Dynamic Analysis of Drive System 


Displacements of the bevel gear set due to 

the load, as far as known, can be 

compensated by flank form modifications. 

Page 21 




5. Outlook Load Capacity of Large Bevel Gears 

power p [kW] ] 

Power transmission and weight of blank for large ring gear diameter 

25000 25000 

Basic parameters: u = 1.72, βm = 26°, KA = 2.0 

today 

20000 

15000 

10000 

yesterday 

7000 

5306 

10450 

7925 

12690 

9729 

14300 

10830 

20950 

16187 

20000 

15000 

10000 

5000 5000 

0 

1969 2855 

0 

1750 2000 2250 2500 2750 3000 


pitch p diameter of ring g gear g [mm] [ ] 

Page 22 




weighht 

of ring gear g [kg]

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