EDITION GEAR DESIGN SOLUTIONS

RELEASE 5.6

www.dontynesystems.com

GEAR DESIGN SOLUTIONS

2022 EDITION

New for Release 5.6Curvic Couple design and TCA (New)

Honing simulation (New)

Update ISO 6336 to 2019

Skiving simulation for pre-finish and finish

Skiving simulation on 5-axis and dedicated machines

Automatic calculation of dressing tools from designed micro-geometry

Beveloid design with non-integer teeth

LTCA allows mixed material properties including PM and Plastics

Korean language option added to Machine Centre

Plus many more...

DONTYNE GEAR DESIGN SOLUTIONS / 1

“Dontyne’s 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.”

Eaton Corporation

“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 Renishaw’s co-ordinate measuring machine (CMM) scanning systems.”

Renishaw plc

“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

For a list of references and technical papers associated with Dontyne Systems products and personnel refer to our website www.dontynesystems.com

GEARBOX SYSTEM MODELGEAR DESIGN ANALYSIS AND OPTIMIZATIONSOFTWARE TOOLSTRAINING AND SUPPORT

Dontyne Offices HQ,

Washington, England


Dr. Michael Fish,Director & Co-Founder,Dontyne Systems Ltd

Dontyne Back-To-Back Test Rig

Since 2014 Dontyne has required a back-to-back rig to test non-involute gears at 3.3 ratio 125mm centres but could not find a realistic market offering or development partner. We developed our own which was commission early 2020. Test gears are in production and should show up to 40% better power density over the Invoute equivalent

Dontyne at EMO 2019

Dontyne took a Booth at EMO for the first time to promote prototyping and testing services. We also took the opportunity to promote the our own products such as back-to-back rig, and our partners products. We are UK & Europe sales and support for Osaka Seimitsu Kikai (OSK) from Japan. This company has over 80% of the Japanese automotive market.

As Dontyne Systems launches it’s latest update to it’s acclaimed Gear Production Suite, Director and Co-Founder, Dr. Michael Fish talks about what customer’s can expect from this update and what lies ahead for Dontyne Systems Ltd.

Due to the expansion of the software range we offer, including custom solutions, we took on an additional 2 dedicated developers at the end of 2019 to help with the work. Most of the development of our GSP 5.6 was made in 2020 when Covid 19 had an extreme influence on every person worldwide personally and professionally but, due to the nature of software business, we were able to continue to develop and support the software without too much difficulty. We are acutely aware that this is not always the case with our clients and we will be working with them to support them while the crisis continues and the inevitable aftermath.

We resolved in 2020 to improve our use of social media platforms which have been undeniably neglected. We commissioned an updated website, www.dontynesystems.com, to have a modern look and work well with mobile devices and we thank Know This for their excellent service. We have also engaged 12th Man Solutions to control our social media content for our various platforms of LinkedIn, Facebook, Twitter, and BGA membership.

We have made important improvements to manufacturing simulations, most notably the skiving simulation. Validation of this simulation was possible through collaboration with Kashifuji. We are working on full Honing validation for next release. We have maintained progress in design tools too with with some excellent additions to the Design and Load Model functionality. Contact us for specific details on our software development or a live demonstration of the functionality.

Dontyne Gears has increased floor space to 2,500 sqft to incorporate 3 back to back test rigs and an Okuma Genos. It is now possible to take on project work to involving design, prototyping, inspection, and testing. The work is controlled by data in the Gear Production Suite, and the results of the work programs used to improve the software.

The facilities have already helped secure projects for design in motorsport, EV, aerospoace sectors. We are adding machine tools and personnel in 2021 and 2022 to reduce that requirement and dramatically reduce lead times. Visit our new website, www.dontynegears.com, developed by Ridgetek for more details about the products and services provided. We have also set up a You Tube channel to stream videos of our work. Much of the development of GPS in 2021 and beyond will be driven by the requirements of Dontyne Gears and its clients.


Dontyne Gears continues to utilise Gear Production Suite Software in all project work carried out internally or for clients. The software can be used to design gear pairs or gear systems, producing tool designs and g-code for manufacturing prototypes, producing files to pass to the inspection equipment, and predict operating performance to be validated by testing. The results from the work programs are reported to Dontyne Systems for the continued improvement and accuracy of the software.

In 2019 Dontyne Dontyne Gears, with the help of Dontyne Systems, collaborated on the development of gear systems to demonstrate the potential of Powder Metal (PM) as an alternative to deliver lighter weight and lower carbon production solutions to the automotive industry. PM is a more efficient way of production as it utilises over 90% of the material supplied. Its light weight makes it an important consideration in Electric Vehicle (EV) construction if considerations such as strength and part cost are appropriate. Dontyne designed a PM version of transmission for an EV for Höganäs of Sweden and, with the motor elements supplied by Alvier Mechatronics, was able to design the system, produce CAD models, animations, and manufacture a physical model to demonstrate the principles. The model is used by the client in exhibitions all over the world.

CAD Model Designed and Animated by Dontyne

Physical gear system manufactured and combined with EV motor from Alvier Mechatronic

Dontyne Gears continues to utilise Gear Production Suite


GEAR PRODUCTION SUITEIDEAL PLATFORM FOR INTEGRATED GEAR DESIGN AND MANUFACTURE

Following on from our Release 5.5 in 2018, we are pleased to announce a new Sub Release for the Gear Production Suite. There are some important updates to Standards such as ISO 6336 for widespread use in our customer base, and some improvements to functionality in Beveloid design, LTCA for mixed materials, and machine simulations for Hobbing, Profile Grinding, and Skiving for use as pre-finishing process. We have introduced Honing to compliment the Skiving functionality, and a Curvic Couple design and LTCA for the aerospace industry. More detailed illustrations of these changes in PDF are available on the website.

Customers can request an update via [email protected]. For a live demo of the software contact us [email protected] and we will agree a suitable time for a webinar for you and your colleagues.

RELEASE 5.6

GENERAL OPERATIONManual licence check in/out for floating licences

Administrator added to licence system

Machine Centre and Inspection Centre modules as Stand Alone Installation (considers single component production ideal for integration to other systems)

GEAR DESIGN PROSpur & Helical / Standard / GDP Spur & Helical ISO 6336 update.

Main changes are :-

- New factor f epsilon for Form factor YF

- New factor fZCa for contact factors ZB and ZD

- Helix angle factor Ybeta

- Formulas 33 to 61 implemented for shaped fillets internal and external

- Spur & Helical / Standard / Additional IGES output for cutting blanks

- Beveloid / Standard / Sectors with non-integer teeth

©2020 Dontyne Systems


MACHINE CENTRE

Cross Axis simulation for high accurancy simulation of profile/thread grinding

Beveloid has non-integer tooth number design and 2DFE analysis

Left: 3D simulation of honing shows cutting region

2D simulation of honing shows tool path

LOAD ANALYSIS MODEL

• Spur & Helical / Standard / Input Surface modifications as per Advanced level

• 2DFE / Standard / Duty cycle

• 2DFE added to Beveloid

• Spur & Helical / Standard / Mixed material allows steel against other such as PM and plastic

• Bevel / Standard / Improved viewing for marking pattern

• Bevel / Standard / Backlash plotted in charts over full revolution

• Honing simulation (NEW)

• Skiving / Standard / Add definition of protuberance on tool for simulation as pre-finish process -with Validation

• Skiving / Standard / simulate by dedicated or 5-axis machine - with Validation

• Hob & Continuous Grind / Standard / Define tool from gear profile mod

• Profile Grind / Advanced / 3D Effects

• Additional Japanese language text

• Korean language text added

NEW


• Integration to inspection (Okuma Grinder)

• Inspection Centre Integration to Hexagon

Curvic Couple tooth contact analysis

RELEASE 5.6

INSPECTION CENTRE


CONNECTIONS

• Curvic Couple design and TCA (NEW)

• Spline / Standard / ANSI B92.1b added

• Spline / Standard / Export surface as 2D IGES

NEW

Design of Curvic Couples linked to Inspection Centre can digitise inspection


DESIGN AND RATING TO ISO AND AGMA

GEAR DESIGN PRO

FEATURES INCLUDE :-

Involute internal and external spur and helical gear geometryISO 6336 and AGMA 2001 – D 04 ratingTolerances to ISO 1328 and AGMA 2015 Standardized tooth proportions or calculate for maximum contact ratioPlots and export of gears in 2D and 3D including micro-geometryMeasurement over balls and chordal span including contact heightGear sizing Flash temperature calculationsGraphical plot of specific slidingPlot of theoretical path of contactMaterial database (including user defined)SN fatigue curve plotsMetric or Imperial (English) units

InspectionMaterial database including user definition

Asymmetric design and analysis option

Beveloid form with tapered tooth face as well as Tilted, Crossed, or Crossed and Tilted for Spur & Helical.

BEVELOID AND CROSSED AXIS GEARS

RELEASE 5.5 2018

PLANETARY

Single Stage LayoutFEATURES INCLUDE :-

Involute spur and helical gear geometryAssembly check for equal spacingSingle or double planet arrangementInterference checks for outer diametersSpeed and torque of all componentsISO 6336 rating (inc. 2008 updates)Tolerances to ISO 1328Cumulative damage and safety factor Standardized tooth proportions or calculate for maximum contact ratioPlots of gears in 2D and 3DDXF output of transverse tooth profileCo-ordinates output of tooth profileMeasurement over balls and chordal pan including contact heightMetric or Imperial(English) unitsMaterial database (user defined)Phasing calculation

SPLINES

FEATURES INCLUDE :-

ISO 4156 SplinesDIN 5480 SplinesANSI B92.1 1970 SplinesAdd remove teeth Override dimensions for custom splineNon-Standard NPA Helix angle and tapered tooth

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

Variable tooth forms including helical thread



ISO/AGMA 23509-A08 BEVEL

GENERIC BEVEL

GEAR DESIGN PRO

Straight Bevel Zerol BevelSpiral 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.

DXF 3D line gridIGES Bspline surfaceASCII X,Y,Z Co-ordinatesG-Code

Surface mismatch

flank 1 flank 2

Contact lines shown

Create a small interference

Define Conjugate Surface Apply Micro-Geometry

FEATURES INCLUDE :-

Straight bevel3 spiral typesMicro modificationsConjugation check90 or non-90 degree designVariable root radius from toe to heelExtend / Crop Tooth Form

GENERIC BEVEL ANALYSIS



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 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.

FEATURES INCLUDE :-

Surface definition, (profile and flank line modification)Contact stressRoot bending stress3D FE model of tooth stiffnessPower loss and efficiencySurface topological modification definitionMultiple load casesDouble helical gearsEffect of gear misalignmentVarious graphical interfacesImport of measured gear surface

Gear contact stress Bearing load pattern

Specific film thickness calculation and ISO TR-

15144 micro-pitting method A

Power loss and efficiency

LOAD ANALYSIS MODEL

GATES , Gear Analysis for Transmission Error and Stress

The asymmteric designer

is linked to 2D FE and tool

design for improved analysis

and ease of production.

Surface modification can be applied to

minimise transmissions error (and hence noise

and vibration effects) at a specific load.

Up to 4 different modification options can be

stored with each component.

Calculation of micro

geometry due to flank

twist effect

SURFACE MODIFICATIONS DEFINED BY :-

Normal pressure angle change Linear / parabolic profile modification4th degree polynomialCalculated bias (flank twist)A user model exported to GPS formatMeasured data compatible to common manufacturing systems

Nominal 3D surface modification / 3D surface

with simulated or measured bias

Micro-geometry definition



ADVANCED LOAD ANALYSIS MODELMICRO GEOMETRY OPTIMISATION

Up to 10 increments for each parameter

Available surface Modifications

Pinion and wheel can be linked so that steps change together

Up to 9 load cases for each modification

Tooth surface stress

Transmission Error (TE)

User selects results for optimum modification parameters

Up to 20,000 micro geometry variations can be defined for each batch run


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 below). Other modules can define tooling for machining and inspection to create a control system for production.

EXAMPLE OF CUSTOMER DEFINED PROFILE®

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.

Reduced stress enables more power

Low tooth numbers and optimized root forms (no undercut)

Increase life potential

Reduced weight

Reduced centre distance

Improvement over involute for same ratio and face width

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

-0.075 mm

+0.075 mm

Links to 2D FE model any root or flank form

ADVANCED LOAD ANALYSIS MODELBEVEL GEAR LTCA

The contact model can include deflections entered directly or passed from Gearbox Model tool

Transmission Error under load Contact Stress

Contact region under load

2D FE can be performed at toe, mid, and heel to find optimum root form.


Phasing 1Shows offset along base tangent for each mesh

ADVANCED LOAD ANALYSIS MODEL PLANETARY GEAR LTCA

Phasing 2Phasing offset plotted in transverse section with line of action scale for comparison

Planetary Load shareThe torque split due to variation in tooth stiffness as the planetary system rotates

The Planetary LTCA model can be used to investigate phase of engagement, critical to optimising design parameters for a given arrangement



MACHINE CENTREAUTOMATIC TOOL DESIGN FOR GEAR FORM

FEATURES INCLUDE :-

Tool designTool databaseSimulation of profile generation and micro geometryAnalysis of max/min tolerances on generated profileProtuberance and short lead hobbing techniques on profileUse tool generated profile in bending stress calculation for accurate rating

Gear hobbing generated profile to check tool design

GENERATE GEAR FROM TOOL DATABASE

Tool database with filter systemDefine new tool

Profile error calculated from existing tooling


HOB & CONTINUOUS GRIND (WITH DRESSING)

ADVANCED FUNCTIONSForce BalancingAccurate modelling of the manufacturing processes allows automatic tool design, including assessment of the effects of tolerancing, prior to cutting metal.

Modelling the effects of small grinding worm diameter and multiple threads for higher accuracy model.

FE analysis function enable engineers to assess potential problems such as stress concentration due to a grinding notch in gear fillet.

Hob roll out diagram including stock allowance and tolerancing

Define micro-goemetry on dressing tool

Grinding simulation shows profile modification on gear with break out and chamfer

Asymmetric and non-involute tool design and roll-out check

Force Balancing


PROFILE/THREAD GRINDING

New profile form grinding simulation introduced, which includes the application of micro-geometry.

Shaving cutter sharpening Diagram

As the tooth thickness is reduced with sharpening along the x axis, the blue line depicts the outer diameter reduction required to maintain force balance. User can click on diagram to create optimum design.

SHAVING

Options added to Machine Centre module with full tool definition.

SHAPING, SKIVING, AND HONING

Protuberance for Shaper Cutters

MULTI AXIS – END MILL AND FACE MILL

FORMING – FORGING,ROLLING, INJECTION MOLDING

Define 5-Axis movement and cutting strategy for Spur, Helical and Bevel

Invert errors on mould

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

Invert errors on mould

Tool calculation and G-code export for 5-axis production.



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 testingStatistical analysis of productionDefinition of master surfaceDiagnostics and optimization of tool and machining process by compensation of errorsSimulation of inspection

Virtual testing – tooth span, measurement over balls, transmission error

Simulation of measurement on CMM or EquatorTM on the machine or at the design stage can avoid problems in inspection.

INSPECTION CENTRECO-ORDINATE EVALUATION DIRECT FROM GEAR INSPECTION AND CMM EQUIPMENT

Standard parameter evaluation

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 model. The adjacent picture shows an Equator® using 3D models from Dontyne Systems Gear Production Suite to inspect helical teeth flanks in as little as 25 seconds. Other tooth forms such as bevel gears, spline, and Convoloid® are also possible.

Advanced Analysis Functions

Statistical evaluation of multiple measurements and creating a master surface

GPS interface to EquatorTM to avoid error in data transfer and utilise measurement data.

Projection Heat Map



GEAR PRODUCTION SUITE (Key)

Gear Design ProDesign and rate gear components using common standardsLoad Analysis ModelSimulate operating characteristics of gear pairsInspection CentreDefine component quality and simulate testing procedureMachine CentreCalculation of component form based on machine and tool settingsOptimalCalculate optimum machine and tool settings

Each module is a powerful tool in it’s 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.

OPTIMAL

Optimal - Tooth measurements before and after correction

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

Before CalculationThe theoretical surface (black) and tool surface (blue) can be designed in Gear Production Suite or imported from CAD, measured data imported from measuring equipment

After CalculationThe error between theoretical and measured surface is mapped by a vector (green) and used to create modified tool surface

Error vectors mapping theoretical and measured surface

New toolsurface

Old tool

Before After

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



3D graphical interface

Gearbox view of motor sport transmissionGearbox contains spur and spiral bevel gears

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.

Static Deflection Model

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.

8 Speed Lepelletier Automatic

8 Speed Lepelletier Automatic

Standard Features include :-

Spur, Helical and Bevel gears

Shaft Deflections

Misalignments in Line of Action

Forces

Shaft Stresses

Fully Coupled Housing Stiffness Matrix

3D Gearbox Graphics

Deflected Plots

Concept or Detailed Gears

Import Nastran data from CAD

Shaft Assembly DesignerThe shaft sections, gear positions and supports are input

Shaft calculations for gear misalignmentPower flow plot


GEARBOX SYSTEM MODELGEAR DESIGN ANALYSIS AND OPTIMIZATIONSOFTWARE TOOLSTRAINING AND SUPPORT

DONTYNE SYSTEMS LIMITED IS A COMPANY REGISTERED IN ENGLAND AND WALES WITH COMPANY NUMBER 05973058REGISTERED OFFICE: OS4 WASHINGTON BUSINESS CENTRE, 2 TURBINE WAY, WASHINGTON, TYNE & WEAR, SR5 3NZVAT REGISTRATION NUMBER: 902 9027 45

UKEMAIL : [email protected] : +44 191 206 4021


EDITION GEAR DESIGN SOLUTIONS

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