KISSsys Instruction-304

Calculation of the gear and bearing frequencies

KISSsoft AG
Rosengartenstrasse 4
8608 Bubikon
Switzerland

Tel: +41 55 254 20 50

Fax: +41 55 254 20 51
info@KISSsoft.AG
www.KISSsoft.AG
Contents

1 Using the template ................................................................................................................................... 4

1.1 Setting up calculations.................................................................................................................... 4
2 Gear meshing frequencies ....................................................................................................................... 4
2.1 Calculating the gear meshing frequencies ..................................................................................... 4
2.2 Meshing order analysis ................................................................................................................... 4
2.3 Output of the results ....................................................................................................................... 5
2.4 Limitations ...................................................................................................................................... 6
3 Bearing defect frequencies ...................................................................................................................... 6
3.1 Calculating the bearing defect frequencies .................................................................................... 6
3.2 Frequency order analysis ............................................................................................................... 8
3.3 Output of the results ....................................................................................................................... 8
3.4 Limitations ...................................................................................................................................... 9
3.5 Frequency calculation formulas ...................................................................................................... 9
3.5.1 Rolling element pass frequency outer race (BPFO) ................................................................... 9
3.5.2 Rolling element pass frequency inner race (BPFI) ..................................................................... 9
3.5.3 Rolling element frequencies (BSF) and (BPF) ........................................................................... 9
3.5.4 Fundamental train frequency (FTF) ............................................................................................ 9
4 Meshing functionality verification ........................................................................................................... 10
4.1 Verifying formulas ......................................................................................................................... 10
4.2 Example........................................................................................................................................ 10
4.3 Frequency calculation formulas .................................................................................................... 10
4.3.1 Helical gear pair ....................................................................................................................... 10
4.3.2 Planetary gear set .................................................................................................................... 10
4.3.3 Epicyclic gear set ..................................................................................................................... 11
4.4 Result check ................................................................................................................................. 11

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General Information

Are you interested to know, what are all the meshing frequencies in your transmission? Gear meshing
frequency is defined as the number of gear teeth that enter in the mesh per unit of time or on the other words;
Gear meshing frequency is the number of teeth multiplied by the rotational frequency of the gear. Meshing
frequency is one of the potential noise sources in the transmission. Gear meshing creates a vibration in its
meshing frequency, because of transmission error, machining errors, stiffness variation, torque fluctuation
and other reasons.

Are you also interested to check if some of your bearings may be reason for the noise or vibration. Most
important bearing frequencies are rotational frequencies and possible defect frequencies in races or in rolling
elements.

Frequency is defined as Hertz (Hz) [cycles / sec.]. For the gear meshing it can be calculated by number of
teeth * rotational speed [rpm] / 60. Gear meshing frequency is a harmonic phenomenon and its harmonics
can be found by multiplying fundamental meshing frequency by whole numbers (1, 2, 3).
Different bearing frequencies are calculated in similar manner from the inner geometry of the bearings using
formulas with number of contacts in possible place of defect.

In KISSsys it will be now possible to calculate meshing frequencies of the gear pairs and possible bearing
defects frequencies for the whole transmission very easily. There is a special template available for that. The
fundamental meshing frequencies and selected number of harmonics can be calculated, results in the
operational point will be shown in one table and it is also possible to do order analysis over the selected speed
range. Results will be shown in Hertz. Selected bearing with all of the calculated frequencies can be also
show in graphical presentation over the selected speed range.

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1 Using the template
1.1 Setting up calculations
Open template file 304-Frequency.ks to be able to use calculate frequencies in your gear box. This template
is available to be downloaded from KISSsoft AG homepage. Use copy paste to adopt tables from the
templates into your model tree. There will be one table named MeshingFrequency and a 2DPlot
OrderAnalysis as well as BearingFrequency with a 2DPlot OrderAnalysis available for you. You may
change names of these components if you want to.

2 Gear meshing frequencies

2.1 Calculating the gear meshing frequencies
Use function MeshFrequency under the table to do the calculation for the gear meshing frequencies. You
may select how many harmonics will be calculated and also if you want to create a plot of the frequencies.

Figure 1. Dialog for meshing frequency calculations

Note! Function will work for the different combinations of helical, planetary and bevel gear pairs. At the
moment it is not possible for the worm or crossed helical gears. If you are interested to calculate gear meshing
frequencies of these gears meshes also, please contact KISSsoft AG.

When number of the harmonics is selected in the dialog and OK is pressed a table with the number of
meshing harmonics is created, showing also the power of the mesh, because this can be then used to check
which meshes are active and will really have some effect.

Figure 2. Gear meshing frequency table

First Line Names of the gear pairs

P Power in the mesh
Harmonic_X Meshing harmonic, X number of the harmonic.

2.2 Meshing order analysis

When you want to plot order analysis of the meshing frequencies and its harmonics, select yes for the
question in first dialog (see Figure 1). Second dialog will then appear to make selections for the order analysis.
Select number of harmonics to plot (up to number of calculated harmonics or maximum 5 harmonics). Select

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minimum and maximum speeds you want to see (use only positive speed values). Select also, which
kSysSpeedOrForce- component will be the reference speed component. After pressing OK a picture of
order analysis will appear. Only meshing frequencies and selected harmonics will be drawn for the meshes
which are active.

Figure 3. Order analysis definition dialog

Figure 4. Order analysis of the meshing frequencies

Number of orders is limited to five (5), because of drawing limitations with different lines. Colors for the gears
are selected from the color list.
No. of harmonic Line style
1st harmonic
2nd harmonic
3rd harmonic
4th harmonic
5th harmonic

2.3 Output of the results

An external file MeshFreq.csv is also created containing the same information as the meshing frequency
table. This file is located to the project folder and can be opened e.g. with excel. The gear meshing frequencies
are always calculated at the operational point.

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 Figure 5. Output file of calculated gear meshing frequencies

2.4 Limitations
There is couple of limitations in order analysis graph.
1. Only limited number of frequencies can be plotted and shown in KISSsys. This may cause in some
cases that all desired orders cannot be seen, use external file in that case to draw all orders.
2. No legend can be shown in the KISSsys order analysis plot.
3. Order analysis is always given for a fixed gear ratio.

3 Bearing defect frequencies

3.1 Calculating the bearing defect frequencies
Use function Frequencies under the table to do the calculation for the bearing frequencies.

Figure 6. Dialog for bearing frequency calculations

Following selections are to be made:

Bearing Select bearing from the dropdown list.
Frequencies of this selected bearing will be draw
in 2DPlot.
No of Harmonics Select from the dropdown list how many
frequency harmonics you want to see (maximum
number 5)
Reference speed min Minimum speed you want to consider (use
positive speed values)
Reference speed max Maximum speed you want to consider (use
positive speed values)

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 Reference point Select speed reference place. Speed is
converted to positive sign even if defined or
calculated value is negative in operational point

When OK is pressed a table with the bearing information and calculated frequencies is shown.

Figure 7. Bearing frequency table

Bearing frequencies are based on the formulas for internal geometry of the bearings. This data is not available
automatically in KISSsoft-Hirnware-04-2006 version and therefore these values are needed to be added
manually for every bearing. Needful information is described in the following table. This information can be
entered easies directly to the BearingFrequencies- table. User can open it manually from the tree structure
using BearingFrequencies- Show.

Data in the table

shaft Shaft where bearing is defined. If calculation for the bearing is not
added then shaft is no calculation and frequencies are not
calculated for that bearing.
n Speed of the bearing. This value is taken from the bearing calculation
speed refer to the previous
BType Bearing type
D Bearing outer diameter (mm)
d Bearing inner diameter (mm)
z Number of rolling elements in assembly.
(USER DEFINED VALUE)
Dpw Reference diameter/cage assembly diameter (mm)
(USER DEFINED VALUE)
Dwe Rolling element diameter (mm)
(USER DEFINED VALUE)
alfa Nominal contact angle (deg)
(USER DEFINED VALUE)
BPFO Rolling element pass frequency outer race (Hz)
BPFI Rolling element pass frequency inner race (Hz)
BSF Rolling element rotational frequency (Hz)
FTF Fundamental train frequency (Hz)
BPF Rolling element contact frequency (Hz)

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3.2 Frequency order analysis
When function Frequencies is operated order plot of the selected bearing frequencies is shown
automatically. Selected number of harmonics is shown. Speed value is according to the selected reference
point.

Figure 8. Order analysis of the meshing frequencies

Number of orders is limited to five (5), because of drawing limitations with different lines. Colors for the
frequencies are also explained in the table.
No. of harmonic Line style Frequency Color
st
1 harmonic BPFO Red
2nd harmonic BPFI Blue
3rd harmonic BSF Green
th
4 harmonic FTF Yellow
th
5 harmonic BPF Magenta
Note! Frequency values are not automatically updated when any values for the bearings, or kinematics is
changed. User need to run the function Frequencies again to update values to meet new operational values.

3.3 Output of the results

An external file BearingFrequencies.csv is also created containing more information as the table. Harmonics
up to 5th are printed for all calculated frequencies. This file is located to the project folder and can be opened
e.g. with excel. All frequencies are calculated at the operational point.

Figure 9. External file created

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 Figure 10. Output file of calculated gear meshing frequencies

3.4 Limitations
There is couple of limitations in order analysis graph.
4. Only limited number of frequencies can be plotted and shown in KISSsys. This may cause in some
cases that all desired orders cannot be seen, use external file in that case to draw all orders.
5. No legend can be shown in the KISSsys order analysis plot.
6. Order analysis is always given for a fixed gear ratio.

3.5 Frequency calculation formulas

Following formulas are used to calculate the bearing frequencies.

3.5.1 Rolling element pass frequency outer race (BPFO)

n D Dwe cos( )
BPFO z pw
60 2 D pw

3.5.2 Rolling element pass frequency inner race (BPFI)

n D Dwe cos( )
BPFI z pw
60 2 D pw

3.5.3 Rolling element frequencies (BSF) and (BPF)

n D pw Dwe cos ( )
2 2 2

BSF , BPF = 2*BSF

60 2 Dwe D pw

3.5.4 Fundamental train frequency (FTF)

n D Dwe cos( )
FTF pw
60 2 D pw

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4 Meshing functionality verification
4.1 Verifying formulas
In the template formulas number of teeth * rotational speed [rpm] / 60 are used to find out meshing frequency
for the helical and bevel gears. In case of epicyclical gear arrangement different formulas are needed to find
out correct meshing frequency. In KISSsys, if normal epicyclical arrangement is used (sun-planet-ring), then
given formula is used (speed of the sun speed of the carrier) * sun gear number of the teeth /60. In all
other cases basic formula for the meshing frequency calculation can be used because gear calculations are
made with helical gear module, which already takes in the account the relative speed between gears.

4.2 Example
Following example is used to verify the formulas. Helical planetary type gearbox configuration is created
with one helical gear pair, one normal planetary gear pair and special planetary gear configuration. Input
speed is given as 1000 rpm.

Figure 11. Schematic view of the example model

4.3 Frequency calculation formulas

4.3.1 Helical gear pair
z z1 n1
Ratio i 2 and meshing frequency f
z1 60

4.3.2 Planetary gear set

zs zr nc
Ratio when carrier is input, sun is output and ring is fixed i and meshing frequency f
zs zr 60

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4.3.3 Epicyclic gear set
z s1 z p 2 z p 4 z p1 z s 2 z p 3
Ratio when sun1 is input, sun2 is fixed and carrier is output i and
z s1 z p 2 z p 4
z
z p 2 s1 ns1 nc
z s1 ns1 nc z z s 2 nc
meshing frequency f s1 p1 , f p 2 p3 p1 and f zs 2 zp 4
60 60 60

4.4 Result check

Given formulas were used to calculate meshing frequencies of the example model. These results are proved
to be equal to the results obtained form with KISSsys meshing frequency template.

Input speed 1000 rpm

Input frequency 16.67 Hz
i Speed Mesh frequency (Hz) Input freq. Harmonic Assemply
Input z1 13 1000.0 216.7 13.0
Output z2 38 2.92 -342.1

Output zs 21 0.20 -1710.5 21

zp 30 957.9
Fix zr -84 0.0
Input carrier 3 -342.1 478.9 28.7

Input zs1 21 -1710.5 342.1 20.5

Fix zs2 16
zp1 42
zp2 20 162.9 9.8
zp3 40
zp4 48
Output carrier 3 2.33 -733.1 195.5 11.7

Figure 12. Gear meshing frequencies calculated with given formulas

Figure 13. Gear meshing frequencies calculated with KISSsys

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