KISSsoft Release 03/2017

Team-SolidSQUAD
File
Name : TACHO STATOR
Changed by: Santosh Reddy on: 03.12.2018 at: 22:18:20

Important hint: At least one warning has occurred during the calculation:

1-> Key way (Key way):

Length is incorrect.

2-> Square groove (Square groove):

Length is incorrect.

3-> Key way (Key way):

Length is incorrect.

4-> Shaft 'SHAFT':

the sum of torques is not zero.
ΔT = -1.000 Nm

5-> The required service life of bearing 'Shaft 'SHAFT', Rolling bearing 'Rolling bearing'' is not achieved!

6-> The thermally safe operating speed of bearing 'Shaft 'SHAFT', Rolling bearing 'Rolling bearing'' could be critical.
Please run the calculation for the 'Thermally safe operating speed'
(in the special tab of menu 'Calculation').

7-> Cross section Limited cross section:

Groove depth cannot be zero.
(t = 0.00 mm)

Analysis of shafts, axle and beams

Input data

Coordinate system shaft: see picture W-002

Label SHAFT
Drawing
Initial position (mm) 0.000
Length (mm) 98.400
Speed (1/min) 9000.00
Sense of rotation: clockwise

Material 42 CrMo 4 (1)

Young's modulus (N/mm²) 206000.000
Poisson's ratio nu 0.300
Density (kg/m³) 7830.000
Coefficient of thermal expansion (10^-6/K) 11.500
Temperature (°C) 20.000
Weight of shaft (kg) 0.029
(Notice: Weight stands for the shaft only without considering the gears)

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Weight of shaft, including additional masses (kg) 0.029
Mass moment of inertia (kg*mm²) 0.198
Momentum of mass GD2 (Nm²) 0.000

Position in space (°) 0.000

Gears mounted with stiffness according to ISO
Consider deformations due to shearing
Shear correction coefficient 1.100
Contact angle of rolling bearings is considered
Tolerance field: Mean value
Reference temperature (°C) 20.000

Figure: Load applications

Shaft definition (SHAFT)

Outer contour

Cylinder (TACHO) 0.000mm ... 14.000mm

Diameter (mm) [d] 7.0000
Length (mm) [l] 14.0000
Surface roughness (µm) [Rz] 8.0000

Square groove (Square groove)

b=0.50 (mm), t=0.50 (mm), r=0.10 (mm), Rz=8.0, Turned (Ra=3.2μm/125μin)

Key way (TACHO KEY) 11.000mm ... 14.000mm

l=3.00 (mm), Rz=8.0, Turned (Ra=3.2μm/125μin)

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Cylinder (GEAR) 14.000mm ... 22.900mm
Diameter (mm) [d] 7.4000
Length (mm) [l] 8.9000
Surface roughness (µm) [Rz] 8.0000

Square groove (Square groove)

b=0.50 (mm), t=0.50 (mm), r=0.20 (mm), Rz=8.0, Turned (Ra=3.2μm/125μin)

Key way (Key way) 17.400mm ... 22.900mm

l=5.50 (mm), Rz=8.0, Turned (Ra=3.2μm/125μin)

Cylinder (BEARING-1) 22.900mm ... 30.900mm

Diameter (mm) [d] 8.0000
Length (mm) [l] 8.0000
Surface roughness (µm) [Rz] 8.0000

Square groove (Square groove)

b=0.50 (mm), t=0.50 (mm), r=0.20 (mm), Rz=8.0, Turned (Ra=3.2μm/125μin)

Cylinder (Cylinder) 30.900mm ... 36.900mm

Diameter (mm) [d] 10.0000
Length (mm) [l] 6.0000
Surface roughness (µm) [Rz] 8.0000

Cylinder (Cylinder) 36.900mm ... 41.900mm

Diameter (mm) [d] 7.0000
Length (mm) [l] 5.0000
Surface roughness (µm) [Rz] 8.0000

Square groove (Square groove)

b=0.50 (mm), t=0.50 (mm), r=0.20 (mm), Rz=8.0, Turned (Ra=3.2μm/125μin)

Cylinder (ROTOR) 41.900mm ... 72.400mm

Diameter (mm) [d] 6.0000
Length (mm) [l] 30.5000
Surface roughness (µm) [Rz] 8.0000

Cylinder (Cylinder) 72.400mm ... 87.900mm

Diameter (mm) [d] 7.0000
Length (mm) [l] 15.5000
Surface roughness (µm) [Rz] 8.0000

Cylinder (Cylinder) 87.900mm ... 92.900mm

Diameter (mm) [d] 7.0000
Length (mm) [l] 5.0000
Surface roughness (µm) [Rz] 8.0000

Cylinder (BEARING-2) 92.900mm ... 98.400mm

Diameter (mm) [d] 5.0000

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Length (mm) [l] 5.5000
Surface roughness (µm) [Rz] 8.0000

Square groove (Square groove)

b=0.50 (mm), t=0.50 (mm), r=0.20 (mm), Rz=8.0, Turned (Ra=3.2μm/125μin)

Forces

Type of force element Centric force

Label in the model Centric force
Position on shaft (mm) [ylocal] 12.0000
Position in global system (mm) [yglobal] 12.0000
Length of load application (mm) 0.0000
Power (kW) 0.0000
Torque (Nm) -0.0000
Axial force (N) 0.0000
Shearing force X (N) 0.0000
Shearing force Z (N) 1.9700
Bending moment X (Nm) 0.0000
Bending moment Z (Nm) 0.0000

Type of force element Centric force

Label in the model Gear force
Position on shaft (mm) [ylocal] 19.9000
Position in global system (mm) [yglobal] 19.9000
Length of load application (mm) 0.0000
Power (kW) 0.0000
Torque (Nm) -0.0000
Axial force (N) 0.0000
Shearing force X (N) 0.0000
Shearing force Z (N) 160.0000
Bending moment X (Nm) 0.0000
Bending moment Z (Nm) 0.0000

Type of force element Centric force

Label in the model ROTOR LOAD
Position on shaft (mm) [ylocal] 57.1500
Position in global system (mm) [yglobal] 57.1500
Length of load application (mm) 0.0000
Power (kW) 0.0000
Torque (Nm) -0.0000
Axial force (N) 0.0000
Shearing force X (N) 0.0000
Shearing force Z (N) 10.3500
Bending moment X (Nm) 0.0000
Bending moment Z (Nm) 0.0000

Type of force element Magnetic force

Label in the model Magnetic force
Position on shaft (mm) [ylocal] 61.9000
Position in global system (mm) [yglobal] 61.9000
Radial magnetic force (N) 0.0000
Direction of the radial force (°) 0.0000
Axial force factor (-) 0.0000
Groove lead right

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Length of load application (mm) 50.0000
Power (kW) 0.9425 driving (Output)
Torque (Nm) -1.0000
Axial force (N) 0.0000
Shearing force X (N) 0.0000
Shearing force Z (N) 0.0000
Bending moment X (Nm) 0.0000
Bending moment Z (Nm) 0.0000

Bearing

Label in the model Rolling bearing

Bearing type SKF 628/8-2Z
Bearing type Deep groove ball bearing (single row)

Bearing position (mm) [ylokal] 28.300

Bearing position (mm) [yglobal] 28.300
Attachment of external ring Fixed bearing
Inner diameter (mm) [d] 8.000
External diameter (mm) [D] 16.000
Width (mm) [b] 5.000
Corner radius (mm) [r] 0.200
Basic static load rating (kN) [C0] 0.570
Basic dynamic load rating (kN) [C] 1.300
Fatigue load rating (kN) [Cu] 0.024
Values for approximated geometry:
Basic dynamic load rating (kN) [Ctheo] 0.000
Basic static load rating (kN) [C0theo] 0.000

Label in the model Rolling bearing

Bearing type SKF 638/5-2Z
Bearing type Deep groove ball bearing (single row)

Bearing position (mm) [ylokal] 95.400

Bearing position (mm) [yglobal] 95.400
Attachment of external ring Fixed bearing
Inner diameter (mm) [d] 5.000
External diameter (mm) [D] 11.000
Width (mm) [b] 5.000
Corner radius (mm) [r] 0.150
Basic static load rating (kN) [C0] 0.260
Basic dynamic load rating (kN) [C] 0.640
Fatigue load rating (kN) [Cu] 0.011
Values for approximated geometry:
Basic dynamic load rating (kN) [Ctheo] 0.000
Basic static load rating (kN) [C0theo] 0.000

Results

Shaft

Maximum deflection (μm) 58.079

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Position of the maximum (mm) 0.000
Mass center of gravity (mm) 45.381
Total axial load (N) 0.000
Torsion under torque (°) -0.208

Bearing

Probability of failure [n] 10.00 %

Axial clearance [uA] 10.00 µm
Lubricant Oil: ISO-VG 220
Lubricant - service temperature [TB] 20.00 °C
Rolling bearings, classical calculation (contact angle considered)

Shaft 'SHAFT' Rolling bearing 'Rolling bearing'

Position (Y-coordinate) [y] 28.30 mm
Equivalent load [P] 0.19 kN
Equivalent load [P0] 0.19 kN
Life modification factor for reliability[a1] 1.000
Nominal bearing service life [Lnh] 610.72 h
Operating viscosity [ν] 912.87 mm²/s
Static safety factor [S0] 3.03
Bearing reaction force [Fx] 0.000 kN
Bearing reaction force [Fy] 0.000 kN
Bearing reaction force [Fz] -0.188 kN
Bearing reaction force [Fr] 0.188 kN (-90°)
Oil level [H] 0.000 mm
Rolling moment of friction [Mrr] 0.001 Nm
Sliding moment of friction [Msl] 0.001 Nm
Moment of friction, seals [Mseal] 0.000 Nm
Moment of friction for seals determined according to SKF main catalog 10000/1 EN:2013
Moment of friction flow losses [Mdrag] 0.000 Nm
Torque of friction [Mloss] 0.002 Nm
Power loss [Ploss] 1.719 W
The moment of friction is calculated according to the details in SKF Catalog 2013.
The calculation is always performed with a coefficient for additives in the lubricant μbl=0.15.
Displacement of bearing [ux] 0.000 µm
Displacement of bearing [uy] -0.000 µm
Displacement of bearing [uz] 10.750 µm
Displacement of bearing [ur] 10.750 µm (90°)
Misalignment of bearing [rx] -1.525 mrad (-5.24')
Misalignment of bearing [ry] -1.301 mrad (-4.47')
Misalignment of bearing [rz] 0.000 mrad (0')
Misalignment of bearing [rr] 1.525 mrad (5.24')

Shaft 'SHAFT' Rolling bearing 'Rolling bearing'

Position (Y-coordinate) [y] 95.40 mm
Equivalent load [P] 0.02 kN
Equivalent load [P0] 0.02 kN
Life modification factor for reliability[a1] 1.000
Nominal bearing service life [Lnh] 115748.57 h
Operating viscosity [ν] 912.87 mm²/s
Static safety factor [S0] 16.12
Bearing reaction force [Fx] -0.000 kN

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Bearing reaction force [Fy] 0.000 kN
Bearing reaction force [Fz] 0.016 kN
Bearing reaction force [Fr] 0.016 kN (90°)
Oil level [H] 0.000 mm
Rolling moment of friction [Mrr] 0.000 Nm
Sliding moment of friction [Msl] 0.000 Nm
Moment of friction, seals [Mseal] 0.000 Nm
Moment of friction for seals determined according to SKF main catalog 10000/1 EN:2013
Moment of friction flow losses [Mdrag] 0.000 Nm
Torque of friction [Mloss] 0.000 Nm
Power loss [Ploss] 0.198 W
The moment of friction is calculated according to the details in SKF Catalog 2013.
The calculation is always performed with a coefficient for additives in the lubricant μbl=0.15.
Displacement of bearing [ux] -0.000 µm
Displacement of bearing [uy] 0.000 µm
Displacement of bearing [uz] -3.750 µm
Displacement of bearing [ur] 3.750 µm (-90°)
Misalignment of bearing [rx] 0.559 mrad (1.92')
Misalignment of bearing [ry] -3.627 mrad (-12.47')
Misalignment of bearing [rz] 0.000 mrad (0')
Misalignment of bearing [rr] 0.559 mrad (1.92')

Damage (%) [Lreq] ( 20000.000)

Bin no B1 B2
1 3274.82 17.28
----------------------------
Σ 3274.82 17.28

Utilization (%) [Lreq] ( 20000.000)

B1 B2
319.94 55.70
Note: Utilization = (Lreq/Lh)^(1/k)
Ball bearing: k = 3, roller bearing: k = 10/3

B1: Rolling bearing

B2: Rolling bearing

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Figure: Deformation (bending etc.) (Arbitrary plane 90 121)

Nominal stresses, without taking into account stress concentrations

GEH(von Mises): sigV = ((sigB+sigZ,D)^2 + 3*(tauT+tauS)^2)^1/2
SSH(Tresca): sigV = ((sigB-sigZ,D)^2 + 4*(tauT+tauS)^2)^1/2

Figure: Equivalent stress

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Eigenfrequencies/Critical speeds

1. Eigenfrequency: 0.00 Hz, Critical speed: 0.00 1/min Rigid body translation Y 'SHAFT'
2. Eigenfrequency: 0.00 Hz, Critical speed: 0.00 1/min Rigid body rotation Y 'SHAFT'
3. Eigenfrequency: 2074.12 Hz, Critical speed: 124447.22 1/min Bending XY 'SHAFT', Backward whirl, Bending YZ 'SHAFT'
4. Eigenfrequency: 2078.04 Hz, Critical speed: 124682.66 1/min Bending XY 'SHAFT', Forward whirl, Bending YZ 'SHAFT'

Figure: Eigenfrequencies (Normalized rotation) (Eigenfrequency: 1. (0 Hz))

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Figure: Eigenfrequencies (Normalized rotation) (Eigenfrequency: 2. (0 Hz))

Figure: Eigenfrequencies (Normalized rotation) (Eigenfrequency: 3. (2074.12 Hz))

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Figure: Eigenfrequencies (Normalized rotation) (Eigenfrequency: 4. (2078.04 Hz))

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Strength calculation according to DIN 743:2012

Summary

SHAFT

Material 42 CrMo 4 (1)

Material type Through hardened steel
Material treatment alloyed, through hardened
Surface treatment No

Calculation of endurance limit and the static strength

Calculation for load case 2 (σav/σmv = const)

Cross section Position (Y-Coord) (mm)
Limited cross section 80.00 Key

Results:
Cross section Kfb Kfσ K2d SD SS
Limited cross section 1.00 1.00 1.00 0.00 0.00

Required safeties: 1.20 1.50

Abbreviations:
Kfb: Notch factor bending
Kfσ: Surface factor
K2d: size factor bending
SD: Safety endurance limit
SS: Safety against yield point

Utilization (%) [Smin/S]

Cross section Static Endurance

Limited cross section Division by zero: 100./Qu [0].sResStatisch Division by
zero: 100./Qu[0].sResErmuedung

Maximum utilization (%) [A] 0.000

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Utilization = Smin/S (%)

Figure: Strength

Calculation details

General statements

Label SHAFT
Drawing
Length (mm) [l] 98.40
Speed (1/min) [n] 9000.00

Material 42 CrMo 4 (1)

Material type Through hardened steel
Material treatment alloyed, through hardened
Surface treatment No

Tension/Compression Bending Torsion Shearing

Load factor static calculation 1.700 1.700 1.700 1.700
Load factor endurance limit 1.000 1.000 1.000 1.000

Reference diameter material (mm) [dB] 16.00

σB according to DIN 743 (at dB) (N/mm²) [σB] 1100.00
σS according to DIN 743 (at dB) (N/mm²) [σS] 900.00
[σzdW] (bei dB) (N/mm²) 440.00
[σbW] (bei dB) (N/mm²) 550.00
[τtW] (bei dB) (N/mm²) 330.00
Thickness of raw material (mm) [dWerkst] 11.00

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Material data calculated according DIN743/3 with K1(d)
Material strength calculated from size of raw material
Geometric size factor K1d calculated from raw material diameter
[σBeff] (N/mm²) 1100.00
[σSeff] (N/mm²) 900.00
[σbF] (N/mm²) 1080.00
[τtF] (N/mm²) 623.54
[σBRand] (N/mm²) 708.00

[σzdW] (N/mm²) 440.00

[σbW] (N/mm²) 550.00
[τtW] (N/mm²) 330.00

Endurance limit for single stage use

Calculation for load case 2 (σ.av/σ.mv = const)

Cross section 'Limited cross section' Key

Comment
Position (Y-Coordinate) (mm) [y] 80.000
External diameter (mm) [da] 7.000
Inner diameter (mm) [di] 0.000
Notch effect Key
Number of keys [n] 1
Groove with manufactured with end milling cutter
Own input of:
[b, t] (mm) 0.000 0.000
Mean roughness (µm) [Rz] 8.000

Tension/Compression Bending Torsion Shearing

Load: (N) (Nm)
Mean value [Fzdm, Mbm, Tm, Fqm] 0.000 0.000 0.000 16.080
Amplitude [Fzda, Mba, Ta, Fqa] 0.000 0.248 0.138 0.000
Maximum value [Fzdmax, Mbmax, Tmax, Fqmax] 0.000 0.422 0.235 27.336
Cross section, moment of resistance: (mm²)
[A, Wb, Wt, A] 0.000 0.000 0.000 0.000

Stresses: (N/mm²)
[σzdm, σbm, τm, τqm] (N/mm²) 1.000 1.000 1.000 1.000
[σzda, σba, τa, τqa] (N/mm²) 1.000 1.000 1.000 1.000
[σzdmax,σbmax,τmax,τqmax] (N/mm²) 1.000 1.000 1.000 1.000

Technological size influence [K1(σB)] 0.000

[K1(σS)] 0.000

Tension/Compression Bending Torsion

Stress concentration factor [a] 1.000 1.000 1.000

References stress slope [G'] 1.000 1.000 1.000
Notch sensitivity factor [n] 1.000 1.000 1.000
Notch effect coefficient [ß] 1.000 1.000 1.000
Geometrical size influence [K2(d)] 1.000 1.000 1.000
Influence coefficient surface roughness [KF] 1.000 1.000 1.000
Roughness factor is included into the notch effect coefficient

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Surface stabilization factor [KV] 1.000 1.000 1.000
Total influence coefficient [K] 1.000 1.000 1.000

Present safety for endurance limit:

Equivalent mean stress (N/mm²) [σmV] 0.000
Equivalent mean stress (N/mm²) [τmV] 0.000

Fatigue limit of part (N/mm²) [σWK] 1.000 1.000 1.000

Influence coefficient of mean stress sensitivity.
[ψσK] 1.000 1.000 1.000
Permissible amplitude (N/mm²) [σADK] 1.000 1.000 1.000
Safety against fatigue [S] 0.000
Required safety against fatigue [Smin] 1.200
Result (%) [S/Smin] 0.0

Present safety
for proof against exceed of yield point:
Static notch sensitivity factor [K2F] 1.000 1.000 1.000
Increase coefficient [γF] 1.000 1.000 1.000
Yield stress of part (N/mm²) [σFK] 1.000 1.000 1.000
Safety yield stress [S] 0.000
Required safety [Smin] 1.500
Result (%) [S/Smin] 0.0

Remarks:
- The shearing force is not considered in the analysis specified in DIN 743.
- Cross section with interference fit:
The notching factor for the light fit case is no longer defined in DIN 743.
The values are imported from the FKM-Guideline..

End of Report lines: 510

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