Romax Designer Training Tutorial
Romax Designer Training Tutorial 1.1
Modelling an Automotive Transaxle Gearbox
Task1. Modelling the Lay Shaft and Bearings
● How to create a new disign
● How to create a shaft
● How to “cut” the shaft into a series of sections
● How to select bearings from the on-line bearing catalogs
● How to locate a bearing on a shaft
● How to import components from an existing design file
Task2. Modelling and Loading a Concept Gear Pair
● The parameters required to create concept helical gear set
● How to place a gear on a shaft
● How to specify the mounting of a gear on its shaft
Task3. Positioning Parallel Shaft in 3D
● How to create a gearbox
● How to migrate existing parts into a gearbox
● How to define the relative shaft positions within the gearbox
● How to check the gearbox geometry
Romax Designer Training Tutorial 1.2
Analysis and Optimization of an Automotive Transaxle Gearbox
Task1. Define Load Case and a Gearbox Duty Cycle
● How to locate a gearbox power load
● How to define the load cases in a gearbox duty cycle
● How to define a gearbox power flow
● How to view the loaded components in each load case
Task2. Running Shaft Static Analyses
● How to run a shaft static analysis for an individual load case
● How to inspect the shaft static analysis results
● How to inspect the performance of the bearings
● What to do when a warning appears in the analysis results
● How to replace a bearing that is overloaded
Task3. Running the Duty Cycle Analysis
● How to perform a complete gearbox duty cycle analysis
● How to view the summarized bearing duty cycle results
● How to improve the design of the gearbox on finding a problem with the bearing duty cycle life
Romax Designer Training Tutorial 1.3
Modelling and Anaysis of an Off-Highway Transmission
Task1. Linking Concentric Shafts using Pocket Bearings
● How to specify the orientation of a taper roller bearing
● How to link two concentric shafts using pocketing bearings
Task2. Modelling a 3-Gear Concept Gear Train
● How to create a concept gear train with more than two gears
● How to mesh two gears together
● Any number of gears can be meshed together to create a complex gear train
Task3. Modelling a Concept Clutch Pack
● How to create a concept clutch pack
● How to define the clutch geometry
● How to connect a clutch component to a shaft
Task4. Running Shaft Static Analyses of Concentric
● How to analyze a concentric shaft arrangement
● Loads are automatically transferred between shafts
● Actual bearing operating speeds are used in the bearing life calculation
● The mesh misalignment of gears depends heavily on the stiffness of bearings pocketed between concentric shafts
Romax Designer Training Tutorial 1.4
Modelling and Analysis of an In-Line Transmission
Task1. Defining and Analyzing a Pocket Bearing
● How to analyze a simple pocket bearing arrangement
● Forces and moments are automatically transferred across the pocket bearing arrangement
● Misalignments and displacements are compatible between shafts
● The analysis includes the calculation of the pocket bearing stiffness
Task2. Defining and Analyzing the 4th Speed Power flow
● How to define the 4th Speed power flow for an in-line transmission
● How to interpret the analysis warnings received for 4th Speed
Romax Designer Training Tutorial 1.5
Analysis of Further Shaft/Bearing Arrangement
Task1. Analyzing a 2-Bearing Pocket Bearing System
● How to analyze a 2-bearing pocket bearing arrangement
● Forces are automatically transferred across the pocket bearing arrangement
● The shaft deflections are compatible with one another and with the pocket bearing displacements
Task2. Analyzing a Multiple Pocket Bearing System
● How to analyze a multiple pocket bearing arrangement
● Forces are automatically transferred across the pocket bearing arrangement
● The shaft deflections are compatible with one another and with the pocket bearing displacements
● The analysis includes the calculation of the pocket bearing stiffness
Task3. Analyzing a 4-Bearing Shaft
● RomaxDesigner provides the sophisticated analysis of multiple supported shaft/bearing system
● Shafts and bearing can be modeled in many different arrangements to create complex shaft/bearing/bearing configurations
Romax Designer Training Tutorial 1.6
Analysis of a Detailed Helical Gear Pair
Task1. Converting a Concept Gear Pair
● How to convert a concept gear pair to a detailed gear pair
Task2. Defining the Main Gear Rating Parameters
● How to select the rating standard
● How to select the quality grade of the gear pair
● How to define the surface roughness
● How to set the nominal backlash
● How to apply tooth thinning in order to achieve a normal backlash
● How to define a new gear material and apply it to the gear pair
● How to define a new gear basic rack and apply it to the gear pair
● How to define the lubricant viscosity and the gearbox operating temperature
● How to set the gear mesh misalignment to zero
Task3. Running Gear Ration Calculations
● How to run a gear rating calculation for an individual load case
● How to run the gear duty cycle analysis
● How to inspect the gear rating results
Task4. The Effect of Mesh Misalignment on the Gear Rating Results
● How to inspect the gear mesh misalignment values
● How to include mesh misalignment in the gear rating calculation
● How to use lead correction to accommodate mesh misalignment
● All automotive gears encounter load cases with varying torque levels, requiring a more comprehensive approach to lead correction
● RomaxDesigner provides advanced gear analysis that reaches beyond the international rating standards
● RomaxDesigner can calculate the mesh misalignment of synchronized gears
Romax Designer Training Tutorial 1.7
Design and Optimization of a Detailed Helical Gear Pair
Task1. Validating the ISO 6336 Gear Rating Results
● The RomaxDesigner ISO 6336 gear rating results are validated against hand calculations and other commercial programs
Task2. Optimizing Gear Macro-Geometry, Retaining the Standard Rack
● How to design a gear pair to standard rack dimensions
● The capabilities of the Gear Geometry Designer dialog box
● How to modify the number of teeth, the helix angle and the normal pressure angle of a gear pair
● How to modify the balance of addendum modification by using either pre-defined setting or manual manipulation
● The module is affected by the number of teeth, the helix angle and the sum of the addendum modification coefficients
● The complexities of using an iterative design optimization process
Task3. Optimizing Gear Macro-Geometry, Designing for Maximum Contact Ration
● How to design a gear pair for maximum contact ratio
● How to specify the geometric limitations on tooth extension
Defining Gear Tip and Edge Chamfers
Task1. Defining Tip and Edge Chamfers
● How to apply tip and edge chamfers to detailed gears
● How to control the way in which a tip chamfer is applied by specifying a fixed tip diameter
● The effect of entering the original Basic Rack to Unit Module Addendum value
Task2. Inspecting the Gear Geometry and Rating Results
● RomaxDesigner handles the application of tip and edge chamfers in an appropriate manner
● A number of geometric parameters are affected by the application of chamfers and the changes can be traced back to first principles
Rating and Optimization of Idler Gear Trains
Task1. Converting to a Detailed Idler Gear Train
● How to convert a concept gear train to a detailed gear train
● How to switch between gear meshes in the Detailed Gear Worksheet
Task2. Running the Gear Rating and Inspecting the Idler Gear Results
● How to determine whether a gear is reverse loaded in a particular load case
● RomacDesigner automatically adjusts the bending strength of the gear material when there is reverse bending, in accordance with ISO 6336 and AGMA 2001
Including Gear Mesh Efficiency Calculations
Task1. Defining Gear Mesh Efficiencies
● How to define an inefficiency in a gear mesh
Task2. Analyzing the Effect of Gear Mesh Inefficiencies
● RomaxDesigner automatically includes gear mesh inefficiencies in the power flow calculation
● The system power loss causes a reduction in output power, output torque and bearing loads
Further Analysis of Rolling Element Bearings
Task1. Including Radial Internal Clearance
● How to define the Radial Internal Clearance of a bearing
● How Radial Internal Clearance affects the bearing Duty Cycle Life
Task2. Including Bearing Pre-Load
● How to apply pre-load to a bearing
● How bearing pre-load affects the performance of the bearings, shafts and gears
Task3. Editing the Geometry of a Bearing
● How to add a new definition to the RomaxDesigner bearing database
● How to create a customized bearing by coping an existing bearing
● How to edit the geometry details of a customized bearing
● How changes to the bearing geometry affect the analysis results
Calculating the Mesh Misalignment of Synchronized Gears
Task1. Mounting a Synchronized Gear on a Needle Roller
● How to re-define the mounting of a synchronized gear
● How to re-define the synchronizer connection using a concept clutch pack
● The axial restraint of a synchronized gear is not straightforward
● How to model the complex axial restraint of a synchronized gear using an axial clearance bearing or “thrust pad”
Task2. Analyzing the Synchronized Gear Arrangement
● RomaxDesigner is able to correctly analyze the complex axial restraint of a synchronized gear
● How to interpret the results of the synchronized gear analysis
● The mesh misalignment of a synchronized gear depends heavily on the tilt stiffness of the needle roller bearing pocketed beneath it
● How to include the effect of the needle roller bearing Radial Internal Clearance in the mesh misalignment calculation
Task3. Mounting a Synchronized Gear on a Clearance Bearing
● How to create a radial clearance bearing
● How a redial clearance bearing affects the mesh misalignment values
Further Analysis of an Off-Highway Transmission
Task1. Defining Pocketed Thrust Roller Bearings
● How to determine the required axial orientation of a pocketed thrust roller bearing
● How to specify the axial orientation of a pocketed thrust roller
Task2. Analyzing a Pocketed Thrust Roller Bearing Arrangement
● It is insufficient to use a simplistic approach to the analysis of pocketed thrust roller bearings
● An accurate thrust pocketed bearing analysis must consider the shaft deflection and the bearing misalignments
● How to internal clearance affects the induced axial loads on the pocketed thrust roller bearings
Modeling Split and Convergent Power flows
Task1. Defining and Analyzing Split and Convergent
● How to support a “floating” Main Shaft with stiffness bearings
● How to define a split and convergent powerflow
● RomaxDesigner automatically assumes that there are no errors in the system when calculating the powerflow
Task2. Creating Uneven Power Splits
● How to define uneven power splits using RomaxDesigner
● The gear mesh coupling in RomaxDesigner is actually represented by a stiffness coupling
● RomaxDesigner calculates the uneven power split when manufacturing errors are applied
● The calculation of uneven power splits requires the stiffness of bearings and shafts to be included
Modeling and Analysis of a Truck Transmission
Task1. Coupling a Clutch Component to the Transmission Housing
● How to create a Ground component
● How to connect a clutch component to Ground
Task2. Defining and Analyzing Range Changer Powerflows
● How to define load cases using a range changer planetary gear set
● How to compare powerflows in different speed ranges
Modeling And Analysis of a Transfer Case
Task1. Modelling a Concept Chain Drive
● How to create a concept chain drive
● How to define the chain drive geometry
● How to connect a chain drive sprocket to a shaft
Task2. Modelling a Concept Planetary Gear Set
● The parameters required to create a concept planetary gear set
● How to place the individual planetary components on their shafts
Task3. Defining and Analyzing Split Power flows
● How to define a split powerflow
● RomaxDesigner has flexible analysis capabilities for concept planetary gear sets
● The analysis includes the calculation of the planet gear bearing loads
