KISSsoft AG, A Gleason Company, Switzerland, [Link].

com
KISSsoft is used wherever there are gears!
KISSsoft covers all common gear types, shafts, bearings, shaft-hub connections,
bolts, springs etc. It is used for the analysis of a single element and to design
complex transmissions and drive trains. Training and consultancy services provided
by KISSsoft AG complement the software business.

Join some 4000 licensees and benefit from 40 years of experience in gear software.

Gears keep track of time.

Non involute gears of low friction are

needed to drive watches, clocks, and
timepieces accurately. KISSsoft works
with proverbial Swiss watch accuracy,
keeping you up with time.
[Link]

8 billion humans need food.

Tractors and other agricultural equipment

are one of the pillars on which food
security is based. KISSsoft is used by
most of the top tractor manufacturers to
design and strengthen transmissions and
axles.
[Link]

You like to go to the dentist?

KISSsoft helps to reduce the noise and

vibration in the gears used in dental drills.
Lower noise level means less nervous
patients and therefore less pain during
the treatment.

Whether you play the violin or do water

skiing, gears drive your hobby.

Any hobby relying on a vehicle or a

mechanism (think of the worm gear in a
violine to tune it) features gears. KISSsoft
makes hobbies fun and affordable.

2 / 52 [Link]
Sometimes, trains are delayed.

KISSsoft ensures that the root cause

for a delay is not a gearbox failure in
the locomotive. The high reliability
and lifetime needed in rail transport,
for example in high-speed trains, is
achieved through detailed life and
failure probability calculation
methods.

The center of the milky way is 25’000 light

years away.

KISSsoft is used to maximize the slewing

bearing stiffness to maintain antennae and
telescope elevation accurately. Highly
detailed images of our solar system are the
result.

We all pay water bills.

Sensors, like fluid flow sensors,

required high ratio, low friction
geared transmissions to drive clocks
metering usage. KISSsoft allows for
optimization of the gears to achieve
high metering precision at low cost.

Space travel. The hobby of the ultra-rich.

And yes, there are gears used in rovers,

satellites, rockets and their actuators. And of
course, KISSsoft is used for the design for
highest reliability at lowest mass.

Gears are everywhere and every

day, new applications of this time-
tested machine element are found.

In what application do you use

gears? Ask for our assistance in your
gear design and verification process,
be it through our software, training,
or consultancy services.

3 / 52 [Link]
Global presence

40 years KISSsoft

4 / 52 [Link]
Applications
Fine pitch, plastic, and sintered gearing
▪ Printers, copiers, tray drives
▪ Geared motors, gearheads
▪ Automotive actuators
▪ Medical, building automatization, HVAC
▪ Power tools, kitchen appliances
▪ Watches, meters, and sensors
▪ …

Energy generation
▪ Turbo gears
▪ Wind turbine main gearboxes
▪ Generator shafts
▪ Engine gear trains
▪ Pitch and yaw drives
▪ …

Aerospace
▪ Rovers, satellites
▪ Geared turbo fans
▪ Helicopter MGB, IGB, TGB transmission
▪ Fuel, oil pumps, alternator drives
▪ Turbine power take off, starter gears
▪ Civil and military drones
▪ Flap actuators, unmanned aerial vehicles
▪ …

Industrial
▪ General purpose and heavy-duty gearboxes
▪ Mining and raw materials handling
▪ Cranes and winches, mill drives
▪ Servomotors, geared motors
▪ Robotics, spindle drives
▪ Open gears, girth gears
▪ 5 axis CNC milling of gears
▪ Bearings, slewing bearings
▪ …

Vehicles
▪ EV transmissions, E-axles
▪ Cars, trucks and buses
▪ Tractors, harvesters
▪ Motorbikes, three wheelers, RVs
▪ Motorsport
▪ Military, tracked, armored vehicles
▪ Construction equipment, forklifts
▪ Engine drive trains, valve drive train
▪ …

5 / 52 [Link]
Modules
General
▪ KISSsoft module as individual modules
▪ KISSsys module requires KISSsoft
▪ CAD and FEM modules require KISSsoft

KISSsoft
▪ Cylindrical, rack & pinion, bevel and hypoid,
beveloid, worm, face gears, crossed axis
helical, non-circular gears
▪ Shafts and rolling element bearings,
hydrodynamic bearings, coaxial shaft
systems, bearing stress and load distribution
▪ Shaft modal analysis and unbalance response
▪ Shaft-hub connections, bolted connections
▪ Spring analysis, chains and belts, clutches
▪ Tolerance stack-up, local stress analysis,
Hertzian contact stress, spindles
▪ Plastic gear materials manager
▪ Load spectrum from time series
▪ Gear body deformation

KISSsys
▪ Library of gearbox models for typical designs
▪ Machine element library to build own models
▪ Programming language module
▪ Suitable for virtually any gearing system
▪ Housing stiffness import from FEM (ABAQUS,
ANSYS, NASTRAN, …)
▪ System efficiency calculation, thermal rating
▪ Load spectrum rating on system level
▪ Modal analysis / natural frequencies
calculation on system level

CAD interfaces and supported formats

▪ Interfaces to other Gleason software like
GEMS®, GAMA®
▪ 2D CAD export in neutral / graphic formats
▪ 3D export to CAD systems (gear geometry)
▪ Interfaces to multi body systems software

Databases
General
▪ Database is user editable and can be
transferred from one release to next
▪ FAG / INA, SKF, Koyo, Timken, …
▪ For standard bearing data and bearing inner
geometry (only through user input)

6 / 52 [Link]
KISSsys, systems module
Overview
KISSsys software combines kinematic analysis,
lifetime calculation, 3D graphics, user defined tables
and dialogs with a programming language. It is the
tool of choice for strength and lifetime analysis of
various kinds of drive trains and gearboxes. KISSsys
lets the user do quick yet detailed parametric studies
of a complete power train in very little time to
compare different variants of a concept or to analyze
a given design for different loads.

In KISSsys, all parts (gears, shafts, bearings,

connections) of the gearbox are linked and the
strength / lifetime analysis is performed
simultaneously for all elements. A three-dimensional
graphical presentation of the current state of the
system immediately shows the geometrical influence
of every change in parameters. This approach
greatly accelerates the design process and results in
a much more balanced design even during the
concept phase.

The machine elements calculated range from gears,

shafts, bearings, shaft-hub connections to bolts. This
will result in a more balanced starting design and
fewer modifications will be necessary further down in
the design process to reach an optimized design.
Furthermore, documentation of the calculation is
simplified and all calculation data for a whole drive
train or gearbox is stored in a single file. KISSsys
uses KISSsoft for the strength and lifetime
calculations of the various machine elements.

Kinematics Calculation:
▪ Power flow / speed with spur, bevel, worms
and face gear stages
▪ Modelling of rotational mechanisms
(planetary, Ravigneaux, Wolfrom, Wilson, …),
▪ Differentials, (with bevel or spur gears), chain
and belt transmissions
▪ Couplings can be activated and deactivated,
slippage taken into account

7 / 52 [Link]
Calculations in KISSsys
Integrated strength and lifetime calculation:
▪ With integrated KISSsoft calculation modules
▪ System deflection is considered in tooth
contact analysis

Machine element library

▪ Spur / helical gear pair and chain of gears
▪ Planetary gears, compound planetary gears
▪ Bevel and hypoid gears, beveloid gears
▪ Worm gears, crossed axis helical gears
▪ Face gears with and without offset
▪ Shaft-bearing systems, coaxial shafts
▪ Shaft-hub connections
▪ Synchronizer

3D representation
▪ Automatic 3D-display (based on the data
defined in KISSsoft),
▪ 3D-model export to CAD platforms, gearbox
housing import, (*.step / *.iges),
▪ Collision check with imported CAD geometry

Special features
▪ Calculations with load spectra for all machine
elements in the model
▪ Integrated programming language for
implementation of special functions
▪ Animation of gear movement
▪ Cut view and deformed systems display
▪ Wizards, libraries and toolboxes for quick
modelling

Typical applications
▪ Analyze wind turbine gearboxes for different
loading conditions
▪ Ensure that the design of a plastic gear set for
an automotive actuator fits into a given design
space
▪ Calculate power flow in CVT transmission
▪ Maintain a database of geared motor gears
▪ Estimate the manufacturing cost of a gearbox
even during the design phase
▪ Optimize bearing lifetime by variation of the
gear’s positions on a shaft
▪ Create specific reports e.g., for certification
▪ And many more …

8 / 52 [Link]
Housing stiffness import
The housing stiffness and the housing deformation
may be considered for the loaded tooth contact
analysis in KISSsys by means of
▪ Input of housing deformation values in a table
▪ Import of housing stiffness matrix / reduced
stiffness matrix

Supported FEM codes

▪ ABAQUS
▪ ANSYS
▪ NASTRAN

Features
▪ Node mapping: connect master nodes of
stiffness matrix to KISSsys model bearings
▪ Deformation vector is calculated inside
KISSsys using bearing forces and stiffness
matrix
▪ Automatic alignment of stiffness matrix
coordinate system to KISSsys model
coordinate system

Modal analysis
▪ Calculate system natural modes and natural
frequencies
▪ Considers bearing operating stiffness matrix
▪ Considers gear mesh stiffness
▪ Considers shaft stiffness, inertias and masses
▪ Animation of modes on system level
▪ Comprehensive report

Thermal rating
▪ Calculates power losses due to gear meshes,
bearing friction, churning and seal friction
torque
▪ Based on ISO/TS 14179-1 / ISO/TS 14179-2
▪ For oil bath or forced lubricated systems
▪ Calculates and lists individual power losses
and system efficiency
▪ Sizing of cooler, calculation of thermal
equilibrium, calculation of required oil flow

Gleason GEMS® interface

▪ Export EPG data from KISSsys
▪ Interface to GEMS® and GAMA®

9 / 52 [Link]
GPK module
GPK module is a set of readymade KISSsys models.
The models are provided to the customers as a
library to be used in KISSsys. The models made
available cover the most typical industrial gearboxes.
The models feature advance level functions to
accelerate the design process of standard industrial
gearboxes. The need for the user to build his own
models is eliminated and detailed reporting functions
further reduce the time to document the design.
Automatic sizing functions for the gears, bearings
and shafts result in a well-balanced gearbox. Price
calculations based on user defined cost per mass
data allow for constant control over gearbox costs.

Types of gearboxes
▪ Helical gearboxes
▪ Bevel, helical-bevel gearboxes
▪ Worm, worm helical gearboxes
▪ Planetary gearboxes

Configurations
▪ One, two, three, four or five stage helical
gearboxes, with or without roller bearings
▪ One bevel without, with one, two or three
helical stages, all with roller bearings
▪ One worm without, with one, two or three
helical stages, all with roller bearings

Functions
▪ Sizing of gear stages (distribution of ratio
among the stages, sizing for given center
distance)
▪ Sizing of shafts and bearings (based on stress
levels and required bearing life)
▪ Cost estimation (considering bearings, shafts
and gears)
▪ Report generation (summary, pricing and
detailed report)
▪ Detailed gear, bearing and shaft design
through KISSsoft
▪ Free arrangement of shafts in space
▪ External forces on input and output shaft
▪ Settings for lubrication, temperature,
orientation of gearbox in space, materials,
calculation methods and graphics

10 / 52 [Link]
Cylindrical gear basis modules
Configurations
▪ Spur or helical gear, herringbone gear,
considering face width offset
▪ Grease or oil lubricated or dry running gears
▪ Metallic or plastic gears
▪ Involute or non-involute gears
▪ Any number of teeth, any type of tooth height,
internal or external gears

Gear geometry calculation

▪ Gear geometry along ISO 21771
▪ Reference profile along ISO 53.2, DIN 867,
JIS, BS5482 or own input
▪ Tolerances along DIN 3967, ISO 1328, own
input or for theoretical gearing
▪ Centre distance along ISO 286, ISO 7168,
DIN 58405 or own input
▪ Gear quality along ISO 1328, AGMA 2015-1-
A01, DIN 3961, DIN 3961, DIN 3963, DIN
23961, DIN 23962, DIN 23963, AGMA 200-
A88

Gear rating
▪ DIN 3990 method B, DIN 3990 method B with
YF along method C, DIN 3990 Part 41
(vehicles) method B
▪ ISO 6336:2006 and ISO 6336:2019
▪ Static rating against yield
▪ AGMA 2001-B88, AGMA 2001-C95, AGMA
2001-D04, AGMA 2101-D04 metric
▪ AGMA 6004-F88, AGMA 6014-A06, AGMA
6011-I03, AGMA 6015-A13
▪ GOST 21354-87
▪ Plastic gears along Niemann, VDI 2545, VDI
2545 modified, VDI2736
▪ As FVA software for DIN 3990
▪ BV / Rina FREMM3.1, Rina 2010, DNV41.2
▪ ISO 13691:2001 (high speed gears)
▪ For nominal load or load spectrum

Reports
▪ For default report or user specific template
▪ Geometry and strength reports
▪ Tooth scuffing, micropitting and wear
▪ Tooth thickness dimensions, tooth tolerances
▪ Modifications, manufacturing

11 / 52 [Link]
Cylindrical gear general modules
Gear geometry calculation
▪ Calculation based on gear or tool reference
profile
▪ Calculation based on true tool geometry
▪ Calculation based on mating gear geometry
▪ Import and export of gear or tool geometry
from CAD system
▪ Calculation of theoretical, acceptance and
operating backlash for metallic and plastic
gears and housings

Load spectrum calculation

▪ Direct input of load spectrum or import from
text or Excel file
▪ Calculation of lifetime based on required
safety factor, safety factors based on required
lifetime and permissible torque based on
required safety factor and lifetime
▪ Calculation of partial damages
▪ Calculation of equivalent torque
▪ For DIN 3990, ISO 6336 and AGMA 2001

AGMA925 calculations
▪ Calculation of scuffing safety
▪ Calculation of contact stress, lubricant film
thickness

Micropitting and scuffing calculation

▪ Micropitting rating along ISO/TR 15144
▪ Specific lubricant film thickness calculation
along AGMA 925
▪ Lubricant film thickness calculation along
ISO/TR 15144 based on true contact stress
▪ Scuffing rating along ISO 6336-20, ISO 6336-
21, DIN 3990-4

Flank fracture calculation

▪ Along ISO/DTS 6336-4 or Annast method
▪ Along method A (based on LTCA) or method
B (based on formulas)
▪ Case crushing calculation along DNV 41.2

Master gear calculation

▪ Calculation of master gear geometry
▪ Meshing of master gear with gear

12 / 52 [Link]
Cylindrical gear sizing modules
Configurations
▪ Sizing functions to find optimized gears (in
terms of mass, power density, stiffness, space
requirements)
▪ Functions to reverse engineer gears
▪ Functions to optimize gear properties

Rough sizing
▪ Proposal of several gear solutions for required
power rating, required ratio, given material
▪ Considers gear quality, permissible ratio error
▪ For single load level or load spectrum

Fine sizing
▪ Define permissible ranges for module,
pressure angle, helix angle, center distance
and profile shift
▪ Define target ratio and permissible deviation
▪ Define maximum number of solutions
▪ Set maximum permissible tip diameter and
minimum permissible root diameter
▪ For pre-defined number of teeth or varying
number of teeth
▪ Different filter and sorting functions
▪ Report with assessment of solutions for
different criteria

Macro geometry sizing

▪ Sizing from gear pair data
▪ Sizing for target profile shift sum
▪ For balanced specific sliding / speed increaser
▪ To avoid pointed tooth or undercut
▪ For maximized strength on flank or root or
maximized scuffing strength

Sizing of tooth height / reference profile

▪ Sizing of reference profile for target
transverse contact ratio
▪ Sizing of maximum possible root radius

Sizing of profile and lead corrections

▪ Sizing of tip and root relief Sizing of end relief
and crowning
▪ Automatic search for optimum corrections

13 / 52 [Link]
Cylindrical gear modifications
Configurations
▪ Considers all modifications in profile and lead
direction
▪ Calculation based on 41 or more gear
sections
▪ Pitch errors may be considered in part or fully
▪ Calculation for nominal or operating center
distance
▪ Calculation for nominal or partial load level
▪ Meshing friction considered in calculation
▪ Considers true gear geometry from
manufacturing simulation

Output
▪ Calculation of load distribution in profile and
lead direction
▪ True stress levels compared to stress levels
calculated along standards (ISO / DIN /
AGMA)

True root stress calculation

▪ Calculation of YS and YF along full tooth root
▪ Considering true root geometry from
manufacturing
▪ Root geometry optimization for minimized root
stresses

Micropitting along ISO/TR 15144

▪ Calculation of specific lubricant film thickness
 along g ISO/TR 15144
▪ Considering true contact stress, temperature
in contact, surface roughness and lubricant
properties
▪ Calculation of micropitting safety, method A
and B

Lead and profile modifications

▪ End relief (left and right end), crowning
▪ Helix angle modification
▪ Linear and progressive tip / root modification
▪ Profile crowning (barreling)
▪ Pressure angle modification
▪ Tip chamfer or rounding
▪ Grinding disk plunge depth
▪ Graphical output in involute diagram
▪ Flank twist
▪ Triangular end relief (left and right end)

14 / 52 [Link]
Gear body influence
Modelling and FEM
▪ Hub / web / rim arrangement
▪ Parametrized geometry
▪ Automatic meshing with parabolic tet elements
▪ Calculation of deformation and stiffness matrix
▪ Stiffness matrix connected to shaft calculation
▪ Geometry preview
▪ In combination with LTCA

Tooth geometry export

Configurations
▪ With or without profile / lead modifications
▪ Modifications may be different per tooth
▪ Modifications may be different per flank
▪ Output in transvers, normal and axial section
▪ Output of tooth or gap, single or half tooth
▪ Output as x,y format to use e.g., in
spreadsheet calculations
▪ Output as x, y, z format in line with Gleason or
Klingelnberg format for measuring machines
▪ Considers true gear geometry from
manufacturing simulation

Load rating with time series

Import and conversion
▪ Import time series of speed and torque from
text file
▪ Convert to load duration distribution load
spectrum (LDD), save LDD for gear rating
▪ Considers changes in torque direction
▪ Considers changes in speed direction
▪ Graphical display of resulting load and speed
distribution

Configurations
▪ Rain flow count method according to
Amzallag or ASME
▪ Simple count method

15 / 52 [Link]
Loaded tooth contact analysis
Configurations
▪ Considers all modifications in profile and lead
direction
▪ Calculation based on up to 41 gear sections
▪ Pitch errors may be considered in part or fully
▪ Calculation for nominal or operating center
distance
▪ Calculation for nominal or partial load level
▪ Meshing friction considered in calculation
▪ Considers true gear geometry from
manufacturing simulation
▪ For internal and external gears
▪ User defined accuracy level in calculation
▪ Line load calculation along ISO 6336-1,
Annex E with consideration of manufacturing
errors

Mesh stiffness calculation

▪ Calculation of Transmission Error for spur and
helical gears, showing peak to peak
transmission error, average and standard
deviation
▪ Calculation of normal force, torque variation,
contact stiffness, bearing forces, kinematics,
specific sliding and local heat generated over
meshing cycle
▪ Results displayed vs. roll angle, pinion
diameter, length on line of action, pinion angle
of rotation
▪ Calculation has been verified in benchmarks
against reference software, practical
experience in full load tests and FEM
calculations

Output
▪ Graphics, exportable as graphic format or
*.dxf
▪ Report including calculation settings and
results summary
▪ Report including all graphics

True contact ratio calculation

▪ Calculation of true transverse contact ratio
under load
▪ Calculation of true total contact ratio under
load

16 / 52 [Link]
Detailed backlash calculation
Backlash from true tooth form
▪ Backlash is calculated as an angular backlash.
▪ Theoretical backlash is calculated based on
true tooth form. Tooth form may be involute,
involute with modifications or non-involute. For
non-involute tooth form or involute tooth form
with modifications, backlash is not constant
over meshing cycle.
▪ Backlash is calculated for highest, lowest and
mean tooth thickness / diameter / center
distance combination, resulting in three
curves.
▪ Collisions and tip to root interferences are
indicated by zero backlash condition.
▪ Gear modifications in lead direction are
considered, backlash is calculated for a
number of slices along the face width.
▪ Tooth deformation and temperature influence
are not considered.
▪ Works also for tooth form from imported *.dxf
files.

Backlash, acceptance backlash, operating

backlash
▪ Theoretical backlash in transverse and normal
section, chordal and arc value, considering
tooth thickness and center distance
tolerances.
▪ Acceptance backlash considering runout,
manufacturing errors and axis misalignment.
▪ Operating backlash considering housing and
gear temperatures and moisture absorption.
▪ Contact and collision check in 2D graphic in
transverse section for any tooth thickness,
diameter and center distance tolerance
combination.
▪ Recommendation of tooth thickness
tolerances in case of gear jamming.
▪ Backlash definition through manufacturing
profile shift or tooth thickness tolerances.
▪ Calculation of tooth thickness / backlash from
span measurement or from diameter over
pins.
▪ Strength calculation on theoretical gear or on
gear with backlash.

17 / 52 [Link]
2D FEM of virtual spur gear
FEM models
▪ 2D plane stress model using parabolic
triangular elements with variable mesh density
▪ Mesh density is maximized for critical area in
the root
▪ Resulting stress levels are calculated for
contact point of 30° (60°) tangent to
theoretical tooth form, for contact point of 30°
(60°) tangent to actual tooth form and for point
with highest stress
▪ Stress levels are reported and compared to
nominal stress calculated along ISO 6336
▪ FEM pre-processor (Salome) and solver
(Code Aster) are remote controlled requiring
no interaction.
▪ Pre- and post-processor may be opened after
calculation to check mesh, boundary condition
and results
▪ Different stress values like von Mises, max
and min principal and others may be shown.
Different color bars may be used.

Root stress calculation

▪ For standard gear geometry with trochoidal
fillet based on circular tip of tool
▪ For non-standard gear root geometry
including machining notches / grinding
notches
▪ For non-trochoidal, e.g., circular or elliptic root
shape
▪ Also, for cycloidal and circle shaped (non-
involute) gears
▪ For asymmetrical involute gears

3 FEM
FEM model
▪ For spur and helical gears
▪ Using non-linear tetraeder elements

18 / 52 [Link]
Planetary gears
Overview
▪ Based on helical gear calculation modules
▪ Calculation of planet pin location for non-
evenly spaced planets
▪ Influence of rim thickness of ring gear and
planet gears considered
▪ Assembly check
▪ Sizing function for load distribution factor
along AGMA 6123
▪ Rough and fine sizing function

Strength rating, planets

▪ DIN 3990 method B, DIN 3990 method B with
YF along method C, DIN 3990 Part 41
(vehicles) method B
▪ ISO 6336
▪ Static rating against yield AGMA 2001-B88,
AGMA 2001-C95, AGMA 2001-D04, AGMA
2101-D04 metric
▪ AGMA 6004-F88, AGMA 6014-A06, AGMA
6011-I03
▪ GOST 21354-87
▪ Plastic gears along Niemann, VDI 2545, VDI
2545 modified, VDI 2736
▪ As FVA software for DIN 3990
▪ BV / Rina FREMM3.1, Rina 2010, DNV41.2
▪ ISO 13691:2001 (high speed gears)
▪ For nominal load or load spectrum
▪ Planet system reliability
▪ Micropitting rating along ISO/TR 15144,
scuffing rating along ISO 6336-20, ISO 6336-
21, DIN 3990, AGMA 925
▪ Flank fracture rating along ISO/DTS 6336-4
and case crushing rating along DNV 41.2

K calculation
▪ For systems with perfect pin position or for
pins with positioning error
▪ Quasi-static load distribution neglecting
dynamic effects
▪ Sun may be floating or stationary
▪ K is calculated for momentary force
equilibrium for different meshing positions
▪ Considering system equilibrium for in-phase
and out-of-phase systems

19 / 52 [Link]
Planetary tooth contact analysis
FEM calculation of planetary carrier
▪ Planetary carrier torsion is calculated inside
KISSsoft with FEM
▪ Salome / Code Aster is used as pre-processor
and solver, using Python scripts
▪ Based on parameterized model of the carrier
(import of carrier geometry is not directly
possible)
▪ Mesh generation is automatic
▪ Includes sizing function for planetary carrier
geometry
▪ Results may also be directly imported from
FEM results file

Ring gear deformation

▪ In case of ring gears supported only on one
side, the conical deformation may be
considered for the planet – ring gear mesh

Sun gear arrangement

▪ Floating or fixed sun gear
▪ In case of floating sun gear, quasistatic
momentary equilibrium is calculated

Link to shaft calculations

▪ Planetary carrier tilting in carrier bearings or
due to manufacturing errors may be
considered from shaft calculation
▪ Sun shaft twist, sun shaft tilting may be
considered in LTCA with planets
▪ Planet pin deformation and planet bearing
deformations is automatically imported from
shaft calculation
▪ Planetary tooth contact analysis may be
integrated into KISSsys models

20 / 52 [Link]
Rack and pinion modules
For spur, helical or double helical arrangement

Strength rating
▪ Along ISO 6336, DIN 3990, AGMA2001,
AGMA6004, BV / Rina FREMM 3.1 for
metallic gears
▪ VDI 2736, VDI 2545 and Niemann for plastic
gears

Output
▪ Reports for manufacturing tolerances, drawing
data, hardness depth proposal
▪ Life and strength results
▪ 2D and 3D gear geometry

Crossed axis rack and pinion

▪ Axis angle ≠ 0°
▪ Calculation of geometry
▪ Calculation of contact ellipse size
▪ Stress calculation, strength rating
▪ No load contact pattern
▪ Considering lead and profile modifications
on pinion
▪ Export of 3D geometry in neutral format
▪ Not for double helical
▪ Part of crossed axis helical gear modules

Elliptical gears
Mesh calculation for wave gears

Geometry
▪ Definition of elliptical external gear
▪ Definition of circular internal gear
▪ With low number of teeth difference

Output
▪ Graphical representation of mesh

21 / 52 [Link]
Functions related to
cylindrical gear manufacturing

Pre-machining tool
▪ How to define the tool addendum length, to
achieve the required gear dedendum?
▪ Which protuberance amount is needed to avoid
the grinding notch with certainty?
▪ Can I use any existing tool for pre-
manufacturing a new gear?

When pre-machining is applied, the tool

addendum needs to be enlarged to
compensate the manufacturing profile shift. As a result, the tip form diameter is shown.
To avoid grinding notches, the Also the reduced contact ratio is shown,
protuberance is applied on the pre- what affects also both the noise and
machining tool, to avoid the increased strength rating of the gear and has to be
stress concentration. documented for further processing. As pre-
machining tools, hobs and pinion type
cutters are available.

Grinding depth
▪ What minimum grinding depth (root grinding,
flank grinding) is required?
▪ Is the grinding depth sufficient to avoid
interference / collision when meshing?
▪ What is the trace of tooth tip when meshing?
The root radius is applied as large as
possible to reduce the root stresses (“full
fillet” design), but to be checked for root The addendum of the hard-finishing tool is
form diameter. calculated for required minimum active root
diameter, maximum root form diameter or
Chamfering and topping tools to avoid grinding the root etc.
▪ What is the contact ratio change due to a
chamfer?
▪ Is the noise behavior still ok with the reduced
contact ratio due to chamfer?

The chamfering of the gear when pre-

machining requires an individual tool.
KISSsoft allows the definition of the ramp
angle and chamfer size.

22 / 52 [Link]
Left: Tool workpiece interference,
Right: No interference

The simulation of rolling the gears shows Diameters, meshing interference and
interference for several tolerance conditions. collisions
The trace curve of the tooth tip shows the ▪ How does the tooth thickness tolerance range
potential collision clearly. affect the range for dFf, dFa and df?
▪ What is the influence of machining stock and
Grinding dresser tool tip shape on the upper root form diameter?

▪ Can we reuse a grinding dresser for another

workpiece? The manufacturing profile shift of the pre-
▪ What is the effect on the gear design if we use machining and final machining tool affect
an existing grinding dresser? the form diameters and thereby the
available involute length. A display of all
relevant diameter, for different tolerance
KISSsoft checks whether, for a given gear
conditions, and for different machining
design, an existing grinding dresser can be
steps visualizes the calculated values.
used or re-used.
Meshing

interferences, safety distances and

collisions may be detected in high
resolution graphics with animation functions.

The software shows the resulting gear

modifications if an existing grinding dresser
is used, reducing tool costs and eliminating
tool lead time. The difference between the
designed modifications and the machined Form diameters, active diameters, tip and root diameter,
reference circle / base circle, operating pitch diameter
modifications is evaluated and the effect and diameter for DOP measurement.
can be checked using KISSsoft functionality.

23 / 52 [Link]
 Hob and shaping cutter data imported in KISSsoft
Influence of tooth thickness on dFf (green / blue: tooth
form, pre- and final machining, highest xE value, red /
black: lowest xE value). Short lead hob
▪ What is the influence of the hob module on the
workpiece root shape?
Hob database
▪ How does a short lead hob affect the gear
▪ How can we ensure that gear designers
strength?
consider existing tools when choosing a
workpiece design?
▪ How can I request for a new tool based on the Short lead hobs create a different root
current gear design? shape resulting in different stress levels that
cannot be assessed using DIN, ISO or
AGMA gear rating standards. When using a
The reference profile, pressure angle, short lead hob, it is then recommended to
module and a tool reference number can be use the FEM calculation in KISSsoft
imported into KISSsoft considering the root geometry and
database from a text file. The tool inventory curvature as manufactured. A comparison
is then reflected in the gear design software. of stress levels for different hob modules
allow for an approval of a certain hob
Gear designers may then check on the design.
availability of a suitable tool for a gear
design and reducing the number of new
tools needed. If a new tool is required, the
gear profile data can be exported and sent
to Gleason tool manufacturer on one click.

24 / 52 [Link]
 In addition, it is also possible to export the
corresponding tool-gear helical calculation
as a KISSsoft file which can then be
opened separately and may be used for
visualization or problem-solving purposes.

Upper image: Root shape hobbed with standard hob. Lower

image: Root shape hobbed with short lead hob.

Power skiving
▪ Can a tooth profile be manufactured with power
skiving? Forming and generating final
▪ Is there sufficient runout for the tool regarding machining
the shaft shoulder? ▪ How can we avoid grinding notches for
generating and forming grinding operation?
KISSsoft allows to estimate the ▪ For a given final machining stock on the flank,
manufacturability of gears using power how can we achieve a desired material
skiving. On one hand, the tooth geometry is removal in the root?
checked regarding machine and tool
limitations, on the other hand, the gear can In different industries, different grinding
optionally also be checked for collisions techniques and strategies are used. While
with the tool. Collisions scenarios which in industrial gears, the root is typically not
shall be checked can be activated. ground, it is ground in most cases for
aerospace gears. For large gears, a
forming final machining process (e.g., hard
hobbing with form cutter) may be used
whereas for e.g., car transmission gears, a
generating grinding process is common.

Grinding notches should be avoided for

high performance application while they
may be found in gears produced with small
batches. KISSsoft allows to tune the stock
removal on the flank and root separately
and final machining tool runout is checked.

25 / 52 [Link]
26 / 52 [Link]
27 / 52 [Link]
 Non involute gears with positive radius of
curvature on the flank can typically be
manufactured in a generating process using
rack type or pinion cutter type tools.
KISSsoft calculates the gear reference
profile through a reverse generating
process. The rack profile may then be
Left: Generating grinding with grinding notch. Right: exported as 2D *.dxf for tool production.
Form grinding with grinding notch.

Green: Non-involute gear with circular tip area

Blue: Basic rack of tool

Measurement and quality

Measurement grid coordinates

▪ 3D models as STEP and measurement grid
▪ Data export in GDE and GAMA® format
Left: Root and flank both ground. Right: Grinding depth ▪ Including microgeometry and tolerances
= hobbing depth. Blue: gear after pre-machining, gray:
grinding disk, green: gear after final machining + root
form diameter
To control a CMM or for the sake of
verification, the measuring grid coordinates,
Tool profile for non-involute gears and the normal vectors are calculated and
▪ How can we determine the tool profile for non- reported in KISSsoft for a user defined
involute gears? number of flank points.
▪ Is the workpiece profile manufacturable with a
generating process?

28 / 52 [Link]
 For involute splines, flattened ball needs to
be applied to avoid the touching of the gear
root.

Tooth thickness is calculated for a given

diameter, for theoretical gear or considering
tooth thickness allowances.

The export formats for GDE and GAMA®

are available. They allow for a fast and safe Calculated diameter over pin for theoretical,
data transfer between various mean, upper and lower value may then be
manufacturing and measurement machines. compared to measured DOP using Gleason
over pins gauges.
Tooth thickness and span width
▪ What are the required tooth thickness values
for pre-machining and final machining?
▪ What are the permitted tooth thickness values
including the tolerances?
▪ Flattened ball for splines

The gear tooth thickness and span width

can be determined for any manufacturing
step. Using the tooth form analysis in
KISSsoft, the analysis of tooth thickness at
any position of tooth height is possible.

29 / 52 [Link]
 Profile and tooth trace modification
▪ Lead, profile and combined modifications
▪ Topological modifications
▪ Tabular, graphical data for manufacturing
drawings

Various gear modifications can be defined

for right and left flanks independently for
optimum running performance for each
flank.

Master gears
▪ Can we use an available master gear or is a
new one required?
▪ Which area of the involute is checked?

Based on a given workpiece design and the

The K-charts are provided in KISSsoft for required diameters to be in contact with a
reference of the measurement machine. master gear, the suitability of a given
Also, the cumulated modifications per flank master gear is checked. Alternatively, a
are available in 3D graphics. new master gear design is calculated
considering workpiece diameter tolerances.
Master gears may then be used on Gleason
GDE format for data exchange and other testers.
▪ How do we communicate gear data easily and
error free between different departments or
companies?
▪ How do we get relevant gear geometry data
that is missing on a drawing?

A unique, simple, accurate and flexible way

to describe gear geometry and
manufacturing data is implemented in
KISSsoft based on VDI/VDE 2610 guideline.
The data exchange between

design department, production and quality

inspection group, or with customers, is
thereby simplified and accelerated. It
serves as a digital gear table and is used in
parallel to a drawing.

30 / 52 [Link]
 There, the designed and the measured
geometry are analyzed (contact pattern
under load, transmission error, force
excitation, …) and performance
characteristics are compared in parallel.
Based on this, the manufacturing process
with its deviations may be approved or the
need for a more accurate or stable process
may be identified.

Lower image: Calculated master gear properties for a Root radius and tooth root stresses
given workpiece, considering tip and root form diameter
tolerances. ▪ What is the stress concentration due to a
grinding notch?
▪ How can we assess root stresses for non-
trochoidal root shapes?
Analysis of manufactured gears

Gear root strength is usually assessed

Design-manufacture-measure using applicable DIN, ISO or AGMA rating
▪ What is the vibration characteristic of the standards. However, in the case of
machined gear compared to the designed nonstandard root shapes or grinding
gear? notches, a FEM calculation is required.
▪ How do machining errors influence the contact
pattern under load?

When grinding notches or other machining

errors are created, KISSsoft provides a 2D
FEM calculation where the stress increase
is shown. Based on the stress level, gears
The design-manufacture-measure loop may be safe for operation or need to be
integrates KISSsoft, Gleason gear scrapped.
machines and metrology solutions.
Machining errors may result in elevated Natural and designed twist
noise levels or poor contact patterns in
▪ What amount of natural twist results from
operation. To predict if the performance
threaded wheel grinding?
characteristics of a machined gear are
satisfactory, the measured flank deviations ▪ What are the resulting deviations from the
are imported into KISSsoft. designed flank geometry?

31 / 52 [Link]
 Assembly contact pattern
In threaded wheel grinding process for
helical gears with lead modifications, a ▪ How can we check that a contact pattern after
natural twist results (unless it is assembly is as required?
compensated). Its effect on the contact ▪ How do bearing play and assembly tolerances
under load and the vibration excitation may influence the contact pattern?
be assessed using KISSsoft. Furthermore,
a desired twist amount to mitigate the No load contact patterns after assembly are
negative effect of gear misalignment under typically available towards the final phase of
load may be designed and optimized. the gearbox assembly only. The contact
pattern at no load, but considering bearing
clearances, can be predicted with KISSsoft.
It then serves as a basis for the acceptance
of the unit under assembly. The marking
compound thickness may be given in the
calculation as an additional parameter.

Sizing functions in KISSsoft automatically

find the optimal flank twist amount to
achieve optimal contact pattern under load.
It then needs to be checked by the
production engineers whether the
calculated twist amount can be
manufactured.

Above: Contact pattern after spin test during gearbox

assembly
Below: predicted contact pattern considering gear
microgeometry and bearing clearance influence.

32 / 52 [Link]
Bevel gear modules
General
▪ Strength rating for nominal load or load
spectrum
▪ Database for reference profile and tolerances
▪ Different geometry configurations with uniform
tooth depth, constant slot width, modified slot
width, different root and tip apex positions
▪ For spur, helical or spiral bevel gears
▪ Rough and fine sizing function
▪ Calculation of measurement grid for
Klingelnberg, Gleason or Wenzel gear tester

Strength rating
▪ Strength rating along ISO 10300, Method B
and C, DIN 3991, AGMA2003, CN3028 /
KN3030 for Cyclo-Palloid gears and along
KN3025 / KN3030 for Palloid gears
▪ Hypoid gear calculation along KN3029 /
KN3030 for Cyclo-Palloid gears, KN3026 for
Palloid gears, ISO 10300
▪ Plastic gear rating along VDI 2545 or
Niemann
▪ Static strength rating and rating of differential
planetary gears, efficiency along Wech
▪ Flank breakage calculation along Annast and
ISO/DTS 6336-4, scuffing rating along DIN
3990-4, ISO/TS 6336-20, ISO/TS 6336-21

Manufacturing
▪ For face hobbed or face milled gears
▪ Considering Klingelnberg machine list
▪ Accurate 3D gear geometry for CNC
machining
▪ No load tooth contact analysis considering
lead and profile modifications

No load tooth contact

▪ Calculated of loaded tooth contact with low
load
▪ Considers all gear modifications
▪ Direct input of misalignment values
▪ For verification of contact patterns after
manufacturing

33 / 52 [Link]
Loaded tooth contact analysis
▪ LTCA of spur, helical and spiral bevel gears
▪ For nominal load or with consideration of KA
and Kv and for load spectrum
▪ Using slice model
▪ Line load distribution over whole face width
(contact pattern under load)
▪ Momentary line load distribution as contact
lines for different mesh positions

Bevel gear transmission error

▪ Loaded or non-loaded (lightly loaded) TE
▪ PPTE values
▪ FFT of transmission error

Further load distribution-based results

▪ Flash and contact temperature
▪ Scuffing safety factor
▪ Flank fracture safety factor
▪ Micropitting (adapted from cylindrical gear
calculation)

Contact for misaligned systems

▪ Input of HGV misalignment
▪ Input of shaft angle deviation
▪ For drive and coast side
▪ Considering housing, bearing and shaft
deformation

Tooth flank fracture calculation

▪ Calculated hardness distribution
▪ Hardness distribution input from
measurements
▪ Calculation along ISO/DTS 6336-4 and
Annast

Differential gears
▪ Fine sizing of differential gears
▪ LTCA for spur gears with modifications

34 / 52 [Link]
Gleason GEMS® – KISSsoft /
KISSsys interface
Two software solutions, one common goal
▪ KISSsys: Design, optimization and analysis of
systems. Considering power losses, load
spectra, housing deformation …
▪ GEMS®: Design, optimization and analysis of
spiral bevel and hypoid gears, preparation of
data for Gleason gear production machines
▪ KISSsys: System deformation (EPG / VHJ
values) for pinion and wheel considering
housing, bearings, shafts.
▪ GEMS®: 2D / 3D LTCA including interactive
root bending stress and contact stress output
with S-N curves.
▪ Interface for gear data and displacement
values between GEMS® and KISSsys

Value proposition
▪ Improved customer experience, human
efficiency and part quality by connecting
system design, gear design and gear
manufacturing software systems
▪ Closed loop to manage manufacturing
process using GEMS® based on gears sized
and designed in KISSsoft
▪ Gear micro geometry preliminary design in
KISSsoft and final design in GEMS® /
CAGE®
▪ Flank and root strength, scuffing resistance,
micropitting safety, flank fracture risk and
static strength calculation in KISSsoft

KISSsoft
▪ Flank and root strength, scuffing resistance,
micropitting safety, flank fracture risk, life
rating with LDD and static strength
▪ Rough and fine sizing, modifications sizing
▪ 3D geometry export

GEMS®
▪ Transfer data with, CAGETM®,
UNICAL®R, and common design software
▪ Import design data files from CAGE® and
UNICAL
▪ Connect with GEMS® on-line via web app
▪ Generate data for blade grinding machines
▪ Closed loop to manage manufacturing
process

35 / 52 [Link]
Worm gear modules
General
▪ For ZC, ZI, ZA, ZN, ZK, ZH geometry
▪ Includes rough and fine sizing function
▪ Accurate 3D geometry

Strength rating
▪ Based on E DIN 3996:2012, DIN 3996:1998,
ISO/TR 14521:2010, AGMA 6034, AGMA
6135
▪ No load contact analysis

System data
▪ Considers drive direction, bearing power loss,
seal loss, permissible wear
▪ Considers cooling through housing and
lubricant and running time

Chain of gears / idler gears

Configurations
▪ Three gear chain with one idler gear
▪ Four gear chain with two idlers
▪ Input on first and output on last gear
▪ Alternating bending is considered on
idler
▪ Definition of two or three center
distances

Calculations
▪ Same calculations as for gear pair and
planetary gears
▪ Independent hardness definitions
▪ ISO 6336-3, Annex B mean stress
influence
Fine sizing function
▪ Calculation as double planet for
several strands
▪ Definition of fourth gear in the chain
as
internal gear
▪ Including assembly condition and
collision
check

36 / 52 [Link]
Crossed axis helical gear
General
▪ Strength rating along ISO 6336 (modified
along Niemann), along Hoechst for worm
gears and along Hirn for worm gears
▪ Calculation of theoretical backlash,
acceptance, and operating backlash
▪ Calculation of flank, root and scuffing safety
factor with single load or load spectrum
▪ Output of control measures like dimension
over pins and balls
▪ With rough and fine sizing function

Configurations
▪ For plastic and metallic materials
▪ Calculation with lead or helix angle
▪ Calculation of meshing efficiency
▪ For worm type or helical gear type mesh (any
helix angle)
▪ Tooth form calculation with modifications like
tip and root relief, chamfer, tip rounding,
elliptic root rounding for improved noise and
strength properties

Gear pumps
General
▪ For involute and non-involute tooth shape
▪ For external or internal gear pumps
▪ Calculation of tooth form, tooth load and
volume flow
▪ Nominal flow calculation or considering elastic
deformation of teeth
▪ Flow calculation can be combined with sizing
functions

Expert options
▪ Changes in important parameters of pump
during contact are calculated
▪ Includes enclosed volume, the volume with
critical in-flow, narrowest point between flanks
of first tooth pair not engaging marking the
boundary of critical in-flow area, in flow
velocity, oil flow, Fourier analysis for
evaluation of noise potential, and total volume
under entry chamber pressure

37 / 52 [Link]
Face gears
General
▪ Strength rating along ISO 6336 (modified
along Niemann, Roth and Basstein), ASS /
Crown Gear / DIN 3990, based on ISO 10300,
based on DIN 3991
▪ For 90° or greater shaft angle, with axis offset,
for spur and helical gears
▪ Axis offset may be positive or negative
▪ 3D models include solid model, skin model,
cutting model (based on shaping cutter
geometry) and solid model of single toot and
single gap of face gear
▪ Calculation of subsystem reliability based on
pinion and face gear life, using three
parametric Weibull distribution

Configurations
▪ Face gear with cylindrical pinion as spur or
helical gear
▪ Calculation of face gear geometry at different
diameters by simulating manufacturing with a
pinion type cutter
▪ Check against undercut and pointed tooth by
varying tooth height
▪ Export of 2D or 3D geometry considering
tolerances such as tooth thickness tolerances,
tip and root diameter tolerances
▪ Crowning of face gear through modifications
on pinion type cutter
▪ Output of contact lines on face gear
▪ Corner modification on inner and outer
diameter

Export
▪ Export of 3D geometry of pinion, face gear
and system as *.stp file
▪ Export of 2D geometry of pinion, shaping
cutter and face gear sections as *.dxf file
▪ Export of surface topology / measurement grid
using Klingelnberg and Gleason data format,
for pinion and face gear, for a user defined
number of grid points
▪ Export of pinion and face gear data table for
CAD drawings

38 / 52 [Link]
Asymmetrical teeth, cylindrical
gears
General
▪ Strength rating along ISO 6336 for left and
right flank / root
▪ Different pressure angle and root rounding for
left and right side
▪ Face width offset may be positive or negative
▪ 3D models include solid model, skin model,
cutting model
▪ Calculation of subsystem reliability based on
pinion and face gear life, using three
parametric Weibull distribution

Configurations
▪ Spur, helical, double helical
▪ Gear pair calculation where pinion is driving or
driven
▪ Rack and pinion, chain of three gears, chain
of four gears
▪ Planetary gears consisting of sun, planet and
ring gear, with any number of planets
▪ Export of 2D or 3D geometry considering
tolerances such as tooth thickness tolerances,
tip and root diameter tolerances
▪ Gear modifications in lead and profile
direction

Features
▪ Export of 3D geometry or of 2D geometry
▪ Allows for LTCA in loaded tooth contact
analysis module with own input of tooth
stiffness (tooth stiffness is not calculated)
▪ No load contact analysis (intersection of skin
models)
▪ Loaded tooth contact analysis for both flanks
considering shaft misalignment and
modifications
▪ Lead and profile modifications may be applied
differently for left and right flank.

39 / 52 [Link]
Non-circular gears
Non-circular gears can be calculated in
KISSsoft based on an operating pitch curve.
Gears may be closed or open.

Design of geometry
▪ required momentary ratio may be defined
▪ required meshing curve may be defined

From there, the following is calculated

▪ calculation of meshing curve from
momentary ratio
▪ calculation of shaping cutter from gear / tooth
data
▪ calculation of backlash such that no
jamming occurs
▪ calculation of non-circular gear contour
▪ export to CAD with different levels of
accuracy (up to 800 points per flank)
▪ add tip rounding
▪ modify root geometry to increase strength
▪ check of meshing / collisions in 2D
▪ calculation of position of rolls for dimension
over rolls measuring

Beveloid gears
Beveloid gears (conical gears) can be
modelled and rated in KISSsoft for small
shaft and cone angles

Calculations, geometry and strength

▪ Cone angle on both gears may be
different
▪ Considers shaft and cone angles
▪ Spur and helical gears
▪ Includes micro geometry model
▪ Strength rating as per DIN, ISO,
AGMA based on equivalent cylindrical
gear
▪ No load tooth contact analysis

Double planet
▪ Assembly condition and collision
check
▪ Strength rating as for cylindrical gear
modules
▪ 2D and 3D geometry

40 / 52 [Link]
Shafts, coaxial shaft systems
General
▪ Graphical shaft editor for fast modelling
▪ Calculates stress concentrations from feature
geometry
▪ Add force elements like gears, pulleys or
couplings for simple load definition
▪ Materials, bearings, lubricants databases
▪ Automatic identification of critical sections

Configurations
▪ Single shaft or coaxial shaft systems
▪ Static deformation, modal analysis
▪ General supports or rolling element bearings,
pilot bearings, internal bearings
▪ Linear or non-linear calculation with Euler or
Timoshenko beam model considering
temperature effects

Strength rating
▪ Strength rating along DIN 743, FKM guideline,
Hänchen & Decker or AGMA 6101
▪ For static and fatigue strength, for single load
case or load spectrum
▪ Using material database or own definition for
S-N curve, different Miner rules
▪ Independent load factors and stress ratios for
static and fatigue rating

Modal and forced response analysis

▪ Modal analysis
▪ Forced response analysis, with damping
▪ Considers bearing stiffness

Deformation and stiffness calculation

▪ Non-linear bearing stiffness is calculated
based on inner bearing geometry
▪ Housing deformation, machining errors and
similar may be defined as initial bearing offset
▪ Any number of loads may be added

Tooth trace calculation

▪ Calculation of shaft deformation of pinion
shaft, calculation of necessary lead correction
▪ Housing stiffness, bearing stiffness and shaft
stiffness may be considered

41 / 52 [Link]
Bearings
Configuration
▪ Calculation of single bearing or bearing-shaft
system, any number of bearings in system
▪ With single load or load spectrum
▪ Sizing function for bearing selection

Bearing life rating

▪ Basic rating using load capacity numbers
▪ Modified rating considering lubricant
properties
▪ Reference rating considering load distribution
▪ Modified reference rating
▪ Along ISO 281, ISO/TS 16281, ISO 76

Bearing stiffness and clearance

▪ Based on bearing inner geometry
▪ Shaft-bearing interaction for shaft and bearing
systems
▪ Considers operating clearance / pre-tension
▪ Considers bearing, shaft, hub tolerances

Load distribution calculation

▪ Load distribution among rolling elements
▪ Contact stresses for balls
▪ Contact stresses for rollers, considering roller
geometry modification (logarithmic)
▪ Contact stress distribution on raceway

Thermal rating
▪ Along DIN 732

Bearing database
▪ Bearing data from different bearing suppliers
▪ For different bearing types
▪ Basic bearing properties
▪ Bearing inner geometry, user editable
▪ Separate database for lubricants, lubricant
purity definitions along ISO 4406

Hydrodynamic bearings
▪ Axial bearings DIN 31653, ISO 12130, DIN
31654
▪ Radial bearings ISO 7902, DIN 31652, DIN
31657, Niemann and Spiegel for grease
lubricated bearings

42 / 52 [Link]
Bearing designer
▪ Sizing function for bearing inner geometry
▪ Define ranges e.g., for rolling element
diameter, pitch diameter, no. of rolling
elements and others
▪ Software calculates possible bearing designs
▪ For each design, load capacity and properties
of inner geometry are calculated
▪ Allows for specific, optimized design of
bearings, in particular slewing bearings

Load distribution with elastic rings

▪ Elastic or stiff rings
▪ Ring deformation influencing load distribution

Calculation by SKF
▪ Cloud based calculation
▪ Bearing forces are transmitted from KISSsoft
to SKF cloud-based tool
▪ Bearings are rated by SKF, and results are
sent back to KISSsoft

43 / 52 [Link]
Shaft-hub connections
Cylindrical interference fit
▪ Strength rating along DIN 7190
▪ Sizing function for tolerances
▪ Stress calculation for stepped hub and hollow
shaft
▪ Considers torsional, radial, and bending load,
including centrifugal loads
▪ Calculation of mounting temperatures

Conical interference fit

▪ For different mounting procedures
▪ Calculation along Kollmann
▪ Considers cone angle and cone angle
tolerances

Key
▪ Geometry along DIN 6885, ANSIB17.1
▪ Strength rating along DIN 6892
▪ Woodruff key

Involute spline
▪ Geometry along DIN 5480, ISO 4156,
ANSIB92, own definition
▪ Tolerances along DIN 5480, ISO 4156,
ANSIB92, own definition
▪ Reference profiles along DIN 5480, ISO 4156,
ANSIB92, own definition
▪ Strength rating along Niemann or DIN 5466
▪ Graphical output

Straight sided spline

▪ Geometry along DIN 5464, DIN 5471, DIN
5472, ISO 14, own definition
▪ Strength rating along Niemann
▪ Graphical output

Serrated spline, polygons

▪ Geometry along DIN 5481
▪ Strength rating along Niemann
▪ 3-sided and 4-sided polygon along DIN
32711, DIN 32711
▪ Strength rating along Niemann

Hirth coupling
▪ Includes Voith ® profiles
▪ Strength and geometry calculation

44 / 52 [Link]
High strength bolting modules
Bolt rating along VDI2230, configurations
▪ Connection under axial load only
▪ Connection under axial and shear load
▪ Flange type bolted connection
▪ Arbitrary bolting pattern
▪ Import of FEM results for loading condition
▪ Sizing function for bolt length and bolt
diameter

Bolt, nut and washer types

▪ Own bolt geometry definitions
▪ Own nut and washer definition
▪ Washers: ISO 7089, ISO 7090, ISO 7093-1,
ISO 7093-2, ANSI / ASME 18.22.1, own
definition
▪ Nut: ISO 274, DIN EN 2432, DIN EN 24035,
DIN EN 28673, DIN EN 28675, ANSI / ASME
B.18.2.2, own definition
▪ Bolt: ISO 4762, ISO 4014, ISO 4017, ISO
1207, ISO 8765, ISO 8676 and others
▪ Strength classes, 8.8, 10.9, 12.9, A1…A5,
SAE J492, own definition
▪ Extension sleeves under bolt and nut

Tightening
▪ Considers different tightening procedures
▪ Considers pre-tension loss
▪ Considers friction in thread and under head /
nut

Temperatures
▪ For low and high temperatures
▪ Considers assembly temperature,
temperature of bolt and temperature of
clamped parts

ANSYS Integration
▪ KISSsoft integrated in ANSYS by CADFEM
▪ Calculate bolt loads in ANSYS and perform
strength rating along VDI 2230 based on
KISSsoft
▪ For arbitrary bolting patterns, considering
clamped parts elasticity

45 / 52 [Link]
Spindle drives
Calculations
▪ Safety factor against buckling, contact
pressure and torsion
▪ Geometry along DIN 103 and own definition
▪ For static, alternating and pulsating loads

Shear pins, circlips

Calculation along Niemann / Seeger
▪ Bolt under shearing
▪ Cross pin under torque
▪ Longitudinal pin under torque
▪ Pin under bending
▪ Shear pin system
▪ Hub and shaft circlip

Calculations
▪ Static or fatigue loads
▪ For full or notched type pins
▪ Material database
▪ Sizing function for pin diameter

General purpose modules

Hertzian contact
▪ Contact between balls, cylinders, ellipsoid and
plane, arbitrary body
▪ Calculation of contact ellipse dimension
▪ Calculation of contact and sub-surface stress

Local stress analysis

▪ Strength verification along FKM guideline
▪ For steel and aluminum
▪ For 1, 2 and 3-dimensional stress state

Tolerance analysis
▪ Min / Max values, statistical calculation
▪ Standardized or user defined tolerances

Belt drives, chain drives, clutches

▪ Chain sprocket geometry
▪ Belt and chain length
▪ Belt and chain strength
▪ Wet clutches along VDI 2241-1

46 / 52 [Link]
Springs modules
Compression springs
▪ Geometry along DIN 2098 or own definition
▪ Tolerances along DIN 2095 or DIN 2096
▪ Calculation along EN 13906-1
▪ Goodman diagram for spring / wire strength
▪ Spring relaxation
▪ Sizing for wire diameter and active coils /
windings

Tensile springs
▪ Different end geometries
▪ Tolerances along DIN 2097 or DIN 2096
▪ Calculation along EN 13906-2
▪ Goodman diagram for spring / wire strength
▪ Spring relaxation
▪ Sizing for wire diameter and active coils /
windings

Garter springs
▪ Tolerances along DIN 2194
▪ Calculation along EN 13906-3
▪ Sizing function for wire diameter and active
coils / windings
▪ For static or dynamic stress loading

Spring disks
▪ Geometry along DIN 2093, Series A / B / C or
own definition
▪ Calculation along DIN 2092
▪ Sizing function for number of disks in stack
▪ For static or dynamic stress loading
▪ Non-linear spring stack stiffness

Torsional spring
▪ Different head forms
▪ Single or multiple springs
▪ Calculation along DIN 2091
▪ Sizing function for selection of torsion bar
diameter and shank length
▪
Conical spring
▪ Tolerances along DIN EN 15800
▪ Spring standard DIN 2076, DIN EN 10270,
DIN EN 10218

47 / 52 [Link]
Scripting
Several scripting options
▪ Scripting language integrated with
KISSsoft
▪ Control of KISSsoft through COM
interface
▪ Address COM interface e.g., through
MATLAB®, VBA® or PYTHON®

Data exchange
Gear data exchange GDE
▪ Defined by VDI, VDI/VDE 2610
▪ Format for the exchange of gear and tooth
data
▪ Based on XML language
▪ Seamless and error free exchange of gear
data between design, manufacturing and
quality control

REXS
▪ Reusable Engineering Exchange Standard
▪ REXS definition by FVA
▪ Neutral format for gearbox data exchange
▪ Exchange gearbox data between non-
compatible software

Data exchange to Gleason GAMA™

▪ Export of macro geometry of cylindrical gear
▪ Import to GAMA™ measuring software

48 / 52 [Link]
CAD interfaces
KISSsoft may include the above CAD
interfaces to various systems. Thus, at the
pressing of a button, the gears defined in
KISSsoft can be exported to any of the
above-mentioned CAD platforms. Gear
Geometries supported are indicated above.

A gear can be generated for an existing

construction or, simply, as a new part. Gears
are generated by polylines, circular arc
approximation or splines. The exact tooth
profile is generated by manufacturing
simulation considering tools like shaping
cutter or protuberance hob. In addition, it is
possible to place several gears on shafts
already modelled in the CAD environment.

Neutral interfaces in 2D and 3D formats

complete the CAD-specific export functions.

49 / 52 [Link]
Export to CAM
KISSsoft includes a highly accurate detailed
modeler for 3D gear geometries. Based on the
geometry generated in KISSsoft, mold cavities,
electrodes or final parts may be machined using 5-
axis CNC machines.

For most gears, the 3D models can be generated

including a protuberance to facilitate a roughing and
a final machining operating. 3D models include gear
modifications like lead, profile or topological
modifications including chamfers or tip rounding.

Applications
Gears or cavities successfully machined by our
customers include:
▪ Spur, helical and herringbone gears
▪ Spur, helical and spiral bevel gears
▪ Bevel gears with constant or varying tooth
height
▪ Spur and helical face gears
▪ Worm gears (different shapes)

Geometries may be imported into any CAM

software. Imported geometry includes profile and
lead modifications, root geometry simulated from
manufacturing, inner diameter, tip chamfer or
rounding. Geometry resolution is finer than 0.1um.

Verification
Tests have confirmed that contact patterns of e.g.,
spiral bevel gears are matching with predictions
calculated in KISSsoft.

Request specific information and technical papers

on the subject from your local authorized reseller.

Gear geometry measurement may be controlled

using KISSsoft measuring data (flank and root
coordinates on measurement grid) and point normal
vectors exported in different formats (e.g., to suit
Gleason, Klingelnberg or Wenzel gear testers).

50 / 52 [Link]
Training
Types of training
▪ Public trainings and technology seminars
▪ Company specific training, worldwide
▪ At KISSsoft AG training center, Switzerland
▪ On site or virtual classes by web meeting

Topics
▪ KISSsoft & KISSsys software usage
▪ KISSsys programming, scripting
▪ Gear theory, gear design technology
▪ Fine pitch and plastic gearing technology

Trainers
▪ Mechanical engineers with application-level
experience
▪ Long-time software users or programmers
▪ Public training in German or English,
company specific training in Korean, French,
Italian

Updates and support

Services
▪ Software updates on annual basis
▪ Service Packs as required
▪ Installation and configuration support
▪ Software support (software usage)
▪ Technical support (software application)

USF modalities
▪ Perpetual by service contract
▪ Annual renewal

Software licenses
Licensing
▪ Perpetual, subscription or rental licenses
▪ Node locked, dongle and floating licenses

Combination of modules
▪ Basic modules for gears, shafts, bearings,
connections, shaft-hub connections
▪ Expert modules as add-on modules
▪ Total of about 130 software modules

Adding modules
▪ Modules may be added to an existing license
▪ Request list from authorized reseller

51 / 52 [Link]
 Stay in touch
If you want to stay in touch with us and be up to date on KISSsoft, register for our KISSsoft
News which will be sent to you approximately every three weeks and/or you follow us on our
Social Media channels: Facebook, LinkedIn and YouTube.

[Link]
[Link]/KISSsoft
[Link]/company/KISSsoft-ag
[Link]/KISSsoftAG

KISSsoft AG
A Gleason Company Rosengartenstrasse 4
8608 Bubikon Switzerland
+41 55 254 20 50
info@[Link] [Link]

Для отримання додаткової інформації

та придбання програмного забезпечення KISSsoft в Україні,
звертайтесь до компанії «Інформаційні технології САПР»:

044 503 95 34 info@[Link] [Link]

52 / 52 [Link]