FVA-Workbench 5.0

 

Modeling, parameterization, and simulation of transmission systems

The FVA-Workbench is a manufacturer-neutral software solution for the modeling, parameterization, and calculation of transmission systems. It bundles 50 years of research and development from the FVA expert network into a single platform and makes this accumulated knowledge directly available for practical application.

Would you like to learn more about FVA-Workbench, or are you interested in an offer? Please get in touch with us. We look forward to hearing from you.

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Non-proprietary and cross-sector

In the FVA e.V. network, leading drive technology companies collaborate with the best research institutions to develop innovative calculation methods. The FVA-Workbench makes the results of this pre-competitive research available to the drive technology industry in a manufacturer-neutral and cross-sector format, and enables individual companies to develop products at the highest level.

Industries

  • Automotive
  • Industrial gearboxes
  • Bearings
  • Aviation
  • Marine
  • Rail transport
  • Wind energie

FVA-Workbench calculation and simulation capabilities

Considered as a whole - total system calculations

An accurate representation of system behavior is essential for detailed analysis of individual machine elements.

The FVA-Workbench automatically performs system-level calculations, and any loads and deformations that are determined are then taken into consideration for all further calculations. In this way, for example, the deformation behavior of the shaft-bearing systems and the casing can have a significant influence on the load distribution of spur gear stages.

Precise knowledge of these constraints enables engineers to make well-informed decisions on the optimal design of transmission systems early in the development process.

Spur gear geometry & load capacity

The FVA-Workbench can be used to calculate the geometry and load-bearing capacity of involute spur gears. The geometry calculations go far beyond the specifications in DIN 3960. They also use two different tools to measure machined cylindrical gears and special gearings.

The calculation of the load capacity is possible using a wide variety of calculation methods. All important national and international standards, regulations of classification societies and calculation methods based on research projects of the FVA are covered.

 


Tooth flank and root stress calculation

The local stress on tooth flanks and tooth root of cylindrical gears can be calculated. This calculation is based on the influence figure method. The following local stress values can be determined:

  • Line load / Pressure distribution
  • Transmission error
  • Flash temperature
  • Lubricating film thickness
  • Sliding speed
  • Safety against micropitting
  • Flank fracture
  • Tooth root stress

[Program documentation STplus  FZG, TU Munich]

Modeling

Planetary stages can be easily created with the help of the insert wizard. This makes it possible to create complex gear structures, even with several coupled planetary stages, in just a few steps.

Calculation

The calculation scope for both standard and load distribution calculations of planetary stages corresponds to that of cylindrical gear stages.

 

Geometry & Load Carrying Capacity

The FVA-Workbench can be used to calculate the geometry and load carrying capacity of bevel gear pairs. This includes bevel gears with addendum modifications and tooth thickness changes as well as axially offset bevel gears. Load carrying capacity can be calculated according to current national and international standards and previous regulations. In addition, the wear resistance, efficiency, and tooth forces as well as the risk of flank fracture can be calculated.

 

Measurement Data Processing

Measurement data can be used to remove measurement outliers from the actual measurement data and calculate flank errors between the nominal and actual geometry, represented by the measurement data.

Micro-Geometry Design

Micro-geometry design can be used to determine the machine setting data of the bevel gear grinding machine used for further calculation of the load carrying capacity.

Tooth Flank and Tooth Root Stresses

The local tooth flank and tooth root stresses of spiral bevel and hypoid gears can be calculated. These calculations are based on the influence coefficient method. Deformation and deviations of the gearbox elements surrounding the gear are also taken into account.

The calculation consists of the following components:

  • Calculation of gear geometry (e.g., Klingelnberg, Gleason, Oerlikon, Hurth-Modul)
  • Calculation of mesh conditions (actual measurement data can be included)
  • Calculation of: meshing interference, circumferential backlash, and ductility
  • Load, pressure, and tooth root stress distribution using generalized influence factors
  • Calculation of load spectra

[KNplus & BECAL program documentation - IMM, TU Dresden]

Simulation of Worm Gears

FVA-Workbench can be used for the design and simulation of worm gears. Contact lines, idle and load contact patterns, load carrying capacity tests according to standards, design of gear sets, simulation of start-up and self-braking processes, and more can all be calculated and displayed.

[SNESYS program documentation - FZG, TU München]

Shaft Calculation

Load capacity calculations according to DIN 743 for shafts and axles can be performed quickly and easily with the FVA-Workbench. Calculations are based on the official state of the art. In addition, the superimposed notch effect in multiple interference fits is taken into account. Notch stresses are determined by an analysis of the overall system. The influence of the bearings and the flank load distribution are taken into account for the shaft load.

[DIN743 program documentation - IKL, TU Wien]

 

Rolling bearing calculation

In the FVA-Workbench, the designer can access the current digital bearing catalogs of several manufacturers. In addition, it is possible to specify a detailed bearing geometry.

Beside the common standards for service life calculation (DIN 26281 / DIN 281) and catalogue calculations, the following parameters can also be calculated:

  • Pressure resolved over the contact surface
  • Slip curves
  • Viscosity ratio (FVA 418)
  • Kinematic characteristics
  • Calculation of modified bearing friction (FVA 701)

 [Program Documentation LAGER2HP - FZG, TU Munich]

Simulation of Slide Bearings

The static and dynamic characteristic values can be reliably simulated using the plain bearing calculation in the FVA-Workbench.

The calculation methods are continuously tested and validated in several research projects at
High performance test rig of TU Clausthal.

The essential features of the calculation are:

  • Precise detection of the bearing bore geometry
  • Improved complete oil supply and "pocket" model with consideration of inlet losses
  • Consideration of the temperature and pressure dependence of the oil viscosity
  • 2D calculation of the pressure distribution in the entire lubrication gap, solving the extended Reynolds equation
  • 3D calculation of the temperature and viscosity distribution in the lubrication gap, solving the energy equation
  • Resolution of turbulent areas in the lubricating film and consideration in oil viscosity.

[COMBROS program documentation - ITR, TU Clausthal]

Simulation of Shaft-Hub Connections

The following shaft-hub connections can be simulated in the FVA Workbench:

  • Tapered interference fits - Calculation according to DIN 7190 Part 1
  • Cylindrical interference fits - Calculation according to DIN 7190 Part 2
  • Multiple interference fits - Calculation according to von Mises' shape modification hypothesis
  • Feather keys - Calculation according to DIN 6892 methods B & C

[PressFit/KeyFit program documentation - IKAT, TU Chemnitz]

Finite Element Analysis (FEA) in the FVA-Workbench

By coupling FEM structures with the analytical calculation model, it is possible to take into account the influence of the gear housing and the planet carrier on the shaft bearing system and the load distribution in tooth engagement.

 

 

 

High-quality reports in a few clicks

 

The new reporting feature in the FVA-Workbench greatly simplifies the documentation of calculation results. Customized, visually appealing, and interactive reports can easily be created using drag & drop functionality. Once they have been created, reporting templates can be used with a wide variety of gear models, greatly simplifying the communication of results with customers and colleagues..

 

Sample reports

FVA virtual gearbox

The FVA virtual gearbox is a fictional example that has been designed to demonstrate the simulation capabilities of various FVA programs.

View Report

Wind turbine gearbox

A model of a typical transmission design used in wind turbines. It consists of a planetary stage and two spur gear stages.

View Report

Planetary carrier modeling and calculations made easy

The planet carrier has a significant influence on the calculation of the gear unit.

With Workbench 5.0, a planet carrier can be modeled, meshed and connected to the analytical model in just a few steps.

The main features are:

  • Internal parameterized modeling of the planet carrier geometry
  • Single and double side plate designs are possible
  • Connection to the analytical gear model
  • Determining the reduced stiffness matrix

Planet carrier modeling in the FVA-Workbench

 

Import of CAD models and automatic FEM meshing

Model simplification & meshing of CAD bodies

For the analysis of complex transmission systems it is of great importance to model the boundary conditions in the best possible way. For this purpose, FE meshes can be imported or CAD bodies can be imported and meshed internally in the FVA-Workbench for the planet carrier and the housing. The FEM meshes are then positioned in the model and connected to the gear model.

A user-friendly wizard simplifies the meshing process, providing interactive user guidance and assistance with  automation. A slider control is used to select the meshing resolution and remove unnecessary details from the CAD model.

To make the workflow more efficient, many different native CAD formats are supported.

 

 

Scripting | automation | batch operation


Scripting

A simple, JavaScript-based language enables the user to control the system to a large degree using text instructions. Possible applications include:

  • Optimization calculations
  • Calculus of variations
  • Mass calculations

The execution of complex tasks is reduced to a single mouse click.

 

FVA-Workbench offers two powerful tools for the control and manipulation of all calculations as well as input and output parameters.

 

 

 

Automation

Parameters can be automatically assigned and calculations can be performed via a graphical interface.  Reports can then be generated automatically..

Batch operation
The batch function in the FVA-Workbench combines scripting features with the option to execute calculations with the push of a button. The results of the calculations can then be saved to a file with your choice of format.

FVA KnowledgeBase

The integrated FVA-Workbench KnowledgeBase is a powerful knowledge-management platform with context-sensitive help.

Here you will find clear, concise descriptions of input attributes, tutorials, and extensive documentation. Many areas also include links to additional research projects, standards, kernel documentation, and technical literature in the Themis knowledge portal.

Choosing the right FVA-Workbench edition for your needs

Workbench Modeler Edition

The Modeler Edition is suitable for all users who model new gearbox concepts, or who want to parameterize existing models or customize them for additional simulations.

Workbench Extended Edition

The Extended Edition offers users throughout the product development process a wide range of calculation and simulation options for machine elements according to national and international standards.

Workbench Advanced Edition

In addition to the standard calculations, the Advanced Edition offers extensive methods for calculation and simulation of the entire transmission system based on the latest FVA research developments.

Flexible licensing options and custom expandability

You can upgrade from one FVA-Workbench edition to a higher one at any time. This form of licensing also offers the possibility to temporarily increase the number of licenses as necessary without tying up valuable capital long-term.

Optional additional functions for special applications are available for each FVA-Workbench edition. These can be added to any FVA-Workbench edition right away or afterwards.

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