Project Overview
Professional gear design validation using KISSsoft software to refine planetary gearbox specifications with detailed lubrication analysis, oil viscosity selection, and comprehensive fatigue life calculations. Integrated load spectrum data and gear parameters from MATLAB optimization to perform industry-standard ISO 6336 fatigue analysis for the UT26 AWD drivetrain.
Previous Work: This professional validation builds upon the MATLAB automated gearbox design tool, using its optimized gear tooth counts and ratios as baseline parameters for detailed fatigue analysis.
KISSsoft interface showing detailed gear analysis results
Key Capabilities:
- ISO 6336 compliant fatigue life calculations
- Load spectrum input for realistic fatigue analysis
- Oil viscosity selection and lubrication regime analysis
- Integration of MATLAB-optimized gear tooth counts
- Thermal analysis and efficiency calculations
Technologies Used:
Analysis Workflow
1. MATLAB Integration
Import optimized gear tooth counts, modules, and geometry from MATLAB sweep results as baseline design parameters.
2. Load Spectrum Definition
Input realistic load profiles from acceleration events, endurance conditions, and peak torque scenarios specific to FSAE competition.
3. Lubrication Selection
Specify oil viscosity grades and evaluate lubrication regime (EHL vs boundary) for contact stress and efficiency optimization.
4. Fatigue Validation
Calculate safety factors for pitting and bending fatigue using ISO 6336 standards to ensure adequate service life.
Engineering Considerations
ISO 6336 Standards
Industry-standard calculation methods for gear strength, contact stress, and fatigue life prediction.
Load Spectrum Analysis
Cumulative damage assessment using Miner's rule across multiple load cases and cycle counts.
Lubrication Regime
Elastohydrodynamic lubrication (EHL) film thickness calculations to prevent metal-to-metal contact and reduce wear.
Impact
🔒 Design Validation
Professional-grade analysis ensures gearbox meets industry safety standards and fatigue life requirements.
⚙️ Lubrication Optimization
Data-driven oil selection balances efficiency, thermal management, and component protection.
Previous Work: This professional validation builds upon the MATLAB automated gearbox design tool, using its optimized gear tooth counts and ratios as baseline parameters for detailed fatigue analysis.
Technical Achievements
This professional-grade analysis provided industry-standard validation for the planetary gearbox design, ensuring compliance with international gear design standards and competition reliability requirements.
- Performed ISO 6336-compliant fatigue calculations for pitting and bending failure modes
- Integrated realistic load spectra from acceleration, endurance, and peak torque events
- Optimized lubrication selection based on elastohydrodynamic (EHL) film thickness calculations
- Generated comprehensive design reports with full traceability to international standards
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