Figure 3—Full wheel assembly model within SolidWorks.

Another major advantage of modeling the whole system accurately within KISSsoft was the ability to apply tip and root relief to the gear profile design based on shaft deflection under loading. Using the microgeometry tool, tip and root relief were applied to the gear profile, which removed contact shocks as shown .

Tip and root relief added to remove contact shocks (circled in red). Being able to implement tip and root relief into the gear design within KISSsoft is advantageous for them based on their manufacturing capabilities which are restricted to wire-EDM. Given their limitation to wire-EDM for manufacturing, they heavily depend on the accuracy of the gear involute model. KISSsoft’s capability to provide precise DXF files of the involute profile, including flank modifications, allows them to confidently send their designs for manufacture. This has been proven by the successful implementation of their first planetary gearbox in their electric vehicle. The support provided by KISSsoft had been crucial for the team to design highly refined gear train solutions.