- Overview
- Applications
- Program 500
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Integrated Gear Software: Setting the Standard in Gear Design Technology
Whether you’re designing metal, plastic, or powdered metal gears, Integrated Gear Software (IGS) is the most comprehensive gear knowledge system for eliminating noise and premature failure, reducing trial and error, lowering design and production costs, and speeding time to market.
With over 75 programs and a broad range of expert consulting services, Universal Technical Systems, Inc. has over 60 years of combined design experience representing a multi–million-dollar commitment to developing industry–standard technology that empowers engineers to design with confidence.
Think of what that means for designing springs and gears or for studying how variables such as loads, pressure, heat, or even loan calculations behave as other inputs change. Setting up problems is fast and easy with TK Solver.
From A to Z
From initial sizing, gear design and analysis, and modeling of environmental extremes, to full optimization with tolerance analysis and manufacturing specs — Integrated Gear Software does it all!
What’s more, a powerful math engine with the unique ability to solve for a variety of combinations of input and output variables — known as backsolving — allows you to easily test what-if scenarios, develop accurate specifications for manufacturing replacement gears, and optimize designs without hours of tedious calculations or programming. Just point, click, and solve.
Managing Expert Knowledge
One of the biggest challenges for many companies in an era of greater employee mobility becomes managing expert knowledge, a valuable resource. Most companies have a core group of long-standing employees that represent the collective repository of gear knowledge. But what happens when that “expert” knowledge walks out the door? With IGS you can capture and share design data, and even reverse-engineer designs, effectively leveraging expert knowledge throughout your organization.
IGS can help you solve manufacturing problems like designing cutting tools, calculating measurement over pins, analyzing batch variations, or locating the appropriate cutting tools from your inventory. You’ll also be able to reuse tools such as hobs, shaper cutters, shaving cutters, and grinding wheels — for big cost savings!
Bottom Line: IGS provides you with everything you need to help you maintain your competitive edge.
Powerful Technology
IGS was developed by gear people, for gear people and combines more than 75 individual programs—each representing a particular stage in the gear design and manufacturing process—into one, interoperable, user-friendly knowledge environment that calculates, shares data, archives designs, performs tolerance analyses, and provides users with virtually unlimited design flexibility.
Integrated Gear Software at a Glance
Project Manager — for tracking and documenting design projects.
Power User Form — for custom data entry.
Data Entry Wizard — for guided data entry.
Plotting — for data analysis and visualization.
Automatic Unit Conversion — for model sharing flexibility.
Report Wizard — for on-demand custom reporting.
Other key components of IGS include a relational database that stores all programs and design data and a powerful, comprehensive reporting engine for producing detailed and insightful reports. Data can be connected horizontally—one program to another—and vertically, by project and program.
IGS Packages
- Advanced Gear Design and Manufacturing
- Basic Gear Design and Manufacturing for Metal Gears
- Basic Gear Design and Manufacturing for Plastic Gears
- Crossed Axis Gear Design
- Epicyclic Gear Design
- Spline Design and Manufacturing
UTS offers classroom training in beginning and advanced plastic and metal gear design at its corporate headquarters and an interactive fundamentals training course via the web. In addition, we offer extensive consulting services in gear design and manufacturing as well as customer site training.
Integrated Gear Software is a powerful solution at an affordable price and is available in both Standard and Premium (includes the TK Solver Solution Optimizer) editions. IGS supports Windows 2000, Windows XP, Windows Vista, Windows 8, 8.1 and Windows 10 platforms.
Bottom line: TK Solver focuses on the math, so you can focus on your business. Imagine that!
Integrated Gear Software [IGS]
Setting the Standard in Gear Design TechnologyWhether you’re designing metal, plastic, or powdered metal gears, Integrated Gear Software (IGS) is the most comprehensive gear knowledge system for eliminating noise and premature failure, reducing trial and error, lowering design and production costs, and speeding time to market. From initial sizing, gear design and analysis, and modeling of environmental extremes, to full optimization with tolerance analysis and manufacturing specs — Integrated Gear Software does it all!
60-050: First Gear
This application requires TK Solver.First Gear is very useful in making preliminary design calculations for external spur and helical gears. The program automatically guides the user through various input data steps, and is simple enough for a beginner, yet powerful enough for an expert. Features include: plot of gear mesh, plot of gear with measurement pins (or balls), single key switch from inch to metric units (or vice versa), and standard as well as non-standard gears. An estimate of load capacity is also calculated. A report includes input data and output calculations as well as plots. On-line, context sensitive help provides an excellent supplement to the user manual.
60-100: AGMA Gear Classification
60-101: Cylindrical Gears - ISO System of Accuracy - ISO 1328
Cylindrical Gears—ISO System of Accuracy - ISO 1328
This model calculates the dimensional tolerances for cylindrical gears in accordance with ISO 1328. The standard supplies single and cumulative pitch deviations, profile deviation, and helix deviation, depending upon the ISO accuracy grade (0-12). For modules outside the ranges covered by the standard, the program issues a warning, but furnishes the tolerances for reference.
60-102: Lead Mis-Match - Gears in Housing
60-103: Profile Shift Coefficients - External
60-104: Mesh Geometry & What-If - External
This is a model of the contact conditions between two external spur or helical involute gears. The contact ratios, start of active profile, specific sliding and many other geometrical conditions are calculated and checked. In addition, the tooth thickness, center distance and backlash are calculated.
60-107: Profile Shift Coefficients - Internal
60-108: Mesh Geometry & What-If - Internal
This is a model of the contact conditions between two internal spur or helical involute gears. The contact ratios, start of active profile, specific sliding and many other geometrical conditions are calculated and checked. In addition, the tooth thickness, center distance and backlash are calculated.
60-124: Crossed Axis Contact - Cutters
This program calculates the contact and crossed axis conditions for a gear in contact with a shaving cutter or hone. The root clearance, finished diameter, contact ratio and the crossed axis angle are solved from the tooth thickness and outside diameters. All values may be input or output data for checking or designing a cutter.
60-125: Crossed Axis Helical Gears
60-126: Crossed Axis Helical Gears - Capacity
60-132: Tooth Thickness at Any Diameter
60-136: Tooth Thickness From Chordal Dimensions
60-145: Tooth Thickness - Effective vs. Measured
The measured and “effective” tooth thickness of involute gears and splines are usually different. Depending on the method used for the tooth thickness measurement, the difference between the measured value and the apparent, or effective, thickness “seen” by the mating gear or spline may be enough to prevent satisfactory use of the part. This program will make the required adjustments between the effective and measured tooth thickness for the usual measuring methods.
60-146: Center Distance - Temperature Effect
60-150: Angular Position Variance
This program calculates the angular position errors (index errors) produced by a train of gears due to the errors allowed by the AGMA tolerances for the gear quality class to which the individual gears are made. It is assumed that the maximum errors allowed are present in all the gears in the system. The statistical effect of the scatter in the actual errors is accounted for by calculating the root-mean-square index error.
60-151: Synchronic Index of Gear System
This program calculates the synchronic index of an in-line geared transmission system. The synchronic index of a geared system is the minimum number of full turns made by the driver to bring the system back to the initial alignment of the gear teeth. After this number of turns, all gears will be back to their initial angular alignment with respect to each other and the gear housing.
60-164: Centers - Idler Gears
60-166: Centers - Gear Mesh With 3 Gears
60-180: Preliminary Sizing - Gear Set
Once a target gear ratio has been determined and the load is known, the next step in the design process is to obtain the geometry for a preliminary gear set. This gear set is then checked with more detailed design equations to determine suitability for the loads and speeds involved (along with a duty cycle if applicable). This program is structured to produce a preliminary gear set from the data usually at hand when the ratio, load, and speed of a single gear set has been determined.
60-196: Involute Properties
60-400: Mesh Geometry & Tooth Plot - External
This program will provide an accurate plot of the final form of external involute spur and helical gears in mesh at any position on the line of action. The data required by the program is from tool and production drawings only and provides a “final” visual check of the processes used to produce the design.
60-410: Tooth Coordinates - External Gear
This program provides an accurate plot of the tooth form produced by hobbing or shaping (and post processing) from the production gear drawing and the tool drawing. In the case of molded gears (plastic or powdered metal) circular arc fillets, chamfers and tip relief may be specified. A set of coordinates for the mold with shrinkage allowance is available. For form ground gears, the coordinates of the grinding wheel form are produced.
60-411: Hobbed Tooth Generation - External Gear
This program will plot the transverse plane projection of the positions of the cutting edges of a hob. (The transverse plane is the plane of rotation of the gear.) It may be used to evaluate the suitability of a hob for the production of a gear. Non-topping, semi-topping, topping, or tip relief hobs may be used. If a roughing hob is used prior to a semi-finishing or finishing hob, the program will provide a plot of both profile patterns.
60-450: Mesh Geometry & Tooth Plot - Internal
This program will provide an accurate plot of the final form of external involute spur and helical gears in mesh with an internal gear at any position on the line of action. The data required by the program is from tool and production drawings only and provides a “final” visual check of the processes used to produce the design.
60-460: Tooth Coordinates - Internal Gear
This program provides an accurate plot of the tooth form produced by shaping (and post processing) from the production gear drawing and the tool drawing. In the case of molded gears (plastic or powdered metal), circular arc fillets, chamfers, and tip relief may be specified. A set of coordinates for the mold with shrinkage allowance is available. For form ground gears, the coordinates of the grinding wheel form are produced.
60-470: Face Gear - Spur - On Center
Spur on center face gear sets consist of a spur pinion meshing with a gear formed on the side of a disc. The axes are at 90 degrees and intersect. The pinion may be produced by any means used to make spur involute pinions. These include hobbing, shaping, extruding and molding. The face gear must be generated by a shaper cutter with the same normal diametral pitch and pressure angle as the pinion.
60-540: Gear Set Stress / Life - B88
This program calculates load ratings for gear sets according to AGMA standard 2001-B88, Fundamental Rating Methods for Involute Spur and Helical Gear Teeth. This standard provides a method by which different gear designs can be compared. Most of the inputs for this program can be transferred automatically from Program 500.
60-541: Gear Set Stress / Life - C95
This program calculates load ratings for gear sets according to AGMA standard 2001-C95, Fundamental Rating Methods for Involute Spur and Helical Gear Teeth. This standard provides a method by which different gear designs can be compared. Most of the inputs for this program can be transferred automatically from Program 500.
60-542: Gear Set Capacity - ISO 6336
Calculation of Load Capacity of Spur and Helical Gears - ISO 6336This model provides an analysis method by which different gear designs can be compared. Calculations in this application conform to the ISSO 6336. The methods are summarized below:
Factors of influence are derived and applied in accordance with ISO 6336-1, Method B.
Calculation of surface durability (pitting) conforms to ISO 6336-2.
Calculation of tooth bending strength conforms to ISO 6336-3, Method B.
Strength and quality of materials conform to ISO 6336-5.
60-543: Worm Gears - Cylindrical
This model covers the design of cylindrical worms and throated gears mounted with axes at a 90 degree angle. The model will give solutions for gear sets whether they comply with the standard or not. If the gear set is outside the standard (or does not comply with suggestions of the standard) this condition will be noted in the message area at the top of the VARIABLE SHEET. Ret: ANSI/AGMA 6022-C93.
60-546: Worm Gear Reducers - Cylindrical
60-548: Worm Gears - Double Enveloping
60-552: Worm Gear Reducers - Double Enveloping
This program covers the rating of double-enveloping worm gear speed reducers of the following types:
1. Single Reduction
2. Multiple Reduction with double enveloping worm gearing for each reduction
3. Multiple Reduction with spur or helical gear reductions combined with double enveloping worm gearing
60-554: Worm Gear Analysis - Cylindrical
This program has been prepared to help you with the design of new worm drives or to analyze existing worm sets. The program has been configured to help you design a worm drive and design the cutting tools required at the same time. If you wish to start with a worm gear hob, the program will allow you to do this quickly and efficiently.
60-560: Scoring Analysis - External Gear
60-610: Gear Design & Analysis - Plastic
The purpose of this model is to provide an accurate set of coordinates for use in plotting the final form of external involute spur and helical plastic gears. In addition to a plot of the teeth, the model furnishes numerical results for many of the design parameters of interest to the designer. The model can be used for the design of a plastic gear set and the necessary tooling and, if load and material data is entered, an analysis of the load capacity will be made.
60-710: Involute Splines - ANSI B92.1-1970
The primary purpose of this model is to provide data from ANSI Standard B92.1-1970 for Involute Splines and Inspection. This is the standard for inch series splines based on a stub diametral pitch design. It is possible to use the model to convert the dimensions to metric but the basic calculations are always based on diametral pitch and the inch system.
The model will automatically calculate data for splines and gauges in accordance with the standard. If data is entered for a modified spline the model will indicate that the spline is not standard and will then calculate data for measurements and gauges for the modified spline.
60-720: Involute Splines - ANSI B92.2M-1980
The primary purpose of this model is to provide data from ANSI Standard B92.2M-1980 for Involute Splines and Inspection (Including B92.2Ma-1984). This is the standard for metric series splines based on metric modules and a series of basic generating racks. It is possible to use the model to convert the dimensions to inches but the basic calculations are always based on the metric module and the basic rack system from the standard.
The model will automatically calculate data for splines and gauges in accordance with the standard. If data is entered for a modified spline the model will indicate that the spline is not standard and will then calculate data for measurements and gauges for the modified spline.
60-740: Involute Splines - Load / Stress Analysis
60-750: Involute Splines - Set Geometry and Plot
60-1103: Shaper Cutter Contact - Internal Gear
This is a model of the contact conditions between an external involute shaper cutter and an internal gear. The possibility of the shaper tooth tip trimming the inner part of the gear tooth as the shaper is fed to full cutting depth is checked. In addition, involute and trochoidal interference is checked.
60-1111: Tip Relief - External Gear Set
This program calculates the proper location and amount of tip (or root) relief for external involute gears by three different methods. The methods of Dudley and Sigg are used, along with a direct method based on data furnished by AGMA Std. 2001. The deflection of the mesh is considered along with the allowable errors in the gears.
60-1161: Simple Epicyclic Gears
60-1162: Compound Epicyclic Gears
60-1163: Simple Epicyclic Differential Gears
This is a model of a simple epicyclic differential system (sun, planet, and ring gear). Power may be input/output to any of the three elements. All geometrical parameters such as ratios, ratio range, center distance, operating pressure angles, and number of planets are treated. Relative power, G loads on planets, etc. are calculated.
60-1164: Compound Epicyclic Differential Gears
This is a model of a compound epicyclic differential system (sun, two gear planet cluster, and ring gear). Power may be input/output to any of the three elements. All geometrical parameters such as ratios, ratio range, center distance, operating pressure angles, and number of planets are treated. Relative power, G loads on planets, etc. are calculated.
60-1165: Gears - Coupled & Series Epicyclic
There are 45 different ways to connect two epicyclic gear sets. 36 are coupled with one reaction member and 9 are series connected with two reaction members. Model 60-1165 furnishes a complete listing and analysis of these sets. The model will select the sun/ring ratios for both sets on a minimum weight or on a minimum diameter basis. The complete geometry of the system is solved and K factor and Unit Loads are calculated. Scale plots of the two stages are available.
60-1441: Measurement Over Pins - External Gear
This program calculates either the measurement over pins/balls or the length over a block of gear teeth from the tooth thickness. Measurement over pins or balls is used extensively for gears and splines and is a very accurate method for control of tooth thickness. By using different size pins or balls, a rough check can also be made of the involute profile. The program also calculates the diameter of a pin (or ball) that will contact the tooth flanks at the diameter where the tooth thickness is equal to the space width. The program may be used when the tooth thickness is known and the span size is needed.
60-1442: Measurement Between Pins - Internal Gear
This program relates the measurement between pins or balls to the space width for internal involute spur and helical gears. This measuring system is used extensively for gears and splines and is a very accurate method for control of space width and tooth thickness. By using different size pins (or balls) a rough check can also be made of the involute profile.
60-1443: Measurement Over Pins - Worm Gear
This program calculates the measurement over pins for an involute helicoid worm. Measurement over pins is used extensively in the industry and is a very accurate method for control of thread thickness. The program also calculates a recommended pin diameter that should contact the thread flanks near the diameter where the thread thickness is equal to the space width.
60-1961: Hob Change Gears - B.C. - "D" & #10
60-1962: Hob Change Gears - G & E Machines
60-1963: Hob Change Gears - B.C. - 6-10 & 16-16
60-1964: Hob Change Gears - Given Ratio
60-5405: Yield Stress - Steel Gear
60-5406: Crowned / Straight Tooth - Gear Stress
The ideal uniform load distribution along gear teeth is seldom obtained due to many factors, including dimensional errors and elasticity in the gear teeth themselves, and also in supporting elements such as shafts, bearings, and housings. The usual design procedure for assessing the compressive stress on teeth with no longitudinal (lead) modification is to use the Hertz equations for parallel cylinders and then to apply a multiplier based on the face mismatch to obtain the actual compressive stress in the misaligned position. One widely used method of relieving the load on the tooth ends due to mismatch is “lead crowning.” When the teeth are crowned, it is necessary to use the Hertz equations for elliptical contacts instead of the parallel cylinder equations. This program incorporates both conditions and uses the parallel cylinder equations for straight teeth and the elliptical contact equations for teeth with crown.
60-5408: Crowned / Straight Tooth - EHL Oil Film
This program calculates the elastohydrodynamic film thickness between spur or helical gear teeth, the film thickness parameter, and the probability of cold scoring (with non-reactive lubricants). The misalignment between teeth is considered for both straight and crowned teeth. The program uses parallel cylinder equations for straight teeth and elliptical contact equations for teeth with crown. The methods of the Mobil EHL Guidebook published by the Mobil Oil Corporation are followed. The program contains lubricant parameters for all oils listed in the guidebook.
10-1941: Minimum Values Simplex Method
The Nelder-Mead Simplex algorithm offers a robust procedure for finding the minimum of an objective function V=f(x1, x2, ..., xn). The procedure involves building a set of n+1 points (simplex) in n-dimensional space, examining values of the objective function at these points, and replacing the points (i.e. expanding or contracting the simplex) until the point with minimum value is reached.
10-1942: Minimum Values Gradient Method
The gradient algorithm offers a robust procedure for finding the minimum of an objective function V=f(x1, x2, ..., xn). The procedure involves finding partial derivatives at a point in n-dimensional space, determining the direction of maximum descent and examining values of the objective function along this path until a minimum is reached. When a minimum on the path is reached, a new direction is found and a new path is then followed. This continues until a point is reached where the variance in terms of the function values at the last 3 path changes is less than a preset value.
20-172: Woodruff Keys
This program calculates all shaft and hub data required to machine the shaft and hub for Woodruff keys. The program is based on USA standard USAS: B17.2-1967.
20-176: Tapered Shaft Calculations
This program relates the diameters, length and taper per unit length for tapers. Any of the dimensions may be input or output data.
20-184: Moment of Inertia & Weight for Cylindrical Parts
This program calculates the moment of inertia and weight of cylindrical sections that make up the elements of rotating equipment. Any of the dimensions may be input or output data.
20-188: Moment of Inertia & Weight for Solids of Revolution
This program calculates the mass, weight, surface area, moments, etc., for a solid of revolution. The solid is described by a set of coordinates for the shape in a radial plane. Green’s theorem of integrals is used.
20-300: Bearing Speed & Contact Frequency
This program calculates the contact frequency at the inner and outer races, the rolling element speed, estimated radial equivalent load due to speed and the speed limit.
20-302: Anti Friction Bearing System Reliability
This program calculates the percent probability that a group of anti-friction bearings will reach a given fatigue life. Required input data consists of the B-10 life of each of the bearings in the system and the desired life of the entire system.
20-303: Timken Tapered Roller Bearings
This program calculates the radial equivalent load on a tapered roller bearing from the actual radial and thrust loads on the bearing pair.
20-304: Taper Roller Bearing Kit
This program calculates the difference between mounted and unmounted end play (or preload) for a set of two tapered roller bearings. Calculation of radial play for a given end play is also furnished.
20-305: Angular Contact Ball Bearing Press Fit
This program calculates the “Kick-In” due to inner ring expansion. “Kick-In” is the distance the inner ring drops below the outer ring thrust face. The change in inner ring diameter is the expansion of the center of the ball path due to press fit between the shaft and inner ring and/or effects of centrifugal force.
20-310: Centrifugal Force & "G" Loading
This program relates the centrifugal force on an object and the “G” load to the radius of rotation, the weight and the rate of rotation. All values may be input or output data.
20-340: Branched System - Natural Frequency Vibration
This program will find the natural vibration frequencies of a branched torsional system with three to five branches. The relative vibration amplitudes and torques are also furnished. Holzer’s Method is used.
20-350: Shrink Fits
This program relates the stress and load capacity to the interference for shrink fit connections. The stress and capacity can be checked at various rates of rotation.
20-370: Exponential Mean Loads Due to Duty Cycle
This program calculates the exponential mean load and average speed for a set of load-speed-time conditions with a given exponent. Load may be force or torque.
20-420: Torsional Spring Rate for Shafts
This program calculates the torsional spring rate of shafts from cylindrical sections making up the shaft. Hollow sections are allowed.
20-3301: In-line System - Natural Frequency Vibration
This program will find the natural vibration frequencies of an in-line torsional system. The relative vibration amplitudes and torques are also furnished. Holzer’s Method is used.
20-3302: Forced Vibration Response: In-line System
This program will find the forced vibration response of an in-line torsional system. The vibration amplitudes are furnished. The torques and amplitudes are found from iterative solution of the vibration equations.
20-5403: Stress / Life Analysis - With Miner's Rule
This program is used for general stress/life analysis. You may store any stress/cycle life curve desired in the program. Miner’s rule for duty cycles is included.
Program 500
Program 500 is a gear analysis program for external involute gears and involute splines. It is based upon American Gear Manufacturers' Association (AGMA) Standards.
The program analyzes spur or helical gear sets to be sure that each gear is compatible with its mate and with the tools which will be used in manufacturing the gears. You may verify that tools (such as hobs, shaper cutters, shaving cutters, grinding wheels, etc.) will produce the gears without problems in the gear shop.