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Application of Romax Software in Gearbox Analysis

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In the design of modern mechanical transmission systems, the simulation and analysis of gearboxes are of crucial importance. They not only optimize performance and predict failure modes but also reduce development costs. ROMAX (now known as Siemens Romax Designer) stands as a world-leading transmission system simulation software, widely applied in the design and analysis of gearboxes, bearings, shafting, and complete machine systems. This article focuses on introducing the core functions, analysis methods, and typical application cases of ROMAX software in gearbox simulation.

1. Overview of Romax Software

1.1 Development Background

ROMAX was initially developed by the UK-based Romax Technology. Later, it was acquired by Siemens and integrated into Siemens Romax Designer. Currently, it finds extensive use in the simulation of transmission systems across diverse fields such as automotive, wind power, aerospace, and industrial machinery.

1.2 Core Functions

Gearbox Modeling and Parametric Design

It supports a wide range of gear types, including spur gears, helical gears, planetary gears, and bevel gears.
It provides comprehensive databases covering materials, bearings, and lubrication parameters.

Multi-Physics Simulation

Structural Mechanics: Capable of analyzing stress, deformation, and fatigue life.
Dynamics: Conducts vibration analysis and Noise, Vibration, and Harshness (NVH) analysis.
Thermal Analysis: Focuses on the optimization of lubrication and heat dissipation.

System-Level Simulation

It enables the integration of other components like motors, couplings, and clutches for the analysis of the entire machine system.

2. Key Technologies of Romax in Gearbox Simulation

2.1 Gear Contact Analysis and Strength Check

Hertzian Contact Stress Calculation: Simulates the distribution of contact pressure on tooth surfaces to predict the risk of pitting corrosion.
Tooth Root Bending Stress Analysis: Evaluates the anti-fracture capacity of gears in accordance with standards such as ISO 6336 or AGMA.
Micro-Geometric Optimization: Reduces edge contact stress through modifications, such as tooth profile modification and helix angle correction.

2.2 Dynamics and NVH Analysis

Modal Analysis: Identifies the natural frequencies of the gearbox to avoid resonance.
Transfer Path Analysis (TPA): Locates vibration and noise sources, such as gear meshing excitation and bearing vibration.
Acoustic Simulation: Predicts the noise radiation of the gearbox, which requires coupling with acoustic software like LMS Virtual.Lab.

2.3 Bearing and Shafting Simulation

Bearing Life Prediction: Calculates the L10 life of bearings based on the ISO 281 standard.
Shaft Deformation Analysis: Considers the impact of bending and torsion on gear meshing.

2.4 Thermal Analysis and Lubrication Optimization

Oil Film Thickness Calculation: Assesses the state of Elastohydrodynamic Lubrication (EHL).
Thermal Network Model: Predicts the influence of gearbox temperature rise on lubricating viscosity and fatigue life.

3. Romax Gearbox Simulation Process

3.1 Modeling Steps

Geometry Import

The 3D model of the gearbox can be imported via CAD interfaces (e.g., STEP, Parasolid), or parametric modeling can be directly carried out within the software.

Material and Boundary Condition Definition

Set parameters for gear materials (e.g., 20CrMnTi), hardness, and surface treatment.
Define input rotational speed, torque, and load spectrum.

Mesh Generation

Automatically generate high-precision finite element meshes, which are suitable for contact analysis.

3.2 Simulation and Analysis

Static Analysis: Computes gear contact stress and bearing loads.
Dynamic Analysis: Performs transient simulations to evaluate impact loads during start-up and braking conditions.
Fatigue Analysis: Predicts the service life of gears and bearings based on Miner's rule.

3.3 Optimization Design

Parametric Optimization: Automatically adjusts parameters such as module and tooth width to meet the requirements for strength and NVH performance.
Sensitivity Analysis: Identifies key design variables, such as the impact of helix angle on noise.

4. Comparison of Romax with Other Software

Function	ROMAX	MASTA	ANSYS MECHANICAL
Gear-Specific Analysis	Deep integration (tooth contact, modification)	Similar, but focuses on system-level	Requires custom contact settings
NVH Analysis	Built-in Transfer Path Analysis tool	Requires third-party coupling	Relies on the Acoustics module
Multi-Physics Coupling	Supports thermal-structural-fluid co-simulation	Limited	Strong (but requires extensive manual settings)
Industry Applicability	Mainly for wind power and automotive	Heavy machinery	General-purpose CAE with high flexibility

5. Conclusion

With its professional, high-precision, and system-level analysis capabilities in gearbox simulation, ROMAX software has become an industry-standard tool for transmission system design. In the future, driven by advancements in intelligent technology and multi-physics coupling technology, ROMAX will further promote the development of gearbox design towards higher efficiency, greater reliability, and lower noise levels.