Adam Marciniec

Method of spiral bevel gear tooth contact analysis performed in CAD environment

Purpose – The purpose of this paper is to present the use of a CAD system for the analysis of meshing of spiral bevel gears. Design/methodology/approach – The TCA computer programs are based on a purely mathematical model and require to get the numerical solution of a set of nonlinear equations. There are situations that the programs fail to obtain the proper solution. In such cases, geometrical gear models defined in CAD environment prove to be a good choice. This paper describes a tool for analyzing tooth contact and transmission errors of spiral bevel gear sets with tooth flanks represented as CAD free-form surfaces. Findings – A new method has been proposed to keep those surfaces in continuous contact in the whole range of meshing of a mating tooth pair. During meshing, the points of contact as well as the corresponding angles of rotation of both the pinion and the ring gear are recorded. Thus, the tooth contact path as well as the motion transmission error graph is determined. Then, the contact patte...

Comparative analysis of numerical methods for the determination of contact pattern of spiral bevel gears

Purpose This paper presents a comparison of numerical methods for determining the contact pattern of Gleason-type bevel gears. The mathematical model of tooth contact analysis as well as the Finite Element Method were taken into consideration. Conclusions have been drawn regarding the usefulness of the considered methods and the compatibility of results. The object of the analysis was a bevel gear characterized by a 18:43 gear ratio, arc tooth line and manufactured according to the SGM (Spiral Generated Modified-roll) method. Design/methodology/approach The mathematical model of tooth contact analysis consists of both the mathematical model of tooth generating and the mathematical model of operating gear set. The first model is used to generate tooth flanks of the pinion and the ring gear in the form of grids of points. Then such tooth surfaces are used for the tooth contact analysis performed with the other model. It corresponds to the no-load gear meshing condition. The FEM model was built on the basis ...

Quality control and inspection of bevel gears of the aircraft gearbox utilizing the ATOS 3D scanner

Quality control gears o aircraft gearbox has become a key component in today’s manufacturing process. Optical 3D scanning, based on the principle of fringe projection, has proven to be both an accurate and cost-effective alternative delivering more dimensional information to aid in quality control and process optimization by creating more meaningful measuring reports. The ATOS 3D BLUE LIGHT optical scanner has a unique capability of being user-configurable to address various measuring requirements. This is accomplished via the user’s ability to change measuring volumes in minutes, in order to increase scan data resolution or increase the measuring field of view. The paper present the opportunity to automate the measurement process of bevel gears, using coordinated optical scanner ATOS 3D “white light” version and “blue light” version. Using coordinate measuring technique, you can specify a set of methods and procedures for the designation of the complex dimensions of physical objects and transform them into a computer program space of coordinate measuring devices. The topics included in the article are intended to show the capabilities of the device used to improve the measurement process and shorten its time, and hence, lower its costs in both version of ATOS Scanner. Another thing described in the paper is the impact of measurement performance in automatic mode on the quality of performance the numerical image of scanned surface, from the standpoint of accuracy and number of collected data points in the shortest time. The article includes an analysis of conditions related to the measurement works, such as the process of preparing the model and measurement equipment and data processing capacity.

Methodology of measurement aeronautical bevel gears using an optical scanner ATOS II Triple Scan

Properly prepared and carried out the measurement process of bevel gears determines its accuracy and productivity. This also has an influence on the final accuracy of bevel gears and the production costs of aeronautical gearbox. In the process of assessing the accuracy of manufacturing, majority of manufacturers of bevel gears use specialized contact coordinate measuring machines. The application of such machines as well as specialized programs dedicated to measuring the geometry of bevel gears are authoritative but in turns this requires substantial financial resources for the purchase of machinery. Thereby, this causes the limitation only of the gear assortment. Therefore, this article depicts different perspective on measurements of bevel gears using a universal measuring

The determination of accuracy of the demonstrator of aeronautic bevel gearbox, accomplished by selected rapid prototyping techniques using an optical scanner Atos II Triple Scan

Designing and manufacturing of aeronautic bevel gearboxes is a complicated and time-consuming process because of complex kinematics of the machining process as well as numbers of manufacturing methods. Machine manufacturers usually provide algorithms used in manufacture process. This requires substantial financial resources and, in consequence, it increases the costs of production. Using other commonly available calculation algorithm requires a lot of studies to verify whether the proposed gearbox works correctly. In order to reduce the manufacturing costs of prototypes, it is possible to use Rapid Prototyping methods. Using both Rapid Prototyping techniques and coordinate optical measurements enables to verify the correctness of assumptions made in the initial stage of product designing. This approach reduces significantly both prototyping time and manufacturing costs. In order to ensure the effectiveness of prototyping process, it is essential to provide the accuracy of manufactured prototypes. That is the reason why it is necessary to determine manufacturing methods that will ensure the highest geometric accuracy. The study presents the modelling and manufacturing process of aeronautic bevel gear of demonstrator taking into consideration the accuracy of selected Rapid Prototyping methods. The gear modelling is based on machining simulation method conducted in Autodesk Inventor. The measurement results are shown in displacement maps obtained with an optical scanner Atos II Triple Scan and universal GOM Inspect Professional software, which determines the prototype accuracy in relation to 3D-CAD models.