Study on Building Digital-Twin of Face-Milled Hypoid Gear From Measured Tooth Surface Topographical Data

2020 ◽  
Vol 142 (11) ◽  
Author(s):  
Yi-Hui Lee ◽  
Zhang-Hua Fong
Keyword(s):  
Coordinate Measuring Machine ◽  
Industrial Applications ◽  
Tooth Surface ◽  
Position Vector ◽  
Normal Vector ◽  
Hypoid Gear ◽  
Principal Curvatures ◽  
Digital Twin ◽  
Design Variables ◽  
Measuring Machine

Abstract A highly accurate digital-twin spiral bevel gear or hypoid gear is often required for dynamic analysis or stress analysis for gear transmission. However, a highly accurate digital-twin solid model is not always available because the final hypoid gear is completed by the gear manufacturer. This study constructs a digital-twin from a sample hypoid gear. The tooth surface of sample gear is digitized as topographical grids using a coordinate measuring machine (CMM) or a gear measurement center. The geometric parameters (the surface position vector, the normal vector, the principal curvatures, and the corresponding principal directions) for the measured tooth surface (MTS) are then extracted using numerical differential geometry (NDG). The machine settings and the cutter parameters for the sample hypoid gear are obtained by minimizing the topographical error between the replicated digital-twin and the sample gear using optimization software. The initial estimation for the machine settings and the cutter parameters is calculated using an explicit form of the modified-roll motion (MRM), which decreases numerical divergence and time that is required for calculation. The machine settings, the cutting tool parameters, and the auxiliary flank modification (AFM) motion are used as the design variables. A numerical example is presented to verify the proposed methodology. The numerical results show that the replicated digital-twin that is developed using the proposed method is sufficiently accurate for industrial applications.

Towards Combining Digitization Techniques in the Generation of Reverse Engineering Data Sets

1999 ◽  
Author(s):  
C. J. Rolls ◽  
W. ElMaraghy ◽  
H. ElMaraghy
Keyword(s):  
Reverse Engineering ◽  
Computer Aided Design ◽  
Laser Scanning ◽  
Single Point ◽  
Laser Scanner ◽  
Coordinate Measuring Machine ◽  
Industrial Applications ◽  
Data Sets ◽  
Error Characterization ◽  
Measuring Machine

Abstract Reverse engineering (RE), may be defined as the process of generating computer aided design models (CAD) from existing or prototype parts. The process has been used for many years in industry. It has markedly increased in implementation in the past few years, primarily due to the introduction of rapid part digitization technologies. Current industrial applications include CAD model construction from artisan geometry, such as in automotive body styling, the generation of custom fits to human surfaces, and quality control. This paper summarizes the principles of operation behind many commercially available part digitization technologies, and discusses techniques involved in part digitization using a coordinate measuring machine (CMM) and laser scanner. An overall error characterization of the laser scanning digitization process is presented for a particular scanner. This is followed by a discussion of the merits and considerations involved in generating combined data sets with characteristics indicative of the design intent of specific part features. Issues in facilitating the assembly, or registration, of the different types of data into a single point set are discussed.

Automatic Coordinate Measuring Machine Inspection

1999 ◽  
Author(s):  
V. A. Albuquerque ◽  
F. W. Liou ◽  
S. Agarwal ◽  
O. R. Mitchell
Keyword(s):  
Path Planning ◽  
Computer Aided Design ◽  
Coordinate Measuring Machine ◽  
Industrial Applications ◽  
Prototype Development ◽  
Development Cycle ◽  
Inspection Process ◽  
Measuring Machine ◽  
Aided Design ◽  
Point Placement

Abstract In many industrial applications, such as product prototype development, automation of inspection process can greatly improve product quality and product development cycle, time. This paper discusses a development of a vision aided automatic inspection using Coordinate Measuring Machine (CMM). We seek to integrate the flexibility afforded by computer vision systems with the precision of numerically controlled coordinate measuring machines to achieve a fully automatic and reliable inspection of the industrial parts. The 3-D design information and part specification from computer-aided design file is used for inspection point placement and CMM path planning. The proposed system demonstrates that optimal collision-free inspection paths can be efficiently generated for geometrically complex parts consisting of multiply intersecting features. This is made possible by using iterative subdivision of surfaces for point placement coupled with, efficient 3-D collision avoidance and path planning. The paper discusses different algorithms used, and presents experimental results.

Research and Application on Reverse Engineering of Tooth Surfaces of Hypoid Gear

2010 ◽  
Vol 42 ◽  
pp. 100-103
Author(s):  
Li Mei Zhang ◽  
Li Xin Nie
Keyword(s):  
Reverse Engineering ◽  
Tooth Surface ◽  
Normal Vector ◽  
Cad Model ◽  
Hypoid Gear ◽  
Dimensional Measurement ◽  
Tooth Surfaces ◽  
Specific Number ◽  
Manufacturing Parameters ◽  
Selection Of

Reverse engineering, which is an approach for constructing a CAD model from a material solid through dimensional measurement and surface modeling, could be used to structure digitized tooth surfaces of hypoid gear. The reverse engineering of a NURBS tooth surface can be considered as specific number of curve's reverse solution, and the key is the structure of control equations and the selection of boundary conditions in each of reverse processes. According to NURBS theory, the coordinate, normal vector and various kinds of curvatures of all of points in the tooth surface can be solved. Thereupon, the engagement analysis of gear pairs can be achieved before manufacturing, and it is possible to amend manufacturing parameters in time so as to obtain tooth surfaces which meet the needs of function.

Analytical and Experimental Tooth Contact Pattern of Large-Sized Spiral Bevel Gears in Cyclo-Palloid System

2009 ◽  
Author(s):  
Kazumasa Kawasaki ◽  
Isamu Tsuji
Keyword(s):  
Coordinate Measuring Machine ◽  
Tooth Surface ◽  
Contact Pattern ◽  
Tooth Contact ◽  
Spiral Bevel Gears ◽  
Form Errors ◽  
Bevel Gears ◽  
Measuring Machine ◽  
Spiral Bevel ◽  
Tooth Flank

The demand of large-sized spiral bevel gears has increased in recent years and hereafter the demand may increase more and more. The large-sized spiral bevel gears with equi-depth teeth are usually manufactured based on Klingelnberg cyclo-palloid system. In this paper, the tooth contact pattern of large-sized spiral bevel gears in this system are investigated analytically and experimentally. First, the tooth contact pattern and transmission errors of such gears are analyzed. The analysis method is based on simultaneous generations of tooth surface and simulations of meshing and contact. Next, the large-sized spiral bevel gears are manufactured and the tooth contact pattern of these gears is investigated experimentally. Moreover, the real tooth surfaces are measured using a coordinate measuring machine and the tooth flank form errors are detected using the measured coordinates. It is possible to analyze the tooth contact patterns of the spiral bevel gears with consideration of the tooth flank form errors expressing the errors as polynomial equations. Finally, the influence of alignment errors due to assembly on the tooth contact pattern is also investigated analytically and experimentally. These analyzed results were compared with experimental ones. As a result, two results showed a good agreement.

scholarly journals An Analysis of Polymer Gear Wear in a Spur Gear Train Made Using FDM and FFF Methods Based on Tooth Surface Topography Assessment

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1649
Author(s):  
Jadwiga Pisula ◽  
Grzegorz Budzik ◽  
Paweł Turek ◽  
Mariusz Cieplak
Keyword(s):  
Additive Manufacturing ◽  
Operating Temperature ◽  
Coordinate Measuring Machine ◽  
Acrylonitrile Butadiene Styrene ◽  
Spur Gear ◽  
Gear Train ◽  
Tooth Surface ◽  
Fused Filament Fabrication ◽  
Measuring Machine ◽  
Manufacturing Techniques

This article focuses on wear tests of spur gears made with the use of additive manufacturing techniques from thermoplastic materials. The following additive manufacturing techniques were employed in this study: Melted and Extruded Modelling (FDM) and Fused Filament Fabrication (FFF). The study analysed gears made from ABS M-30 (Acrylonitrile Butadiene Styrene), ULTEM 9085 (PEI Polyetherimide) and PEEK (Polyetheretherketone), and the selection of these materials reflects their hierarchy in terms of economical application and strength parameters. A test rig designed by the authors was used to determine the fatigue life of polymer gears. Gear trains were tested under load in order to measure wear in polymer gears manufactured using FDM and FFF techniques. In order to understand the mechanism behind gear wear, further tests were performed on a P40 coordinate measuring machine (CMM) and a TalyScan 150 scanning instrument. The results of the gear tests made under load allow us to conclude that PEEK is resistant to wear and gear train operating temperature. Its initial topography undergoes slight changes in comparison to ABS M-30 and Ultem 9085. The biggest wear was reported for gears made from Ultem 9085. The hardness of the material decreased due to the loaded gear train’s operating temperature.

scholarly journals Digital Twin of an Optical Measurement System

Sensors ◽  
2021 ◽  
Vol 21 (19) ◽  
pp. 6638
Author(s):  
Michiel Vlaeyen ◽  
Han Haitjema ◽  
Wim Dewulf
Keyword(s):  
Measurement Uncertainty ◽  
Measurement System ◽  
Optical Measurement ◽  
Coordinate Measuring Machine ◽  
Plane Angle ◽  
Optical Measurement System ◽  
Digital Twin ◽  
Digital Twins ◽  
Measuring Machine ◽  
Line Scanner

Digital twins of measurement systems are used to estimate their measurement uncertainty. In the past, virtual coordinate measuring machines have been extensively researched. Research on digital twins of optical systems is still lacking due to the high number of error contributors. A method to describe a digital twin of an optical measurement system is presented in this article. The discussed optical system is a laser line scanner mounted on a coordinate measuring machine. Each component of the measurement system is mathematically described. The coordinate measuring machine focuses on the hardware errors and the laser line scanner determines the measurement error based on the scan depth, in‑plane angle and out‑of‑plane angle. The digital twin assumes stable measurement conditions and uniform surface characteristics. Based on the Monte Carlo principle, virtual measurements can be used to determine the measurement uncertainty. This is demonstrated by validating the digital twin on a set of calibrated ring gauges. Two validation tests are performed: the first verifies the virtual uncertainty estimation by comparison with experimental data. The second validates the measured diameter of different ring gauges by comparing the estimated confidence interval with the calibrated diameter.

Challenges and Solutions in Distortion Engineering of an Aluminium Die Casting Component

2011 ◽  
Vol 690 ◽  
pp. 443-446
Author(s):  
Ole Karsten ◽  
Kai Schimanski ◽  
Axel von Hehl ◽  
Hans Werner Zoch
Keyword(s):  
Die Casting ◽  
Coordinate Measuring Machine ◽  
Dimensional Accuracy ◽  
Industrial Applications ◽  
Efficient Solutions ◽  
Solution Annealing ◽  
Process Chain ◽  
Initial State ◽  
Structural Part ◽  
Measuring Machine

The demand for increased efficiency of resources in industrial manufacturing processes requires continuous developments of materials and production processes. Aluminium components especially used in automotive applications meet the requirements of weight optimised and energy efficient solutions. In this context vacuum die casting enables the production of complex weight optimised components. However, in view of ensuring the needed dimensional accuracy, the productivity potential of the process is still restricted. Hence, the distortion behaviour within the whole process chain of a die casting structural part made of alloy AlSi10Mg was systematically investigated. Starting with the initial state after casting the analysis was focused on the quenching, punching, precipitation hardening and machining of the components. Contour deviations were recorded via a photogrammetry system and a coordinate measuring machine. Especially after die casting and solution annealing significant contour deviations were observed. Residual stress measurements along the process chain pointed out that residual stresses from die casting were released by solution annealing. By the knowledge of distortion sensitive component areas and the understanding of distortion mechanisms compensation strategies were derived based on the investigated processes. Within the paper these deduced strategies and the way to reduce expensive straightening processes and to raise efficiency will be given for industrial applications.

DIMENSIONAL INSPECTION OF TRANSLATING CAMS BY CNC COORDINATE MEASURING MACHINE

2012 ◽  
Vol 36 (3) ◽  
pp. 259-270
Author(s):  
Jung-Fa Hsieh
Keyword(s):  
Kinematic Model ◽  
Coordinate Measuring Machine ◽  
Least Square ◽  
Normal Vector ◽  
Transformation Theory ◽  
Fitting Method ◽  
Cam Profile ◽  
Measuring Machine ◽  
Normal Vectors ◽  
Nc Data

In this paper, a simple and analytical method is proposed for accomplishing the inspection procedure. In the proposed approach, a kinematic model of the cam profile is derived using homogenous coordinate transformation theory. The normal vectors and principal curvature of the designed translating cam are then derived from the analytical expression for the cam profile. Based on the coordinates and normal vector of each specified point on the cam profile, the NC data required to move the CMM inspection probe to the surface of the cam are then obtained. A least-square fitting method is proposed to minimize the inspection error caused by a misalignment of the actual evaluation frame relative to the ideal frame.

Effects of Wheel Dressing Errors on the Accuracy of CNC Gear Form Grinding

2013 ◽  
Vol 328 ◽  
pp. 400-407 ◽  
Author(s):  
Hu Zhang ◽  
Xiao Diao Huang
Keyword(s):  
Mathematical Model ◽  
Theoretical Foundation ◽  
Coordinate Measuring Machine ◽  
Tooth Surface ◽  
Wheel Surface ◽  
Precision Control ◽  
Form Grinding ◽  
Measuring Machine ◽  
Grinding Machine ◽  
The Mathematical Model

Gear form grinding is a finish machining method for hard tooth surface with a form wheel. Wheel dressing is an important process in gear form grinding, and affects the precision of the ground gear directly. Based on the envelope theory the mathematical model of the dressed wheel surface was built in the case of wheel dressing errors. Then the real profile of the ground tooth in the transverse plan was solved and its deviations from the designed profile were evaluated. Finally the effects of each dressing error on the precision of the ground gear were analyzed using the proposed mathematical model. The results provided theoretical foundation for the precision control during manufacturing a gear form grinding machine. A grinding experiment was implemented using the gear form grinding machine and the ground gear was measured by a three-coordinate measuring machine. The measure result indicated that the accuracy grade of the ground gear achieved 4 (ISO1328-1: 1997).

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