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Dimensional Control Systems DCS

Metrology

Webinar: Understanding Multitooth Gear Contact Modeling

Jan. 27, 2022, at 9 a.m. Pacific; Feb. 24, 2022, at 8 a.m. Pacific

Published: Tuesday, January 18, 2022 - 12:00

(Dimensional Control Systems: Troy, Michigan) -- Dimensional Control Systems (DCS) is hosting a webinar to showcase a digital twin gear model and the results from simulation that provide insight into the design and allow for operational optimization and reductions in tooling changes. The webinar demonstrates the value and results of a multitooth contact gear variation model. Created by the DCS analyst team to provide answers to common gear issues during the digital phase, this model and a supporting whitepaper will be shown at the webinar on Jan. 27, 2022, at 11 a.m. Eastern.

The webinar shows how a CAD digital twin can use 3DCS Variation Analyst software to validate the design and tolerancing of an individual gear. This method uses Monte Carlo simulation for running standard tests and gear-specification measurements, predicting results as deviation from nominal values and predicted range of values. This analysis, along with analysis metrics, contributors, and risk of failure, combine to give engineers the information needed to make decisions about design, manufacturing processes, and assembly that reduce the chances of problems as well as the number of physical tests and prototypes needed to optimize the design itself.

3DCS Variation Analyst software is a CAD-integrated tolerance stack-up simulation tool developed by DCS. Integrated into all the major CAD platforms, CATIA, CREO, SOLIDWORKS, NX, 3DEXPERIENCE, 3DCS software provides real insight into both the risk of failure from variation and the sources of variation within an assembly. As inputs, 3DCS uses part tolerances, often represented using GD&T, as well as assembly processes and assembly sequences. In order to handle gears and other mechanical components, 3DCS leverages an add-on, Mechanical Modeler, which includes a unique tool called the 3DCS Gear Module. This allows users to simulate gear contact surfaces and standard tests, both at a stationary position and through gear rotations.

The 3DCS Gear Module now provides additional predictions that include multitooth contact with gear rotation. The location of the tooth-to-tooth in multitooth contacts corresponds to the flank test results. Additionally, the digital twin model provides performance validation of gear assemblies, including the standard tests: total composite deviation, and single-pitch deviation. These tests are in addition to measurements for axial backlash, angle backlash, and pressure angle.

The 3DCS Gear Module has also been enhanced to simulate a rolling gear gauge to measure the total radial composite deviation. In the simulation model, the master gear rotates, and the work gear is pressed against it, forcing contact at two locations, which will change as rotation occurs and new teeth come into contact.   

The results for gear tests and studies are calculated from the measurement distance between gear centers. In addition to this measurement, the angular deviation between teeth is also taken into account. These tests, leveraging the digital twin, provide savings by avoiding tooling changes and by optimizing the gear parameters, such as crowning.

To see the crowned spur gear model and results yourself, and get access to a free whitepaper about the process, join the DCS webinar on Jan. 27, 2022. Register for the webinar here. Learn more about DCS’ software and services at the Dimensional Control Services website.

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Dimensional Control Systems DCS

Dimensional Control Systems (DCS), based in Troy, Michigan, is focused on the methodology of dimensional engineering. DCS offers world-class tolerance analysis and quality data management software solutions and services to manufacturing companies worldwide. No matter what the product or process, dimensional engineering is an effective element of product life-cycle management (PLM). Dimensional engineering emphasizes digital assembly variation simulation and web-based data management of inspection data for comprehensive support of a company’s quality objectives.