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1 3-D Printing: We Ain't Seen Nothing Yet (March/April 2015)

NASA is now 3-D-printing spare parts up at the ISS (International Space Station). And in zero-gravity environments. And some of these parts are small gears and actuators, for starters. Every indication is that the list of power transmission-type parts to be converted will soon grow.

2 Meshing of a Spiral Bevel Gear Set With 3-D Finite Element Analysis (March/April 1997)

Recent advances in spiral bevel gear geometry and finite element technology make it practical to conduct a structural analysis and analytically roll the gear set through mesh. With the advent of user-specific programming linked to 3-D solid modelers and mesh generators, model generation has become greatly automated. Contact algorithms available in general purpose finite element codes eliminate the need for the use and alignment of gap elements. Once the gear set it placed in mesh, user subroutines attached to the FE code easily roll it through mesh. The method is described in detail. Preliminary result for a gear set segment showing the progression of the contact line load is given as the gears roll through mesh.

3 Need a Snack - Try 3D Printing Technology (June/July 2013)

3-D printing offers a new way to create food, even gear-shaped snacks are now available via this new technology.

4 Performance Analysis of Hypoid Gears by Tooth Flank Form Measurement (July/August 2002)

The traditional way of controlling the quality of hypoid gears' tooth flank form is to check the tooth flank contact patterns. But it is not easy to exactly judge the tooth flank form quality by the contact pattern. In recent years, it has become possible to accurately measure the tooth flank form of hypoid gears by the point-to-point measuring method and the scanning measuring method. But the uses of measured data of the tooth flank form for hypoid gears have not yet been well developed in comparison with cylindrical involute gears. In this paper, the tooth flank form measurement of generated face-milled gears, face-hobbed gears and formulate/generated gears are reported. The authors discuss the advantages and disadvantages of scanning and point-to-point measuring of 3-D tooth flank forms of hypoid gears and introduce some examples of uses of measured data for high-quality production and performance prediction.

5 Adding Up Gear Spheres (March/April 2016)

Paul Nylander is something between an entrepreneur and a Renaissance man. He has degrees in engineering and physics, but he’s also a creative artist who’s put together sketches and 3D renderings alike. His website, bugman123. com, features everything from an in-depth explanation of a Tesla coil to 3D renderings of physics equations to an extensive library of fractal-based artwork. At first glance, one might find Nylander’s many pursuits to be somewhat scattershot, but at their core, his works are tied together by his love for all things mathematical.

6 A Practical Approach for Modeling a Bevel Gear (March/April 2015)

The geometry of the bevel gear is quite complicated to describe mathematically, and much of the overall surface topology of the tooth flank is dependent on the machine settings and cutting method employed. AGMA 929-A06 — Calculation of Bevel Gear Top Land and Guidance on Cutter Edge Radius — lays out a practical approach for predicting the approximate top-land thicknesses at certain points of interest — regardless of the exact machine settings that will generate the tooth form. The points of interest that AGMA 929-A06 address consist of toe, mean, heel, and point of involute lengthwise curvature. The following method expands upon the concepts described in AGMA 929-A06 to allow the user to calculate not only the top-land thickness, but the more general case as well, i.e. — normal tooth thickness anywhere along the face and profile of the bevel gear tooth. This method does not rely on any additional machine settings; only basic geometry of the cutter, blank, and teeth are required to calculate fairly accurate tooth thicknesses. The tooth thicknesses are then transformed into a point cloud describing both the convex and concave flanks in a global, Cartesian coordinate system. These points can be utilized in any modern computer-aided design software package to assist in the generation of a 3D solid model; all pertinent tooth macrogeometry can be closely simulated using this technique. A case study will be presented evaluating the accuracy of the point cloud data compared to a physical part.

7 Local 3-D Flank Form Optimizations for Bevel Gears (September/October 2003)

Optimizing the running behavior of bevel and hypoid gears means improving both noise behavior and load carrying capacity. Since load deflections change the relative position of pinion and ring gear, the position of the contact pattern will depend on the torque. Different contact positions require local 3-D flank form optimizations for improving a gear set.

8 3-D Finite Element Analysis of Long-Fiber Reinforced Composite Spur Gears (March/April 2002)

This article describes a method and a computer program that were developed for 3-D finite element analysis of long-fiber reinforced composite spur gears, in which long fibers are arranged along tooth profiles. For such a structure, the gear is composed of two regions; namely the long fiber reinforced and the chopped-fiber reinforced regions.

9 An Approach to Pairing Bevel Gears from Conventional Cutting Machine with Gears Produced on 5-Axis Milling Machine (June 2015)

Developed here is a new method to automatically find the optimal topological modification from the predetermined measurement grid points for bevel gears. Employing this method enables the duplication of any flank form of a bevel gear given by the measurement points and the creation of a 3-D model for CAM machining in a very short time. This method not only allows the user to model existing flank forms into 3-D models, but also can be applied for various other purposes, such as compensating for hardening distortions and manufacturing deviations which are very important issues but not yet solved in the practical milling process.

10 Swiss Watchmaking - with 3-D Printing (January/February 2017)

For centuries, Switzerland has been considered home to the greatest watchmakers in the world. Works of fine beauty and optimal precision have been the norm there seemingly forever.

11 Finite Element Analysis of Tooth Flank Fracture Using Boundary Conditions from LTCA (September/October 2016)

This paper demonstrates an application of the tooth interior fatigue fracture (TIFF) analysis method, as implemented in SMT's MASTA software, in which loaded tooth contact analysis (LTCA) results from a specialized 3-D contact model have been utilized to determine the load boundary conditions for analysis of tooth flank fracture (TFF).

12 Solid Model Generation of Involute Cylindrical Gears (September/October 2003)

This paper presents approximate and accurate methods to generate solid models of involute cylindrical gears using Autodesk Inventor 3-D CAD software.

13 Optimizing Gear Geometry for Minimum Transmission Error, Mesh Friction Losses and Scuffing Risk Through Computer- Aided Engineering (August 2010)

Minimizing gear losses caused by churning, windage and mesh friction is important if plant operating costs and environmental impact are to be minimized. This paper concentrates on mesh friction losses and associated scuffing risk. It describes the preliminary results from using a validated, 3-D Finite Element Analysis (FEA) and Tooth Contact Analysis (TCA) program to optimize cylindrical gears for low friction losses without compromising transmission error (TE), noise and power density. Some case studies and generic procedures for minimizing losses are presented. Future development and further validation work is discussed.

14 Design Unit Evaluating New Software from SMT (January/February 2007)

MASTA 4.5.1 models complete transmissions and includes 3-D stress analysis.

15 Manufacturing Method of Large-Sized Spiral Bevel Gears in Cyclo-Palloid System Using Multi-Axis Control and Multi-Tasking Machine Tool (August 2011)

In this article, the authors calculated the numerical coordinates on the tooth surfaces of spiral bevel gears and then modeled the tooth profiles using a 3-D CAD system. They then manufactured the large-sized spiral bevel gears based on a CAM process using multi-axis control and multi-tasking machine tooling. The real tooth surfaces were measured using a coordinate measuring machine and the tooth flank form errors were detected using the measured coordinates. Moreover, the gears were meshed with each other and the tooth contact patterns were investigated. As a result, the validity of this manufacturing method was confirmed.

News Items About 3-D

1 KISSsoft Releases 3-D Variant Skin Model (November 17, 2011)
Crossed helical gears are helical gears that are mounted on crossed axes. The shaft angle is usually Σ = 90 degrees. In contrast to... Read News

2 Ipsen Collaborates with ExOne on 3-D Printing Solutions (June 21, 2013)
When constantly out-doing the competition is the name of the game, meaningful collaborations are of the utmost importance. Ipsen is pleas... Read News

3 Local Motors to Deliver 3-D Printed Electric Vehicle at IMTS 2014 (March 3, 2014)
Local Motors, Inc. recently announced that the Association for Manufacturing Technology (AMT) will be the first customer for its previous... Read News