Gears are common machine components used in many engineered systems, such as automotive vehicles, aircraft engines, automation and robotic systems and more. The machining process to manufacture gears is typically done by trial and error — or is based on an operator's previous experience — to produce acceptable results.
Researchers from the University of Waterloo’s Faculty of Engineering Precision Controls Laboratory, led by Dr. Kaan Erkorkmaz, a professor in the mechanical and mechatronics engineering department, have developed software to simulate and optimize the gear cutting process to save time and money for large and medium-sized manufacturing.
The new software, called ShapePro, simulates gear cutting by predicting the complex chip geometry and cutting mechanics (e.g., machining forces, tool/workpiece deflections) in three of the major gear machining processes: shaping, hobbing and power skiving. With these predictions, the software enables accurate analysis, as well as automated or manual optimization of the machining process parameters.
“The software allows you to both cut and measure virtually,” says Erkorkmaz. “This simulation engine is very helpful in terms of improving the productivity, but also retaining the quality of the part.”
The Waterloo Commercialization Office (WatCo) has helped the ShapePro team commercialize their work and secure grants to support the development of the software, necessary modules, and present their work to industry. Multiple technical papers on this technology have also been published by the team.
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