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1

Rekonstrukcja kół zębatych z zastosowaniem systemów CMM/CAD/RP

Budzik G., Dziubek T., Kozik T., Zaborniak M.

Mechanik

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2015

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R. 88, nr 12CD2

18--21

PL

W artykule przedstawiono metodykę rekonstrukcji kół zębatych przekładni lotniczych z zastosowaniem powiązanych systemów CMM/CAD/RP. Współrzędnościowe techniki pomiarowe (CMM) oraz systemy CAD umożliwia identyfikację i odtwarzanie geometrii kół zębatych, natomiast systemy RP dają możliwość wykonania prototypu zrekonstruowanego koła zębatego.

EN

This paper presents a reconstruction methodology of the transmission airline gears connected systems using CMM/CAD/RP. The use of coordinate measuring techniques (CMMs) and CAD systems enables to identify and reconstruct gear geometry. In contrast, while the RP systems make it possible to create a prototype with the reconstructed gear.

2

The determination of accuracy of testing gear wheel for aeronautical dual-power path gear after heat treatment

Dziubek T.

Diagnostyka

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2015

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Vol. 16, No. 2

61--66

EN

Manufacture of aircraft gearbox elements requires control of gear geometric parameters at different stages of technological process. The aim of this study is to present develop and execute the analysis accuracy of the geometry of the gear of aeronautical dual-power path gear after the roughing operation using coordinated optical scanner ATOS II Triple Scan. Research was carried out in order to detect errors occurring in the machining process and to determine the value of founded the machining allowance finishing in relation to the CAD model. On this basis, it is possible to determine the accuracy of the gear wheel as the workpiece after heat treatment. The results will be the basis to determine the effect of heat treatment on changes in the geometry of the gear and the benchmark for determining the correctness of the finishing.

PL

Produkcja elementów przekładni lotniczych wymaga kontroli parametrów geometrycznych kół zębatych na różnych etapach procesu technologicznego. Celem niniejszej pracy jest przedstawienie opracowania i wykonania analizy dokładności geometrii koła przekładni dwudrożnej po obróbce zgrubnej przy użyciu współrzędnościowego skanera optycznego ATOS II Triple Scan. Badania przeprowadzono w celu wykrycia błędów powstałych w procesie obróbki skrawaniem oraz określenia wartości założonych naddatków na obróbkę wykańczającą w odniesieniu do modelu CAD. Na tej podstawie możliwe jest określenie dokładności wykonania koła zębatego, jako półwyrobu po obróbce cieplnej. Otrzymane wyniki będą podstawą do określenia wpływu obróbki cieplnej na zmiany geometrii koła zębatego ze wzorcem odniesienia dla określenia poprawności wykonania obróbki wykańczającej.

3

Methodology of measurement aeronautical bevel gears utilizing an optical 3D scanner using white and blue light

Budzik G., Dziubek T.

Diagnostyka

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2015

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Vol. 16, No. 1

51--56

EN

Accuracy diagnostics bevel gears of aircraft gearbox has become a key component in today’s manufacturing process. Properly prepared and carried out the measurement process of bevel gears determines its accuracy, productivity 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. Therefore, this article depicts different perspective on measurements of bevel gears using a universal measuring device, which is an optical 3D scanners ATOS, using in the process of measuring white and blue light. Due to the use of the optical scanners ATOS in measurement process, it was necessary to develop a methodology dealing with the process of assessing and accuracy, in order to achieve the desired results of measurement. The studies take into account the economic aspects of the use of technical diagnostics in the production process. The article presents an analysis of conditions and developed rules concerning the preparation of a model for measurement. It also contains hints and a description of the measurement process. Furthermore, it depicts the rules specifying the interpretation of measurement results as well as the technical rules of their realization.

PL

Diagnostyka dokładności wykonania stożkowych kół zębatych przekładni lotniczych stała się obecnie kluczowym elementem procesu ich wytwarzania. Odpowiednio przygotowany i przeprowadzony proces pomiaru stożkowych kół zębatych determinuje jego dokładność, wydajność oraz koszty produkcji przekładni. Większość producentów stożkowych kół zębatych w procesie oceny dokładności wykonania, stosuje specjalistyczne stykowe współrzędnościowe maszyny pomiarowe. Dlatego niniejszy artykuł będzie innym spojrzeniem na pomiary stożkowych kół zębatych z zastosowaniem uniwersalnego urządzenia pomiarowego, jakim są optyczne skanery 3D ATOS wykorzystujące w procesie pomiaru białe i niebieskie światło. Z uwagi na zastosowanie w procesie pomiaru optycznych skanerów Atos, w celu osiągnięcia pożądanych wyników pomiarów niezbędne było opracowanie metodologii dotyczącej przebiegu procesu pomiaru oraz oceny dokładności. Przeprowadzone badania uwzględniają ekonomiczne aspekty zastosowania diagnostyki technicznej w przebiegu procesu produkcyjnego. Artykuł przedstawiał będzie analizę warunków oraz opracowane zasady dotyczące przygotowania modelu do pomiaru. Zawarte zostaną w nim również wskazówki oraz opis samego procesu pomiaru. Ponadto przedstawiono zasady określające interpretację wyników pomiarów wraz z technicznymi zasadami ich wykonania.

4

Measurement of cylindrical gear air, gear with standard software CMM

Zaborniak M.

Diagnostyka

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2015

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Vol. 16, No. 1

47--50

EN

Air gears must meet high performance criteria for accuracy, therefore quality control is necessary for their production. CMM Software determines the capabilities and scope of the measuring machines. The choice of measurement method should be carried out taking into account the accuracy of gear and taking into account the capabilities of the system and measurement needs. Item will present the methodology of measurement of cylindrical gears using a standard CMM software. The results of these diagnostic tests to prevent the need to purchase additional software, the measuring machine and its setup. You should only choose a method of analysis that will be carried out directly in the environment measuring machine, or will be made in the CAD system based on the geometry acquired during the measurement with respect to the virtual model. In the second case export is needed in the appropriate format measurement data to CAD software.

PL

Koła zębate przekładni lotniczych muszą spełniać wysokie kryteria dokładności wykonania, dlatego niezbędna przy ich produkcji jest kontrola dokładności. Oprogramowanie współrzędnościowych maszyn pomiarowych decyduje o możliwości i zakresie zastosowania maszyn pomiarowych. Dostępne są na rynku specjalistyczne maszyny pomiarowe wyposażone w oprogramowania do pomiaru kół zębatych, które umożliwiają w pełni automatyczne pomiary odchyłek zarysu (ewolwenty), linii zęba, podziałek i bicia promieniowego, topografii boku zęba. Wybór metody pomiarowej powinien odbywać się z uwzględnieniem dokładności wykonania koła zębatego oraz z uwzględnieniem możliwości sytemu i potrzeb pomiarowych. Artykuł będzie przedstawiał metodykę pomiaru walcowych kół zębatych z zastosowaniem standardowego oprogramowania CMM. Zaletą pomiarów kół zębatych z wykorzystaniem uniwersalnego oprogramowania pomiarowego, jest możliwość pomiaru kół o dowolnej geometrii w odniesieniu do modelu CAD. Wyniki powyższych badań diagnostycznych zapobiegają konieczności zakupu dodatkowego oprogramowania maszyny pomiarowej oraz jej przezbrajania. Analizy przeprowadzać można bezpośrednio w środowisku maszyny pomiarowej, albo w systemie CAD, na podstawie geometrii pozyskanej podczas pomiaru w odniesieniu do modelu wirtualnego. W drugim przypadku niezbędny jest eksport w odpowiednim formacie danych pomiarowych do oprogramowania CAD.

5

The influence of contour number on load carrying capacity of gears in aircraft gearbox demonstrator made by MEM

Budzik G., Kozik B, Łączek A., Cieplak M

Journal of KONES

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2014

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Vol. 21, No. 3

29--34

EN

The paper presents an outcome of load carrying tests of gears in an aircraft gearbox demonstrator made of ABS B601polymer by means of INSPIRE D290 device. These tests checked an influence of an additional number of contours in gear models on durability of cooperating wheel pair during stand tests. The CAD models of the gears for stand tests were made in Autodesk Inventor program and were used as a base for making physical models. Therefore, Inventor files were exported to STL format. The following stage of data preparation was made in Model Wizard. The gears for stand tests were made by means of MEM method on INSPIRE D290 printer. Unlike most devices, this printer makes it possible to control not only the density of the filling in a model, but also to increase the number of contours. ABS polymer was chosen to make the gears. The choice was due to its good properties and because it is commonly used and also because it was possible to make the parts of the gearing at the Rzeszow University of Technology. Subsequently the gear pair was fixed on a test stand. The stand was designed in an open system. It was powered by a three-phase 0.75 kW electric motor. The control was provided by a single-phase inverter. Load on the stand was provided by an electromagnetic powder brake. This paper is a part of implementation of the research task number 4 „Development of a new, simpler and cheaper toothed gear in place of complicated and expensive planetary gears” of the project „Modern material technologies in aerospace industry."

6

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

Marciniec A., Budzik G., Dziubek T., Sobolewski B., Zaborniak M.

Journal of KONES

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2014

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Vol. 21, No. 3

205--209

EN

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.

7

Methods of measurement of cylindrical gear air, gear with standard software CMM

Budzik G, Dziubek T., Kozik B, Zaborniak M.

Journal of KONES

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2014

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Vol. 21, No. 1

37--42

EN

Air gears must meet high performance criteria for accuracy; therefore, quality control is necessary for their production. CMM Software determines the capabilities and scope of the measuring machines. Measuring machines equipped with specialized software for the measurement of the gears are commercially available. An example might be a company offering Wenzel TGEAR XY software. This specialized software for the measurement of gears allows fully automatic measurement of the contour deviation (involute), line tooth pitch, and radial run out, tooth flank topography. If you do not have a special software to measure the gear, you require a measurement process based on 3D CAD model of the gear. It is necessary in this case, the preparation of a strategy based on measurements of 3D CAD model and load points or paths with the CAD model. The results of the measurement refer to the CAD model treating it as the nominal model. Item will present the methodology of measurement of cylindrical gears using a standard CMM software. Cylindrical gears can be measured through non-contacting or contacting methods – measuring point or scanning. The choice of measurement method should be carried out taking into account the accuracy of gear and taking into account the capabilities of the system and measurement needs. An important advantage of the measurement using the gears multipurpose measuring software is that it is possible to measure any geometry of the wheels in relation to the CAD model. Using this measurement strategy avoids the need to purchase additional software, the measuring machine and its setup. You should only choose a method of analysis that will be carried out directly in the environment-measuring machine, or will be made in the CAD system based on the geometry acquired during the measurement with respect to the virtual model. In the second case, export is needed in the appropriate format measurement data to CAD software.

8

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

Marciniec A., Budzik G., Dziubek T., Sobolewski B., Zaborniak M.

Journal of KONES

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2014

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Vol. 21, No. 2

201--208

EN

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 device, which is an optical 3D scanner ATOSII Triple Scan. Due to the use of the optical scanner ATOS II Triple Scan in measurement process, it was necessary to develop a methodology dealing with the process of assessing and accuracy, in order to achieve the desired results of measurement. This need arises from the fact that the optical scanner ATOS is not dedicated, specialized device for measuring gears. Despite of this fact, maintaining the appropriate measurement procedures and a proper preparation of the measured model allows for rapid and accurate assessment of the accuracy ofproduction. The article presents the analysis of conditions and developed rules concerning the preparation of a model for measurement. It also contains hints and a description of the measurement process. Furthermore, it depicts the rules specifying the interpretation of measurement results as well as the technical rules of their realization.

9

The determination of accuracy of test gear wheel for aeronautical dual - power path gear before heat treatment

Dziubek T., Budzik G., Kozik B., Sobolewski B.

Journal of KONES

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2013

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Vol. 20, No. 2

83--90

EN

Manufacture of aircraft gearbox elements requires control of gear geometric parameters at different stages of technological process. In case of measurement of gear wheels using modern technologies based on numerical machines, measurement process is based on processing of numerical data obtained by measurement using coordinate measuring machines. The goal of this paper is to present the measurement process of gears, using coordinated optical scanner ATOS II TripleScan by GOM, equipped with a turntable. The aim of this study is to develop and execute the analysis accuracy of the geometry of the gear of aeronautical dual-power path gear after the roughing operation using optical coordinate measuring methods. Executed research will enable the detection of errors occurring in the machining process and to determine the value of founded the machining allowance finishing in relation to the CAD model. Using coordinate measuring technique, one 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. On this basis, it is possible to determine the accuracy of the gear wheel as the workpiece prior to heat treatment. The results will be the basis to determine the effect of heat treatment on changes in the geometry of the gear and the benchmark for determining the correctness of the finishing.

10

Automated measurement of bevel gears of the aircraft gearbox using GOM

Marciniec A., Budzik G., Dziubek T.

Journal of KONES

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2011

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Vol. 18, No. 4

259-264

EN

Manufacture of aircraft gearbox elements requires control of gear geometric parameters at different stages of technological process. Acceleration and automation of measurement process can affect the duration of the finished item production. In case of measurement of gear wheels using modern technologies based on numerical machines, measurement process is based on processing of numerical data obtained by measurement using coordinate measuring machines. The goal of this paper is to present the opportunity to automate the measurement process of bevel gears, using coordinated optical scanner ATOS by GOM, equipped with a turntable. 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. 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. The result of the work will be presented methodology for automated scanning measurements of bevel Sears.

11

Automated measurement of bevel gears of the aircraft gearbox using GOM

Marciniec A., Budzik G., Dziubek T.

Journal of KONES

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2011

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Vol. 18, No. 2

287-292

EN

Manufacture of aircraft gearbox elements requires control of gear geometric parameters at different stages of technological process. Acceleration and automation of measurement process can affect the duration of the finished item production. In case of measurement of gear wheels using modern technologies based on numerical machines, measurement process is based on processing of numerical data obtained by measurement using coordinate measuring machines. The goal of this paper is to present the opportunity to automate the measurement process of bevel gears, using coordinated optical scanner ATOS by GOM, equipped with a turntable. 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. 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 ofpreparing the model and measurement equipment and data processing capacity. The result of the work will be presented methodology for automated scanning measurements of bevel Sears.