This presentation is about how the rp process used in examination and manufacturing of gears

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A Review on
Use of rapid prototyping method for
Manufacturing and examination of
Gear Wheels
By
M.Saras chandra
14MMF0011

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Index
1. Introduction
2. Analysis of RP methods in terms of Application
for the manufacture of gear wheels
3. Method for preparing geometrical data for RP
process
4. Analysis of geometric accuracy for gear wheels
5. Possibility of RP system application for gear
wheels Testing

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1.INTRODUCTION
• Rp Systems Make it possible to manufacture
prototypes of complex shapes including gear
wheels Prototypes.
• It is important for process of manufacturing gear
wheels of non-standard tooth profiles.
• For tooth contact analysis and Fatigue tests
Rapid Manufactured Non-standard Gear wheels
are used.

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2.ANALYSIS OF RP METHODS
IN TERMS OF APPLICATION
FOR THE MANUFACTURE OF
GEAR WHEELS

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2.Analysis of RP methods in terms of Application for
the manufacture of gear wheels

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2.1.JS method
• Layered jetting process known as JS method
introduced by Jetting Systems.
• Application of layer of polymer from the print head
and subsequent hardening of polymer layer by U.V.
Light emitted by lamp integrated with print head.
• Models are print layer by layer.

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2.2.SLS METHOD
• SLS method consists of hardening the surface
of powdered material by means of laser beam.

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2.3.SLA METHOD
• Oldest Method of Rapid Prototyping
• By photo polymerisation of polymer resin

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2.4.FDM METHOD
• FDM is the process consists of use of material in
filament form is heated , fused ,melted , extruded
through nozzle and part fabricated layer by layer

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2.5.3D-PRINTING
• 3D-Printing consists in combining a powdered
material in layers by means of binding agent
applied by a printing head.

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COMPARISON OF RP PROCESS

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3.METHOD FOR PREPARING
GEOMETRICAL DATA FOR RP
PROCESS

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3.1.DATA FORMATS FOR RP PROCESS
• STL
• IGES
• STEP
• HP/GL
• CT DATA
• SLC
• CLI
• RPI

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3.2 COMPARISON OF PROBLEMS IN STEP
AND IGES
• In general Mapping errors between the facets
will be occurred in IGES.
• In STEP accurate mapping is there but it is not a
standard model for RP process. It is generally
used for CNC-Programming.

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3.3.Stl file
Edge and vertex redundancy in
Stl file

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STL Defects
1. Gaps , Cracks, Missing Facets:
Due to Tessellation of surfaces with large
curvature can results in errors at intersections
of surfaces, leaving gaps, holes along edges of
part model.

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STL Defects
2. Degenerate Facets:
These may be occur when all of the facets ,
edges are collinear even though all vertices are
distinct. By stitching algorithms we can avoid
shell punctures.

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STL Defects
3. Over lapping facets:
Due to numerical round-off errors occurred
during tessellation. The vertices are represented
as Floating integers in 3d-space instead of
integers.

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STL Defects
4.Non-Manifold Conditions:
1. Non-manifold edge
2. Non-manifold Point
3. Non-manifold face
Due to tessellation of fine features susceptible to round-
off errors

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3.4.Accuracy of Model mapping in STL format
complex gear teeth wheels profiles are complex in shape and
while converting into Stl format there are so many mapping
errors discussed before are occurred.

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3.5. DATA PROCESSING IN CAD SYSTEMS
• In mechanical desk top and Catia software
consisting of Rapid proto typing modules have
tessellation option to verify the model.

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3.6.DATA PROCESSING IN MAGIX
R.P.SOFTWARE

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4.ANALYSIS OF GEOMETRIC
ACCURACY FOR GEAR
WHEELS

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4.Analysis of geometric accuracy for gear
wheels
1. Measurement of test prototypes with CMM
2. Measurement of test prototypes with ATMOS-
GOM system

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5. POSSIBILITY OF RP SYSTEM
APPLICATION FOR GEAR WHEELS
TESTING

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5.Possibility of RP system application for gear
wheels Testing
• Tooth Contact Analysis
• Fatigue Tests for non- involute Gear wheels

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5.1.TOOTH CONTACT ANALYSIS
• Steps:
1. Making the stereo lithographic model of gears
2.Stand tests of contact area

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5.2.Fatigue testing of Non-involute Gears
• Finite element analysis will be done for the cad
models
• Next for prototypes produced in SLA,FDM will be
tested using Fatigue test machine.
• Minor difference is observed between the FEM
results and gear wheel stand test fatigue
machine

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The End