A team of researchers from the University of Waterloo has created software that simulates the gear-cutting process in a bid to cut costs and improve productivity for manufacturers.

Currently, machining is used in the manufacture of gears, which are machine components found in countless engineered systems, ranging from automotive vehicles and aircraft engines to robotic systems and more.

Source: University of Waterloo

However, designing a machining process requires consideration of such factors as cutting speed and material removal thickness per pass to develop the machined part. Currently, these considerations are determined via trial and error, which can be both time consuming and resource draining.

As such, the University of Waterloo team developed new software, dubbed ShapePro, which simulates gear cutting by predicting the chip geometry and cutting mechanics — machining forces and the tool/workpiece deflections, for instance — in three gear machining processes including shaping, hobbing and power skiving. According to its developers, the software reportedly allows for the accurate analysis of the machining process parameters, thereby enabling users to cut and measure virtually.

The University of Waterloo team explained that ShapePro improves productivity, enabling manufacturers to perform simulations of gear machining processes virtually, with parameters both manually or automatically entered onto the computer to determine their impact on the process ahead of actually performing such operations on the actual material.

In addition to improving productivity, the team suggests that the software also helps preserve the quality of the gear and also reduces material use and energy waste.

"You cut and measure in the virtual environment first, then you can start from a near optimal setting when using the actual machine," the researchers added. "These are really expensive machines that take up factory space and operating resources."