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3DCS Variation Analyst Software Provides Gear Digital Twin

3DCS Variation Analyst software from Dimensional Control Systems provides a CAD Digital Twin that can be used to validate the design and tolerancing of an individual gear. The software uses Monte Carlo simulation for running standard tests and gear specification measurements, predicting results as deviation from nominal values and predicted range of values. The analysis, along with analysis metrics, contributors, risk of failure, combine to give engineers the information needed to make decisions about design, manufacturing processes, and assembly that reduce the chances of problems as well as the number of physical tests and prototypes needed to optimize the design itself.

3DCS Variation Analyst software is a CAD integrated tolerance stack up simulation tool developed by DCS. Integrated into all the major CAD platforms, (CATIA, CREO, SOLIDWORKS, NX, 3DEXPERIENCE), 3DCS software provides real insight into both the risk of failure from variation and the sources of variation within an assembly. As inputs, 3DCS uses part tolerances, often represented using GD&T, as well as assembly processes and assembly sequences. In order to handle gears and other mechanical components, 3DCS leverages an Add-on; Mechanical Modeler, which includes a unique tool called the 3DCS Gear Module. This allows users to simulate gear contact surfaces and standard tests, both at a stationary position and through gear rotations.

The 3DCS Gear Module provides additional predictions which include multi-tooth contact with gear rotation. The location of the tooth-to-tooth in multi-tooth contacts corresponds to Flank Test results. Additionally, the Digital Twin model provides performance validation of gear assemblies including the standard tests: Total Composite Deviation, and Single Pitch Deviation. These tests are in addition to measurements for Axial Backlash, Angle Backlash, and Pressure Angle.

The 3DCS Gear Module has been enhanced to simulate a Rolling Gear Gage to measure the Total Radial Composite Deviation. In the simulation model, the Master Gear Rotates and the Work Gear is pressed against it, forcing contact at two locations, which will change as rotation occurs and new teeth come into contact.

The results for Gear Tests and studies are calculated from the measurement distance between gear centers. In addition to this measurement, the angular deviation between teeth is also taken into account. These tests, leveraging the Digital Twin, provide savings by avoiding tooling changes and by optimizing the gear parameters, such as crowning.

Dimensional Control Systems are hosting a webinar ‘Gear System Digital Twins to Show How to Reduce Tooling Changes and Improve Gear Performance’ on January 27th 2022 at 11:00 am EST. Learn how the Digital Twin comes to life by adding dimensional, and operational information in order to simulate product accurately to reduce the risk of failure and problems in operation.

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