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APPLICATIONOFVIRTUALMANUFACTURINGINGENERATIONOFGEARSRECEIVED29NOVEMBER2004/ACCEPTED5MAY2005/PUBLISHEDONLINE24NOVEMBER2005SPFINGERVERLAGLONDONLIMITED2005ABSTRACTTHEMANUFACTURINGPROCESSOFGEARSISFAIRLYCOMPLICATEDDUETOTHEPRESENCEOFVARIOUSSIMULTANEOUSMOTIONSOFTHECUTTERANDTHEJOBINTHISPAPER,ANATTEMPTISMADETOGENERATEMEANINGFULDESIGNDATAFORSPURANDHELICALGEARSANDTHECORRESPONDINGRACKFORMCUTTERNECESSARYFORTHEMANUFACTURINGUSINGTHISINFORMATION,SOLIDMODELSFORTHECUTTERANDBLANKAREDEVELOPEDANDFINALLYGEARMANUFACTURINGPROCESSESARESIMULATEDINAVIRTUALMANUFACTURINGENVIRONMENTTHEUSERHASTHEOPTIONTOCHOOSEBETWEENDESIGNSANDMANUFACTUREMODEATWILLTHEINTEGRATEDPROCESSMAYALSOHELPTODEVELOPANOPTIMIZEDPRODUCTFORBETTERUNDERSTANDINGOFTHEOPERATIONALPRINCIPLE,ANANIMATIONFACILITYINTHEFORMOFAMOVIEISINCLUDEDINTHEPACKAGEKEYWORDSVIRTUALMANUFACTURING；ANIMATION；GEARGENERATION1INTRODUCTIONAGEARISAVERYCOMMONMACHINEELEMENTINMECHANICALENGINEERINGAPPLICATIONSHOWEVER,MANUFACTURINGOFTHEGEARSEEMSTOBEFAIRLYCOMPLICATEDEVENTOTHEPERSONHAVINGTHOROUGHTECHNICALKNOWLEDGEINTHERELATEDFIELDTHECONVENTIONALGEARGENERATIONPROCESSESLIKEFORMING,SHAPING,HOBBING,ETCAREUSUALLYREPRESENTEDINTWODIMENSIONALSKETCHTHEREMAYBESOMECOMPONENTSTHATARENOTADEQUATELYDESCRIBEDBYTHETWODIMENSIONALAPPROACHINTHECASEOFGEARGENERATION,ITMAYBEDIFFICULTTOUNDERSTANDTHECOMPLEXGEOMETRIESANDTHEMANUFACTURINGARRANGEMENTWITHTHEHELPOF2DMODELSTHESELIMITATIONSCANBEPARTIALLYOVERCOMEANDUNDERSTANDINGWILLBEMOREMEANINGFULIFONEUSES3DSOLIDMODELSINSTEADHOWEVER,THEDEVELOPMENTOFTHEMODELSUSING3DSOLIDSMAYNOTALWAYSENSURETHECLARITYOFTHECOMPLEXGEARGENERATIONPROCESSUNLESSONEUSESANIMATIONTOREPRESENTTILEMOTIONOFTHEGEARBLANKANDTHEGEARCUTTERTHISCANBEACHIEVEDVERYEFFICIENTLYWITHTHEHELPOFTHEVIRTUALMANUFACTURINGTECHNIQUEITISATECHNOLOGYTOCREATEAVIRTUALENVIRONMENTONTHECOMPUTERSCREENTOSIMULATETHEPHYSICALWORLDTHEKNOWLEDGEBASEANDEXPERTISEGAINEDFROMTHEWORKINTHEVIRTUALENVIRONMENTENABLESTHEUSERTOAPPLYTHEMMOREMEANINGFULLYINREALLIFESITUATIONSAHOSTOFLITERATUREISAVAILABLEONVIRTUALMANUFACTURINGINDIFFERENTAREASAMONGWHICHSOMEOFTHERECENTANDIMPORTANTWORKSAREREFERREDBELOWTESICANDBANELJEE1HAVEWORKEDINTHEAREAOFRAPIDPROTOTYPING,WHICHISANEWTECHNOLOGYFORDESIGN,VISUALIZATIONANDVERIFICATIONGRAPHICALUSERINTERFACES,VIRTUALREALITYTECHNOLOGIES,DISTILLATION,SEGREGATIONANDAUTOINTERPRETATIONARESOMEOFTHEIMPORTANTFEATURESOFTHEIRWORKBALYLISSETAL2DEALTWITHTHEDEVELOPMENTOFMODELSINAVIRTUALENVIRONMENTUSINGTHEVIRTUALREALITYTECHNOLOGIESPROVIDINGANOUTSTANDING3DVISUALIZATIONOFTHEOBJECTIN1994,GMBALYLISSETAL3PRESENTEDTHEORETICSOLIDMODELINGTECHNIQUESUSINGTHEVMTOOLS,LIKEVP,MI,VIRTUALREALITYMANUFACTURINGLANGUAGEAND3DSLUDIOMAXTHEYHAVEDEVELOPEDDIFFERENTPARTSOFANAUTOMOBILEANDTHROUGHTHESPECIALEFFECTOFANIMATIONIMPARTEDALLPOSSIBLEMOTIONTOTHEMODELTHETECHNOLOGYISFURTHERENHANCEDBYKIULERA4,WHOTREATEDPRODUCTANDPROCESSMODELINGASAKERNELFORTHEVIRTUALMANUFACTURINGENVIRONMENTINHISWORK,KIMURAHASINCORPORATEDSIGNIFICANTMODELINGISSUESLIKEREPRESENTATION,REPRESENTATIONLANGUAGE,ABSTRACTION,STANDARDIZATION,CONFIGURATIONCONTROL,ETCARANGARASAUANDGADH5CONTRIBUTEDTOWARDSTHEVIRTUALPROTOTYPINGTHATARECONSTRUCTEDUSINGSIMULATIONOFTHEPLANNEDPRODUCTIONPROCESSUSINGVIRTUALMANUFACTURINGONAPLATFORMOFMAYA,3DSTUDIOMAXANDVRML,ETCATJADAVPURUNIVERSITY,RESEARCHWORK6,7ISBEINGCARRIEDOUTTOSIMULATETHEGEARMANUFACTURINGPROCESSESUSINGAIILLCADAND31STUDIOMAXASPLATFORMSSOFTWAREHASBEENDEVELOPEDTHATHELPSTHEDESIGNENGINEERSTOUNDERSTANDTHEPROBLEMSRELATEDTOSPURGEAROPERATIONANDITSMANUFACTURINGPROCESSASTUDYOFTHESTATEOFTILEARTANDLITERATUREREVIEWREVEALTHATTHESCOPEOFVIRTUALMANUFACTURINGISWIDEOPENFORSIMULATINGSPURGEARGENERATIONPROCESSESCOMPUTERSIMULATIONCANBEVERYEFFECTIVELYUSEDFORVIEWINGALONGWITHAIDINGSUBSEQUENTANALYSISOFDIFFERENTCOMPLICATEDMANUFACTURINGPROCESSESUSINGTHECONCEPTOFDESIGNCENTEREDVIRTUALMANUFACTURINGWITHTHISOBJECTIVEINMIND,ANATTEMPTISMADETOVIRTUALLYMANUFACTURESPURANDHELICALGEARSFROMTHEBLANKUSINGARACKCUTTERTHESCOPEOFTHEWORKINCLUDESTHEGENERATIONOFDESIGNDATAFORTHESPURANDHELICALGEARSANDTHERACKFORMCUTTER,THEGENERATIONOFSOLIDMODELSFORTHECUTTERANDBLANK,ANDFINALLYTOSIMULATEGEARMANUFACTURINGPROCESSTHROUGHANIMATIONTHEMAINMOTIVATIONOFTHEWORKISTOSIMPLIFYTHETASKOFDESIGNING,ANDTOSTUDYTHEGEARGENERATIONPROCESSTHATCANBEUNDERSTOODBYALAYMANANDTOPRESENTAREALISTICVIEWOFITALLTHEPROCESSESAREDEVELOPEDONTHEPLATFORMOFTHE3DSTUDIOMAX,WHICHISONEOFTHEMOSTIMPORTANTVIRTUALTOOLSTHESOFTWAREISDEVELOPEDUSINGMAXSCRIPT,ANOBJECTCONTAINEDPROGRAMMINGLANGUAGETHATCANBERUNIN3DSTUDIOMAXENVIRONMENT2DESCRIPTIONOFTHESOFTWARETHEMAXSCRIPTLANGUAGEISBASICALLYANIMAGEPROCESSORTHATCREATESTHEVISUALEFFECTSIN3DSTUDIOMAXINADDITION,ITCANBEUSEDFORDESIGNCALCULATIONANDSUBSEQUENTCHECKINGANATTEMPTISMADETODEVELOPTHEENTIREPACKAGEINMODULARFORMSOTHATANYFURTHERIMPROVEMENTCANBEIMPLEMENTEDEASILYWITHOUTAFFECTINGTHEOTHERSTHEENTIREWORKISCARRIEDOUTINA3DENVIRONMENTTHEMODULARSTRUCTUREOFTHEENTIREPACKAGEISPRESENTEDINFIGLTHEMAJORMODULESAREINPUTMODULE,GEARDESIGNMODULE,VIRTUALMANUFACTURINGMODULEANDSPECIALMODULEABRIEFDESCRIPTIONOFTHESEMODULESISMENTIONEDBELOW21INPUTMODULETHISMODULEISDEVELOPEDTOPROVIDEINPUTPARAMETERSTHATAR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