Virtual manufacturing of transmission elements

1 . A software structure which when adapted in an apparatus is capable of virtual manufacturing of transmission elements for example gear means with chip formation, the software structure comprising:

a start module for loading the source file in a main editor-file that contains the computer program;

an input module for providing input parameters that are essential for the configuration of a product and a cutting tool;

a product design module for evolving the parameters for the manufacturing of the product; and

a virtual manufacturing module having at least three sub-modules one each for tool generation, visualisation of machining operation, and disassembly of the product from the machine bed.

2 . The software structure as claimed in claim 1 , wherein the input module is enabled to check the validity of the input data and further check the default data.

3 . The software structure as claimed in claim 1 , wherein the tool-generation sub-module creates a solid model of the tool with all the cutting geometry for example, major cutting angles including a clearance angle in respect of the cutter, and wherein the solid tool is enabled to animate in the virtual environment during the cutting process.

4 . The software structure as claimed in claim 1 , wherein the visualisation of machining operation sub-module is adapted to generate the product.

5 . The software structure as claimed in claim 1 , wherein the disassembly sub-module is enabled to simulate the activities of dismantling the job from the worktable in a virtual environment.

6 . The software structure as claimed in claim 1 , which when loaded and operated in an apparatus enables performing the following method steps:

designing a cutting machine preferably a milling machine;

forming a blank to be configured with gear teeth;

forming a cutting tool, preferably disc type cutter adaptable to the milling machine;

inputting desired data in respect of speed of the gear, module of the gear, transmitted power, transmission ratio, pressure angle, material of construction of the gear and the cutter, and helix angle in case of helical gear;

activating parameters of optional modules such as material, camera, light, animation, and render;

inputting data relating to a predefined path for chip movement; and

activitating the automatic cutting operation of the transmission element with the input of data respecting rotational speed of the cutter, angle of cut, blank rotation, rotational angle of the cutter, depth of cut, and number.

7 . The software structure as claimed in claim 6 , wherein said predefined path for chips movement is selected based on the relationship of θ=−(π/2−γ), wherein Vc=chip velocity, v=cutting speed, θ=chip movement angle, φ=shear angle, ψ=Rack angle, t 1 =width of cut, and t 2 =chip width.

8 . A computer apparatus for virtual manufacturing of transmission elements for example, gears comprising a general purpose computer interfaced with input devices and a display device; and a software support structure as claimed in claim 1 .

9 . The software structure as claimed in claim 3 , wherein the visualisation of machining operation sub-module is adapted to generate the product.

10 . The software structure as claimed in claim 1 , wherein the disassembly sub-module is enabled to simulate the activities of dismantling the job from the worktable in a virtual environment.

11 . A computer apparatus for virtual manufacturing of transmission elements for example, gears comprising a general purpose computer interfaced with input devices and a display device; and a software support structure as claimed in claim 7 .