Master of Science in Mechanical Engineering

Parametric gear tooth mesh generation

Professor: Candidate:
Prof. Carlo Rosso Giancarlo Riva Gan
Tutor:
Ing. Luca Ronchiato
1st December 2017
Agenda

1. Overview
2. Mesh generation
2.1 Spur/helical gears
2.2 Spiral bevel gears
2.3 Export

3. Conclusions

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 1. Overview

Current Desired

Geometry and mesh

CAD model
accuracy parameters

FEM model FEM model

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 1. Overview

Commercial software
Manual mesh generation • Long time requested
• Specialist required
• Software licences cost

Automatic mesh generation • Low degree of customization

• Closed architecture
• Software licences cost
• Parametric

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 1. Overview

MATLAB tool
Automatic mesh generation • Short time requested
• NO Software licences cost
• Open architecture
• High degree of customization
• Robust tool due to automatic checks
• Completely parametric

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
Agenda

1. Overview
2. Mesh generation
2.1 Spur/helical gears
2.2 Spiral bevel gears
2.3 Export

3. Conclusions

6
The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2. Mesh Generation Tool

Gear tooth geometry Gear tooth mesh

parameters accuracy parameters

Mesh generation tool

Nodes matrix

Gear tooth FEM model Elements matrices

Groups matrix

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
Agenda

1. Overview
2. Mesh generation
2.1 Spur/helical gears
2.2 Spiral bevel gears
2.3 Export

3. Conclusions

8
The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.1 Spur/helical gears

2D/3D mesh
• Structured mesh for internal and external gears
• Multi-block type mesh generation
• Customizable number of elements on tooth profile

Gear profile from 2D mesh 3D mesh

pre-existing tool

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.1 Spur/helical gears

2D mesh

• 2D mesh model automatic switch depending on mesh accuracy and tooth

geometry parameters

Automatic switch

2 zone model 3 zone model 5 zone model

(abandoned)

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.1 Spur/helical gears

2D mesh
• Main nodes relocation in
order to obtain always a
good discretization

Dlim upper
D
Dlim lower

5 zone model
Example of main node D posItion check

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.1 Spur/helical gears

3D mesh
• 2D elements in 3D representation using MATLAB
• Time requested: around 5 seconds for 3D mesh generation and
representation

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
2.1 Spur/helical gears

3D mesh
• Internal spur gear
representation

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
2.1 Spur/helical gears

3D mesh
• External helical gear
representation

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
Agenda

1. Overview
2. Mesh generation
2.1 Spur/helical gears
2.2 Spiral bevel gears
2.3 Export

3. Conclusions

15
The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.2 Spiral bevel gears

Gear tooth geometry Gear tooth mesh

parameters accuracy parameters

Tooth surface by points

Tooth section on conical surface

(through
(through self
self developed
developed 3D
3D intersection
intersection algorithms)
algorithms)

3D direct mesh generation

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.2 Spiral bevel gears

3D mesh
• The pre-existing tool is edited to obtain the surface by points of the tooth.

Tooth profile Tooth surface profile

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.2 Spiral bevel gears

3D mesh
• It is not possible to start from 2D mesh. The starting geometry is a surface by points.

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.2 Spiral bevel gears

3D mesh
• After the intersection points are found, using cone equations, they are transported in
a computational space (u,s).
• The 2D mesh is generated using a new faster algorithm.
• The 2D mesh points in the cartesian coordinates system are eventually computed.

uu
ss

u
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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.2 Spiral bevel gears

3D mesh
• The mesh is still fully customizable in terms of number of elements.

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.2 Spiral bevel gears

Comparison
• Computation time: less than 2 seconds.

CAD Mesh
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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
Agenda

1. Overview
2. Mesh generation
2.1 Spur/helical gears
2.2 Spiral bevel gears
2.3 Export

3. Conclusions

22
The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 2.3 Export

Informations export
• Another MATLAB script is able to transform the output matrices of the mesh generator
into Hypermesh BDF format

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 3. Conclusions

Achievements

 3D mesh generation of internal/external spur and helical gears

 3D mesh generation of spiral bevel gears
 Mesh export from MATLAB to Hypermesh file format
 Self standing tool but flexible: it is possible integration with GBX system
analysis tool “Dyno” of Avio Aero

Next Steps
 Introduction of tooth micro-corrections
 Automated mesh generation of shafts

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.
 Thanks for the
attention

Giancarlo Riva Gan

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The information contained in this document is GE Avio S.r.l. proprietary and is disclosed in confidence.
It is the property of GE Avio S.r.l. and shall not be used, disclosed to others or reproduced, without the express written consent of GE Avio S.r.l.