Parametric modeling and integration with cae systems in the design of disk gear cutters in ptc creo parametric environment

Abstract

The article addresses the urgent problem of improving the efficiency of designing complex metal-cutting tools in the context of modern mechanical engineering. The object of the study is disk gear cutters designed for cutting spur gears using the copying method. Since these tools are standardized and manufactured in sets (typically comprising 8, 15, or 26 cutters per module depending on the required accuracy), they represent an ideal object for applying parametric design automation methods. The paper substantiates the transition from obsolete modeling methods, which used approximate spline constructions based on characteristic points (characteristic of systems like APM WinMachine), to precise mathematical modeling in high-level CAD systems such as PTC Creo Parametric. The authors present a comprehensive methodology for creating a fully adaptive 3D model of a gear cutter. The core of the proposed approach is the use of the Parameters tool as a central control unit for variables (module, number of teeth, pressure angle) and the Relations tool to establish mathematical dependencies for calculating derived geometric characteristics (pitch, base, and root diameters). A significant part of the study is calculating and building the exact geometry of the cutting tooth. The article details the process of generating the involute profile using theoretical equations in Cartesian coordinates via the "Equation Driven Curve" feature, followed by mirroring the profile relative to the tooth symmetry plane. Furthermore, the specific geometry of the relief surface (backing off), which is necessary to ensure proper clearance angles during cutting, is modeled using the Archimedean spiral equation in cylindrical coordinates. Special attention is paid to design automation using the Family Table tool, which allows generating the entire nomenclature range of the cutter set from a single generic model without manual rebuilding. The article also covers the integration of the CAD model with the CAE system ANSYS for engineering analysis. It describes the sequence of static, dynamic (modal), and coupled thermal-structural analyses required to evaluate the tool's strength, vibration resistance, and thermal stability under operating loads. The result of the work is a verified technique that significantly reduces design time, minimizes errors, and prepares the model for complex strength calculations.