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    Welcome to

    zakgear.com

    Image gallery.

    Click on image to see a large picture.

    1. Complex form of gear cutter.This complex tooth form was

    proposed by Dr. Zhuravlev G.A. We have developed practical solutions for

    manufacturing and inspection of the complex tooth geometry in 1986-1992 at MILHelicopter in Moscow, Russia. DDS method was extensively used for 3-dimensional

    modeling of the tooth geometry and bearing contact.

    http://www.zakgear.com/gallery/Lunin1.gif
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    2. This is an output from the authors computer program that

    simulates 3-dimentional complex tooth geometry from the cutter presented on the

    picture above. AVI animation 0.2Mb.

    3. 3-dimentional model of the bearing contact for the gear tooth

    geometry presented on pictures #1 and #2. The rainbow colors show distances between

    mating tooth surfaces. The black short lines are the 3-dimentional sliding vectors. The

    author used the sliding vectors for calculation of the integrated driving efficiency. The

    direction of sliding and friction is calculated on each point of the 3-d model. Then it is

    integrated in to driving efficiency. AVI animation 0.3Mb.

    http://www.gearideas.com/IP_3d.avihttp://www.gearideas.com/aa2_s.avihttp://www.gearideas.com/Tooth_contact_IP.jpghttp://www.gearideas.com/IP_tooth_3d.jpghttp://www.gearideas.com/IP_3d.avihttp://www.gearideas.com/aa2_s.avi
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    4. Reverse engineered tooth contact taken from a real spiral

    Bevel gear set.The reverse engineering program allows to see the tooth contact without

    mating the real gears. The program uses the only 3-dimentional mapping of the real gear

    tooth surfaces. The image is not looking very good because of the manufacturing

    deviations on the real gear tooth surfaces. This programming module replaces an

    expensive single flank contact inspection machine on a manufacturing floor.

    5. Marine application for ultra globoid gear. It is a sample

    application of an extreme Globoid (Hourglass) gear. The driving efficiency would not beas high as with spiral bevel gear. But the compact design decreases the hydrodynamic

    http://www.zakgear.com/gallery/Lunin5.jpghttp://www.gearideas.com/CMM_sontact_inspection.jpg
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    drag of the submerged gear housing. The combined propulsion efficiency is higher than

    with similar spiral bevel gear design.

    6. Example of 3-d modeling of hypoid gear in AutoCAD.The

    DDS method can be used with simple programming of standard CAD software. This

    image shows a virtual spiral bevel gear cutting machine created in AutoCAD.

    7. Globoid or Hourglass pinion. The globoid gear set has higher

    driving efficiency and higher load capacity than a worm gear set. But the manufacturing

    may be more complex. But in same application the cost can be significantly decrease.

    Unlike a worm gear the only a half of the gear is working when it rotates one direction.It is the same on the pinion. That makes it possible to mold plastic globoid gears.

    http://www.zakgear.com/gallery/Lunin7.jpghttp://www.zakgear.com/gallery/Lunin6.gif
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    8. This picture shows advanced surface analyses of the DDSmethod. The author presents an example of spiral bevel gear tooth surface. Different

    colors show different curvatures on the surface.

    9. Unlike most of the researchers the author investigates

    Wildhaber-Novikov tooth contact in 3-dimentional space. The image shows different

    positions of the Novikov tooth contact for a rotating gear set. AVI animation 0.4Mb.

    http://www.gearideas.com/Novikov.avihttp://www.gearideas.com/Novikov_tooth_contact.jpghttp://www.gearideas.com/Spiral_bevel_tooth.jpghttp://www.gearideas.com/Novikov.avi
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    10. Worm face gear has higher driving efficiency than a worm

    gear. It is also more compact. The common problem in manufacturing is cutter design

    and modification of the tooth surface to make the gears not sensitive for the

    manufacturing errors. The inspection of the finished gear is also a common problem

    because of the difficulties with gear tooth CAD modeling. The author has an extensive

    experience in manufacturing and CAD modeling of the worm face gears based on DDS

    method. The gears can be cut by a worm cutter and then inspected against a DDS 3-d

    model on CMM. The tool for injection molded plastic gears can be manufactured onCNN from a DDS CAD model without involving expensive gear cutting tools and

    machines.

    11. Tooth cutting simulation of (10).The DDS method provides

    very detailed visualization of the gear cutting. This example shows common areas of

    undercut and cutting marks on a worm face gear tooth.

    http://www.zakgear.com/gallery/Lunin11.gifhttp://www.zakgear.com/gallery/Lunin10.jpg
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    12. High ratio hypoid gear model has been simulated by the

    author in 1988 as a proposal for a tail helicopter rotor drive. However the evaluation of

    the driving efficiency showed that on high ratio the gear set becomes not reversible (not

    backdrivable). Driving efficiency was improved by using advanced tooth profiles. But it

    did not go in production because of poor manufacturing capabilities in 1990.

    13. Ideal Novikov tooth contact. Concave and convex profiles

    have the same radiuses of curvature. This 3-dimentional simulation shows how would

    http://www.gearideas.com/Contact_pattern_1.jpghttp://www.zakgear.com/gallery/Lunin12.jpg
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    the contact look like it to mesh Novokov gears without crowning on profile. The original

    idea of the Novikov gear incorporated a small difference of the radiuses for decreasing of

    the contact stresses. Smaller the difference smaller the stress? Would be the maximumcontact stress unlimited when the radiuses are the same? The classic Hertz theory says

    yes. But in reality nobody made a strong Novikov gear yet. The 3-dimentional simulation

    explains it. The contact pattern really spreads across the tooth but it is still very short

    along the tooth.

    14. Spiral Bevel tooth contact. This contact is not what one

    normally sees on a spiral bevel rolling tester. The rolling tester shows a combined toothcontact. More correct it shows a footstep. But it does not show the way it was generated.

    The DDS software for spiral bevel gears shows the tooth contact in its development. AVI

    animation 0.4Mb.

    15. Spiral Bevel tooth contact and sliding. Calculating of correct

    sliding in 3-dimentional space is very important for driving efficiency calculation. The

    integrated efficiency calculation program takes into account every point in the tooth

    http://www.gearideas.com/involute1.avihttp://www.gearideas.com/involute1.avihttp://www.gearideas.com/Tooth_sliding.jpghttp://www.zakgear.com/gallery/Lunin14.jpghttp://www.gearideas.com/involute1.avihttp://www.gearideas.com/involute1.avi
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    surface that contributes to the overall driving efficiency. The detailed simulation allows

    predicting and comparing the driving efficiency for different tooth forms and different

    cutting machine settings.AVI animation 0.6Mb.

    16. 3-d model of tooth contact for (2).

    17. 3-d model of tooth contact for (2).

    18. 3-d model of tooth contact and sliding for (2).

    http://www.zakgear.com/IN_Sliding.avihttp://www.zakgear.com/IN_Sliding.avihttp://www.gearideas.com/Tooth_contact_IP_1.jpghttp://www.zakgear.com/gallery/Lunin17.jpghttp://www.zakgear.com/gallery/Lunin16.jpghttp://www.zakgear.com/IN_Sliding.avi
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    19. 3-d model of tooth contact and sliding for (2).

    20. This is a 3-dimentional computer simulation of a classic

    Wildhaver-Novikov tooth contact. The mating profiles have different radiuses of

    curvatures. In many published papers one can read about an ellipse of the contact. Some

    authors even discuss the size of the ellipse axis. We do not confirm the elliptical shape of

    the tooth contact on Novokov gears and on any other gears. Our first objection isaddressed to using word ellipse for describing a complex 3-dimentional surface. What we

    can see on an exact 3-d model of mating teeth does not even look like an ellipse. AVI

    animation 0.7Mb.

    21. The sliding and efficiency simulation program allows detailed

    calculation of the driving efficiency for different tooth forms including Novikov tooth

    form. With a help of DDS we are capable to compare a small difference of driving

    efficiency for different designs. For example the authors have developed the tooth

    http://www.zakgear.com/Novikov3.avihttp://www.zakgear.com/Novikov3.avihttp://www.gearideas.com/gear_tooth_1.jpghttp://www.zakgear.com/gallery/Lunin20.jpghttp://www.gearideas.com/Tooth_contact_IP_2.jpghttp://www.zakgear.com/Novikov3.avihttp://www.zakgear.com/Novikov3.avi
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    geometry that improves driving efficiency on commonly used gears including hypoid

    gears for automotive applications.

    22. Palloid gear.

    23. DDS method was used for developing of software code for

    variable ratio rack geometry. The advance capabilities of the DDS method allowed

    testing different tooth forms on the generating pinion. It helps to increase the range of

    the ratio and increase the load capacity in the same time. The other important

    achievement is a low-pressure angle. The low-pressure angle decreases the separation of

    the rack and the pinion.

    http://www.zakgear.com/gallery/Lunin23.jpghttp://www.zakgear.com/gallery/Lunin22.jpg
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    24. Calculation of sliding and contact pressure in each point of the

    gear tooth surface may be extremely important. It provides valuable data for

    development low noise and high efficiency drive.

    25. This spiral bevel gear set with not involute tooth form has

    been cut on DDS bases computer code and visualized with a help of OpenGL platform.

    The DDS tool helps the author to create the highest resolution digital gear models since

    the beginning of development of the method in 80s.

    AVI animation 0.7Mb.

    http://www.zakgear.com/IP.avihttp://www.zakgear.com/gallery/Lunin25.jpghttp://www.gearideas.com/Spiral_bevel_TCA.jpghttp://www.zakgear.com/IP.avi
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    26. It is important to see the contact action on all participating

    teeth. The contact ratio is not a constant number in the real gear action. It is changing

    permanently depending on the combined area of contact on all teeth. AVI animation

    0.2Mb.

    27. DDS based software generated 3-dimentional CAD models of

    the worm face gear and the tapered pinion. The models can be used for CNC

    manufacturing and CMM inspection. The CAD files are comparable for machining of

    injection molding tools.

    28. Pinion for (27). DDS method gives very realistic output of thedigital model. One can see the cutting marks and the undercut on the worm face tapered

    pinion tooth surface. Almost all the worm face tapered pinion would have an undercut

    http://www.gearideas.com/Involute.avihttp://www.gearideas.com/Involute.avihttp://www.zakgear.com/gallery/Lunin28.jpghttp://www.zakgear.com/gallery/Lunin27.jpghttp://www.zakgear.com/gallery/Lunin26.jpghttp://www.gearideas.com/Involute.avihttp://www.gearideas.com/Involute.avi
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    on the front low angle tooth side. A small undercut does not effect the load capacity of

    the drive. The DDS based contact simulation program allows to find the maximum

    allowed size of the undercut.

    29. Worm gear set. It becomes common to predict the worm tooth

    contact before cutting a real gear. Unfortunately all the advertised software products are

    too expensive. DDS based software provides much lower cost and higher qualitysolution.

    30. Ultra Globoid Gear set. DDS method works similar for

    different gear forms. This is an example a practical application. The computer program

    generates an IGES file of this exotic gear including contact and sliding simulation for

    misalign gears.

    http://www.zakgear.com/gallery/Lunin30.jpghttp://www.zakgear.com/gallery/Lunin29.jpg
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    31. Detailed sliding simulation on hypoid gear tooth surface. The

    accurate calculation of driving efficiency would not be possible without high-resolution

    digital modeling. The DDS method provides unlimited resolution on the tooth geometry

    calculation. The method allows to catch a very little driving efficiency change for

    different cutting machine settings. The program takes in to account every point on the

    tooth surface with an elementary friction and load in that point. The driving efficiency iscalculated by integrating millions of individual point in the mating surfaces.

    32. Spiral Bevel gear and pinion in contact. It is not a problem forDDS software to show the gear and the pinion tooth surface on the same screen. The

    http://www.gearideas.com/spiral_bevel_contact_2.jpghttp://www.gearideas.com/3_dimentional_gear_tooth.jpg
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    existed programming technology allows to paint the gear and the pinion in different

    colors and make one surface partially transparent.

    33. Novikov gear and pinion tooth in contact. The contact pattern

    and sliding vectors are rendered on a gear tooth and the pinion tooth surface is in wire

    frame.

    34. Novikov WN gear tooth. Novikov gear is normally bigger and

    has more teeth. The tooth form of the Novikov gear is normally convex. The pinion

    would have more cycles of load so it should have a stronger tooth. The image below

    shows common convex tooth of Novokov pinion.

    http://www.gearideas.com/Stepan_Lunin_3d.jpghttp://www.gearideas.com/Hypoid_Novikov.jpg
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    35. Novikov WN pinion tooth.

    36. Spiral Bevel tooth. AVI animation 0.4Mb.

    37. Helical tooth contact. Output form DDS based software. It

    shows the gear and pinion teeth with contact pattern rendered on the gear tooth surface.

    http://www.zakgear.com/IN_3d.avihttp://www.zakgear.com/gallery/Lunin37.jpghttp://www.zakgear.com/gallery/Lunin36.jpghttp://www.gearideas.com/Novikov_tooth_3d.jpghttp://www.zakgear.com/IN_3d.avi
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    38. WN Novikov tooth contact. Output form DDS based software.

    It shows the gear and pinion teeth with contact pattern rendered on the gear tooth

    surface. AVI animation 0.4Mb.

    39. Double WN Novikov tooth contact. The DDS method can

    simulate the contact between anything. This example show what we have by inputting

    double Novikov tooth form in our program.

    http://www.zakgear.com/Novikov1.avihttp://www.zakgear.com/gallery/Lunin39.jpghttp://www.gearideas.com/Novikov_tooth_contact_3d.jpghttp://www.zakgear.com/Novikov1.avi
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    40. Hypoid pinion tooth. The Hypoid gear is common in

    automotive. There is still question how to increase the driving efficiency of hypoid gear.

    The DDS efficiency simulation can help. The efficiency of different designs would be

    very small to identify in experiment. It will be also expensive. The computer program for

    integrated efficiency simulation would allow to see very small efficiency improvement.

    http://www.zakgear.com/gallery/Pinion_11_teeth.gif
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    41. Double Novikov mesh.

    42. Novikov mesh.

    43. Palloid gear set.

    http://www.zakgear.com/gallery/Lunin43.jpghttp://www.zakgear.com/gallery/Lunin42.jpghttp://www.zakgear.com/gallery/Lunin41.jpg
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    44. Tooth contact under load. The accurate stress analyze is

    possible because of the very high geometrical resolution of the DDS method.

    http://www.gearideas.com/Tooth_contact_load.jpg
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    45. Double Novikov contact on helical gear. Ideal profiles: same

    radiuses.

    46. WN Novikov contact on helical gear. Ideal: same radiuses.

    AVI animation 0.5Mb.

    http://www.zakgear.com/Nov.avihttp://www.zakgear.com/gallery/Lunin46.jpghttp://www.zakgear.com/gallery/Lunin45.jpghttp://www.zakgear.com/Nov.avi
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    47. Nice gear set. It is really looking nice. It is nice for

    presentation and for understanding as well. The modern technology provides nice tools

    for designer. One example is CAD. Another example is DDS. With CAD and DDS an

    engineer can see much more that on a drawing board.

    48. Novikov gear tooth.

    http://www.zakgear.com/gallery/Lunin48.jpghttp://www.zakgear.com/gallery/Lunin47.jpg
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    49. Novikov pinion tooth.

    50. 3-d cutting simulation.

    http://www.zakgear.com/gallery/Lunin50.gifhttp://www.zakgear.com/gallery/Lunin49.jpg
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    51. 3-d cutting simulation.

    52. Ball and undercut on gear tooth.

    53. More teeth in contact.

    http://www.gearideas.com/Tooth_contact_hypoid.jpghttp://www.zakgear.com/gallery/Lunin52.jpghttp://www.zakgear.com/gallery/Lunin51.gif
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    54. Hyperbolic gear. DDS gives a freedom for imagination. Before

    DDS one would spend a life to design, make and test a new idea. DDS does is all fast,

    accurate and nice looking. The hyperbolic gear would be complex to make in real life.

    DDS makes the hyperbolic gear as a computer file. It puts it in contact and generates

    efficiency and load capacity. Ii is easy to change design parameters and make a numberof virtual test to optimize the design. Then a real prototype can be manufactured from a

    CAD file on a low cost CNC equipment.

    Home page: http://www.zakgear.com/

    http://www.zakgear.com/http://www.zakgear.com/gallery/Lunin54.jpghttp://www.zakgear.com/