Page 402 - Gear Technology Solutions

they might belong to two different jobs. The program outputs the expected
amounts of deeper cutting (shallower cutting is omitted) to allow the gear engi-
neer to decide if the consolidation was successful or if certain jobs have to be
eliminated from the consolidation variety.

Case 2:
The user selects a pinion and a gear master from the list of consolidation jobs.
The program processes this input and calculates modified basic settings for
each job except the master job(s) in order to minimize the individual job devia-
tions. The program outputs the expected amounts of deeper or shallower cut-
ting to allow the gear engineer to decide if the consolidation was successful or
if another master job has to be selected in order to improve the result.

Case 3:
The user allows the program to develop a virtual master job. The user can
specify the consolidation task with a number of switches and input values
which will allow:

• Controlled amounts of shallower cutting in order to minimize the absolute
depth deviations
from the original jobs
• Using an average Toprem, or the largest existing Toprem or a certain per-
centage thereof
• Using an average edge radius or the largest edge radius or a certain per-
centage thereof
• Using an average blade curvature radius or the smallest radius or a certain
percentage thereof

From this point on, the consolidation program develops the ideal (virtual) con-
solidation master which minimizes deviations to all existing jobs within the
physical possibilities. All real consolidations which have been performed so far
prompted, at first, a suspicious reaction from the involved gear engineers. It
was not believed that the rather good results were even possible across a
large consolidation variety with one single pinion cutter and one single gear
cutter.

After several hours of result checking by making some hand calculations and
running CAGE™ or UNICAL™ programs, the involved gear engineers con-
vinced themselves that the result was sound and practically applicable. The
general conclusion was that all the experience gained in the past by manually
consolidating several jobs could not compare with the possibilities a computer
app has when it processes several hundred data for up to 10 jobs simultane-
ously, while it applies about 20 sophisticated library programs.

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