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Parametric Modeling of Machine Tools for Designers

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DOI: 10.7546/PMMTD.2018

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 Krol O., Sokolov V.

PARAMETRIC MODELING OF MACHINE

TOOLS FOR DESIGNERS
Monograph

Prof. Marin Drinov Publishing House of

Bulgarian Academy of Sciences

Sofia 2018
 Reviewers:

Permyakov Oleksandr, Doctor of Sc., National Technical University “Kharkiv

Polytechnic Institute”, Ukraine
Nemtinov Vladimir, Doctor of Sc., Tambov State Technical University, Russia
Tsankov Petko, PhD, Technical University of Sofia, Bulgaria
Kovalevskyy Sergiy, Doctor of Sc., Donbass State Engineering Academy, Ukraine

Oleg Krol, Volodymyr Sokolov

PARAMETRIC MODELING OF MACHINE TOOLS FOR
DESIGNERS: monograph / Krol O., Sokolov V. – Sofia: Prof. Marin Drinov
Academic Publishing House of Bulgarian Academy of Sciences, 2018. – 112 p.:
Table. 7. Fig. 74. Bibliogr. 79 names. English language.

DOI: https://doi.org/10.7546/PMMTD.2018

The monograph deals with the problems of machine tools computer-aided design
based on the methods and means of parameterization for the main components of metal-
cutting machune and equipment in the CAD “APM WinMachine” environment. The
models and algorithms of parametric modeling for the configurations of machine tools
lathe and milling groups of by criteria of maximum rigidity and minimum reduced load on
the front spindle support are developed. The express procedure for generating the
transverse layout of the main drive in the multivariate design mode has been
implemented. The parametric models of the gear boxes basic elements – V-belt-, poly-V-
belt and toothed belt transmission pulleys, as well as the stepped shafts of the machine
drives are built. Analytical forms for the construction of the main functional elements of
the projected machine parts are proposed. Parametric models of instrumental equipment
for machine tool systems on the examples of shaped lathe cutters and gear milling cutters
are developed. The models of involute and teeth shaped profiles for disk and worm gear-
cutting mills in a parametric form are generated. The efficiency of using the
parameterization apparatus in multivariate design problems is substantiated. Particular
attention is paid to the use of the APM WinMachine parametrizator in the tasks of
production design preparation.
For leading designers, experts in the field of computer-aided design of machines and
tools, scientists, lecturers, graduate students and students.

ISBN 978-617-11-0105-0 8
© Krol O., Sokolov V., 2019

Prof. Marin Drinov Academic Publishing House of Bulgarian Academy of Sciences

Acad. Georgi Bonchev Str., Bl. 6, 1113 Sofia, Bulgaria
www.baspress.com
 INTRODUCTION

The level of information technology in the design has grown

significantly and radically changed the idea of the design engineer
workplace. The success of an enterprise requires a faster than the
competition from competitors, the release of engineering products to the
market at a lower price and higher quality. At the same time, in the
design process, it is necessary to evaluate and optimize the functionality
of the product and reduce the manufacturing cost. To achieve this,
product development tools must provide strategic advantages over
competitors.
The role of the designer in the modern machine tool industry is
difficult to overestimate. The specific estimates of labour costs
attributable to the process of designing and preparing the technology are
given, which reach 80 ... 85% of the total costs of new products. Only 15
... 20% are spent in the production process.
The disproportionate correlation makes it necessary to create
methods and techniques of rational design, which suggest the possibility
of continuous improvement of the performance for the designed machine
tools and machine tools equipped with various tooling. At the same time,
a reasonable combination of new design solutions with the already
existing traditional ones is necessary, choosing from the entire design
arsenal the most appropriate for these conditions.
The difficulty of design is the need to predict some new state of the
design object, while relying on modern data. Designing is always
original, regardless of how the problem is solved – intuitive or based on
analogs.
The problem of the creative process of creating a machine is the
holistic perception of the entire design and technological problem of both
3
layout, kinematic and constructive tasks, on the one hand, and the
possibility of manufacturing, assembling and repair conditions – on the
other. Especially this problem is characteristic of the early stages of
design, where the experience and intuition of developers often becomes
decisive. Even carrying out pilot work in the early stages, when special
attention is paid to contentious places, can only reduce the number of
mistakes in making decisions.
The prevailing number of machine tools was created on the basis of
the classical design method, based on the partitioning of individual nodes,
the development of which continues until the moment of meeting the
requirements of the design task.
A promising direction in the design work is a systematic approach,
which involves a coordinated choice of alternatives between
technological capabilities, level of automation, modern design solutions
and price, flexibility and performance. The system approach underlies the
modular design principle of machine tools.
In the works [1, 2, 3], the concepts of the modular principle are laid
and are effectively developed. On their basis, technologically necessary
machine versions are created with different levels of automation and the
subsequent systematic replacement of the machines that are currently
being manufactured with new ones. At the same time, the problems of
multivariance continue to be relevant for the designer of new equipment
and tools. Given the minimum number of machine modules at least three,
a simple enumeration of possible options generates 218 design
alternatives of the machine, differing only by the modules themselves [4].
Using each module in the machine twice raises the number of alternatives
to 65000.
The ubiquitous transition to the multivariate design of machine tools
creates problems with exceeding the normative terms of design and
carrying out a large amount of duplicate design activities. Similar
problems arise when modeling the important properties of the studied
parts and machine components. The resolution of these problems is
associated with the creation of reference models and design procedures

4
that to change the number and composition of the alternatives are flexible
setting. Such creation is directly related to the procedural aspects of the
developer’s activities.
The subject of study of this monograph is a set of procedures for the
design of machine tools and instruments aimed at the formation of their
promising options in a multivariate construction. Methods and models of
parametric modeling will be used as a working tool. The parametric
model is understood as a geometric model with parameters, by changing
the values of which it is possible to obtain different versions of the
project. Parametric modeling is a fundamental concept of CAD, which
allows to significantly reducing the cost of making changes to the project,
creating new product modifications, etc.
The improvement of the machine design is associated with the
improvement of the layout of the machine and the responsible, unified
components of machine and tool systems. The latter include a variety of
belt drives and transmission shafts. The tool component of the machine
tool system includes such common cutting tools as shaped tools and gear
milling cutters.
The purpose of this kind of research is to increase the technical level
of the adopted design decisions and significant reduce the time for the
creation of finished projects.
To achieve this goal, the main research objectives are formed:
- development of parametric models of transverse layout
configurations of machine tools, providing maximum rigidity and
minimum reduced load on spindle bearings;
- study of the designs for V-belt, poly-V-belt and toothed belt
transmissions using parametric modeling methods;
- parametrization of the stepped shafts design process for gear boxes
of machine tools;
- construction of the parameterization procedures of shaped cutters
for processing complex profile details;
- construction of parametric models of the back tooth relieving for
gear-cutting tool.

5
 1. AUTOMATED DESIGN PROCESS AND
PARAMETRIZATION

Modern computer-aided design (CAD) constructive and

technological purposes are widely used methods and means of
parameterization to increase productivity, on the one hand, and improve
the quality of design decisions make – on the other. In the modern
“medium” and “heavy” class systems, the presence of a parametric model
is embedded in the ideology of the CAD systems themselves. The
existence of a parametric description of an object is the basis for the
entire design process [5].
The process of parametric modeling is associated with the use of
model elements parameters and the relationships between these
parameters, which makes it possible to effectively generate various
versions of designed objects using variation of parameters or geometric
relations. Unlike traditional 2D and 3D constructions, the use of
parameterization tools allows to create a mathematical model of a
structure with parameters that, when changed, leads to change the
configuration of the structure, and relative positions of the parts in the
assembly, etc.
One of the designer priorities is to create a conceptual design of the
future product and the initial linking of structural elements.
Parameterization is a very valuable tool, which allows for a short time to
analyze various design schemes and avoid fundamental errors.
PTC (Parametric Technology Corporation) is considered the pioneer
of parameterization, which in 1988 was the first to implement a
procedure for creating parametric models.
As is known, the design of machines and tools is primarily
associated with the determination of the geometric shapes of detail and
6
their relative position [6–9]. Therefore, the history of automation is
interconnected with the history of computer graphics. Software
automation systems had to be invariant with respect to a set of computing
tools and equipment input and output of graphic information. This has led
to the emergence of various standardization systems. Thus, the standard
for the basic graphic system consists of a functional description and
specification of graphic functions for various programming languages.
As early as 1982, the Graphical Kernel System (GKS) is appeared.
In the software environment GKS is given primitives, segments and
transformations of graphic data. GKS is becoming the standard.
Following this, a version of the standard GKS-3D with a focus on 3D
graphics. Graphic format provides the ability to memorize graphic
information in a unified way, transfer it between different systems and
interpret it for output to various devices. Such formats are CGM –
Computer Graphics Metafile, PostScript – Adobe Systems' Language,
GEM – GEM Draw File Format, etc.
In the field of design automation, the unification of the geometric
modeling basic operations gave rise to invariant geometric cores intended
for use in various CAD systems. As known, the core includes a library of
a CAD system basic mathematical functions, which defines and stores
3D-forms, processes commands, saves results, and outputs the results of
processing. The most widely used are two geometric cores: Parasolid (a
product of Unigraphics Solutions) and ACIS (Spatial Technology). The
Parasolid core, developed in 1988, becomes the core of solid modeling
for CAD/CAM Unigraphics, and since 1996, the industry standard.
Parasolid supports SMP (multiprocessor hardware), which allows for
increased performance. Parasolid includes more than 600 object-oriented
features for Windows applications. Parasolid developers are focused on
expanding computer modeling in the most technically complex areas.
They were pioneers of direct modeling, which allows users to intuitively
modify non-parameterized models as if they had parameters.
The Parasolid core is constantly being improved. The new versions
provide support for advanced design processes that provide a significant

7
increase in productivity when creating complex structures. Thus,
Parasolid V19.0 version is fully compatible with the Windows operating
system and provides extended support for the main functions: modeling,
editing, blending and rendering.
The new version of Parasolid V19.1 contains a number of functional
improvements related to the procedures:
- creating a surface along a scattered set of points and normal vectors
is a powerful tool of the designer, especially convenient when working in
the context of an already existing geometry;
- automatic recognition and correction of self-intersecting body
elements, which allows you to perform complex sequences of operations
without the intervention of the system and the end user as well as get
more correct models in less time.
Parasolid V19.1 is the first version with support for 64-bit operating
systems, using the full power of 64-bit technology to increase the
productivity of the creative design process, creating a single 3D modeling
platform for the entire Product Lifecycle Management (PLM) industry.
Using the powerful Parasolid core in such well-known CAD
Unigraphics allows solving all problems not in external applications, such
as in CATIA, where parameterization is performed at the external module
level, but at the core level and all its applications working the same way
inside the system.
This in-system approach enables the provision of the entire product
creation cycle: from conceptual idea to implementation within the system
itself, without the additional use of external applications. It is also
important that providing a unified environment for product development
allows you to create a single digital model with which all project
participants can work simultaneously. In this case, it is necessary to have
sufficiently powerful means of parameterization, allowing for changes of
complex structures in large assemblies, to be able to build complex
associative links, and also certain flexibility, since the product is
constantly changing in the design process.

8
 However, in almost all systems, such as Autodesk Mechanical
Desktop, Unigraphics, CATIA, I-DEAS, etc., one parameterize of the
British company D-CUBED is used. The D-CUBED parameterize
includes two components: a sketcher designed to build a parametric
profile, on the basis of which a 3D operation will be created, and a
mathematical library that allows to link individual parts into assembly
structures.
The parameterize D-CUBED, focused on 3D modeling, is
ineffective in 2D drawing. The mathematics that successfully works on
dozens of profile lines in the 3D system sketcher does not cope with
thousands of interrelated elements of drawings. And the need for a
complete dimensioning of the D-CUBED parametric model turns the
process of parameterization of even a simple drawing into an almost
unreal task.
In the well-known T-FLEX CAD [10, 11], both directions were
simultaneously developed and evolutional – parametric drawing and
parametric solid modeling. T-FLEX CAD is based on its own parametric
technology, which has proven itself in the 2D version. Mechanical
Desktop, which is essentially an extension of the AutoCAD system, and
T-FLEX CAD started as 2D systems, unlike Solid Edge and SolidWorks,
and have in this connection certain advantages in terms of a broader and
more mature technology for designing technical drawings both separately
and in integration with 3D. Thus, it was possible to avoid the drawbacks
of "clean" 3D systems. Those who develop drawings in T-FLEX CAD
have no problems creating three-dimensional models based on these
drawings. In turn, the 3D model, you can easily get a projection and
arrange the necessary drawing. In situations where the design has a
limited number of unified elements that vary within a single product
range, partial parameterization of these elements is advisable.
The fully parameterized ProEngineer system of PTC [5] incorporates
the so-called tough parameterization and a connection with the history of
model building. This leads to the fact that in the process of building a
model of a product, all parameters must be tough specified and defined

9
explicitly. At change of parameters of one model, the program of
parameterization of the model interconnected with it is launched. While
the detail is simple, all this is quickly recalculated, without requiring
large resources. But when a complex model is built, which, in turn, is
included through the binding of parameters in the assembly. Then by
changing one link, we affect many subsequent links, and on a complex
model, as a rule, topological collisions occur in some place, which do not
allow actually carry out this operation. As a result, despite the fact that
the system is fully parameterized, it is almost impossible to change the
parameters on a complex model.
In addition, this method of parameterization is characterized by
opacity for the user. To change the geometric shape, it is required to find
the necessary structural element in the construction tree and understand
which parameter value should be changed. With this approach, the
fundamental principle of the WYSIWYG user interface does not work
(you see exactly what you get as a result), because the text or numerical
value of the element parameter is being edited, and the body shape
changes as a result.
Another well-known disadvantage of parameterization based on the
model building history is that the decision on which parameters of the
model can be changed is made in the process of its creation. If you later
need to change some parameter that is not in the construction tree, the
solution will not be easy. Either rebuild the model from scratch or use
complex optimization algorithms that, by varying the values of the
governing parameters, try to find the desired value of the required
parameter.
This deficiency reflects the general problem of the procedural
approach to parameterization, a variation of which is the method of
regeneration of the construction history. The procedural approach
involves the separation of all model parameters into input and output.
Only the values of the parameters of the first group can be changed, and
the output values are calculated in accordance with predefined
procedures, formulas, construction history, etc. [12].

10
 Another key problem of parameterization based on history is the
impossibility of applying this technology when working with
heterogeneous (multi-CAD) and legacy data. This is due to the procedure
of translating the model from one format to another, in which the history
of construction is usually lost – only the geometry itself is broadcast,
which in this case is called “dumb”. Some expensive translators are able
to convert structural elements from one system to another, but since the
nomenclature of structural elements in each system is different, then
100% translation is impossible in principle. The same applies to the
methods of automatic recognition of structural elements (automated
feature recognition) in "dumb" geometry: they work only in the simplest
cases and do not solve the general problem.
Therefore, the field of rational use of ProEngineer is such
production, where there are no large assemblies, no complex topological
forms, but there is a large range of typical parts.
All the shortcomings of history-based parameterization noted above
were successfully overcome in the dynamic modeling system Solid
Designer, which for the first time gave the user the means of direct
manipulation of geometric model elements in three-dimensional space.
This was made possible primarily due to the core solid modeling ACIS.
The core of ACIS is an object-oriented C++ geometric library that
models the geometry of a rigid body through a boundary representation
(BRep) and implements Boolean operations between bodies (which serve
as the basis for procedural structural elements). Boolean operations are
global in the sense that the union, intersection or difference of two bodies
requires time-consuming actions on their full boundary structures (in fact,
this is the problem with the performance of parametric systems based on
the history of construction). However, Spatial also implemented in its
core so-called local operations, for which it suffices to work only with a
certain neighborhood of the body boundary. In many cases, local
operations do not require a change in the topology of the model (the
number and connectivity of its faces, edges, and vertices), which means
that they can be performed quite effectively. The geometric core of ACIS

11
gives software developers a rich choice of geometric operations for
constructing and manipulating complex models, as well as a complete set
of Boolean operations. Its mathematical interface, Laws Symbolic and
NURBS-based deformation, allows for the integration of surface and
solid modeling. The ACIS core provides output to the SAT file format,
which any ACIS-capable program can read directly. Improved models of
this core allow software developers to have more options when creating
applications. ACIS now contains more than 50 components, including
blending, local operations, precise hidden lines, spatial zoom, advanced
surface tools, mesh topology, and VISMAN (Visualization Manager).
Another tool in ProEngineer is two-way associativity [13]. Direct
associativity is associated, for example, with an automatic change in the
design of a snap when changing a part, which is made using this snap.
But if a change in equipment is made in ProEngineer, then the part is
automatically changed, which reflects the inverse associativity. However,
such a design process is often uncontrollable. The desire to simplify the
product can lead to the loss of detail of its functionality.
Thus, the parameterization is useful only at the initial stages of the
constructor, when the parameterization scheme is still quite simple. If the
number of parameters begins to exceed a certain value, of the order of 10-
50 parameters, depending on the type of construction), then the labor
costs for the coordination of the parameterization scheme become
unnecessarily large, and it is easier not to use parameterization at all.
One very useful use of parameterization is the creation of standard
element libraries. The cost of creating a parameterization scheme pays off
by reusing libraries. So, in the KOMPAS system of the company ASCON
[14–17], a simpler approach to the creation of libraries of standard
elements has been successfully implemented. It consists in the rejection
of the expensive borrowed parameterize and the use of proprietary
software for programming a large number of standard elements in plug-in
libraries and the transfer to third-party companies of the means for
creating such libraries. This allowed the use of an inexpensive software
product for obtaining a large set of parameterized libraries.

12
 The process of computer-aided design is constantly being improved.
An example of an innovative approach in the field of CAD is the
emergence of synchronous modeling (CT) tools proposed by Siemens
PLM Software. CAD NX is the flagship CAD/CAM/CAE PLM system
(formerly Unigraphics) [18, 19].
This technology allows two main approaches to modeling:
parametric design and direct editing. Thanks to synchronous technology,
the possibilities of defining the functions of structural elements are
expanded, which does not require the description of elements and their
limitations manually. New methods for selecting objects automatically
recognize logical and intra-element relationships even on models
imported from other CAD systems, which contributes to the reuse of
design data. For the first time, solutions are proposed for element-wise
direct editing without a construction history, which is now available in
NX.
CT technology allows to set fixed dimensions, parameters and
design rules at the time of creating or editing a model, without using the
history of its creation. Synchronous modeling technology simultaneously
synchronizes geometry and design rules by applying a new decision-
making mechanism based on an expert system. It allows designers to use
geometry from other CAD systems without creating it again. The
suggestive selection technology automatically determines the functions of
structural elements, without requiring manual description of the elements
and their limitations.
The concept of CT combines several developments. The two main
ones are the core of Parasolid and the development of D-Cubed called
DCM (Dimensional Constrain Management). This 3D solver (solver) is
an innovative development. Parasolid, in turn, provides support for
geometry and parameterization. A geometric CAD solver is a software
package that is built into a CAD system by its manufacturer and allows
an engineer to assemble complex structures from simple ones. The
engineer imposes geometric constraints (parallelism, perpendicularity,
coincidence, alignment, etc.) on geometric objects (points, straight lines,

13
planes, circles, spheres, etc.) and after the work of the solver receives a
new arrangement of objects and related parts or a message about
incompatibility models.
As a result, the solver provides the core with information about what
and how to do it, and Parasolid does it in accordance with the request.
Then this data is transmitted on NX environment.
Thanks to the CT technology, such complex problems as the
standardization of design solutions and the translation of various data
formats are simplified (the cost of individual translators is very high).
Designers will not be able to treat standardization tasks as hard as they
will be able to work effectively with data created in a CATIA or
ProEngineer environment. Data translation is still needed, and this
remains a problem. Translation errors cannot be completely corrected,
since the database structures of the designers are completely different,
therefore, this can be done only partially.
Another innovation of CAD NX is the technology of "current rules"
(Live rules), according to which the recognition of interconnections, such
as parallelism, touch, alignment, horizontal position, verticality, and their
storage in the editing process, is carried out automatically.
Procedural structural elements allow changing the parameters of
holes, arrays, thin-walled shells and rounding’s in accordance with the
concept of element-by-element modeling, without imposing
interconnections between the individual elements of the model. 3D
control dimensions can be put on the already finished models and change
their values, and for completeness of the geometry control, the options for
specifying the direction of the size shift are introduced.
The tabular and formula setting of the model parameters provides
the possibilities of automated parametric design. The synchronous solver
provides bi-directional geometry editing. Elements can be changed
regardless of the order in which they were created, thereby eliminating
parent-child relationships between elements within the limits of an
individual part, as well as the entire assembly.

14
 The well-known CAD/CAE system APM WinMachine [20–23] also
does not use expensive borrowed parameterize and implements its own
software to create a drawing and graphic parametric editor APM Graph,
which can be used both as part of the system as a whole and
independently.
Consider the main features of the use of the parameterization toolkit
in the APM WinMachine CAD system [22]. In the mode of creating a
parametric model, the drawing or any part of it is drawn by creating a
special parametric model. The parameters have a numerical expression in
drawing units, and their set will determine the dimensional characteristics
of the particular part. Parameters are set either numerically or through
analytical expressions, and the drawing law is a sequence of drawing
commands and their corresponding logical and analytical expressions
with the specified parameters. The parametric model created in this way
can be inserted into a regular drawing as a parametric unit.
Input data is divided into source and derivatives. For the source data
(numeric and string), only the value is specified, and for derivatives, also
an expression that is a function of the source and already declared derived
data; while if a numeric variable is specified by an expression (analytic or
string), its value will be automatically recalculated in the future. The
order of variables can be changed, supplemented, and the variables
themselves are edited.
When drawing graphic images, a sequence of commands is given
leading to the construction of the desired model. In the list of parametric
commands, all the commands through which the model was created are
sequentially located. Each command has its own unique set of
parameters.
The parameterization interface is quite convenient - navigation
through commands is performed either through a list of commands, or
using certain keyboard shortcuts. When you go to any command on the
screen displays the status of the drawing before the execution of this
command. If the current command is a drawing command, then the object
that should be drawn by this command is highlighted on the screen.

15
 Working with commands is accessible and understandable for the
designer and involves several steps:
- the creation of a parametric model at the command level, which is
the binding of graphical objects to the numerical data or equations of
communication, which were set as variables. In this case, auxiliary
variables can be used as input data in the parameters of subsequent
commands;
- an indication of the type of the created primitive and its index in
the commands for creating graphic primitives. Indexes are used in those
commands for the execution of which requires the indication of one or
more objects existing in the drawing (drawing a line parallel to the
indicated one, deleting objects, etc.);
- editing the list of commands, consisting in the possibility of
removing from the list of any command and replace it with another.
Accordingly, the appearance of the parametric model may change or
errors may occur due to the fact that together with the remote command
any data needed in subsequent commands have been deleted. The control
points created with the object are also automatically indexed and can be
used in subsequent commands to directly refer to the control points
already existing by the model being created.
When editing, the principle of the maximum possible update is
observed – for example, there may be a change of variables in the model
and all components of the displayed primitive can be changed and edited.
Parameters of the created array, line types, text styles, layers, etc. can also
be changed.
When inserting a parametric block into a drawing, the user is given
the opportunity to visually view the model and edit its source data. The
user has the opportunity to insert a parametric block into the drawing
with changing any of its parameters, including changing the scale and
angle of rotation of the inserted block.
The graphical part of the single database of the APM WinMachine
system [23] is organized in a similar way. It stores not only the numerical
parameters of standard parts and elements, but also their parametric

16
models. When inserting a graphic object from the database, the user has
the opportunity not only to insert any standard element into the drawing,
but also to change any of its parameters.
The advantage of the drawing and graphic parametric editor APM
Graph is that the developed software user interface is very simple and
intuitive to use. The process of creating a parametric model is as
forthcoming as possible to the usual drawing of parts [24–27]. In order to
obtain a parametric model, you simply need to match the numerical
parameters of mathematical formulas and/or logical expressions (if
required). You can visually monitor the correct execution of the
parametric commands used by your model.
If the model is incorrectly drawn, the program will indicate to the
sequence number and the name of the incorrectly executed command.
Having opened the list of parametric commands, it is necessary to correct
erroneous data and re-test the operation of the model. This debugging
method is very convenient and has proven itself in the construction of
complex parametric models.
The APM Graph module contains a database [23], which can be
used to draw typical parts, assemblies and graphic fragments. The
presence of the developed parameterize allows the user to create their
own libraries of parts and components of varying degrees of complexity.
A single database of the APM WinMachine system was supplemented by
a graphic library in a parameterized form. The library includes:
- a set of standard parts most commonly used in engineering design
(fasteners, sealing elements, bearings, etc.);
- versions of the mechanical gears elements (gear, worm, belt and
chain);
- conditional graphic designations of electric, pneumatic and
hydraulic schemes;
- standard design documentation drawing elements (formats, stamps,
etc.);
- cutting tools and technological data in the form of corresponding
databases for parametric models, which makes it possible in each specific

17
case to easily obtain working drawings of tools, and not only their outline
representation.
The connected knowledge base contains the necessary theoretical
and informational information for the mechanical equipment designer
(tolerances, mechanical characteristics of materials, etc.).
Thus, we can say that the current state of the graphical editor APM
Graph allows you to quickly and accurately draw up the graphical part of
the design documentation with the possibility of adding and improving
existing functions and adding new ones; as well as the replenishment of
the graphical database editor, which gives a significant increase in the
productivity of the designer.

18
 2. PARAMETRIC MODELING OF METAL-CUTTING
MACHINE TOOLS

2.1. Build optimal layouts

Requirements for the design of specific machine tools vary

depending on their types, while the construction of the basic layout is
one of the most decisive steps. The layout of the machine is
predetermined by the layout of the gearbox and the carrier system of
the machine. The design of gearboxes for machine tools (main drive,
feed box) is aimed at achieving a large range of rotational speeds
(regulation range R n of modern machines can reach R n = 100 ... 250)
and high rigidity.
When designing speed boxes (SB), they seek to simplify the
design and make it more compact by reducing the number of stages
and limiting the gear ratios. So, the reduction of the radial dimensions
can be carried out [6, 28, 29]:
1) the replacement of the three-shaft box to double-shaft;
2) rational distribution of gear ratios between several pairs of
wheels;
3) use of parallel transmissions, so that power is transmitted over
parallel streams and the size of the SB are significantly reduced;
4) coaxial-mounted shafts, etc.
The use of CAD at various stages of designing assemblies of
units and components of the machine involves the integration of a set
of design and graphics modules, united by a single design concept
with the ability to access common databases [3].

19
 For the whole variety of machines of a certain group (type) it is
impossible to use one or two SB structures. Most often, one has to
either develop a new design using structural optimization methods, or
create a new version of the already known prototype design using the
parametric optimization method.
The parametric model is a sequence of drawing commands with
the specified parameters. Parameters are set either numerically or
through mathematical expressions. A new parametric model is created
using the File/Create Model command.
A feature of the automated design process of a SB is a variety of
alternative layout options and the need for adjustments and
refinements to the specific features of the design object.
The efficiency of the SB design depends on the adopted
transverse layout (convolution), including the position of the output
shaft. In the existing works on the design of the SB convolutions, the
methodology and algorithm for constructing an effective variant of the
box design according to the criteria of rigidity and reliability are not
given.
In turn, the position of the output shaft in the optimal layout also
depends on the position of the resultant cutting force R. Thus, for the
range of lathes in the cutting process, tangential Pz and radial Py
components of cutting forces R arise (Fig. 2.1).
When determining the spatial position of gears that transmit
torque to the machine spindle, it is necessary to consider two
mutually exclusive situations:
1. Parallelism and unidirectionality of the cutting force R and
the resultant force Q in gearing “Output Shaft – Spindle” (Fig. 2.2,
a) provides the maximum rigidity of the spindle assembly (minimum
deflection of the spindle front end). This option is used in machines
for finishing processing methods.

20
 Q R

Fokr
P Pz

Py

Fr

Fig. 2.1. Diagram of the forces acting during turning

Fig. 2.2. The influence of the position of the drive wheel on the spindle
deflection: a – forces R and Q are directed in one side;
b – forces R and Q are directed in opposite side
21
 2. Parallelism and directivity in opposite directions of the forces
R and Q (Fig. 2.2, b) provides the least load on the front support (as
the most loaded during the machine operation). In this case, the
deflection of the front end of the shaft is maximum, which is
permissible only for roughing.
The many options for the design of parts of the SB and their
mutual arrangement, on the one hand, as well as the need to increase
the productivity of the designer, on the other, make it possible to use a
parametric modeling apparatus. It is this mechanism that allows
reducing the development time of a new or modification of known
structures, implemented in all modern CAD systems [14, 22].
The parametric model is a sequence of drawing commands with
the specified parameters. Parameters are set either numerically or
through mathematical expressions. A new parametric model is created
using the File/Create Model command.
The parameterization mechanism is characterized by the presence
of interconnections and constraints between the geometric objects that
make up this structure (as opposed to non-parametric). At the same
time, a part of the indicated interrelations and restrictions can be
formed automatically when entering graphic information and the rest
can be assigned by the user independently.
In this monograph, a procedure for constructing parametric
models of transverse layouts of gearboxes for machine tools has been
developed. The solved problem is formulated as follows:
To develop such a parametric model of the transverse assembly of
the SB, which in one variant will provide the maximum rigidity of the
designed machine (its spindle assembly), and in another variant, the
minimum reduced load on the front spindle support.
The known algorithm for designing layout schemes is constructed
in the following sequence:
1) shaft axes are drawing;
2) structural elements of the parts located on the shafts are
determined;

22
 3) put the axial dimensions of all structural elements;
4) convolution of the SB is drawn, which will determine the
angles of the gear pairs, the direction of circumferential and radial
forces, etc.
To improve the above algorithm, a parametric model for the
structural synthesis of the spatial layout of the SB are proposed.

2.1.1. Transverse lathe layout

As a design object, a small-sized multi-purpose machine tool

model MS-03 was selected. The MS-03 is intended for the machining
of metals by the technological operation: turning, threading, milling,
drilling, boring and grinding [30–32].
In the first variant, the criterion of maximum stiffness is used
(Fig. 2.3, a), which is realized under the condition of parallelism and
unidirectionality of the forces R and Q. Below is a fragment of the
program for synthesizing the layout according to the criterion of
maximum stiffness.
In the second variant, the criterion of the minimum reduced load
on the front support (Fig. 2.3, b) is used, which is realized under the
condition of parallelism and directionality in the opposite direction of
the forces R and Q. Below is a fragment of the layout synthesis
program according to the criterion of maximum rigidity.

23
 a b

Fig. 2.3. Scheme of the transverse layout of the gearbox:

a – by criterion of the maximum rigidity; b – according to the criterion of the
minimum reduced load

Depending on the adopted cutting pattern, tool geometry and cutting

conditions, the inclination angle of the resulting cutting force will change,
and, therefore, the position of the output shaft of the SB will also change
in accordance with the proposed program.
On the basis of the proposed parameterization algorithm, a
parametric SB model of the MS-03 machine has been developed
(Fig. 2.4).
The limitations of this model include the limiting distances between
the outer surface of the gear and the side wall (x), as well as the bottom of
the housing (k). Starting with WinMachine 9.5, there is a new variable
type – message variable, which makes the design interface more
“friendly”.

24
 193

Q R

120
K

Fig. 2.4. Speed box machine model MC-03

(parametric model)

Below is an example of a “message variable” (Fig. 2.5), which is

visualized in the working window in case of violation of the limit values
x and k. For example: “Distance between the bottom of the housing and
the wheel surface should exceed 24 mm”
Attempting to implement the criterion of maximum rigidity with the
existing dimensions of the SB housing led to an unacceptable location of
the output shaft relative to the bottom of the housing (Fig. 2.6).
To determine the difference between the factory version of the
machine model MC-03 (Fig. 2.4) and the optimum in rigidity (Fig. 2.6),
we use the shaft calculator APM Shaft.

25
Fig. 2.5. "Variable-message" – unacceptable distance

Fig. 2.6. Maximum stiffness layout option

26
 Evaluation of stiffness is feasible for a dual-support spindle
assembly of a multi-purpose machine model MC-03 with combined
loading (Fig. 2.7) mounted on duplexed angular contact ball bearings 4-
46209 and 4-46112 according to the tandem-O scheme [33–35]. The
spindle has a spring-type preload (rear support) and a preload with two
intermediate sleeves for a duplexed front support.
M45 1,5

®85

®56
®52

®30
®48

®95
®60

®66
32 215

294 67

a
Y

EJ2 EJ1
EJ3
Z
m2
d1
d0

d3

d2

J2x

P0(t)
Ft c1
c3 h3
Fr h1 P Pz
F2(t)
k3
l3 l2 k1 l1
L Py

Fig. 2.7. Constructive (a) and calculated (b) spindle assembly schemes

With the help of the AP Shaft module, a comprehensive calculation

of the spindle for the MS-03 multi-purpose lathe was carried out, the
results of which are presented in fig. 2.8.
27
Fig. 2.8. Calculation of the spindle for the machine MS-03 in the "APM Shaft"

28
 The calculation of the maximum deflection of the spindle front end
in the factory version (deviation from the cutting force 32,40) differs from
the optimal one by only 4%.
In the APM Graph environment, a transverse convolution of the MC
of the machine model MC-03 was constructed (Fig. 2.9).

Fig. 2.9. Design of the box speeds multipurpose machine (transverse layout)

2.1.2. Transverse layout of drilling and milling-boring machine tools

As a prototype, we will choose a horizontal machine tool with

advanced technological capabilities of the model SF68VF4. The layout of
this machine model involves moving along the horizontal slideway of the
spindle head (Z axis) to which the vertical head or additional devices are

29
attached (shaper and angle spindle heads, cantilever overarm with a
package of milling cutters).
The spindle head includes a spindle unit with a tool clamping
mechanism, a camshaft transmitting rotation to a horizontal or vertical
spindle using an automatic gear drive switching device, a two-speed
gearbox, as well as a number of other parts and assemblies ensuring the
normal operation of the spindle head. Rotation from the electric motor
through the poly-V-belt is transmitted to the input shaft and through
gearing to the camshaft of the gearbox. From the latter, rotation is
transmitted to the coupling of the vertical head, or to the gear of a
horizontal spindle (Fig. 2.10).

Fig. 2.10. Kinematic diagram of the main drive

The transverse convolution of the machine during the boring

operation, taking into account the location of the cutting forces (Рz, РY)
and the forces in the gearing (Р0, Pr), is shown in fig. 2.11.

30
 Fig. 2.11. Transverse convolution of the box speeds
for the machine model SF68VF4

Analysis of the transverse arrangement shows the non-optimal

spatial position of the machine tool output shaft (nv) relative to the
spindle (nsp), caused by non-parallelism of the resulting forces P and R.
This leads to an increase in the reduced load on the front spindle bearing
and lowering its carrying capacity. However, this spatial arrangement
simplifies the design of the gearbox housing, which is shown in
Figure 2.12.
Rather simple design of the housing differs in two original solutions:

31
 1. On the right side of the housing there is a joint for mounting the
gear in a spatial layout. At the same time, the overall technologically
feasible rectangular housing shape with minimal dimensions is
maintained.
2. In the lower part of the housing, a spherical shape is deepened,
which allows minimizing the size of the housing with fixed initial data.
The presence of the bottom of the non-rectilinear housing is an
interesting version for the gearbox of a turning lathe multifunctional
machine. This design allows you to implement such a spatial position of
the shafts and the spindle, which ensures maximum rigidity of the spindle
node and the machine tool as a whole.

Fig. 2.12. The design of the speed box machine SF68VF4 (transverse layout)

32
 However, to achieve the minimum load on the front spindle support,
an adjustment of the housing structure is necessary, and the housing joint
should be made on the opposite side (Fig. 2.13). To assess the change in
the position of the shafts of the SB, a parametric modeling program has
been developed for the APM Graph environment, whose Command
window is shown in Fig. 2.14.

Fig. 2.13. Housing variant with minimum driving force

33
 Fig. 2.14. Command window of the parametric modeling program in APM
Graph environment

The arrangement of the wheels relative to each other affects the

magnitude of the forces acting on the elements, so that the power
characteristics can be improved. Thus, the location of the intermediate
gear wheel (Fig. 2.15, a, b) affects the forces acting on the shaft
supports of this wheel.
In scheme 2.15, b, the forces in the engagement F1 and F2 are
almost parallel and the total force F acting on the supports is large. In
scheme 2.15, a due to a change in the direction of the forces F 1 and F2,
they are largely compensated, and the resultant forces are less than in
scheme 2.15, b. It should be noted that for reversing transmission, it is
preferable to arrange the axis of the wheels in the same plane.

34
 n1
n1

F2
F1
F
F2 F

F1

n2 n2

a b

Fig. 2.15. Scheme influence intermediate gear

Rational installation of wheels also affects the accuracy

characteristics of kinematic chains. The error of the parasitic wheels in
the kinematic chain (Fig. 2.16) can influence itself in the error of the
output link by a magnification doubled. The location of the parasitic
wheel for a given direction of rotation also influences. In the diagram
(Fig. 2.16), the dashed line shows the best (from the standpoint of
accuracy) mounting scheme of the parasitic wheel for a given direction of
rotation [4, 6]. The general rule of mounting requires that the transfer of
rotation on the parasitic wheel takes place at the minimum angle γ
between points of contact 1 and 2. When reversing the transmission of the
axis, it is desirable to place on one line, as in the previous review
(Fig. 2.15).

35
 1


Fig. 2.16. Diagram of the parasitic wheel influence on accuracy

The use of the developed parameterization mechanism significantly

increases the efficiency of the study of permissible layouts based on the
constructed parametric models. In addition, each new version is
synthesized only by changing the optimization criterion. Such an
approach to designing on the basis of parametric models improves the
quality of design decisions made and the productivity of designers.

2.2. Construction of parametric models of belt drives

2.2.1. V-belt transmission

The widespread use of belt transmissions

in machine drives is largely determined by
the elasticity of the belt and the smoothness
of the transmitted rotation. Especially for
the transmission of rotation with a

36
significant distance between the axes of the shafts on which the pulleys
are mounted. In addition to the traditional transmissions from the motor
pulley to the machine drive pulley, the belts are also used to directly
transfer the rotation from the electric motor to the spindle, when the latter
needs to communicate high rotational speeds. Especially this version of
the transfer of rotation is used in cases where the vibration-free operation
of the machine is to be achieved (high-precision machines, master
machines).
The pulleys used in machine tools in their form in many cases do not
differ from pulleys common in other machines. The variety of
nomenclature used in pulley drives, on the one hand, and the availability
of regulatory documentation governing the shape and size of their
structures, makes it promising to use the parameterization mechanism
[36–39].
For a wide range of V-belt pulleys, design forms have been
developed that are used in the Variable windows of the APM Graph
module (Fig. 2.17).

Fig. 2.17. Variable window of the APM Graph module

In metal-cutting machines, mainly belts of Z, A, B, C sections are

used, which are selected according to the nomogram (Fig. 2.18). Section
O should be used for power up to 2 kW. Parameters of standard V-belts
are given in Table. 2.1.

37
 Table 2.1
Key parameters of V-belts, according to GOST 1284.1-89, mm

Belt section Belt designation Wp W T d p min

Z 8,5 10,0 6,0 63

А 11,0 13,0 8,0 90

B 14,0 17,0 10,5 125

C 19,0 22,0 13,5 200

At the first stage of the design calculation of the belt transmission,

the choice of the belt section is made. In accordance with the syntax of
parametric modeling in the CAD APM WinMachine, a calculation form
for selecting a belt section was developed, consisting of a set of logical
selection conditions (Fig. 2.19).

Fig. 2.18. Selection of belt section

38
 Fig. 2.19. Selection of belt section

Standard GOST 20889-88 provides nine types of solid pulleys for

drive V-belts according to GOST 1284.1-89. The profile of the grooves
of the pulleys is shown in Fig. 2.20, and its parameters are given in the
corresponding GOST.

Fig. 2.20. Pulley groove profile

To determine the size of the pulleys and the size of the belt, an
appropriate calculation form has been developed, which is presented in
the Variable window (Fig. 2.21).
39
 Fig. 2.21. Selection of belt size parameters

The calculation forms for determining the kinematic and power

characteristics of the V-belt transmission are determined in a similar way.
On the basis of the calculation form, a graphical procedure has been
developed for constructing a parametric model of V-belt transmission
pulleys, the Command window of which is shown in Fig. 2.22.

Fig. 2.22.Creating a mirror copy in the command window

40
 The versatility of the parametric model is provided by considering
the various options for implementing the design of the belt drive. The
choice of the graphic profile for the formation of the pulley design will
depend on the transmitted power, the belt section and the coordinates of
the base point of configuration groove symmetry (Table 2.2).

Table 2.2
Groove profiles
Selection conditions
Initial groove profile Belt Transferred Coordinates
section power N, kW base point

х = f;
А N≤ 1
y = dр–h

х = f+е/2;
А 1<N<1,9
y = dр+b

А 1,9≤N<2,8
х = f+е;
В 3,6<N<5,3
y = dр-h
С 7,6<N<9,3
А 2,8≤N<3,5
х = f+3е/2;
В 5,3<N<7,0
y = dр+b
С 9,3 <N<12,5

Based on the developed calculation forms, a procedure for

parametric modeling of V-belt drive pulleys in the APM Graph module is
proposed. A sketch of the pulley design with a shortened hub against the
background of the Command window is shown in fig. 2.23.
When designing V-belt transmissions in the WinMachine shell (the
APM Trans module), the designer receives a great deal of analysis, since
the results of the calculations are a complex of multivariate solutions
(with the same initial data). In principle, the totality of these design
solutions can be reduced to the problem of multiparameter optimization
41
by one or several criteria. The theoretical foundations and methods of
such optimization are well developed, for example, [40, 41].
As the variable parameters of the V-belt transmission can be
considered:
1) estimated diameters of the driver and driven pulleys d p1 and
d p2 ;
2) center distance;
3) number of belts;
4) type of the belt section.

Fig. 2.23. Sketch of pulley construction in parametric form

The optimization criterion can justifiably take the estimated

durability (life) of the belts Т 0 (h), which is a comprehensive indicator of
the efficiency of the transmission. However, such a choice of parameters
and optimization criteria is not the only possible one.

42
 If one of the main requirements for a machine is its dimensions, then
the center distance a will go from optimization parameters to
optimization criteria. If the size a is given (for example, according to the
basic model of the machine), then it will generally be considered a
constant in the calculations. If the machine layout conditions impose a
limit on the size of the larger pulley, then the optimization parameters are
excluded d p1 and d p 2 . Other combinations of parameters and
optimization criteria are possible.
Thus, depending on the specific conditions of the design of the
machine, a certain optimization criterion is selected (or several), at the
achievement of which the search for the corresponding values of
optimization parameters will be directed.

2.2.2. Poly-V-belt transmission

In modern metal-cutting equipment with CNC, gears

with poly-V-belts are increasingly being used - endless
flat belts with longitudinal wedges that enter circular
wedge grooves on pulleys (fig. 2.24). Such a wide
distribution is due to the fact that these belts combine
the advantages of flat (flexibility) and wedge (high traction ability).
Thanks to these advantages, the poly-V-belts can operate at speeds up to
65 m∙s-1 and at powers up to 1000 kW.
In metal-cutting machines, mainly K, L and M section belts are used,
which are selected according to the nomogram (Fig. 2.25).
The use of parameterization tools allows designing poly-V-belt gears
with any belt section based on parametric models [42–44].
At the stage of design calculation, it becomes possible to associate the
estimated ratio of the driving pulley pitch diameter d1 with the torque
value T specified in the source data or calculated as a function of the
transmitted engine power. Using the syntax of parametric modeling, the
standard value of the pitch diameter d1 is selected (Fig. 2.26).
43
 Fig. 2.24. Drawing of poly-V-belts

Fig. 2.25. Choice of cross-section poly-V-belt

44
 With the help of similar logical expressions, the main geometrical
parameters are determined: belt pitch p, groove height e, rim thickness t
and others (fig. 2.26).
With the help of parametric modeling tools, the choice of the smaller
pulley diameter d1 by the criterion of durability is effectively realized
when it is possible to achieve higher traction characteristics of the belts.
For this purpose, the choice of such a diameter d1, which exceeds the
permissible minimum diameter for this belt section is made.

Fig. 2.26. Variable window in the pulley poly-V-belt transmission

design task

Thus, by means of parametric modeling, it becomes possible to solve

a multicriteria problem of choosing optimal parameters on criteria set of
durability and minimum dimensions [45]. Moreover, this is
algorithmically solved quite simply by switching selection criteria.
On the basis of the developed calculation forms, a procedure for
parametric modeling of poly-V-belt transmission in the APM Graph
module is proposed. A sketch of a disk-type pulley at the stage of the
“creation of a mirror copy” operation is shown in fig. 2.27.

45
 Fig. 2.27. Creating a mirror copy in the Command window

The coordinates along the X axis and the first and second points of
the mirror copy are set analytically, as a function of pitch p, the number
of edges z and the size coordinating the position of the first wedge
relative to the end face of the pulley s, namely

X2 = p * z + 2 * (s-p / 2).

The coordinates along the Y axis are set numerically by typing in the
"Value" input field.
To check the correctness of the constructed model, you need to open
a list of all its variables and change them (within reasonable limits),
checking how the created parametric model works out these changes. If
an error was made when creating a model, it is easy to notice and correct
it in this way by returning to the list of parametric commands.
On the basis of the developed parametric model, 3D models of a
pulley (Fig. 2.28) were built in the APM Studio module in order to
further calculate the stress-strain state by the finite element method.

46
 Fig. 2.28. Solid model poly-V-belt pulley

2.2.3. Toothed belt transmission

When designing toothed belt

transmissions, which are widely used in
drives of modern machine tools, one of the
essential factors is the distribution of the
transmitted load between the belt teeth that
are in mesh with the pulleys. Toothed belts
have the largest number of design variations, compared with flat, round
and V-belts. They have several advantages, providing a smoother
transmission, eliminating the possibility of slippage relative to the pulley;
at the same time they create not so high load on the shafts and bearings
from the tension of the belt drive and provide the highest efficiency.
Available analytical dependencies for describing the influence of many
influencing factors on the distribution of the load often have a significant
discrepancy with the practical results. An alternative to this approach is
the use of parametric modeling for the accelerated design of transmission
elements with a toothed belt and the study of the stress-strain state using
the finite element method.
The existing methods of strength calculation and analysis of load
distribution during transmission operation [46] assume the introduction of

47
an amendment K to the outer diameter of the pulley, which is taken from
the table in proportion to the diameter of the pulley and takes into account
only the belt elongation. To determine the effect of the pulley
circumferential pitch on the distribution of the load on the belt teeth on
the spanning arc, an attempt was made [47] to describe analytically the K
coefficient as a function of factors such as the transmitted load and the
compliance of the turns of the belt carrier (rope). In this case, the optimal
value of K can be obtained by jointly solving two equations that
determine the load on the belt teeth with equal steps of the belt teeth tb
and the pulley tp and under condition tp> tb. At the same time, the load
distribution is a multifactorial dependence, and to increase the adequacy
of the analytical description, parameters are introduced to influence the
nature of loading, the gear ratio and the number of belt teeth, that is in the
engagement [48]. Such a complication of mathematical dependencies
does not always give a practical effect in design calculations.
To improve the design process, it is advisable to use a parametric
model of a toothed belt transmission for various design variations, on the
basis of which to carry out a comprehensive study of the the stress-strain
state characteristics for pulley teeth and belt, choose the best transmission
design, characterized by uniform distribution of the load and lowering its
greatest value [49].
In drives of the main motion for metal-cutting machines with CNC
and multi-purpose machines, drives with a DC motor and a thyristor
voltage converter are widely used. Drives of this type need two-zone
regulation. So for a DC motor of the 2P series, the control range for the
spindle speed is 1:4. Often, according to the technological requirements,
this range must be increased, which is done by introducing an additional
gearbox.
A typical representative of CNC machines with an extended range of
regulation is a specialized multi-purpose machine model MTs200 PF4V.
This machine has a portal layout with a longitudinally movable cross
slide, along which transversely moves the portal column carrying a

48
vertically movable spindle head. In fig. 2.29 shows the kinematic diagram
of the machine tool main movement drive models MTs200 PF4V.
Rotation from the 4PF 112MUHL4 direct-current motor through a
toothed belt gear (18:25) is transmitted to the input shaft and through a
two-stage gearbox to the spindle unit with a tool clamping mechanism.
From the SB output shaft, rotation through the second toothed belt gear
(38:38) is transmitted to the actuator of the feedback sensor. This
multipurpose machine uses an angle sensor (circular sensor) ROD 700
from HEIDENHAIN, which is based on an optoelectronic reading
method and is designed to determine the position coordinate and ensure
positioning accuracy in the kinematic control circuit.
To assess the main geometric and kinematic characteristics of
toothed belt transmission, the traditional calculation method was used
[29, 50]. The results of the calculation are presented in Table. 2.3.

Fig. 2.29. Kinematic diagram of the main drive

At the same time, for the study of transmission structures, a

parametric modeling tool is effective [29].
49
 Table 2.3
Calculation results
Pulley number
Pulleys parameters
1 2
Pitch diameter of the pulley, d = m∙zp (mm)
72 100

Tooth outside diameter dа = d - 2∙δ±K (mm)

«+» – for driver pulley 70,43 98,34
« – » – for driven pulley
Correction K, taking into account the load level
0,0336 0,0562
К = 0,2∙(Fр/b)∙λ∙zp
Circular pitch of pulley Рp in the midline of the teeth
11,596 11,855
Рш = (dа – hш)/zp (мм)
Pulley groove width Sp (mm) 4 4
Depth of pulley hole hp (мм) 4 4
Rounding radii on the tops of the teeth r1 (mm) 1,0 1,0
Rounding radii in the roots of the teeth r2 (mm) 1,3 1,3
Angle between the branches of the belt γ (deg.) 40 40
Tooth pulley length В = b + m (mm) 54 54

The parametric models of the toothed belt and pulley are constructed
in accordance with the following algorithm.
1. Input of initial data in the form of variables in the "Variables"
dialog box (Fig. 2.30).

a b
Fig. 2.30. Variables window in the parametric modeling problem:
a – toothed belt; b – pulley

50
 2. A graphical assignment of a sequence of commands in the
“Commands” window, leading to the construction of the desired toothed
belt model (Table 2.4). In the list of parametric commands, if necessary,
parameters for commands are specified. In this case, the variables used in
the calculation expressions are specified in Fig. 2.30, or auxiliary
variables created in the process of building the model. Each graphic
procedure (composing a graphic form) corresponds to analytical
expressions (analytical form). Similarly, a model of a pulley toothed belt
transmission is built (Table 2.5).

Table 2.4
Elements of toothed belt parametric model
Creating a rectangular Create a rectangular
Creating a tooth shape
array of teeth array of ropes

Rows: x  1 Rows
h1 b
L ;   90  
Column: x  1; t p 
cos( rad (2)  n1  1
zo  z p  1
360 Column: n1 ;   180

Table 2.5
Elements of the parametric pulley model
Creating a circular tooth Create a circular
Creating a tooth shape
array array of tooth roots

 h 
L
hp
;   270   2       1 
cos( rad (2)) n  zp; t  2 
zp

51
 3. Conformity analysis of the model thus formed with the required
one, and, if necessary, correction of command parameters or change in
the method of constructing the entire model or its part. In Fig. 2.31
depicts a sketch of a toothed belt transmission with side and radial
clearances.

Fig. 2.31. Sketch toothed belt transmission

4. Analysis of the constructed model correctness for different values

of the source data.
To stress-strain state evaluation the and the uneven distribution of
the transmitted load between the teeth, a 3D model of a pulley in the
APM Studio module are built (Fig. 2.32, a). As the initial data will take:
toothed belt transmission (18:25) of the main motion drive for the
machine model MTs200PF4V, including belt 4-112-50 OST 38.015114-
76, module m = 4 mm, number of teeth Zр = 112, belt length lр = 1407, 84
mm, belt width b = 50 mm, nominal rotation frequency nrat = 1000 rpm,
power N = 5.5 kW.
As is known [51], the normal load on the teeth is unevenly
distributed and reaches a maximum at the base of the teeth (Fig. 2.31, b).

52
 2

P1

Q1 Т1

a b
Fig. 2.32. 3D model of driver pulley: a – 3D model; b- diagram of power

Using the built-in finite element [52–55] grid generator, the

procedure of its construction with the subsequent complex calculation is
carried out (Fig. 2.33). When the pulley and belt steps are unequal (tp>
tb), the load on the first pulley teeth at the beginning of the driving
pulley’s grip arc and on the last belt teeth at the end of the driven pulley’s
grip arc decreases. In this case, the load is redistributed to the belt last
teeth of the drive pulley circle arc and the driven belt first teeth of the
circle arc.
A comprehensive analysis of the stress-strain state of the toothed
pulley teeth and belt was carried out using the numerical method of finite
elements in the APM Studio environment. The stress and displacement
fields are constructed at the nodal points of the tooth surface for toothed
belt transmission pulley.
On the basis of a comprehensive analysis of the toothed belt
transmission design, ideas on the stresses distribution in various sections
of the pulley tooth and belt were obtained, and the load distribution over
the belt teeth on the pulley circumference arcs was estimated. It opens up
the possibility of effectively modeling the process of a more even
distribution of the load across the belt teeth, depending on the ratio of the
belt teeth and pulley pitch’s.

53
 a b

c d
Fig. 2.33. Strength calculation of the pulley: a – displacements;
b – deformations; c – the safety factor; d – stress

2.3. Parametric simulation of shafts in CAD APM WinMachine

The dimensions of the shafts in the

machines in most cases are determined by the
conditions of rigidity. The diameters of the shafts
according to this criterion are larger than in the
same strength calculation procedure, resulting in the work of the shafts in
the zone of low stresses. On this basis, the calculation of shafts can be
simplified, without taking into account the dynamic nature of the load,
i.e. without entering directly into the calculation formulas, stress
concentration factors and characteristics of loading cycles. The factors of
the presence of concentrators and cyclist are taken into account
approximately by the appropriate choice of permissible stresses.
The procedure for calculating the shaft strength includes:
54
 1. Determination of torque T = 9550 N η/n on the shaft depending on
the power N (kW), efficiency gears from the engine to the calculated
shaft η and rotational speed n (rpm).
2. Determination of the loads acting in the cross sections of the shaft,
carrying gears, pulleys and other parts that transmit torque. At this stage,
the directions and magnitudes of the acting forces are determined.
3. Determination of projections on the horizontal and vertical planes
of circumferential and radial forces acting on the gear teeth.
4. Plotting bending moments acting in horizontal and vertical planes.
5. Determination of the shaft dangerous section on the basis of
finding the maximum value of the moment’s geometric sum (Mi). In case
of uncertainty of the dangerous section, the value Mi is determined in two
or several sections.
6. Determination of the required diameter of the shaft by finding the
moment of resistance for the shaft cross-section.
7. If a shaft verification calculation is made for a known diameter,
then the stress σi acting in a shaft dangerous section is determined, the
value of which should not exceed the allowable stress [56].
The drive shaft of the metal-cutting machine is a stepped cylindrical
body, the quantity and the number of the steps of which depend on the
number and size of the parts mounted on the shaft. There are a number of
relationships that allow one to roughly determine the geometrical
dimensions of each shaft step: its diameter d and length l, taking into
account the underestimated values of the permissible torsional stress τk.
So, for the first step of the input shaft for the main drive of the machine,
on which the belt pulley is mounted, the following relations are
characteristic:

T  10 3
d1  l1 = (1,2 … 1,5)∙d1.
0,2   k 

55
 Similar relations [2] are characteristic for the geometrical parameters
for the steps under:
- sealing the cover with a hole and bearing;
- gear wheel;
- thread.
Traditional design techniques for a wide range of shafts are
characterized by high labor intensity and a high degree of duplication of
design operations. An alternative to this approach is a design technique
based on parameterization mechanisms [57–60]. As in the previous
sections, the APM Graph module is used, which is part of the
CAD/CAE/PDM APM WinMachine”.
As the object under study, the input stepped shafts of the main
motion drive for metal-cutting machines are considered. For each step,
parametric expressions are formed that describe the structural laws of the
main components for the shaft shape.
The output end of the shaft (the first step for an open gear), on which
the belt pulley is mounted, can be cylindrical or conical. Circular
fastening of the pulley belt transmission is carried out by fits, keyed joints
and connections with interference fit. Axial fixation of the pulley on the
shaft can be performed in one of the following ways: a) by friction forces
arising in high interference fit; b) a set screw with a cylindrical end, for
which a cylindrical socket is made on the shaft; while on the surface of
the pulley hub a narrow groove to prevent from spontaneous unscrewing;
the bar entering into the cross groove executed in a spline or spring stop
rings.
For verification calculations, the design form RF-07-01 is used [61].
The strength of the connection is guaranteed if the resulting stresses do
not exceed the allowable values given in the form table. Key connections
count on bearing stress (reliability of connection) and on a cut (strength
of connection).
For the first step an open gear, a sequence of parametric expressions
is proposed that simulate the procedure for specifying a cylindrical step
and keyway (Fig. 2.33). When creating a parametric model, the

56
expression syntax developed within the framework of the APM Graph
module is used.

Creating a cylindrical step Creating key groove of the

under the open transmission first step

b1 = 8*(d1>=20&d1<30)+
d11 =
+10*(d1>=30&d1<36)+
floor((T*10**3/(0.2*tau))**(1/3));
+12*(d1>=36&d1<42);
d1 = 32*(d11>=29&d11<34)+
h1 = 7*(d1>=20&d1<30)+
+36*(d11>=34&d11<38);
+8*(d1>=30&d1<42);
l1 = (1.5*d1)*lst+(0.8*d1)*kst.
l11 = 2*1000*T/(d1*sigmasm*.4*h1).

Fig. 2.34. Formation of the shaft first step model

Different variants of axial fixation are realized in the parametric

model (Fig. 2.34) by choosing a pulley hub design according to the
criterion lst/d1> 0.8 – elongated hub (Fig. 2.35, a), otherwise – shortened
(Fig. 2.35, b). In the Command window, a certain variant of axial fixation
is called up by forming the conditions for executing the command. When
building a parametric model of the transition section between two shaft
steps, one should take into account a number of relationships between the
diametrical dimensions of the steps and the parameters of the transition
sections.
The second and fourth shaft steps for radial ball bearings are
calculated based on the standard dimensions of the bearings. When
forming the parametric model of the second step, an algorithm is
proposed for correcting the obtained value of the step diameter d2 in order
57
to obtain a normal overall size. The calculation form (fig. 2.36) for the
formation of a parametric model for the second step of support on rolling
bearings is presented. In accordance with the proposed algorithm, the
diameter of the step d2 is determined, the size of which ends with 5 or 0
(with d above 20 mm).

a b

Fig. 2.35. Methods of pulley axial fixation: a – additional step with fixing nut
with slotted grooves; b – screw radial mount in the hub

Creation of a cylindrical step under Creating step under the chain of

the support with diameter d2 gears

58
 d22 = (d1+2*t)/5
b3 =
d21 = abs(floor(d22)-d22)
=8*(ls1>4&ls1<=8)+10*(ls1>8
d2 =
&ls1<=10)...
(floor(d22)*5)*(d21>=.01&d21<
t3 =
.5)+
=3.5*(d3>17&d3<24)+4*(d3>=
+(ceil(d22)*5)*(d21>=.5&d21<.
24&d3<30)…
99)
а б

Fig. 2.36. Formation of second and third steps models

In metal-cutting machines, splined joints of both movable and

stationary type are used, characterized by improved centering and
direction when moving along the shaft of various parts; reduced stress
crumpling on the faces of the slots and increased strength of the splined
shafts at dynamic and alternating stresses.
In both cases, the calculation is carried out on the crumpling of the
teeth side surfaces (slots). For normal sizes of spline joints used in
machine tool construction, the crumpling stress σcm depends on the
projection of the working surface of the tooth F (with outer diameter d3,
internal (d3–2∙t3), number of teeth z and working length of the teeth 1
mm) indicative dependencies [51, 56]:

Dd 12,5  T
F  0,8 ; см  .
2 z   D 2  d 2   l
 

The book proposes an algorithm for the formation of a splined

surface parametric model for straight-barred spline joint, which are most
prevalent in machine-tool construction. In fig. 2.36, b shows a fragment
of a spline joint and the design form for determining the parameters: slot
width b3 and slot height t3. These attributes are assigned the appropriate
names and set the necessary numerical and functional relationships.
Functional relationships can be described by arbitrary analytic functions.

59
Thus, the outer diameter d3 of a straight-barred spline joint of an average
series is determined by the following relationship:

d3=36*(d31≥33&d31<37)+42*(d31≥37&d31<43)+46*(d31≥43&d31<47)+5
2*(d31≥47&d31<53),

where the value of d31 = d2 + 3,2∙t depends on the fillet radius t of the
transition surface between the second and third steps.
In Figure 2.37 shows a fragment of a spline joint and Command
window in which the sequence of executed commands and their attributes
is recorded. These attributes are assigned the appropriate names and set
the necessary numerical and functional relationships. Functional
relationships can be described by arbitrary analytic functions.

Fig. 2.37. Fragment of the parametric model for the spline surface

As a result of performing all the above analytical and graphic

procedures, a parametric model of a stepped shaft was obtained
(Fig. 2.38).

60
 Fig. 2.38. Parametric model of a stepped shaft

On the basis of the parametric model created, the input shaft of the
speed box for the machine tool (Fig. 2.38) was designed.

A В
6,3
( )

0,04 0,04 B L
2x45 0
R*
2 chamfer 0,8

30js6
25n6

®30js6

B 25
0,8
0.8
37 0.01 B d-8x32f7x38a11x6f8 33
82 1,5х450
0.8

315

A В-В В
I
A-A ®38a11( -0,3) 0.03 B 1- Surface L to carburizing h 0,7...1,1 56...63 HRC
T0,04 2 - Demensions provide a tool
0.01 B 3 - Provide gap in the spline to 0,02 mm
6f8***
8H9

4 - Substitute steel 20 MnCr5G and G51200

5 - H14, h14, ±IT14/ 2
®25n6

2,5
f7
®32

R0,4**
3,2

4+0,2 I
0.8
0,5+0,3x45 0
in
1,75m
®29,4

Fig. 2.39. Input shaft drawing of machine tool main drive

The presence of two parametric models of the shaft and the pulley of
the belt drive allows you to effectively solve design problems of
mounting these parts and their axial fixation. As is known, with small
calculated diameters of the driven pulley dr2 ≤ 100 mm, a monolithic
pulley design is used. The preferred method of axial fixation is the use of
61
nuts with spline grooves. In this case, there is a need to add another shaft
with a thread (Fig. 2.40).

Fig. 2.40. Fragment of a parametric model "Shaft-monolithic pulley" node

For large diameters of pulleys dp2 ≤ 400 mm, a pulley of disc type is
used. With an elongated hub, axial fixation with a locking screw is most
rational. The developed parametric model of the shaft node provides for
the choice of such an option of axial fixation (Fig. 2.41).

Fig. 2.41. Sketch of the shaft-disk pulley node based on parametric model
62
 2.4. Creation of specialized databases in CAD APM WinMachine

Along with an increase in the volume of general-purpose reference

information (assortments of workpeace, materials, standard products),
specialized information flows (internal, informational data) is increased –
archives of results by various methods, ready-made parametric models,
characteristics of equipment are used in production. Also very important
moment is the quality of the information with which the work is
conducted. The new information concept implemented in APM software
products [23, 62] is aimed at organizing effective work with specialized
information obtained not only in the APM WinMachine environment, but
also in other environments (for example, MS Word, Excel, etc.). One of
the means focused on the development of this concept is the new APM
Base module, part of the APM WinMachine.
The APM Base Module provides the user with mechanisms for
implementing their own databases. The use of these mechanisms can
significantly expand the application area of the APM Base module. For
example, if necessary, the user can independently create his own database
(DB) with parametric models of one or equipment and tools and then use
it either to create drawings and other documentation, or as a source of
additional data used in the calculation modules. Based on the provided
databases, it is also possible to create a user archive where the most
frequently used models and data will be collected.
This monograph describes the procedures for developing specialized
information characteristic of the designing equipment process of the same
type – multi-purpose milling and drilling-boring machines. For this
purpose, a separate user database “Machine Tools” has been created in
the APM Base module, the structure of which is shown in fig. 2.42 and
which will be used to create a project drawing and graphic documentation
and for additional data used in the calculation modules [62].

63
 Fig. 2.42. User Database Structure “Multipurpose Machine Tools”

The main advantage of the proposed approach to creating a user

database is the use of parametric models obtained in the parametric
drawing and graphics module APM Graph as objects. This makes it
possible to add entire classes of data using a small set of models for a
wide range of projected objects. At the same time, an effective tool is the
concept of a group of models, when combined, their common summary
table of geometric parameters is formed (Fig. 2.43).

64
 Fig. 2.43. Summary table of parametric models "Pulleys"

The monograph proposes an algorithm for constructing parametric

models of V-belt and poly-V-belts for a wide range of machine tools.
Within the borders of a unified parametric model, a minimum set of input
data is formed (Fig. 2.44). They used in the calculation of derived data in
the form of expressions.
In the case when the syntax of expressions does not match when
combining several parametric models, the system issues a diagnostic
error message (Fig. 2.45). In this case, the magnitudes of the variation
ranges the drive power when selecting the section of the belt «A».

65
 Fig. 2.44. Variable window in pulley design tasks

Fig. 2.45. Diagnostic Error Message

The toolkit of the APM Base allows you to create and store
information not only about geometrical, but also about other parameters
in the form: a) tables of numerical data that can be used by the
66
corresponding calculation programs; b) figures that can exist
independently in the database structure or be part of a table; c) text files
in * .txt or * .rtf format. This database object is designed to store textual
explanations and technical documentation. In fig. 2.46 is a text file in *
.rtf format (characteristics of electric motor), which is designed to select
the bore diameter of the hub pulley for V-belt and poly-V-belt
transmissions.

Fig. 2.46 Text file database “Machine Tools”

The integration of two modules, APM Base and APM Graph, proved
effective. The designer has the ability to determine how this or that model
will look like before inserting it into the drawing (Fig. 2.47). In addition,
the user can analyze the entire size range and select the appropriate set of
parameters. Such a connection with the database is important for all
CAD/CAE/PDM APM WinMachine calculation modules – this is both a
set of information necessary for carrying out calculations and a library of
models, which as a result of the calculation will be drawn during the
67
execution of documentation. The user has the ability to access this data
and, if necessary, independently expand the capabilities of these modules.

a b
Fig. 2.47. Inserting parametric models into the APM Graph module:
a – choice of scale; b – select the insertion point

Along with enhanced graphic capabilities, the module for creating and
editing APM Base databases has been added to enable advanced database
search, for example, in the names of tree elements or in model comments.
Database security is guaranteed by the ability to set a password to protect
information and to solve the problem of user rights when installing a
database on a computer. The problems of uploading tables to XLS-format
and unloading of APM Graph – documents (*.agr) from the database in
DXF format have been solved.

68
 3. PARAMETRIC MODELING OF CUTTING TOOLS

3.1. Construction of parametric models of shaping cutters

Shaped prismatic and round cutters are

widely used in mass and large-scale production for
processing a complex profile of rotary parts or
prismatic parts. Ubiquitous use is associated with
a number of advantages of shaped cutters,
including high productivity (machine and
auxiliary time are significantly reduced); high
accuracy of the shape and size of the workpiece; ease of operation
(regrinding is carried out only on the front surface).
When developing designs of cutting tools consisting of working,
connecting and guiding parts, two fundamentally different approaches are
used:
1. Analog design, when used fairly well-developed and well-known
design, with the subsequent revision of them for specific conditions of
use.
2. Compilation design - synthesizing tools from common to them
elements with the best properties.
The second approach with the use of high-performance elements
allows you to create designs that have higher properties than known
analogues. However, the disadvantages of this method are the increased
complexity and laboriousness of the design, the need to perform all the
required calculations and the finalization of the design during the
production tests.

69
 Creating an optimal design tool is possible with the use of
progressive solutions, advanced methods of calculation and design. At the
same time, it is advisable to use standardized elements in any original
design, which not only accelerates the development, but also increases
the reliability of the tool.
Analysis and comparison of formulas for calculating profiles of
various types of shaped cutters showed that formulas sometimes coincide,
and in other cases they have much in common. Thus, the formulas for
calculating the heights of the profile of the outer prismatic and round
shaped cutters on the front face are the same. Therefore, it is possible to
develop common design forms for shaped cutters, which will form the
basis of the developed parametric models.
In most cases, when calculating profiles of shaped tools, it is usually
limited to finding the coordinates of the extreme and node points of the
profile, which determine the dimensions of the angular and arc values of
the tool. To the nodal points include such points at which one elementary
section of the profile details goes into another. In addition, the
characteristic points include the midpoint on the conical section and three
points for the curvilinear section, chosen at equal distances from each
other.
In the simplest cases, the calculation of the parameters of the straight
sections and the radii of the arc sections of the profile is not difficult.
However, if there are details of various combinations of direct and
conjugate arcs of circles, the calculation of these quantities on the tool is
difficult. In the case when the profile of the part is accurate, for example,
precise spherical or conical surfaces, processed by shaped tools; the
profile of the latter is given by the coordinates of points, which are
calculated by the formulas for the nodal points of the profile. When
profiling the cutter, the radii of the conjugate points of its profile are
found, which process the corresponding points on the part profile.
The calculation of prismatic and round shaped cutters includes two
stages:

70
 1. Determination of overall dimensions and geometry of the cutters
working surfaces. The overall dimensions of the shaped cutters are
selected from the tables [63], depending on the depth of the workpiece
profile tmax. (Fig. 3.1)

tmax
b

t max

+

a  b
Fig. 3.1. Workpiece profile depth: a – prismatic shaped cutters;
b – round shaped cutters

It should be noted that round shaped cutters (Fig. 3.1, a), as less rigid
in the method of fastening, are used for processing workpieces with
smaller profile depths than prismatic cutters (Fig. 3.1, b).
2. Calculation of the cutter profile heights in the plane of the front
faces (Fig. 3.2, upper diagrams). As is known, the profile of the shaped
cutter (for values of front γ and rear α angle that are not equal to zero)
does not coincide with the profile of the original workpiece, which leads
to the need to adjust the profile of the tool. In this case, the depth profile
of the cutter C1, C2 ... will always be less than the depth profile of the
part. The dimensions of the part profile measured along its axis are
exactly equal to the dimensions of the tool profile measured in the same
direction, only when the axis of the tool is parallel to the axis of the
workpiece.
To ensure the required height and shape of the profile, appropriate
corrective calculations of the tool profile are made.

71
 The purpose of corrective calculations for a prismatic cutter is to
calculate the distance from the rectilinear generatrix of the first node-
point to the rectilinear generators of the back surface of the cutter parallel
to it, drawn through the nodal points 2, 3, ... defining the sizes Р1, Р2, ...
for a prismatic cutter and finding the radial dimensions corresponding to
the nodal points of the round shaped cutter (Fig. 3.2).

A3 A5
A4
A2
A3
A1 C4
A2
A1 C3
C2
C2
С1
C1





a b




 P1
P2
P3
P1

P4
P2

P5

c d

Fig. 3.2. Shaped turning schemes: a – round profile depth in front surface;
b - prismatic profile depth in front surface; c - round profile depth in back
surface; prismatic profile depth in back surface

72
 The algorithm for calculating the profile of a prismatic shaped cutter
is shown in [64, 65], and its main parameters – on fig. 3.3.
It should be noted that with an accuracy class of axial and radial
dimensions within 4 ... 8 classes, the accuracy of the tool dimensions
should not be lower than 2 ... 3 classes. In turn, the dimensions of the
template and the counter-template are accepted by 1 ... 2 accuracy classes
higher than the accuracy of the dimensions of its profile.
When designing shaped cutters, a number of algorithms and
programs [66] are used, automating the process of developing new
designs. At the same time, the successful implementation of any
computer-aided design system is primarily associated with an increase in
productivity. It was the desire to create a mechanism to reduce the
development time of a new or modification of an existing design, which
led to the emergence of a parameterization mechanism in modern CAD
systems.
Parameterization mechanisms can significantly reduce the amount of
settlement procedures. With an accurate graphic image of the tool and
part in the cutting scheme, the correction calculation of the profile depth
Ti is realized graphically. At the same time, the accuracy of dimensioning
is set in the appropriate dialog box for specifying dimensions.
To implement the parametric modeling procedure, the computational
resources of the CAD APM WinMachine are used [20, 21]. In the
environment of the drawing and graphic editor APM Graph a set of
parametric models that provide the process of designing shaped cutters
are formed.
The sequence of creating a parametric model cutter includes the
following procedures:
1) Analysis of the initial data and their separation into source and
derivatives. The source data includes the diametrical dimensions of the
workpiece and the geometrical parameters of the shaped tool (front and
rear corners). Derivatives can be attributed to the size of the cutter base,
which is mounted at an angle to the workpiece.

73
 2) Entering input data in the “Variables” dialog box. For the source
data, only the value is specified, and for the derived data, also an
expression that is a function of the source and already declared derived
data.

Fig. 3.3. Diagram of the depth profile of the tool

3) Graphic assignment of a commands sequence in the “Commands”

window, providing for building a shaped tool model and its fragment. In
the list of parametric commands, their parameters specified in p. 2, or
auxiliary variables created in the process of building the model are
indicated.

74
 4) Analysis of the conformity of the model thus formed with the
required and, if necessary, correction of the model parameters, or
changing the method of constructing the entire model or its part.
5) Analysis of the construction correctness of the created model for
different values of the initial data.
In the dialog box "Variables" enter the following initial data for a
prismatic shaped cutter:
- radial dimensions of the workpiece – ri;
- geometrical parameters of the working part – front angle γ (g) and
rear angle α (a).
- overall dimensions of the cutter – b, e, h.
As derived data, the length of the cutter front surface n, the
analytical expression of which is given in the Variable window is
considered (Fig. 3.4).
For a round shaped cutter in the parameters window are entered:
- radial dimensions of the workpiece – ri;
- geometrical parameters of the working part – front angle γ (g) and
rear angle α (a);
The derived data are considered the length of the front surface of the
cutter n, the analytical expression of which is given in the Variables
window: n = (b+e)/cos(rad(γ + α)
- linear dimensions of the cutter – the gap on the front face k, the
maximum radial dimension on the front face bmax, etc;
- radial dimensions of the cutter – the outer radius of the cutter R, the
radius that coordinates the position of the mounting holes R1, the radius
of the mounting hole R2 and other dimensions.
Shown in Fig. 3.4 analytical expressions are made taking into
account the syntax of CAD APM WinMachine. Thus, the radius of the
mounting hole R2 is determined as a function of the cut depth t as
follows:
R2: = 2.5 * (t >= 6 & t <11) + 3 * (t > = 11 & t <= 14) + 4 *
* (t > 14 & t <= 25).

75
 Fig. 3.4. Initial and derived data in Variable windows

The graphical procedure for constructing a circuit for shaped turning

is carried out using an algorithm proposed in the environment of the
APM WinMachine and including the following sequence of actions:
1) setting the starting point of the model. As a starting point when
creating a shaped tool model, it is desirable to use a point with
coordinates {0; 0}. With this choice, the expressions describing certain
parameters of the objects are more compact;
2) parameterization of the command in the Command window. It is
advisable to parameterize each command immediately after its execution,
i.e. to assign an expression consisting of variables to its parameters. In
this case, it is possible to visually verify that the object was created
correctly, because if an error was made during its creation, it will
immediately become noticeable. If you create several objects at once, and
then proceed to the procedure of their parameterization, then it will be
much more difficult to find an error, which is due to the need to track all
the steps performed. An exception is the graphic procedure for sequential
construction of a segments chain for which the beginning of the next
segment coincides with the end of the previous one. In this case, an

76
additional binding to the control points of the entered segment is not
necessary;
3) verification of the correctness of the constructed model.
Verification is carried out in the Variable window by changing all
variables (within reasonable limits), while fixing how the created
parametric model works out these changes. If an error is found in the
process of model building, it is easy to notice and correct it by returning
to the list of parametric commands. It should be noted that all the
commands involved in model building are documented, therefore, when
an object is created incorrectly and then deleted, all commands related to
this process will nevertheless enter the command list. Thus, the model in
this case will turn out clearly not optimal;
4) setting the base point of the model. The position of the base point
determines the convenience of the subsequent embedding of the created
parametric model into the drawing. If the position of the base point is not
set, then by default its coordinates coincide with the coordinates of the
initial point {0; 0}, which is not always convenient. The position of the
base point is determined by the value of its coordinates (Fig. 3.5),
including the analytical expression, or the position of any model control
point (the switch is set to Attach to the point.

Fig. 3.5. Base point dialog box

77
 As a result of performing the above actions, a parametric model of
the designed object is created, after which it can be embedded in the
drawing using the Insert Block function.
Consider the graphical procedure for constructing a parametric
model of a round shaped tool. In Fig. 3.6 shows the operation of
constructing the outer diameter of the tool, and, consequently, the radius
of the most prominent point. Such an operation is formed by the
command Drawing an arc on the initial, central and final points. In this
case, it is possible to specify the coordinates of points using the Values
input field (including in the form of an analytical expression) or using the
Attach to control point option (as shown in Figure 3.6). The Command
window provides the ability to change the attributes of the image layer
and line type. The advantage of the drawing and graphic editor APM
Graph is the use of the Line Type Manager to speed up the process of
changing the line types.

Fig. 3.6. Graphic procedure construction of the cutter outer diameter

Similarly, a circular array of mounting holes is built. In this case, the

center point of the array is set by attaching to the corresponding control

78
point - the center of the shaped tool. In the command window (fig. 3.7) it
is possible to set the characteristics of the array - the number of objects (6
mounting holes) and the angle parameter of the array (the angle between
the holes).

Fig. 3.7. Graphic procedure for constructing a circular array

A parametric model of a prismatic shaped cutter is constructed in a

similar way. In Fig. 3.8 shows the graphic procedure Drawing a line
parallel to the existing one, which forms the projection of the fixing part
of the tool.
Prismatic shaped cutters are fixed by the forces of friction between
the surfaces of the tool shank, made in the form of a dovetail, and the
clamping part of the holder. At the same time, friction forces are created
by tightening bolts during deformation of the split part of the holder or
movement of the clamping bar. Structurally, the dimensions of the
mounting part are taken depending on the depth of the profile of the part.
In fig. 3.9 shows the graphical procedure for the formation of the
mounting part of a prismatic shaped tool in the form of a dovetail. The
correctness of the dimensions is checked with control rollers.

79
 Fig. 3.8. Graphic procedure for constructing a segment

Fig. 3.9. Graphic procedure for drawing a circle two tangential and center

As an example, the drawing and profile of a prismatic cutter,

obtained on the basis of a parametric model are presented (Fig. 3.10).

80
 Fig. 3.10. Fragment of drawing prismatic shaped cutter

Skillful and competent use of parametric modeling technology will

significantly reduce the time spent on the development, profiling and
editing of models for the cutting shaped tool.

3.2. Construction of parametric models of gear cutting tools

The milling cutter is a rotary workpiece, on the generatrix or end

surface of which (or on both at once) there are teeth. When rotating and
feeding at the same time, the teeth one after another enter into operation
and remove the chips.
According to the design of the teeth, there are mills with pointed
(sharp-pointed teeth) and relieving back teeth. The profile of the teeth is
distinguished: a) thread-cutting cutters; b) gear-cutting disk and finger
cutters; c) gear-cutting worm cutters; cutters for grooves of tools [67–69].
81
 Cutters with relieving back teeth are widely used in mechanical
engineering and are used mainly for parts with a shaped profile. Cutters
milled are divided into two groups - with unpolished and ground profiles.
The main advantage of a ground milling cutter is that it gives a
constant and identical profile in the process of shaping (taking into
account the regrinds). In practice, the Archimedean spiral is mainly used
as a relieved curve, which is caused by the simplicity of making cams for
relieving.
Most gear milling cutters are supplied with a ground profile, and
consequently, the number of teeth on these cutters is less than that of a
cutter with an unpolished profile. In this case, there is a danger of cutting-
in the grinding wheel of the adjacent tooth. In this case, the grinding does
not produce the entire width of the tooth, which means that the tooth gets
a stepped shape (thickening in the back of the tooth - the saddle). To
eliminate the increased in height and along the sides of the tooth,
additional relieved (double relieving back teeth) with an increased cam
decay parameter cutter is used.

3.2.1. Disk modular gear milling cutters

Disk modular gear milling cutters are special tools. In terms of

construction and design methods, they are similar to shaped cutters
with teeth, relieved in radial direction, with straight or submilling
sides of the chip grooves. Disk gear cutters are mainly used in
single- volume or low-volume production for rough and finish-cutting of spur
gears, rough cutting of helical gears teeth, rough and sometimes finish-cutting
of bevel wheels, gear racks, splined shafts by copying on universal milling
machines with using dividing head [70–72].
Since the disk gear-cutting modular cutter has a zero rake angle and
when cutting a cylindrical spur wheel works by copying, the profiling of
its cutting edges is reduced to determining the shape of the teeth cavities
for the workpiece.

82
 According to GOST 10996-64, the profile of the mill tooth consists
of the involute, non-involute and straight sections (Fig. 3.11). The type I
profile is intended for cutters No. 1-5 (z ≤ 34; rb > rf) and is formed by
the involute CDE section, the straight section CB and the circular arc AB
with radius R. The type II profile is intended for cutters No. 6-8 (z > 34;
rb <rf) and consists of an involute BDE and a segment of a straight line
OA conjugated along an arc of a circle AB.

Type I Type II

a b
Fig. 3.11. Construction of the profile for the disk modular gear milling cutters: a
– type I; b – type II

Institute VNII proposed a special table of x(S) and y(H) coordinate

values for any point of the cutter profile measured from the bottom of the
tooth root, coordinates xz – centers of curvature in the tooth root, values
of radii r, and also points B, C, D, E profiles (Fig. 3.12). The coordinates
S3, H3 – set the position of the involute point D, lying on the addendum
circle; S4, H4 – set the position of the involute last point and the
transition to the dimensions of the cutter width B.
The calculation of the coordinates for the cutter profile points (Fig.
3.12) is performed either in a tabular manner, or using the calculation
form presented in Table 3.1 [73]. The capabilities of modern integrated
CAD systems predetermine the expediency of transferring information
from a tabulated form into analytical expressions (calculation form),

83
which ensures higher accuracy of calculations with a significant reduction
in the time required for this.

Fig. 3.12. Main parameters of disk modular milling cutter profile

84
 Table 3.1
Dependences for disk modular milling cutter calculation
№
Designation Dependence
dependences
 2  tg S
1 δд д   
2z z mz
2 δb δb=δд -invα
rb
3 x cosαx =
ρx
4 x  x   b  inv x   b   x
5 x x   x sin  x
6 y y   x cos  x
7 S S  2x
8 t t=y-rf

An even more effective means of increasing designer productivity is

the use of a parametric modeling apparatus in the practice of research and
design of a gear-cutting tool. For a wide range of cutting tools, a
parametric model of the involute profile (Fig. 3.13, Fig. 3.14) was
constructed using analytical expression (Table 3.1).
In the Variables window, the following values are entered as the
initial data: modulus m and the number of teeth of the cut gear z; the
displacement coefficient x (pitch straight tool rack relative to the pitch
circle of the gear); pressure angle α, tooth thinning Δs for providing side
gaps in gear [73]; c* – the coefficient of radial clearance; ha* – head
height factor (GOST 13775-81); p0 – the number of the involute profile
points.

85
Fig. 3.13. Variable window in the involute construction problem

Fig. 3.14. Command window in the involute constructing problem

86
 The number of p0 points for the calculated profile is taken within the
range of p0 = 8 ... 25 depending on the required accuracy of the profile.
The difference Δp of the adjacent radii-vectors is a derivative and is
determined by the formula

Ra  Rf
p  ,
rb  1

where Ra and Rf are the radii of the pinion outer circle and the dedundum
circle;
rb – radius of the generating circle.
Derived data presented in the Variable window include:
- half of the tooth root angular width along the pitch circle δd;
- polar angle coordinating the position of an arbitrary x point of the
evolvent θх;
- pressure angle at an arbitrary point αх and others.
To calculate the derived data, use the calculation form from the
table. 3.1.
The algorithm for constructing a parametric model is similar to the
one that was considered when modeling shaped cutters. In the Command
window (Fig. 3.15), the syntax of the CAD APM WinMachine is used.
When profiling tools using the copying method, along with the
involute part, it is necessary to investigate the profile of the non-working
and non-involute part of the milling tool, which, in turn, depends on the
teeth number of the cut wheel z1, as well as the teeth number of the pair
wheel z2.
There is a method of finding the point K on the involute section of
the tooth profile, which is the boundary of the tooth profile active part
that is actually involved in the engagement [70]. The position of point K
is given by radius Rk. With further rotation of the wheel will come out of
mutual contact.
For large numbers of teeth, the radius of the wheel generating circle
rb will be less than the radius of the root Rf (Fig. 3.15) and the tooth
87
profile of the wheel AB from the addendum circle to the dedendum circle
is involute.

Fig. 3.15. Tooth profile with a ratio of rb> Rf

Consider the option when the radius of the generating circle rb is

either equal to the radius of the dedendum circle Rf, or exceeds it by a
small amount (Figure 3.16). In this case, the radius rb remains less than
the radius Rk of the lower point of the wheel active part.

K
C
B
Rk

Rf

rb

Fig. 3.16. The position of the generating circle relative to

active part of the profile
88
 In this case, the profile of the wheel tooth will be involute only over
the AC – from the addendum circle to the generating circle. The CB area
bounded by the dedendum circle with radius Rf will be non-involute.
When calculating the radius Rk, it is assumed that the cut wheel z1
can engage with the wheel z2, the number of teeth of which is unknown
and can be equal to infinity, which corresponds to the procedure for
calculating the disk gear cutters. In this case, the position of the point K
(Fig. 3.16) is determined by the formula

Rk   rд  m 2   m  tgд 2

This analytical dependence is used in the Variable window of the

parameterization procedure when specifying the derived parameters of
the active involute part boundary (Fig. 3.15).
Profiling the non-working part of the profile is as follows [70]. On
the involute constructed with the help of the calculation form (Table 3.1)
on the ab segment, the position of the lower point K of the profile active
part is determined by the radius Rk (Fig. 3.17).
The point of K is attached to the area of elongated epicycloid (when
two gears are engaged) or an extended involute (when the wheel is rolling
on the rack). The construction of these curves can be performed
graphically on an enlarged scale (Fig. 3.18).
The extended epicycloid as well as the extended involute is the
upper limit beyond which the non-working part of the profile should not
go. At the same time, the non-working part can be located below this
boundary, in terms of the gears engagement, in any way.
The graphic procedure for constructing a tooth profile is as follows.
After drawing a root circle with radius Rf and a tangent to it are formed,
the connection by an arc of the circle Ke is an involute at point K with the
radius bottom of the root Rf. For a smooth conjugation of the arc and
involute, the center of the arc O must lie on the normal to the involute NK
(which is tangent to the generating circle of radius rb). The position of NK

89
is determined by the half of the central angle δ0 and the pressure angle αk.
The pressure angle is determined by the ratio
r
cos  k  b .
Rk

Fig. 3.17. The scheme of building the non-working part

90
 Fig. 3.18. Construction of elongated epicycloid

The conjugation arc of Ke should pass below the elongated

epicycloid. For the case of designing a disk modular cutter, the profile of
a tooth with a conjugation arc is shown in Fig. 3.19.

Fig. 3.19. Tool profile design

91
 It is also necessary to consider the correct location of the center of
the arc Ke, which for the right side of the profile should be on the right
side of the trough symmetry axis or on the axis itself. Otherwise, the
conjugation arcs for the right and left sides of the profile will not
smoothly conjugation with each other and intersect on the symmetry axis.
In this case, the radius of the arc pairing Ke is advisable to take the
maximum, which is associated with an increase in the resistance of the
milling cutters.
Thus, for the designed disk modular cutter, the tool profile will be
delineated by the involute bK and the arc of the circle Ke. In this case,
there is no other section – tangent to the dedendum circle, which indicates
the best option for the criterion of resistance in the absence of cutting the
root for the cut wheel.
On the basis of the proposed parametric models of the involute
profile and the transition curve, an exact tooth profile is constructed for
tool profiling, shown in Fig. 3.20, and the design of a disk modular
milling cutter (Fig. 3.21) was developed.

16,7596
15,615
13,995
12,98
11,841
10,733
9,733
11,778
11,119
10,148
9,472
8,698
7,894
7,106
6,306
4,284

R1
3,058

4,332
4,805

5,645
6,676
7,878
8,769

Fig. 3.20. Profile cutter in the plane of the front face

92
 Fig. 3.21. The design of the modular disk cutters

3.2.2. Worm Gear Cutters

Worm milling cutters for machining

cylindrical gears are used for roughing,
semi-finishing and finishing cutting spur and
helical gear modules 0.1 ... 40 mm [63].
According to GOST 9324-80 E, depending on
the purpose and size, worm milling cutters
are made of accuracy classes AAA, AA, A,
B, C, D and are recommended for cutting
gears of 5–6, 7, 8, 9 and 11th accuracy
respectively. The labor intensity of gear milling for wheels m = 1 ... 20
mm is 15 ... 10% less than the labor intensity of gear shaping. In addition,
the same cutter can be cut into both spur and helical gears. The shape of
the teeth profile for the milling cutters depends on the shape of the teeth
profile of the wheels being cut - involute, cycloidal, etc., which, when
designing, must be defined by the profile of the rack original contour.
Worm gear milling cutters are divided into mounted and tail, right and
left, single and multiple flute cutters, one-piece, composite and
interlocking side mill. Worm milling cutters operate on special gear-
milling machines of models 5K30I, 5K320, 5K32, 5342, 5445, 5364, etc.
93
 During gear cutting, the profile and dimensions of the wheels teeth
are determined by the original contour in accordance with GOST 13755-
81 when they run in a wheel. The run-in can be carried out at different
positions of the initial production contour relative to the wheel. In the
process of rolling, the sides of the teeth for the rack original contour form
the involute contour of the wheel teeth. The dimensions of the initial
contour determine the dimensions of the wheel teeth: the thickness of the
teeth along the arc Sn; the height of the pitch head ha; addendum diameter
dа and dedendum diameter df, etc.
To ensure smooth conjugation of the teeth in the process of
engagement, an initial contour with a modified tooth head profile is used.
In the process of cutting teeth, a shearing of the teeth side profile at the
wheel addendum circle is formed. In GOST 13755-81, the values of the
modification parameters are regulated – height factor h *g (not more than
0,45) and depth factor Δ*.
As it is known, the producing contour milling cutter differs from the
initial contour in dimensions: head height ha (by the size of the radial
clearance in the engagement); Sno tooth thickness (increased by the
amount of required lateral clearance) and the location of the flank (af and
hfo) on the tooth root. In Figure 1 shows the parametric models of the
original contour and the producing contour with the flanking of the tooth
root.
For a more productive construction of the initial contours of the gear
and gear cutting tool, it is advisable to use a parameterization facility in
the environment of the APM GRAPH module. In this module, parametric
models of initial contours are built (Fig. 3.22 and Fig. 3.23). With a
minimum number of initial parameters of the cut gear (window of
variables, Fig. 3.22), all derived data in the command window (Fig. 3.23)
are determined.

94
 Fig. 3.22. Variables window in the task of building the original contour

Fig. 3.23. Command window in the task of building the original contour

To determine the length of the side surface of the tooth root as a

derived parameter, the dependency is used, formed in accordance with
the syntax of the APM GRAPH module:

hf * m/cos (rad (20)).

On the basis of the obtained parametric models, the profile of the

cutters teeth is built (Fig. 3.24)

95
 Pno Pno
Sno
20 о Sno
rao
hao

rao

hfo hao
ho

ho
rfo
rfo

m
20 о af

a b
Fig. 3.24. Parameterized contours: a – source
b – producing with modification

When designing a tool running on the form generating method, three

conditions of workability [74] are taken into account:
1. Ensuring the simultaneous touch or at different points in time of
the workpiece profile and tool profile. At the moment of contact, the
general normal to the conjugate profiles must pass through the pole of
engagement.
2. The intersection of the initial lines (part circle, straight tool)
normal to the part profile. As is known, the normal to the involute tooth
profile touch the generating circle.
3. Lack of adjacent areas intersection of the instrumental surface.
For processing complex shaped surfaces according to the form
generating method, a widely used relieving back too, which gives a
constant and identical profile during the entire period of its operation.
The relieving back surface of the cutter is most often outlined by the
Archimedean spiral due to the simplification of manufacturing
technology (ease of cams manufacture for relieving backing and the use
of a wide range of machines with consistent rotational and rectilinear
motions). In addition, each relieving backing curve provides sufficient
rear corners for all points of the cutting edges (taking into account
possible regrinding’s). In the APM Graph module, parametric models of
one- and double-relieving back surfaces of cutters defined by an
Archimedean spiral are constructed (the increment value of the vector

96
radius is directly proportional to the polar angle increment) [75]. In Fig.
3.25 shows the window of parametric commands in the task of
constructing a one-relieving back tooth and a parameterized contour of a
doubly- relieving back tooth of the mill.
Having constructed a parameterized contour of the relieving back
tooth in the graphics editor of the APM Graph, a sketch of the gear
cutting tool is formed using the “circular array” command. This allows
you to extend the parameterization tools to a wide range of gear cutting
tools, while significantly increasing the productivity of the designer
toolmaker.

a b
Fig. 3.25. Parametric model relieving back tooth: a – Command window;
b – relieving back tooth contour

The organization of computer technology for creating complex

engineering products is based on the formation of a complete electronic
product layout, since it is the creation of three-dimensional electronic
models that are adequate to the actually designed product, which opens
up opportunities for creating better products (especially complex, high-
tech products) and in a shorter time. Three-dimensional modeling is
necessary as a reliable, flexible and easy-to-use tool for optimizing the
design process of a complex profile tool and, finally, combining
CAD/CAM tasks in one environment [76-79].

97
 In the environment of the APM Studio module, a three-dimensional
model of a worm gear-cutting cutter (Fig. 3.26, a) was constructed and a
finite element mesh was generated with a certain partitioning step (Fig.
3.26, b). In the finite element analysis mode, the fastenings are set
(displacements along the X, Y, Z axes are fixed) and forces are applied
(Fig. 3.26, b).

a b
Fig. 3.26. Solid model cutter: a – cross-section; b – finite element presentation

Within the environment of the APM Studio module, a static

calculation of the structure was carried out, the results of which can be
visualized in graphic and numerical form (Fig. 3.27).

Fig. 3.27. Calculation results: a – stress fields; b – displacement fields

98
 CONCLUSION

The introduction of parameterization mechanisms in the traditional

design process makes the work of the designer as efficient as possible. At
the same time, the improvement of the project decision making process
takes place in the following directions.
1. The use of the developed parameterization mechanism
significantly increases the efficiency of the metal-cutting machine tools
study at various steps of design through the use of parametric models.
This approach opens up the possibility of transition to solving complex
project problems of a multi-criteria nature.
2. The introduction of the parameterization mechanism contributes
to the formulation and solution of designing machine tools problems and
their components in the multivariate mode. This significantly increases
the level of design decisions made both at the design stage of individual
parts, and their assembly.
3. A significant effect in increasing designer productivity is the
ability to quickly solve the problems of the design process with recurrent
information flows (reengineering), when a set of parametric models
implements an effective approximation to the best design option.
4. The correctness of the results obtained is due to the use of a wide
regulatory base (GOST, departmental normal) in the process of
developing parametric models.
5. In the process of parametric modeling, it is possible to introduce
into consideration a wide range of parts of a certain class, which reduces
the set of necessary models for the design tasks of machine tools and
makes more visible the size of the CAD databases of machines.
Based on the proposed methods and parametrization facility, the
following results were achieved.
99
 1. Developed parametric models of transverse configurations
(layout) of machine tools representative of the turning and milling
groups. With the help of these models, built in accordance with the APM
WinMachine syntax, it is possible to synthesize optimal transverse
layouts both by the criterion of maximum rigidity and the criterion of the
minimum load on the front spindle bearing.
2. Using the proposed algorithms for determining the spatial position
of nodes in the main motion drive housing, it is possible to determine the
distances from the external surfaces of gear wheels to the side walls and
the bottom of the housing, as well as to estimate the degree of their
approximation to the limit values. This will provide recommendations for
reducing the size of the machine drives. On the other hand, the presence
of a friendly interface in the APM Graph module promptly provides
information to the designer about the unacceptable values of the gaps for
rotating parts and the gearbox housing.
3. Based on the developed parametric layout models,
recommendations are made for the improvement of housing parts. So, in
the design of the main drive housing for the turning multi-purpose
machine MS-03, it is proposed to change the configuration of the housing
bottom in order to ensure optimal spindle stiffness. In the machine
drilling, milling and boring group model SF68VF4 proposed to perform
the joint of the housing side wall to achieve the optimal design of the
spindle unit.
4. Using the integrative capabilities of CAD/CAE/PDM "APM
WinMachine" allows the designer to quickly estimate the magnitude of
the discrepancy between the optimal and traditional factory solutions. So,
with the help of the shaft design module APM Shaft in this work, the
difference in the values spindle stiffness values for the factory and
optimum variants is determined. In this case, the designer receives the
calculation form for the main indicators of strength and rigidity.
5. Parametric models of pulleys for V-belt and poly-V-belt
transmission have been developed as a means of productive design and
modeling in modern CAD systems.

100
 6. With the help of parametric modeling, pulley designs are selected
that meet the criteria for minimizing dimensions and maximizing
reliability. In the developed modeling program, a compromise solution is
effectively chosen at the stage of determining the estimated pulley
diameter. The constructed models of pulleys make it possible to
significantly reduce the time needed for designing working drawings and
forming design documentation.
7. For a wide range of stepped shafts of the main movement drive of
machine tools, a parametric model has been developed in the APM Graph
module included in the CAD/CAE/PDM APM WinMachine. On the basis
of the constructed parametric model, the design process of stepped shafts
with a significantly higher productivity is implemented.
8. A parametric model of the shaft node has been formed, with the
help of which problems of the pulley axial fixation are solved. On the
example of two versions of pulley structures – monolithic and disk, one
of the ways of fastening is selected – a) using a nut with a spline groove
for the case of a monolithic pulley; b) using a locking screw for a disc
pulley design with an elongated hub.
9. The database “Machine Tools” as a unified environment in which
standards, normal, scientific and practical information that summarizes
knowledge and practical experience in the field of machine tool
construction was developed. This database is an effective shell for
designing user databases in machine-tool construction, which leads to a
significant increase in designer productivity and an increase in the
technical level of the design decision making. The effectiveness of the
database is due to the ability to present information of various types: a)
tables of numerical data; b) drawings; c) text files in *.txt or *.rtf format;
d) tables in XLS- format; e) APM Graph-documents (*.agr); e)
documents in DXF- format. A distinctive feature is the possibility of
using graphical parameterized models in the database.
10. Parametric models of shaped prismatic and round cutters are
developed, including various variants of the working profile. These
models are based on a single calculation formulary having an invariant

101
part of the profile depths calculation and a variable part that is
customizable for the features of the manufactured product. An algorithm
for modeling the mounting part of a prismatic shaped dovetail cutter is
proposed.
11. Parametric models of gear cutting tools are created. For modular
disk milling cutters, the profile of the milling cutter tooth consisting of
the involute, non-invariable sections and straight was constructed. This
allows to effectively designing both a type I profile for cutters No. 1-5
and a type II profile for cutters No. 6-8. In the parametric model there are
various options for the ratio of the generating circle and dedendum circle
dimensions for the disk modular milling cutter are considered.
12. Two parametric models of initial contours of gear and tool racks,
defining a profile and the sizes of teeth’s of the cut wheels are offered.
The feature of profiling a modified contour in the form of a flank is
considered. This option is used for undercutting the pinion tooth heads of
transmission boxes for machine tools.
13. In the APM Graph module, parametric models of single and
double relieving surfaces of cutters, outlined by an Archimedean spiral,
are constructed. It provides a significant increase in the productivity of
designers, both in design and in the simulation of gear cutting tools. At
the same time, the design process becomes a very efficient procedure
using the means of finite element analysis and solid modeling.

102
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 CONTENT

INTRODUCTION ................................................................................... 3
1. AUTOMATED DESIGN PROCESS AND
PARAMETRIZATION .......................................................................... 6
2. PARAMETRIC MODELING OF METAL-CUTTING
MACHINE TOOLS .............................................................................. 19
2.1. Build optimal layouts ................................................................... 19
2.1.1. Transverse lathe layout ......................................................... 23
2.1.2. Transverse layout of drilling and milling-boring
machine tools.................................................................................. 29
2.2. Construction of parametric models of belt drives........................ 36
2.2.1. V-belt transmission............................................................... 36
2.2.2. Poly-V-belt transmission ...................................................... 43
2.2.3. Toothed belt transmission..................................................... 47
2.3. Parametric simulation of shafts in CAD
APM WinMachine............................................................................... 54
2.4. Creation of specialized databases in CAD APM WinMachine .... 63
3. PARAMETRIC MODELING OF CUTTING TOOLS................. 69
3.1. Construction of parametric models of shaping cutters ................ 69
3.2. Construction of parametric models of gear cutting tools ............ 81
3.2.1. Disk modular gear milling cutters ........................................ 82
3.2.2. Worm Gear Cutters .............................................................. 93
CONCLUSION...................................................................................... 99
REFERENCES .................................................................................... 103

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