Digi-Shape - digital simulation & optimization software for gear shaping

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The objective of this project is to develop the next-generation of a proprietary software called Digi-Shape which has been developed at the University of Waterloo for virtual gear shaping. Gear shaping is a versatile and prominent machining method for manufacturing cylindrical gears. It is a highly complex and expensive process that requires highly trained engineers and technicians to run competently. Digi-Shape is capable of simulating the gear shaping operation and predicting the final quality of the machined part. It can be used to virtually optimize gear shaping processes to achieve higher productivity, and to minimize wasted resources in physical trial and error based process design that would otherwise be needed. In case studies performed at a local gear manufacturer, Digi-Shape was used to yield a significant 20-30% productivity improvement above current industry standards. This I2I project aims to develop and implement new features into Digi-Shape, in order to fortify its commercial value and its usability so that it can be easily and comfortably adopted by industry. Three features are outlined in this proposal that have been identified through collaborative discussions with industry. The first feature is collision detection of the cutting tool, which is an essential safety requirement to prevent damage to the cutter and machine. The second is automatic optimization of the process parameters, such that less-experienced personnel in industry can use the software to easily design gear shaping processes which yield maximum productivity and adequate quality. Finally, the third feature is refinement of the gear quality prediction algorithms to include factors which are currently not being simulated within Digi-Shape. Successful development of these features will greatly improve Digi-Shape's commercial value and increase industry's confidence in using this product.