Case Study:

Mechatronic System Simulation

Prof. Dr.-Ing. Stefan Scherbarth
Production and Manufacturing Technology

innovativ & lebendig – Bildungsregion DonauWald

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0. Case Study: Mechatronic System Simulation

Opening
0.1. Personal introduction
0.2. Structure of case study Mechatronic System Simulation
0.3. Teaching materials
0.4. Bibliography

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e 2

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0.1 Personal Introduction

● Dr.-Ing. Stefan Scherbarth ([email protected])
• Study of mechanical and production engineering, TU Hamburg-Harburg
• Scientific assistant at the Institute of Manufacturing Engineering I,
TU Hamburg-Harburg, Prof. Christian Nedeß
• Head of the Machining Technology Group at the Institute of Manufacturing
Engineering I
• Promotion: The influence of the geometry of the cutting wedge on the
(PhD.) machining behaviour when milling steel materials with
coated tungsten carbide.
• SANDVIK Tooling Germany GmbH
● Application Engineers for Rotating Tools - Grades & Geometries
● Specialist for cutting material development (GDS)
● Group Manager Cutting Material Technology
● Manager Application Center Stuttgart
● Global Application Manager 5-Axis Gearmilling
• From WS2014 Professor at the TH-Deggendorf
production and manufacturing technology

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0.2. Structure of Case Study: Mechatronic System Simulation

● Student workload:
ECTS = 6 => 6 x 30h = 180h student workload
180h / 14 semester weeks = 12,9h per semester week
11/2 working days!
● Group work: 5 to 6 students per group:
Group working time approx. 1000h
● Conclusion:
The result of the group work should be on professional level!
● Task - Goal:
Build a flexible simulation on gear tooth pointing on 5-axis
machine centers in “pure” MATLAB including the necessary
calculations for generating the CNC-file.
(pure: without help of tool-boxes)

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Rules Case Study: Case Study Mechatronic System Simulation

● All 4 tasks packages of the case study has to perform

inside the deadline to pass the exam!
You failed the examination if one task is not performed
independent of the performance in the other areas.
● There is no filing extension with the exception of illness.
● In case of illness you have to submit the documents you have until your
illness to the ilearn platform until the deadline and inform about your
illness. But you can perform the task later with updated documents.

● Hint: Start as early as possible working on a task!

You will need more time then you have planed and
you must keep the deadline.
And however the work must be done!
So keep on working!

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Rules Case Study: Mechatronic System Simulation

● All groups has the same task,

anyhow all groups must work independently from each other!
● If two or more groups has the same or similar results (MATLAB coding,
slides, animations etc.) it is a attempt to defraud and the groups are not
clearing the case study.
● The use of any external material is prohibited,
if external sources are used the group is not clearing the case study.
● At the end of the semester all groups present their simulation package,
at the Deggendorf campus. If traveling is restricted due to COVID-19 the
presentation is online. The groups will get a new workpiece for the
simulation.
● All group members get the same grade.
● You can build the working groups yourself.

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Task description

● Build a flexible simulation on gear tooth pointing on 5-axis machine

centers in “pure” MATLAB including the necessary calculations for
generating the CNC-file.
● flexible: The input for work piece, cutting tool, clamping table,
headstock geometry is parametric.
● simulation: Optical simulation – animation of the cutting process,
Simulation of the difference between ideal and
machined geometry.
● “pure” MATLAB: without help of tool-boxes
● necessary calculations for generating the CNC-file:
The customer / user of the simulation package must be able to write a
CNC-file depending on the output of the simulation.

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Task description: Gear Tooth Pointing

● Build a flexible simulation on gear tooth pointing on 5-axis machine

centers in “pure” MATLAB including the necessary calculations for
generating the CNC-file.
● gear tooth pointing: Chamfering of the top of a gear tooth in a
continuous milling process with rotating workpiece and tool.

source: www.amtechinternational.com/portfolio/pinion-ring-gear-supplier/ source: www.amtechinternational.com/portfolio/pinion-ring-gear-supplier/

fetch-date: 2020-10-11 fetch-date: 2020-10-11

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Task description: Gear Tooth Pointing

● gear tooth pointing: Chamfering of the top of a gear tooth in a

continuous milling process with rotating workpiece and tool.

source: www.mendritzki.de/unsere-gruppe/gesellschaften/finova/#Anspitzen-Abdachen source: www.mendritzki.de/unsere-gruppe/gesellschaften/finova/#Anspitzen-Abdachen

fetch-date: 2020-10-11 fetch-date: 2020-10-11

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Task description: Gear Tooth Pointing

● gear tooth pointing: Chamfering of the top of a gear tooth in a

continuous milling process with rotating workpiece and tool.

source: www.mendritzki.de/unsere-gruppe/gesellschaften/finova/#Anspitzen-Abdachen source: www.mendritzki.de/unsere-gruppe/gesellschaften/finova/#Anspitzen-Abdachen

fetch-date: 2020-10-11 fetch-date: 2020-10-11

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Task description: Gear Tooth Pointing

● gear tooth pointing: Chamfering of the top of a gear tooth in a

continuous milling process with rotating workpiece and tool.

source: www.kristen-goermann.de/65/ source: www.kristen-goermann.de/65/

fetch-date: 2020-10-11 fetch-date: 2020-10-11

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Task description: Gear Tooth Pointing

youtube: „Gear Pointing Animation – GMTA“, https://www.youtube.com/watch?v=seePhM7jhh4

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e
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Task description: Gear Tooth Pointing

youtube: „CNC GEAR POINTING WITH SYNCRO SPINDLE“, https://www.youtube.com/watch?v=-ezotHAfoBw

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e
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Task description: 5-Axis Machine Centers

● Build a flexible simulation on gear tooth pointing on 5-axis machine

centers in “pure” MATLAB including the necessary calculations for
generating the CNC-file.
● 5-axis machine centers: 5-axis milling machine or turn-milling center.

source: https://www.starrag.com/de-de/machine/heckert-x-serie/197/
fetch-date: 2020-10-11

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Workpiece example: Gear Tooth Pointing

flat roof
geometry

flat roof geometry

You can focus on

external spur gears
with flat roof geometry!
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Expectations
● Don‘t ask me what is expected!
● Ask yourself what a customer will expect form a professional
simulation and calculation software for gear tooth pointing
on 5-axis machine centers!

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Overall task

Build a flexible simulation

on gear tooth pointing
on 5-axis machine centers
in “pure” MATLAB
including the necessary calculations for
generating the CNC-file.

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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October tasks package – deadline 31.10.2020 23:59

● Specification of demands
● Write a specification of demands, a list of the software feature or what your
gear tooth pointing simulation package will deliver to the customer according to
the overall task.
● Headline plus a short description:
e.g. Graphical simulation: The simulation software show the toolpath, tool and
workpiece in motion, including the possibility for zooming and changing of
camera position.
● Format: pdf-file

● Customer Presentation:
● Make a 15 min customer presentation about the features of your simulation
software with the goal that the customer is ordering the software package from
your team.
● Format: Video presentation in mp4 format.
● Delivery via nextcloud

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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November task – deadline 30.11.2020 23:59

● Components for simulation

● The components or parts for the simulation are ready and can be shown in a
graphical window (‘plot’).
● Components: Workpiece, clamping table, spindle headstock, tool, inserts
● The components design is parametrical, by the input of the key figures the
components are generated. E.g. insert: corner radius, corner angle, clearance
angle, axial-, radial-rake angle inserts thickness, edge length
● HINT: A simplification of the components is allowed as long as the function of
the simulation is not affected! E.g. Workpiece tooth profile: the foot rounding
and also the tooth back taper can be neglected.
● Format: Animated gif file and MATLAB coding (script, functions)

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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December task – deadline 22.12.2020 23:59

● Graphical motion simulation

● Demonstration of the graphical simulation of the gear tooth pointing
● Two modes: a.) Tool and workpiece are rotating
b.) All motion is transferred to the tool,
the tool rotates in the spindle and moves around the workpiece
● Showing the generating surface in the simulation (machining surface).
The face that is defined by the main cutting edge and the tool/workpiece rotation
● Format: Animated gif file and MATLAB coding (script, functions)

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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January tasks package – deadline 31.01.2021 23:59

● Calculation of the optimal tool position

● The optimal tool position is calculated so that the mismatch between the given
flat roof geometry and the machined surface is minimal.
● Calculation of the max. mismatch between the given flat roof geometry and the
machined surface
● Graphical output of the mismatch between the given flat roof geometry and the
machined surface
● Format: example calculation, as animated gif file and MATLAB script, functions

● Customer presentation of the software package

● All groups present their simulation package at the Deggendorf campus. If
traveling is restricted due to COVID-19 the presentation is online. The groups will
get a new workpiece/tooling for the simulation.
● Format: live presentation and MATLAB script, functions

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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0.3. Teaching Materials

● The teaching materials are provided via the moodle platform,

Fakultät Angewandte Naturwissenschaften & Wirtingenieurwesen/
Master Mechatronische und cyber-physische Systeme …/
MCS-1: Case Study Mechatronic System Simulation (WS2020/21)
The access password will be announced during the lecture.
Password: mmd-ws2021-1

● The teaching materials are used for personal lesson preparation and follow-up,
and may not be passed on to third parties.

● The teaching materials are supplemented by the THD library's range of books
and ebooks on the subject.

● The teaching materials serve to supplement the lecture and cannot

replace active participation in the lecture.

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e 28

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Matlab Introduction

● Essential MATLAB for Engineers and Scientists

Brian Hahn and Daniel Valentine e-book
ebook THD
● Beginning MATLAB and Simulink: From Novice to Professional
Sulaymon Eshkabilov
e-book
ebook THD
● Advanced Engineering Mathematics with MATLAB
Dean G. Duffy
e-book
ebook THD
● INTRODUCTION TO MATLAB FORENGINEERING STUDENTS
David Houcque Northwestern University
https://www.mccormick.northwestern.edu/documents/students/undergraduate/introduction-to-matlab.pdf

● MATLAB - The Language of Technical Computing

https://www.mathworks.com/help/matlab/index.html

● A brief introduction to MATLAB

M. Gerritsen, Stanford Univ.
https://web.stanford.edu/class/cme001/handouts/matlab.pdf

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Robotics Introduction

● Introduction to Robotics: Pearson New International Edition

John J. Craig e-book
ebook THD
● Introduction to Robotics : Analysis, Control, Applications
Saeed B. Niku
e-book
ebook THD
● Springer Handbook of Robotics
Bruno Siciliano and Oussama Khatib
e-book
ebook THD
● A Mathematical Introduction to. Robotic Manipulation.
Richard M. Murray. California Institute of Technology.
Zexiang Li. Hong Kong University of Science and and Technology
S. Shankar Sastry, University of California, Berkeley
https://www.in.tum.de/fileadmin/w00bws/i23/murray-li-sastry-94-complete.pdf

● Robot Dynamics Lecture Notes

Robotic Systems Lab, ETH Zurich
https://ethz.ch/content/dam/ethz/special-interest/mavt/robotics-n-intelligent-systems/rsl-
dam/documents/RobotDynamics2017/RD_HS2017script.pdf

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e

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Gear Basics

● Why gear tooth pointing is necessary? – How the synchronizing works!

youtube: “Manual Transmission, How it works ?”
https://www.youtube.com/watch?v=wCu9W9xNwtI

● Gear Knowledge:
https://khkgears.net/new/gear_knowledge/

● Geometry of involute gears:

https://www.tec-science.com/mechanical-power-transmission/involute-gear/geometry-of-
involute-gears

● Involute Gear Profile:

https://khkgears.net/new/gear_knowledge/gear_technical_reference/involute_gear_profile.ht
ml

● The Synchronization – Präwema DVS Group

http://praewema.dvs-gruppe.com/uploads/tx_xpctypedownloadssimple/PRAEWEMA-
Antriebstechnik-Synchronizer-DE-EN.pdf

Prof. Dr.-Ing. Stefan Scherbarth w w w. t h - d e g . d e