Designing and manufacturing of aeronautic bevel gearboxes is a complicated and time-consuming process. This is due to the high quality requirements to the aviation industry products and the complex kinematic of the machining process. So far, in practice, this process has required a series of research and prototypes testing. The development, has been made in the field of Computer Aided Design systems, allows increasing use in design process and carry out the necessary research in the CAD environment. This approach simplifies and accelerates the aeronautic bevel gearboxes design process. The study presents process of gears solid models generating and carrying out simulate of cooperation bevel gearbox in the CAD environment. Solid models has been prepared by the solid machining simulation, while the performed analyzes are used to determine temporary tooth bearings, summary tooth bearing and motion graphs.

Summary Designing and manufacturing of aeronautic bevel gearbox is a complicated and time-consuming process due to complex kinematics of the machining process and numbers of manufacturing methods. Algorithms used in manufacture process are usually provided by machine manufacturers. Using other and commonly available calculation algorithms requires a lot of studies to verify whether the proposed gearbox works correctly. In order to reduce the manufacturing costs of prototypes, it is possible to use Rapid Prototyping methods. Using coordinate optical measurements enables to determine the accuracy of prototypes manufactured by selected methods using and introduce such changes in the model to get the best accuracy of mapping models. Increasing the accuracy of the models enables to verify the correctness of assumptions made in the initial stage of product designing. This approach reduces significantly both prototyping time and manufacturing costs. The article presents the model ling and manufacturing process of aeronautic bevel gear taking into consideration the accuracy of selected Rapid Prototyping methods. The gear modeling is based on machining simulation method conducted in Autodesk Inventor software. The measurement results are shown in displacement maps obtained with an optical scanner Atos II Triple Scan and universal GOM Inspect Professional software, which determines the prototype accuracy in relation to 3D-CAD models.

Manufacture of aircraft gearbox elements requires control of gear geometric parameters at different stages of technological process. Acceleration and automation of measurement process can affect the duration of the finished item production. In case of measurement of gear wheels using modern technologies based on numerical machines, measurement process is based on processing of numerical data obtained by measurement using coordinate measuring machines. The goal of this paper is to present the opportunity to automate the measurement process of bevel gears, using coordinated optical scanner ATOS by GOM, equipped with a turntable. Using coordinate measuring technique, you can specify a set of methods and procedures for the designation of the complex dimensions of physical objects and transform them into a computer program space of coordinate measuring devices. The topics included in the article are intended to show the capabilities of the device used to improve the measurement process and shorten its time, and hence, lower its costs. Another thing described in the paper is the impact of measurement performance in automatic mode on the quality of performance - the numerical image of scanned surface, from the standpoint of accuracy and number of collected data points in the shortest time. The article includes an analysis of conditions related to the measurement works, such as the process of preparing the model and measurement equipment and data processing capacity. The result of the work will be presented methodology for automated scanning measurements of bevel Sears.

The paper presents the results of studies on the possibility of replacing the special powder used for the manufacture of molds using the ZCast 3DP technology with the universal ZP131 powder. The ZCast technology allows the direct generation of the molds using the three-dimensional printing process. The type of powder used in the process is designated as ZCast501. That enables printing the molds which can resist the temperature of an alloy poured into as high as 1100 °C. Preparing the equipment to print molds with 3DP-ZCast technology requires removing formerly used powder, cleaning and refilling the apparatus with ZCast501 powder. In case, when the 3DP equipment is used as a universal Rapid Prototyping device for building all purpose models, frequent powder refilling is time-consuming and costly. For this reason, research was conducted on the possibility of application of universal ZP131 powder as an alternative material for ZCast technology. The objective of the study was to determine the thermal resistance of such molds for aluminum alloy casting. The results showed that there is a possibility of using ZP131 powder as a material for casting molds.

article presents the researches of geometrical precision of silicone casting form manufactured with using of the process of rapid prototyping of the tools (RT - Rapid Tooling). The testing casting form is applied to the production of prototypes of sprockets with the polymer resins and also the casting waxes. The determining of real geometrical precision of silicone form in the relation to the theoretical assumptions determined on the basis of the parameters of the material card of applied silicone was the purpose of researches. Silicone form was created on the basis of the stereolitographic model of sprocket. The coordinates measurable machine WENZEL LH 87 was applied to researches. The measurements of form and also base model were executed in the scanning mode on the basis of model 3D-CAD of sprocket. In purpose of the acceleration of measurable process of base model, silicone form and also prototypes manufactured in form, the special program CNC was written. Program enables the executing of measurements in automatic mode. Measurements enabled determining of precision of manufacturing of form in the relation to nominal model 3D-CAD and also in the relation to stereolitographic base model. The next stage of the research works will concern of the execution of geometrical measurements of prototypes casted in silicone form with chosen materials: casting waxes, the polyester, the epoxy and polyurethane resins. Executed measurements will enable on determining of real precision of prototypes manufactured in silicone casting forms. The problems concerned of determining of geometrical precision of silicone forms and manufactured in them prototypes are considered seldom in the analysed literature from the range of rapid prototyping. From this reason presented researches in article create the original work in the theoretical and practical aspect.