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Sustainable Rotor Shaft Manufacturing

The automotive industry and its suppliers are undergoing profound structural change. Electrification, volatile markets and geopolitical instability, along with increasingly intense global competition, are creating high costs and innovation pressures across the entire value chain. These developments not only affect the general drivetrain components but also rotor shafts for electric motors, which combine high functional density with demanding manufacturing and quality requirements. Recent restructuring efforts, plant closures and bankruptcies have highlighted the need to critically reassess existing manufacturing concepts, especially for components such as rotor shafts with integrated functional elements. For automotive suppliers, technological capability and cost efficiency are no longer the only priorities; process robustness and investment security are increasingly moving into focus. New manufacturing solutions must not only be technically convincing, but also enable a substantial reduction in manufacturing costs, energy consumption, the associated CO2 emissions and process complexity (Refs. 1,2).

Perceive, Understand & Perform

AICA and Schaeffler demonstrate the role Physical AI can play in the manufacturing environment

The Near Future of Mechanical Drive for Humanoid Robots

AI has moved humanoid robots forward, but safety, reliability and cost in the actuator drivetrain still stand in the way of commercial deployment

Strain Wave Gear Production in the Age of Humanoid Robots

Humanoid robots need precise strain wave gears in their joints, and building and inspecting those gears at scale will call for equally advanced production technology

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Technical Articles

Smart Alloying Eliminates Manufacturing Steps in Automotive Gears

20NiMo9-7 alloy achieves up to 48 percent higher fatigue strength than conventional carburizing steels in the as-carburized condition, eliminating the need for shot peening and grinding in automotive gear applications.

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Conjugate Bevel and Hypoid Gears

An excerpt from Gear Technology Solutions by Dr. Hermann J. Stadtfeld exploring the mathematics behind conjugate bevel and hypoid gears—from the fundamental laws of gearing and the conditions for perfect conjugacy to why real-world power transmissions require deliberate crowning rather than theoretically exact conjugate designs.

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Design Principles of Bevel Gears: Rationale for Zero Sum Profile Shifts and Generating Gear Choices

This article demonstrates why bevel gears are designed with a zero sum of profile shifts—showing that independent shifts merely replicate what a modified pressure angle already achieves—and explains the practical benefits of using conical generating gears for tooth profile crowning.

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Analytical Calculation of the Gear Body Stiffness of Face Gears

This paper presents a new analytical method using plate and disk mechanical models to calculate the gear body stiffness of face gear wheels, showing that stiffness decreases toward the outer radius—a behavior that conventional cylindrical gear approaches fail to capture.

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Design

The toothed belt and pulley system known by the designation T, which has been selected as an example within this paper, was developed in the 1950s and standardized first in DIN 7721 (1977) and then in ISO 17396:2014. In this case study, the authors check if a single hob can properly cut T5 profile pulleys with 25 and 30 teeth—and if
so, define the range of the number of teeth covered by this hob.

Grinding

The Swabian transmission and drive solutions manufacturer SPN Schwaben Präzision Fritz Hopf GmbH manufactures gearboxes, gears, and drive systems according to individual customer requirements.

Inspection

In the present paper, a spline-joint design and the extension of a back-to-back test rig were presented, which enable the testing of crowned spline-joints under high rotational speed, medium torque, high test temperature, and angular misalignments.

Heat Treating

The roots of heat-treating run deep within ASM (American Society for Materials) International, as its society was founded in Detroit in 1913 as The Steel Treaters Club. The heat-treating constituency of ASM created the Heat Treating Society (HTS) to provide focused leadership, communications, and service development to its network of worldwide membership of captive and commercial heat treaters, equipment manufacturers, researchers, governments, and technicians. To discuss Heat Treat 2023, the 32nd annual HTS Conference and Exhibition, Gear
Technology took a moment to catch up with conference chair Andrew Banka, vice president of Airflow Sciences Corporation. Heat Treat 2023 is colocated with IMAT and Motion + Power Technology Expo in Detroit, October 17–19.

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Videos

Liebherr Hobbing Machine LC 280 DC with FlexChamfer

​The LC 280 DC gear hobbing machine from Liebherr is designed for precise gear cutting up to module 4.5 mm. It combines high productivity with advanced technology, featuring simultaneous FlexChamfer for efficient deburring and chamfering during the hobbing process.

Industry News

Nick Piselli recently joined the sales team at Piselli Enterprises located in Statesville, NC. He joins his father Richard and his brother Matthew to serve the gear industry with high-quality new and used gear machinery equipment. 

Product News

Verisurf Software demonstrated Renishaw's new PH20 PLUS 5-axis touch-trigger probe head at IMTS 2026 in Chicago, running it with Verisurf's CAD-based inspection software. The PH20 PLUS has a maximum working length of 300 mm from the center of the A-axis. That is more than 50 percent more reach than the current PH20.

Calendar

AIoT World Expo

Feb 9, 2027 - Feb 11, 2027

The AIoT World Expo (Ft. Lauderdale, FL) explores the potential of intelligent machines, prescriptive analytics, sensor driven analytics and block chain solutions. Attendees learn about IoT technologies that are driving the transformation in manufacturing, supply chain and operations.

Additive Manufacturing Strategies 2027

Feb 23, 2027 - Feb 25, 2027

CES 2027

Jan 6, 2027 - Jan 9, 2027

PowerGen 2027

Jan 18, 2027 - Jan 21, 2027

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