At first sight the appearance of 5-axis milling for bevel gears opens new possibilities in flank form design. Since in comparison to existing machining methods applying cutter heads no kinematic restrictions exist for 5-axis milling technology, any flank form can be machined. Nevertheless the basic requirements for bevel gears did not change. Specifications and functional requirements like load carrying capacity and running behavior are still increasing demands for design and manufacturing. This paper describes the demands for gear design and gives an overview about different design principles in the context of the surrounding periphery of the gear set.

In the design process of transmissions, one major criterion is the resulting noise emission of the powertrain due to gear excitation. Within the past years, much investigation has shown that the noise emission can be attributed to quasi-static transmission error. Therefore, the transmission error can be used for a tooth contact analysis in the design process, as well as a characteristic value for quality assurance by experimental inspections.

Excessive machine tool vibration during a precision grinding operation can result in poor workpiece quality in the form of chatter, rough finishes, burn, etc. One possible reason for excessive vibration is directly associated with the relationship between natural frequencies of a machine tool system and the operating speed of the grinding wheel spindle.

How local stresses obtained from FEA can be used to determine fatigue strength of worm wheel teeth.

This proposed standard would not make any recommendations regarding the required quality for any application. The intent is to establish standard pre-finish quality classes for typical finishing operations, which only include the inspection elements that are important to properly evaluate pre-finish gear quality as it applies to the finishing operation. It would be the responsibility of the manufacturing/process engineer, quality engineer, or other responsible individual to establish the required pre-finish quality class for their application.

This paper demonstrates an application of the tooth interior fatigue fracture (TIFF) analysis method, as implemented in SMT's MASTA software, in which loaded tooth contact analysis (LTCA) results from a specialized 3-D contact model have been utilized to determine the load boundary conditions for analysis of tooth flank fracture (TFF).

The common calculation methods according to DIN 3990 and ISO 6336 are based on a comparison of occurring stress and allowable stress. The influence of gear size on the load-carrying capacity is considered with the size factors YX (tooth root bending) and ZX (pitting), but there are further influences, which should be considered. In the following, major influences of gear size on the load factors as well as on the permissible tooth root bending and contact stress will be discussed.

This paper addresses the lubrication of helical gears - especially those factors influencing lubricant film thickness and pressure. Contact between gear teeth is protected by the elastohydrodynamic lubrication (EHL) mechanism that occurs between nonconforming contact when pressure is high enough to cause large increases in lubricant viscosity due to the pressure-viscosity effect, and changes of component shape due to elastic deflection. Acting together, these effects lead to oil films that are stiff enough to separate the contacting surfaces and thus prevent significant metal-to-metal contact occurring in a well-designed gear pair.

The increasing demands in the automotive industry for weight reduction, fuel efficiency and a reduced carbon footprint need to be addressed urgently. Up until now, widely used conventional steels have lived up to expectations. However, with more stringent emissions standards, demands on materials are increasing. Materials are expected to perform better, resulting in a need for increased fatigue strength. A possibility to increase torque on current generations without design changes can be achieved by selecting suitable materials.

Gear-loaded tooth contact analysis is an important tool for the design and analysis of gear performance within transmission and driveline systems. Methods for the calculation of tooth contact conditions have been discussed in the literature for many years. It's possible the method you've been using is underestimating transmission error in helical gears. Here's why.