As the challenges in bevel and hypoid gear manufacturing need to be addressed, the objective of this paper is to show the tool and process design can be optimized based on the results of the manufacturing simulation BevelCut.

For the research developed in this work, an existing simulation model of the generating gear grinding process based on a penetration calculation approach is used. Further, an extension of the model considering a realistic modeling of the grinding worm topography and the macro movements of the grinding worm during the process is presented. The result of the simulation is the microinteraction characteristics throughout
the grinding of the gear flank. In the end, the information about microinteraction characteristics obtained will be used for the calculation of force and energy in generating gear grinding.

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.

Due to near-net shape production, additive-manufactured (AM) gears have a high potential to decrease costs and increase resource efficiency. The decreasing product life cycles as well as the increasing individualization of components demand high flexibility in manufacturing processes

Aircraft engines can be made more efficient by integrating planetary gears. In such an application, the planetary gears experience very high load cycles under fully reversed bending loads. Pulsator test rigs, which nowadays offer the possibility to perform UHCF investigations, can only be used for purely pulsating loading of gears. Therefore, for the investigation of the UHCF tooth root load carrying capacity under fully reversed bending load, a back-to-back test rig is required. Back-to-back test rigs usually have speeds of n = 3,000 rpm, which makes investigations in the UHCF range take a very long time. Therefore, a high-speed back-to-back test rig was developed.

The objective of this paper is to develop a method for the algorithm-based design and optimization of the macrogeometry of stepped planetary gear stages.