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Gear Geometry

ADDENDUM | 2025-02-27

Mandelbrot Meets Machine

Benoit B. Mandelbrot (1924–2010), the mathematician who coined the term “fractal,” revolutionized the way we understand complexity in nature. His groundbreaking work introduced the concept of self-similar patterns—structures that repeat at varying scales—which appear in phenomena as diverse as coastlines, clouds, and market fluctuations. Fractals provide a mathematical framework for describing irregular shapes and dynamic systems, making them invaluable for tackling problems where traditional linear approaches fall short. Building on Mandelbrot’s groundbreaking work, the application of fractals in engineering reveals exciting possibilities for gear design.

EVENT | 2023-09-15

Aachen Forum on Gear Production

In this seminar, attendees will learn about gearing, electromobility and their interrelationships. How gearing can increase the efficiency and performance of electromobility, and which components are needed for this. Also, a detailed look at the design and manufacture of gears for electric vehicles. Attendees will explore the challenges of gearing for electromobility, such as adapting to hard-to-reach places, increasing durability, and reducing energy consumption, and discuss how grinding technology and tool design must meet requirements to improve the properties and improve the quality of gears for electric vehicles. The Aachen Forum on Gear Production (AFGP) is held annually in alternation with the Aachen Conference on Gear Production (ACGP). While the Forum at the RWTH Aachen Campus is dedicated to a technical focus (2023 the interlocking in the E-Mobility sector) the conference, on the other hand, is dedicated to various facets of gear technology.

INDUSTRY NEWS | 2021-06-01

Hybrid Metrology with Klingelnberg

An overview of tactile and optical metrology

INDUSTRY NEWS | 2020-12-11

FVA Examines Load Capacity Calculations to Determine Cylindrical Gear Geometry

FVA has released its latest tech blog on the advantages of local load carrying capacity approaches compared to standardized methods. ...
INDUSTRY NEWS | 2019-11-20

Liebherr and Morat Swoboda Collaborate on E-Mobility Solutions

Few topics are currently so intensely discussed as climate and the question of future-viable mobility. Stress caused by car traffic, particularly a...
GEAR TALK WITH CHUCK | 2019-10-03

Toying with Old Recipes

A consultant’s code is similar to a medical doctor’s; e.g. — Rule #1 is to “do no harm.” Sometimes I feel like a real buzz kill while explaining to...
GEAR TALK WITH CHUCK | 2019-08-15

A Global Gear Community

Roman Cisek’s journey from Poland to the United States is an example of how the gear trade has become one big international community. A few weeks ...
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GEAR TALK WITH CHUCK | 2019-07-30

Pieces of a Puzzle

One of the things I most enjoy about teaching newbies is the need to come up with different ways to explain important concepts. Today’s high school...
GEAR TALK WITH CHUCK | 2019-07-16

Watching the Chips Fly

It was a real treat to spend a day at a gear shop this week. After all these years, I still enjoy watching a round blank get transformed into a gea...
GEAR TALK WITH CHUCK | 2019-04-24

Yefim Kotlyar — My Story

Yefim Kotlyar is a wonderful example of how gears unite the world. His background is much different than mine, yet we share a deep appreciation...
GEAR TALK WITH CHUCK | 2018-08-30

Gearbox Design: Checks and Double Checks

We have been devoting this year’s blogs to fundamentals. I frequently remind my clients that the gear geometry is the easy part of gearbox design. ...
GEAR TALK WITH CHUCK | 2018-07-16

Planetary Gears: A Few More Things

Before we move...
GEAR TALK WITH CHUCK | 2018-05-10

What’s Your Angle?

Hulet self-unloader image courtesy of ASME. Interesting things happen when you start using “non-standard” gear geometry. As early as th...
GEAR TALK WITH CHUCK | 2018-03-15

What About Worms?

It is difficult to know where to start when writing about worm gears, because this market segment has defied “standardization” within the United St...
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GEAR TALK WITH CHUCK | 2018-01-11

The Beginning of Wisdom

Faithful followers of this blog can complete that mantra without prompting, but for new readers — the beginning of wisdom is calling things by thei...
GEAR TALK WITH CHUCK | 2016-03-22

The Beginning of Wisdom

Aphorisms, pithy statements of fact, are a favorite of mine. They appeal because when you need to remember things you cannot always count on ...
TECHNICAL ARTICLES | 2015-03-01

A Practical Approach for Modeling a Bevel Gear

The geometry of the bevel gear is quite complicated to describe mathematically, and much of the overall surface topology of the tooth flank is dependent on the machine settings and cutting method employed. AGMA 929-A06 — Calculation of Bevel Gear Top Land and Guidance on Cutter Edge Radius — lays out a practical approach for predicting the approximate top-land thicknesses at certain points of interest — regardless of the exact machine settings that will generate the tooth form. The points of interest that AGMA 929-A06 address consist of toe, mean, heel, and point of involute lengthwise curvature. The following method expands upon the concepts described in AGMA 929-A06 to allow the user to calculate not only the top-land thickness, but the more general case as well, i.e. — normal tooth thickness anywhere along the face and profile of the bevel gear tooth. This method does not rely on any additional machine settings; only basic geometry of the cutter, blank, and teeth are required to calculate fairly accurate tooth thicknesses. The tooth thicknesses are then transformed into a point cloud describing both the convex and concave flanks in a global, Cartesian coordinate system. These points can be utilized in any modern computer-aided design software package to assist in the generation of a 3D solid model; all pertinent tooth macrogeometry can be closely simulated using this technique. A case study will be presented evaluating the accuracy of the point cloud data compared to a physical part.
GEAR TALK WITH CHUCK | 2015-01-29

Feedback and Comments

[starbox] We are starting our second year of this blog and are pleased that it was named one of the Top 50 Design and Development Blogs on the Int...
ASK THE EXPERT | 2014-11-01

Small-Module Gear Design

Gears with a diametral pitch 20 and greater, or a module 1.25 millimeters and lower, are called fine-pitch or low-module gears. The design of these gears has its own specifics.
GEAR TALK WITH CHUCK | 2014-07-08

Better to be Lucky than Smart

[starbox] The special 30th Anniversary Issue of Gear Technology magazine represents a lot of extra work on the part of...
GEAR TALK WITH CHUCK | 2014-06-17

School’s Out for Summer?

[starbox] June has always been a favorite month for me because it signaled the start of summer vacation. In the many years since I graduated hig...
ADDENDUM | 2012-03-01

The New Now: U.S. Workforce Sustainability

Faithful Addendum readers are accustomed to finding upbeat, whimsical and oddball stories about gears in this space. What follows is not about gears, exactly. Rather, it is, as opposed to the usual bleak news about America losing its manufacturing mojo—a look at a positive, hopeful development in that regard.
PRODUCT NEWS | 2011-05-01

Dearborn Precision Puts Dual Purpose Zeiss CMM to the Task

When parts you manufacture pass through numerous processes such as deep hole drilling, machining, hobbing and grinding, a CMM is essential when your customers require 100 percent in-process and final inspection.
INDUSTRY NEWS | 2001-01-01

Industry News

Complete Industry News for January/February 2001.
EVENTS | 2000-07-01

Technical Calendar

Complete Technical Calendar for July/August 2000.
INDUSTRY NEWS | 1999-09-01

Industry News

Industry News for September/October 1999.
TECHNICAL ARTICLES | 1999-03-01

Fatigue Aspects of Case Hardened Gears

The efficient and reliable transmission of mechanical power continues, as always, to be a central area of concern and study in mechanical engineering. The transmission of power involves the interaction of forces which are transmitted by specially developed components. These components must, in turn, withstand the complex and powerful stresses developed by the forces involved. Gear teeth transmit loads through a complex process of positive sliding, rolling and negative sliding of the contacting surfaces. This contact is responsible for both the development of bending stresses at the root of the gear teeth and the contact stresses a the contacting flanks.
TECHNICAL ARTICLES | 1999-01-01

ISO 6336-5: Strength and Quality of Materials

This is the fourth and final article in a series exploring the new ISO 6336 gear rating standard and its methods of calculation. The opinions expressed herein are those of the author as an individual. They do not represent the opinions of any organization of which he is a member.
TECHNICAL ARTICLES | 1997-05-01

Eddy Current Examination of Gear Systems

Nondestructive examination (NDE) of ferrous and nonferrous materials has long proved an effective maintenance and anomaly characterization tool for many industries. Recent research has expanded its applicability to include the inspection of large, open gear drives. Difficulties inherent in other NDE methods make them time-consuming and labor-intensive. They also present the user with the environmental problem of the disposal of used oil. The eddy current method addresses these problems.
TECHNICAL ARTICLES | 1991-03-01

The Lubrication of Gears - Part 1

This is a three-part article explaining the principles of gear lubrication. It reviews current knowledge of the field of gear tribology and is intended for both gear designers and gear operators. Part 1 classifies gear tooth failures into five modes and explains the factors that a gear designer and operator must consider to avoid gear failures. It defines the nomenclature and gives a list of references for those interested in further research. It also contains an in-depth discussion of the gear tooth failure modes that are influenced by lubrication and gives methods for preventing gear tooth failures.
EVENTS | 1989-05-01

Technical Calendar

May 18-21. AGMA Annual Meeting, "The Changing World of Gears." Loews Ventana Canyon Resort, Tucson, AZ. July 12-14, 1989. ASM international Conference on Carburizing. Sheraton Hotel & Conference Center, Lakewood, CO. September 12-20, 1989. European Machine Tool Show, Hannover, West Germany.
INDUSTRY NEWS | 1984-05-01

The Process of Gear Shaving

Gear shaving is a free-cutting gear finishing operation which removes small amounts of metal from the working surfaces of the gear teeth. Its purpose is to correct errors in index, helical angle, tooth profile and eccentricity.
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