6th International Conference on Gear Production 2025

• International Conference on Gears 2025
• International Conference on High Performance Plastic Gears 2025
• International Conference on Gear Production 2025 
  Prof. Dr.-Ing. Karsten Stahl, Full Professor, Institute of Machine Elements, Director, Gear Research Center (FZG), TUM School of Engineering and Design, Technical University of Munich, Garching, Germany 
  Caroline Körber, Productmanagement, VDI Wissensforum GmbH, Duesseldorf, Germany

Prof. Dr.-Ing. Prof. h. c. Christoph Gehlen, Dean, TUM School of Engineering and Design, Technical University of Munich, Garching, Germany

Prof. Dr.-Ing. Burkhard Pinnekamp, former Head of Central Technology, RENK GmbH, Augsburg, Germany; President, Research Association for Drive Technology (FVA), Frankfurt, Germany; Hononary Professor, Gear Research Center (FZG), TUM School of Engineering and Design, Technical University of Munich, Garching, Germany

Matthew E. Croson, President, American Gear Manufacturers Association (AGMA), Alexandria, USA

Moderation: Prof. Dr.-Ing. Karsten Stahl, FZG, TUM School of Engineering and Design, Technical University of Munich, Garching, Germany

• Tech-Driven: Digitization, automation, IoT increase efficiency and enable new business models
• AI-Powered: AI transforms development and maintenance, unlocking new potentials despite limitations
• Customer-Centric: AI enables tailored solutions and faster, more precise customer responses 
  Fabian Ziegler, Founder & Managing Director, TEAM23 GmbH, Augsburg, Germany

• The “Digital Engineer”: AI-driven design and optimization of “Flender One” gearboxes
• Closed loop data utilization with AI: Continuous adaptation and right-sizing in gearbox development
• Digital end-to-end backbone for future AI value creation 
  Dr.-Ing. Jan Reimann, Project Director “Flender One“, Dipl.-Ing. Julia Zundel, Head of Digital Business, Dr.-Ing. Tim Sadek, Head of Technology & Innovation Flender GmbH, Bocholt, Germany

• The role of AI in production
• Requirements for the implementation of AI in production: Data, models, processing
• Potential of AI applications in production: Deep dive and application examples 
  Prof. Dr.-Ing. Christian Brecher, Full Professor, Chair of Machine Tools, Laboratory for Machine Tools and Production Engineering (WZL), Faculty for Mechanical Engineering, RWTH Aachen University, Germany

• DriveRadar®: Functional components, innovative forecasts, IT and data security, use-cases
• Contribution on sustainability and future developments 

• Potential of smart maintenance: Transparency, early detection of faults, reduced downtimes 
  Dipl.-Ing. (DH) René Maisenhelder, Manager, Service Field Solutions, Condition Monitoring & Analysis, SEW-EURODRIVE GmbH & Co KG, Bruchsal, Germany 

  + Discussion with plenary speakers

Meet & greet in the exhibition area, poster presentation area and GearArena

Moderation: Prof. Dr.-Ing. Christian Brecher, Full Professor, WZL, RWTH Aachen University, Germany

• Calculate target values and tolerances for microgeometry of gears and all other influence parameters which may have an impact on NVH/acoustic
• Predict process parameters with method and engineering AI: Grinding wheel dressing geometry for final gear finishing processes, grinding shift speed, grinding wheel dressing time
• Cost and time savings: 30 % cost reduction and 50 % time savings, with real-time quality control via AI 
  Dipl.-Ing. Peter Stirnweiß, Lead Engineer and project manager, Lean Six Sigma and Design for Six Sigma Black Belt, mts Consulting & Engineering GmbH and Contech Software & Engineering GmbH, Fürstenfeldbruck, Germany

• Innovative use of powder metallurgy (PM) process for enhanced NVH performance
• AI-driven gear design solutions with: Net-shape compaction features, improved noise transfer path, enhanced damping
• Proven success in >100 Gearbox test anstelle von Proven success with >15dB noise reduction
  Dr.-Ing. Philipp Kauffmann, Director, Research and Innovation, Preetham Jonnalagadda, M. Sc., Senior Engineer, Patricia de Oliveira Löhrer, M. Sc., Senior Engineer, Research and Innovation, Johnson Electric Aachen GmbH, Aachen, Germany

• Function-oriented gear specification for e-drives: Friction losses caused by roughness
• Multisensor approach for surface analysis: Amplitude vs. gradient-based parameters
• Capable metrology in the shopfloor environment 
  Boris Brodmann, Head of strategic research & development, OptoSurf GmbH, Ettlingen, Germany

Meet & greet in the exhibition area, poster presentation area and GearArena

Moderation: Christian Westphal, M. Sc., Chief Engineer, Head of Gear Technology, WZL & MTI, RWTH Aachen University, Germany

• Analytical approach for printing optimization of 1.6657: Powder bed fusion, analytic models, process mapping
• Process monitoring for properties control of 1.6657 gears: Melt pool monitoring, Porosity features evaluation, production quality management
• Shape to shape printing parameter transfer: Cube matrix, gear design, vector merging 
  Dr. Briac Lanfant, Senior Research Associate, Additive Manufacturing, Institute of Product Development and Production Technologies (IPP), ZHAW Zurich University of Applied Sciences, Winterthur, Switzerland

• Analogy trials for wear investigation
• Methods of data analysis: Feature engineering, descriptive and predictive analytics
• Influence of the sensor position and the process parameters 
  Steffen Hendricks, M. Sc., Research Assistant, Dr.-Ing. Mareike Davidovic, Chief Engineer, Prof. Dr.-Ing. Thomas Bergs, Full Professor, Chair of Manufacturing Technology, Manufacturing Technology Institute – MTI, Faculty for Mechanical Engineering, RWTH Aachen University, Germany

• Comparison of traditional and deep learning-based computer vision methods for wear detection on gear cutting tools
• Validation of the algorithm by comparing manually measured and algorithmically generated wear curves 
  Melina Kamratowski, M. Sc., Research Assistant, Dr.-Ing. Mareike Davidovic, Head Engineer Gear Manufacturing, Gear Technology Department, Prof. Dr.-Ing. Thomas Bergs, Full Professor, Chair of Manufacturing Technology, Manufacturing Technology Institute – MTI, Faculty for Mechanical Engineering, RWTH Aachen University, Germany

Dr.-Ing. Franz Völkel, Sr. Vice President R&D, Business Division Automotive Bearings, Schaeffler Technologies AG & Co. KG, Herzogenaurach, Germany 
Prof. Dr.-Ing. Karsten Stahl, Full Professor, FZG, TUM School of Engineering and Design, Technical University of Munich, Garching, Germany

Innovation on fire: When human intelligence and artificial Intelligence collaborate 

‘We stand on the threshold of an era of extreme productivity – a symbiosis of human developmental power and the computing strength of AI. It is our responsibility to seize this opportunity – while also embracing a commitment: To unlock the ‘gold in our minds’ and collaborate with AI at eye level. This requires a radical expansion of our neuro-knowledge to develop neuro-loyal modules, processes, and tools in a structured and pragmatic way – and to integrate them strategically into business processes.’ 
Dr. Karin Koert-Lehmann, MY InnoTrinsic/Rethink & Move, Krefeld, Germany

Join us for a special evening at the‘Löwenbräukeller’ – a chance to enjoy tradition, connect, and exchange ideas in a relaxed atmosphere.

Moderation: Prof. Dr.-Ing. Thomas Bergs, Full Professor, MTI, RWTH Aachen University, Germany

• Microstructures with high amounts of retained austenite: Hardness, retained austenite content, residual stress
• Experimental investigations of the tooth root load-carrying capacity in the pulsator test rig
• Increase of tooth root load-carrying capacity through stabilized retained austenite 
  Adrian Sorg, M. Sc., Research Associate, Institute of Machine Elements, Gear Research Center (FZG), TUM School of Engineering and Design, Technical University of Munich, Garching, Germany; Mustafa Tarik Boyraz, M. Sc., Research Scientist, Materials Science, Leibniz Institute for Materials Engineering – IWT, Bremen, Germany

• Gear heat treatment: Deformation, case-hardening depth inhomogeneity, test-bar control
• Non-Destructive Testing (NDT) measurement of case-hardening depth in gears: Electromagnetic signal, correlation with destructive testing, challenges
• Case-hardening depth: Affection on calculation, optimum range, evaluation 
  Ainhoa Okariz Gabellanes, Industrial Eng., Material Science & Production Technologies Engineer, Gearbox by Gamesa (Siemens Gamesa), Alfredo Fernandez Sisón, M. Sc. Mech. Eng., Gearbox Engineering Manager Gearbox by Gamesa (Siemens Energy), Zamudio, Spain

• 2D-3D tooth flank mapping via photogrammetry: Photogrammetry, 3D data, tooth flank analysis
• Quadratic modelling of displacement behaviour: Variation, Model, Approximation
• Automated contact pattern correction using TCA: Validation, Automation, Optimisation 
  Dipl.-Ing. Constantin van Oss, Research Associate, Dr.-Ing. Stefan Schumann, Senior Engineer, Prof. Dr.-Ing. Berthold Schlecht, Full Professor and Head of Institute of Machine Elements and Machine Design, Faculty of Mechanical Science and Engineering, Technische Universität Dresden, Germany

Meet & greet in the exhibition area, poster presentation area and GearArena

Moderation: Christian Westphal, M. Sc., Chief Engineer, Head of Gear Technology, WZL & MTI, RWTH Aachen University, Germany

• Research at cross-rolling process characterized by two round tools with outer gearings: Tool construction, clamping concepts, forming simulations, rolling trials module 4 mm
• Realization of prototype machine for hot forming process/gear rolling of larger gear applications: Machine dimensioning process, rolling trials module 9.5 mm
• Gear measurements: Actual results/optimization possibilities/ alternative components 
  Dipl.-Ing. Matthias Milbrandt, Scientific Employee, Department Bulk Metal Forming/Radiation Safety, Fraunhofer Institute for Machine Tools and Forming Technology IWU, Chemnitz, Germany

• Modelling of the meshing-interference in the production of globoidal worm gears
• Impact of different manufacturing methods on tooth contact: Tool kinematics, tooth flank clearance and gear overlap
• Consideration of assembly and manufacturing deviations 
  Dr.-Ing. Christian Kirchhoff, Team Leader Worm and Crossed Helical Gears, Prof. Dr.-Ing. Manuel Oehler, Head, Chair of Drive Technology (ante), Ruhr University Bochum (RUB), Germany

• Limit line theory of 2DOF engagement
• Determining tooth surfaces scope of cutting worm proposed
• Methodology to compute limit point: Equations, iteration, envelope 
  Prof. Dr. Yaping Zhao, Professor, Xiaonan Zhang, Ph.D. student, School of Mechanical Engineering and Automation, Northeastern University, Shenyang, China

Meet & greet in the exhibition area, poster presentation area and GearArena

Moderation: Prof. Dr.-Ing. Thomas Bergs, Full Professor, MTI, RWTH Aachen University, Germany

• Alternative, resource-efficient gear manufacturing chains
• New manufacturing methods for optimized gear and gearbox performance: Additive manufacturing, binder jetting, powder metallurgy
• Gear power density: Tooth flank load capacity, pitting damage, simulation of local contact stress 
  Emil-Elias Breuer, M. Eng., Research Assistant, Dr.-Ing. Mareike Davidovic, Head Engineer Gear Manufacturing, Gear Technology Department, Prof. Dr.-Ing. Thomas Bergs, Full Professor, Chair of Manufacturing Technology, Manufacturing Technology Institute – MTI, Faculty for Mechanical Engineering, RWTH Aachen University, Germany

• Traditional bending fatigue test method was adapted to better suit additively manufactured gear materials
• Gear tooth samples were manufactured from Dievar material and tested
• Results presented include the test methodology, stress-life data, metallurgical analysis, and fracture analysis 
  Dr. Aaron Isaacson, Managing Director, Gear Research Institute and Head, Materials and Mechanicals Development, Penn State University, Matthew Wagner, Senior Research & Development Engineer, Materials and Mechanicals Development, Penn State University, Gear Research Institute, State College, USA; Dr. Diego Montoya-Zapata, R&D Additive Manufacturing Engineer, Ikergune, Inzu Group, Elgoibar, Spain

• Design of damping structures
• Enhancing vibration damping in gears via additive manufacturing
• Integrating lattice structures for lightweight gear design 
  Matheus Fernandes Vieira, M. Sc., Research Assistant, Guilherme Fernandes Guimarães, M. Sc., Research Assistant, Prof. Dr. Ronnie Rego, Professor, Manufacturing Competence Center, Aeronautics Institute of Technology, São José dos Campos, Brazil

Meet & greet in the exhibition area, poster presentation area and GearArena

Moderation: Prof. Dr.-Ing. Karsten Stahl, Full Professor, FZG, Technical University of Munich, Garching, Germany

• Meshing contact theory and practicality of non-parallel axis gears: Involute cylindrical gear, meshing contact line of action, constant velocity contact
• Gear cutting method of non-parallel axis gears: External bevel shaped gear, inner bevel shaped gear, transmission error
• Prototyping and evaluation of involute conjugate gears 
  Noritsugu Maeda, B. Sc., Research and development engineer, OGASAWARA PRECISION LABORATORY LTD., Kanagawa, Japan; Prof. Dr. Syuhei Kurokawa, Professor, Kyushu University, Fukuoka, Japan

• Generating method for curved tooth gears: Gear skiving, tooth trace, spiral angle
• Mathematical model of skived tooth surfaces: Position, normal, curvature
• Tooth contact analysis of skived tooth surfaces: Contact ellipse, contact path, transmission errors 
  Peng Wang, Ph.D., Associate Professor, College of Mechanical and Energy Engineering, Beijing University of Technology, China

• Ring-dexel cutting simulation method for face milling bevel gears, enabling precise determination of material removal rates (MRR)
• Real-time feed rate optimization through CNC software for improved efficiency
• Linear relationship between MRR and tool torque to optimize feed rates 
  Yi-Pei Shih, Ph.D., Professor, Department of mechanical engineering, National Taiwan University of Science and Technology; Dr. Bor-Tyng Sheen, Developer of FG CAD/CAM Software, Dragon-City Technology Co., Taipei City, Taiwan

We are pleased to invite you to our evening reception at the end of the second conference day. Enhance your personal network and use the relaxed and informal atmosphere for deepening talks with other participants and speakers.

Moderation: Christian Westphal, M. Sc., Chief Engineer, Head of Gear Technology, WZL & MTI, RWTH Aachen University, Germany

• Advanced tooth flank modifications using higher-order polynomials to improve gear meshing and reduce contact pressures
• Optimization framework that targets bending stress reduction and enhanced tolerance to misalignment
• Precision manufacturability ensured through specialized numerical strategies for modern CNC-controlled bevel gear generators 
  Eugeniu Grabovic, Ph.D., Assistant professor, Prof.-Ing. Alessio Artoni, Ph.D., Associate Professor, Prof.-Ing. Marco Gabiccini, Ph.D., Associate Professor, Department of Civil and Industrial Engineering, University of Pisa, Italy

• A mathematical model of continuous generating gear grinding: Continuous generating gear grinding, calculation of tooth flank, gear meshing principle
• Gear flank high-order modification method: Polynomial trajectory, intelligent algorithm, electronic gearbox
• Experimental verification: Polynomial interpolation, trajectory validation, gear grinding 
  Professor Xiaoqing Tian, Ph.D., Director, Intelligent Manufacturing Equipment and Technology Institute, School of Mechanical Engineering, Hefei University of Technology & Anhui Engineering Laboratory of Intelligent CNC Technology and Equipment, Hefei, China; Yukai Sun, Ph.D. student, Intelligent Manufacturing Equipment and Technology Institute, School of Mechanical Engineering, Hefei University of Technology, Hefei, China

• Targeted micro geometry scattering improves the NVH behavior of cylindrical gears
• Fast dressing methods enable high productivity in the continuous generating grinding process
• Simulation and evaluation of possible micro geometry scattering through the use of special dressing gears 
  Alexander Mann, M. Sc., M. Sc., Research Associate, Christian Westphal, M. Sc., Chief Engineer, Head of Gear Technology, Prof. Dr.-Ing. Christian Brecher, Full Professor, Chair of Machine Tools, Laboratory for Machine Tools and Production Engineering (WZL), Faculty for Mechanical Engineering, RWTH Aachen University, Germany

Meet & greet in the exhibition area, poster presentation area and GearArena

Moderation: Dr.-Ing. Joachim Thomas, Managing Director, ZG Hypoid GmbH, Aschheim, Germany

• Strong correlation exists between the scattering or the standard deviation of Debye-ring crater height and prior-austenite grain size
• Capability of detecting the coarsening of prior-austenite grains with high-speed analog-measurement of successive cross-section of Debye-ring by scanning
• Proposal of Debye-ring shape analysis to substitute the etching method for checking steel quality 
  Prof. h.c. Dr.-Ing. Aizoh Kubo, President, Dr.-Ing. Masahiro Nagae, Research fellow, Research Institute for Applied Sciences, Kyoto, Japan

• Novel alloying strategy to improve surface integrity and fatigue strength of case carburized gears
• Increased performance of as-carburized gears while keeping standard heat treatment processes
• Synergy effects between steel grade and process selection: Performance, reliability, manufacturing efficiency 
  Elias Löthman, M. Sc., Manager – Testing and Validation, Technical Specialist – Applications, Patrik Ölund, M. Sc., SVP & Head of Group R&D, Ovako Sweden AB, Hofors, Sweden; Christoph Gallo, M. Sc., Application Engineer, Ovako GmbH, Erkrath, Germany

• Low-time-consuming Finite Element Method (FEM) simulation models: FEM, Ansys, fast and accurate
• Induction hardening process definition and optimisation: Inductor geometry, electrical variables, scanning speed
• Evaluation of the influence of induction hardening on fatigue performance: Fatigue, mechanical properties, residual stresses 
  Unai Segurajauregi, Ph.D., Industrial Engineer, Researcher, Aritz Goñi, Industrial Engineer, Ph.D. Student, Mikel Escalero, Ph.D., Industrial Engineer, Researcher, Mechatronic Technologies, Ikerlan, Mondragon, Spain

Prof. Dr.-Ing. Karsten Stahl, Gear Research Center (FZG), TUM School of Engineering and Design, Technical University of Munich, Garching, Germany 
Caroline Körber, Productmanagement, VDI Wissensforum GmbH, Duesseldorf, Germany 

+ Lunchtime snack