Read interesting interviews and exciting technical articles from our experts
From precise design and advanced simulation to highly optimized manufacturing processes and the rise of innovative plastic gears, the field of gear technology is continuously evolving. Artificial intelligence is playing an increasingly role – not only in design and simulation but also in condition monitoring and product development.
Image source: WZL, RWTH Aachen University
Discover a novel method to tailor gear flank geometry and enhance noise, vibration, and harshness (NVH) performance. Learn how targeted micro geometry scattering in continuous generating grinding can reduce tonal noise and deliver a quieter transmission experience.
Image source: Ovako Sweden AB
Optimized carburizing steel reduces post-treatment processes while achieving higher fatigue strength. Controlled alloy design minimizes surface oxidation, allowing manufacturers to simplify gear production and reduce costs.
Envalior introduces a research initiative focused on the predictive modeling of sliding wear in fiber-reinforced thermoplastic spur gears. The study integrates advanced simulation techniques with experimental validation to explore the complex interplay between material behavior, contact pressure, and wear mechanisms.
Compared to steel gears, the challenges in designing plastic gears lie primarily in modelling the complex material behaviour. By modelling the material and damage behaviour as accurately as possible, more reliable lifetime predictions can be made for plastic gears. This article presents a modelling strategy that can be used to describe the combined material behaviour of fibre and matrix for fibre reinforced plastic gears.
Image source: RENK
This presentation will show the model-based design of a geared solution in the form of a multi-motor drive and outline control engineering measures to compensate for the disadvantages of gear backlash and the lower transmission dynamics compared to direct drives.
Image source: FZG, Technical University of Munich
The findings of the study support the design of gearboxes lubricated by aqueous polyalkylene glycols. The effect of water evaporation on the power loss behavior was evaluated experimentally, and possible monitoring, control, and operation strategies were introduced.
Source: Ogasawara Precision Laboratory LTD.
A method was proposed to cut a gear that meshes with an involute cylindrical gear using a gear-shaped tool, and bevel-shaped gears were prototyped. This demonstrated that it is possible to manufacture a conjugate gear that meshes with an involute cylindrical gear at a free shaft angle.
How reliable are the results of gearbox oiling CFD simulations? The article presents a validated simulation methodology for gearbox oiling using Smoothed Particle Hydrodynamics. The approach is benchmarked against experimental data, demonstrating high accuracy and efficiency. The advantages in modeling complex multiphase flows and its potential to replace physical prototyping are highlighted.
Source: RD Motion’s internal archive
Plastic gears are revolutionizing modern machinery with their lightweight, low-cost, and quiet operation. But can they truly replace metal? Discover how cutting-edge models and experimental methods are tackling their biggest challenges—thermal stress, fatigue, and wear—and why missing material data is the key barrier to wider adoption. Dive into the future of plastic gear design.
SEW-EURODRIVE uses a multi-physics simulation workflow to optimize gear unit thermal behavior. Internal oil flow is modeled via SPH in DIVE, while external convection is simulated using FVM in ANSYS Fluent. Coupled heat transfer data are mapped to ANSYS Mechanical for surface temperature analysis. Experimental validation confirms accuracy, enabling predictive thermal design.
Source: ante
A simulation-based method enables accurate generation of globoidal worm flanks using tool-specific cutting paths. Comparing hob gear, grinding wheel, and finger milling shows how flank shape affects contact quality and how simulation helps optimize gear design in globoidal worm gear drive systems.
A design strategy for geared rotary actuators is proposed, capable of generating multiple solutions that can be classified in terms of reliability and efficiency. This approach aims to provide new opportunities for this type of gear reducer, particularly as a motorized hinge in flight support systems for next-generation aircraft.
Today bodybuilder solutions that require a gearbox mounted PTO to be operational while driving, has been using automatic torque converter gearboxes. Traton has explored the possibility of offering Traton’s own, weight- and cost optimized, AMT gearbox instead.
Source: FEV
Hybrid BEVs combine electric drive with a small combustion engine for extended range—ideal for commercial fleets. This article explores hybrid powertrain options, cost efficiency, and battery innovations, showing how these vehicles offer flexibility and lower emissions while bridging the gap toward full electrification.
Source: MSE – RWTH Aachen University
To date, mobile machinery has mostly been powered by combustion engines and contributes significantly to environmental impact in Germany [1]. Increasing environmental awareness is reflected in legislation aimed at making European mobile machinery the cleanest in the world [2]. Hybrid H2 drives with battery and fuel cell promise zero well-to-wheel emissions and therefore offer the potential to meet future climate targets. However, integrating hybrid H2 FC drives into mobile machinery presents a notable challenge due to the complex mechatronic nature of these systems.
Designing an electric drive system for an off-road application had new and unique challenges. Cooling of the electric motors and integration into the tractor cooling system will be discussed below.
Source: CNH
The energy efficiency and reducing CO2 emissions is essential to promote sustainable agriculture. The main research areas are automation of tractors and implements, as well as the development and use of new technologies and alternative fuels such as methane, biofuels and synthetic fuels, hydrogen, and battery electric vehicles (BEV). It is becoming clear that advances in energy efficiency and propulsion technology are critical to meeting energy needs while minimizing environmental impact.
Source: IPEK-Institute of Product Engineering at KIT
Design Approaches for Circular Economy – Ways to Increase Sustainability of Vehicles Source: IPEK-Institute of Product Engineering at KIT At IPEK sustainability is not only seen as a boundary...
An adaptive strategy to improve the measurement informativeness and effectiveness Laboratory experiments are broadly applied in transmission loss investigations. These measurement results are further...
Central electric drive concept for heavy duty applications Source: J.M. Voith SE & Co. KG Enhancing the electrification of existing commercial vehicle platforms by an innovative drive concept...
Source: L. Becker, Chair IFA, Ruhr-University Bochum
Today, industry is mostly using crossed helical gears with steel worm and plastic wheel. The behavior of plastic in gears has been studied in scientific work.
Cylindrical involute gears are measured on a broad variety of coordinate measuring machines. The quality inspection includes the measurement of profiles, helices and pitch points on the spur or helical gear flanks.
Figure 1: Different failure modes for polymer gears: (a) thermal degradation, (b) root fatigue, (c) flank fatigue, (d) tooth deformation and flank wear.
Gearboxes, actuators and other systems that employ polymer gears are being used in an ever-increasing number of applications.