2025 Fall Technical Meeting

Wednesday, October 22 – 10:00am-1:00pm

Our kickoff session is planned to be a great one!  We have new technology for bevel gear manufacturing relating to profile shift as well as a deep dive into sub-case fatigue fracture for automotive straight tooth bevel gears.  Crown gears will be examined for their load capacity compared to bevel gearing.  Not all of this session is on bevel gearing though!  We will hear about planetary gear micro-geometry design factoring in carrier deformation and a unique gear repair using additive manufacturing methods.  The session will wrap up with a special presentation by the convenor of ISO Technical Committee 60, working group 6, which is responsible for all ISO gear rating standards, on the scope and current work being performed by that international group of experts.

Session Topics:

• Independent Pinion and Gear Profile Shift for Bevel Gears

• Repair and Fabrication of Gears Using Laser Directed Energy Deposition

• Gear Scuffing Analysis Comparison Study

• Design and Load Capacity of Crown Gears in Comparison to Bevel Gears

• TIFF Identification and Resolution of Automotive Straight-Toothed Bevel Gears

• Local Damage Based Micro Geometry Design Method for Planetary Gears Considering Axis Misalignments and Load Deformations

Special Presentation: Activities and Responsibilities of ISO/TC 60/SC 2/WG 6

Wednesday, October 22 – 2:30pm-5:30pm

A new session for this year! As the session title indicates, the papers presented here will cover a lot of emerging topics such as plastic gear performance, plastic gear coatings and their performance, and additive manufacturing gear designs for NVH characteristics. We will also hear about optimization techniques and performance goals for EV drivetrain design. Normally incorporated by a factor in gear rating formulas, impact loading in automotive applications will be discussed in depth.  Quite a way to round out our first day.

Session Topics:

• Nanocomposite Coatings for Thermoplastic Gears
  
• Performance-Driven Design of Multi-Stage Gear Transmissions for E-Drive Systems
  
• Investigations on the Wear Behavior of Plastic Crossed Helical Gears
  
• Impact Load Considerations in Automotive Gear Design
  
• High-damping Lightweight Design for Laser Powder Bed Fusion 20MnCr5 Gears
  
• Interaction of Gear and Bearing Simulation for Planetary Gear Stage Optimization

Thursday, October 23 – 10am-1pm

Where the part goes from concept to reality, Manufacturing and Inspection is always a topic with continuous innovation.  We will hear about optical inspection techniques, using acceleration data to monitor tool wear, and new developments in hard gear skiving.  Microstructure impacts on residual stress relaxation will be investigated in one of the papers in this session. In another, surface geometry characterization will help evaluate contact fatigue damage potential.

Session Topics:

• Areal Surface Characterization of Involute Gears with Microgeometry Corrections and Contact Fatigue Damage for Tooth Contact Analysis
  
• Acceleration Data-Based Analysis of Tool Wear in Gear Hobbing
  
• Extraction of Imaged Tooth Contact Patterns by Iterative Least Squares Approach
  
• Residual Stress Evolution and Stability: Assessing Heterogeneity and Relaxation in Gear Operation
  
• Vibration Signal Analysis for Cycloidal reducer
  
• Hard Gear Skiving with High-Performance Tools – An Innovative Technology for Future Drivetrains

Thursday, October 23 – 2:30pm-5:30pm

Wrap up our second day with some in-depth topics on transmission error, plastic gear NVH considering wear, lubrication, and materials, and powder metal gearing optimization to reduce NVH. Also, presenters will discuss bevel and hypoid gear efficiency and statistical analysis of manufacturing deviations and component damping effects on NVH.

Session Topics:

• A Novel Prediction of the Transmission Accuracy by Means of the Integrated Position Error Phenomenon for a Gear Pair
  
• Investigating the Effects of Wear, Lubrication and Material Pairing on the NVH Performance of Plastic Gears
  
• Application of PM Solutions for Optimization of Transmission Gear Noise in Battery Electric Vehicles
  
• Efficiency of Bevel and Hypoid Gears – Calculation Approach and Comparison with Experimental Test Results
  
• Statistical Analysis of Manufacturing Deviations on Gearbox Transmission Error, Vibrations, and Acoustic Performance
  
• A Comparative Study of the Effect of Damping in the Dynamic Analysis of Drivetrains for NVH Performance Evaluation

Friday, October 24 – 9:00am to 12pm

Our last session focuses on the major elements of a geared system: the building block of material and the end goal of performance. Methods to evaluate the performance of tooth roots under various conditions such as shot peening and superfinishing will be presented, as well as a review of the state of the art in surface hardening techniques.  We will be treated to a summary of testing specific to helicopter transmissions covering 20 years of test information and hear about a unique combination of vacuum heat treatment and spray quenching to achieve high cooling rates. These in-depth papers will make sure to finish up the FTM with our trademark quality and new topic presentations.

Session Topics:

• Strategy for Accounting Residual Stresses Heterogeneity on the Stress Modelling Oriented to Tooth Root Bending Fatigue
  
• Optimizing the Surface Integrity of Gears: Combined Effects of Peening and Superfinishing Processes
  
• Twenty Years of Pulsator Tests on Helicopter Gears
  
• Surface Engineering of Gears: Current State of the Art and Prospects
  
• A New Intensive Quenching Process for Case Hardening of Gears