Course Description
Format: Live Online Course
Date: July 21-22, 2026
- Tuesday, July 21 – 10:00-2:00pm CT
- Wednesday, July 22 – 10:00-2:00pm CT
Operator Gear Grinding
Explore precision gear grinding processes, machine input variables, kinematics and Gear Geometry in Part A, Grinding Simulator, machine alignment, setup errors, pitfalls, common gear fatigue failures and expectations related to finish ground gearing in Part B. Learn definitions of gearing component features, application loads and process steps from blanking, through heat treatment to finished part ready to ship. Study aspects of Quality Assurance, Inspection Documentation and corrective actions for measured non-conformances. Understand pre-heat treat, heat treatment distortion and post heat treatment operations including the how’s and why’s to produce finished gears that conform and perform to end user expectations. Calculate gear form grinding cycle times for real life examples for various accuracy levels on commercially available software.
The Operator Level courses are made possible through the generous support of the AGMA Foundation. Thank you for your continued support and partnership in educating the industry!
This course is online. A webcam on your computer equipped with a microphone and speakers/headset are required for participation. Space is limited to 20-25 participants per course. Course materials will be mailed in hard copy. Please make sure to indicate your preferred mailing address in the registration process.
Registration Rates
Early Bird First Registrant – $600
(Deadline until 5/7/26)
Regular First Registrant – $650
(Deadline: 5/8/26 – 6/23/26)
Late First Registrant – $675
(Deadline: 6/24/26 – 7/7/26)
NON-MEMBER RATE
Early Bird First Registrant – $700
(Deadline until 5/7/26)
Regular First Registrant – $750
(Deadline: 5/8/26 – 6/23/26)
Late First Registrant – $775
(Deadline: 6/24/26 – 7/7/26)
You will earn 8 clock hours upon completion of the course and they will be listed on your certificate of completion.
Learning Objectives
- Be able to ask questions of gear designers and manufacturing engineers to acquire all information required to produce conforming finished gears
- Understand basic and advanced gear tooth geometry, loads and target accuracy
- Review and challenge control of part datums through 5 gear processing steps, use datum’s consistently through all operations given part process prints
- Anticipate and correct for part distortion during heat treatment knowing the actual heat treatment process used.
- Understand gear geometry and typical field failures, achieve compliance with finished parts to meet print requirements and customer performance expectations
- Select tooth grinding parameters Qw, metal removal rate and Vw, volumetric limit for dressing given part print, heat treatment and grinding wheel specification used
- Understand gear grinding kinematics for both form and generating machines
- Learn about gear performance optimization techniques used to optimize power density
- Accurately measure pre and post finish gear tooth Helix, Profile and tooth thickness given finished tooth geometry specifications and modifications calculated from Loaded Tooth Contact Analysis
- Review calculations on form grinding cycle times based on various target accuracies, Qw material removal rate, Vw volumetric limit for dressing and grinding techniques
- Avoid and detect the presence of Twist Error
- Avoid and detect presence of grind burn temper
- Avoid typical gear fatigue failure modes, bending fracture, macro-pitting and micro-pitting resulting from improper tooth finishing
- Identify common non-conformances, causes and re-create them on gear grinder models, apply problem solving techniques and corrective actions suggested in trouble shooting guide provided with course material”
Who Should Attend
This course would be of interest to both entry and high level generating and form gear grind operators, inspectors, process Engineers and quality assurance people who need to better understand why and how gear designs are optimized and how to work with non-standard gear geometry. The course would also benefit pre-finishing operators by understanding part datum control and subsequent gear finishing processes. Participants can also gain insight on how improper finishing techniques can contribute to premature gear failures. Entry level gear designers, process and manufacturing engineers can develop a basic understanding of gear finishing cycles, cycle times and cost. Gear manufacturing project managers and production managers can develop a better understanding of time required to set up and finish high performance gear sets that will meet or exceed application expectations.
Instructors
Terry Klaves
Terry Klaves semi-retired from the Milwaukee Gear Division of Regal Beloit in 2017 after 45 years of work in the gearing industry with four different companies, positions varying from gear engineer to VP of Engineering and responsibilities including gear design, optimization, manufacturing and Quality Assurance. He has a passion for solving gearing related problems and continues to serve the gearing industry as part time consultant and trainer for AGMA, in addition, he is Chairman of the AGMA TC-60 Committee, contributing to development of ISO gearing standards. Terry graduated with a BS-Engineering in 1976 and a MS-Engineering from UW-Milwaukee in 1981 and enjoys sharing his knowledge and passion for gears through formal consulting and training activities.
Photo Release
From time to time MPMA uses photographs, survey answers and testimonial of MPMA events in its promotional materials. Unless this permission is revoked in writing to the MPMA, by virtue of your attendance all attendees agree to the use of their likeness in such materials.
Cancellation and Payment Policy
Please view our cancellation policy.
Please view our late registration policy.
Please view our code of conduct.