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Gear Design

TECHNICAL ARTICLES | 2025-03-01

Mitigation of Gear Whine Noise in Agricultural Tractor Application

In the realm of tractor gearbox applications, gear whine noise has long been a persistent challenge that significantly impacts the user experience and overall perceived performance of the vehicle. This paper delves into a comprehensive study that discusses the approach to tackling this issue through a combination of design optimizations, simulation techniques and physical validation processes.

INDUSTRY NEWS | 2025-02-18

GWJ Introduces 2025 Seminar Schedule

GWJ Technology is starting a new seminar schedule in 2025. This year, GWJ is once again offering a wide range of different seminars that can be booked as online seminars or, if desired, as traditional face-to-face events. The online seminars are designed to be interactive and provide a comprehensive insight into the respective topic. Practical exercises deepen the content. Online seminars take place over two or three days and last two hours each. 

TECHNICAL ARTICLES | 2024-09-13

UGRacing’s Gear Train Solutions from Combustion to Electric

UGRacing is the University of Glasgow’s Formula Student team. Since its inception in 2005, the team has been working to compete at Formula Student UK (FSUK). Over the last decade, the team has grown to over 150 members across ten disciplines. With a strong focus on knowledge transfer and iterative design, the team has worked year after year to develop new technologies and a more refined package. In 2022, the team saw a culmination of all their hard work when they placed first overall in FSUK with their final internal combustion vehicle. The following switch to an electric powertrain brought new challenges. Through the constraint of a new powertrain architecture, the team has explored and innovated drivetrain concepts which, in future years, will improve vehicle performance.

| 2024-08-07

Berg Compares Spur and Helical Gears

Mechanical design engineers planning a drivetrain typically have a range of component options to choose from, and many decisions will boil down to the specific application. When it comes to creating optimal torque output, rotational speed and direction, few decisions are as important in designing high performing gear drives as choosing the right gear for the job. 

INDUSTRY NEWS | 2024-08-06

Timken Agrees to Acquire CGI Inc.

The Timken Company has agreed to acquire CGI Inc., a Nevada-based manufacturer of precision drive systems serving a broad range of automation markets with a concentration in medical robotics. The deal is subject to customary closing conditions, including regulatory approval, and is expected to close in the third quarter.

FEATURE ARTICLES | 2024-08-05

Avoiding Failure and Downtime

Gear drives are fundamental in most processing operations, connecting the prime mover to the driven equipment and ensuring that the system has enough torque to effectively move product. Correctly specifying and selecting the proper gear drives for critical applications leads to reliability, greater uptime and profitability.

TECHNICAL ARTICLES | 2024-08-05

Holistic Assessment of Drive Systems with Gears, Shafts and Bearings Using Measured Torque-Speed Data

Verification of a drive system should include all main elements of the system, which are gears, bearings, shafts, and depending on the application other parts such as screws, couplings, and connections. Gears are clearly the most complicated parts for verification, but in many cases, a gearbox failure has its origin in a shaft or bearing failure. The subject of this paper is to explain how verification of a drive system based on measured or simulated torque-speed-time data can be handled. 

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REVOLUTIONS | 2024-07-22

Massive Machinery and Innovation at MINExpo International 2024

MINExpo boasts 1,900+ companies involved in the global mining industry. Opening sessions allow the industry to come together to debate global challenges, market fluctuations and the future of mining. Resources include exploration, mine site development, open pit mining, underground mining, smelting and refining, processing and preparation and reclamation.

PRODUCT NEWS | 2023-08-07

MESYS Software Introduces Version 07/2023

A new version of the MESYS shaft and rolling bearing analysis software including new functionality is available. The bearing analysis software allows the calculation of the load distribution within the bearing and bearing life according to ISO/TS 16281 and it is integrated in a shaft system calculation with additional possibilities like modal analysis, strength calculation for shafts and interfaces to gear calculations. Currently the software is used by customers in 31 countries on 4 continents. The new version is now available.

PRODUCT NEWS | 2023-06-20

Faulhaber Drive Units Adjust Shutter and Focus for Camera Application

Sports fans want to see every little detail, and the TV cameras deliver whether the goalie is clenching his jaw before the spot kick or how many millimeters the serve cleared the net in a tennis match, everything is captured in detail. Images like these are only possible when the camera is up-close and doesn’t interfere with the action. Many major tournaments and Olympic Games use miniature devices, which even fit in a corner flag, from the Wiesbaden-based specialist LMP Lux Media Plan. Drive units from Faulhaber are used to adjust the shutter and focus.

INDUSTRY NEWS | 2023-06-05

Salim Haffar Discusses EUROTRANS Priorities in 2023 and Beyond

Salim Haffar, deputy general manager at I-MAK, was reelected as president of EUROTRANS in 2022. This is Haffar’s third term in this role. PTE recently caught up with Haffar to discuss the evolution of EUROTRANS, the focus of the International Drive Conference at Hannover Messe and the current state of I-MAK’s gearbox business in Turkey.

INDUSTRY NEWS | 2023-04-06

KISSsoft Expands Fine Sizing Capabilities with Release 2023

In an urgent assignment, a gear has to be designed, with the engineer already knowing the required reduction ratio, torque and speed. On the manufacturing side, the preferred materials, possible qualities and the reference profiles are specified. This initial situation represents an everyday task.

FEATURE ARTICLES | 2023-04-06

Having a Ball: The Technology Behind the Ball Drop

More than a billion people around the world unite to ring in the New Year, their eyes set upon the glittering New Year’s Ball in Manhattan. Thousands are gathered at Times Square — the famed “Bow Tie” of Midtown — braving the December cold and peering through glasses with numerically shaped frames. Millions more tune in from their various screens at home.
With so much riding on its descent, the Ball, along with the mechanical and electrical systems responsible for its operation, must operate like clockwork.

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FEATURE ARTICLES | 2023-04-06

KISSsoft Supports Student Racing Team in Taiwan

NYCU (National Yang Ming Chia Tung University) Vulpes Racing—founded in 2008—is a Formula Student Team that combines mechanical engineering, industrial design, public relations, video production and marketing expertise. 

TECHNICAL ARTICLES | 2023-03-22

A Model for Considering Wheel Body Deformation in Tooth Contact Load Distribution

This study presents a simulation method for considering complex wheel bodies in an analytical tooth contact model. The wheel body is considered using reduced FE stiffness. Reduction points are defined over the width and linked with the analytical gear.

For cylindrical wheel bodies, comparative calculations show fewer deviations from the expected results with the new method. This is due to the additional degrees of freedom in the FEM model. In the calculation with cylindrical wheel bodies, bending due to axial force in tooth contact could also be verified in addition to the deformation in tooth contact and the influence of the shaft-bearing system.

TECHNICAL ARTICLES | 2023-02-08

Unconventional Gear Profiles in Planetary Gearboxes

Today, gearboxes are inevitable in numerous applications requiring high power density including wind turbines, electric vehicles, cranes, robotics, etc. A combination of high-ratio gearboxes with high-speed, low-torque motors is often used to achieve high power density. Planetary gear trains (PGTs) help achieve a high gear ratio in a compact arrangement. Several configurations of planetary gears are widely studied in this article where the gear profiles used in these studies are primarily involute.

PRODUCT NEWS | 2023-01-23

Harmonic Drive Announces HPF Series

Harmonic Drive announces the release of its HPF series of hollow shaft gear units. Designed for heavy-duty industrial applications, these advanced gear units offer high torque outputs and flexible installation options, making them ideal for use in demanding environments.

INDUSTRY NEWS | 2023-01-11

Auto Gear Joins Gear Motions

Gear Motions is proud to announce that Auto Gear Inc. has joined the Gear Motion’s family. Auto Gear located in Syracuse, New York, specializes in efficient and economical low-volume gearbox production, from design to delivery. 

INDUSTRY NEWS | 2023-01-06

Interact Analysis Looks at Global Geared Motors and Heavy-Duty Gears Market

Interact Analysis have recently released the 3rd edition of the Geared Motors and Industrial (Heavy-Duty) Gears report. This market study covers finished geared motors and gearboxes for general industrial use, including light- and heavy-duty products, as well as planetary gears, with the exclusion of precision gearboxes and loose gear parts. In this edition, amidst global macroeconomic uncertainty, market trend projections have become more volatile compared to previous years.

REVOLUTIONS | 2023-01-03

FVA Presents Transmission Design Considerations

For optimal gear design in accordance with requirements, it is essential to consider load spectra under the most realistic conditions possible as early as the virtual basic design phase. This is the only way to ensure that all components are loaded as evenly as possible to avoid overdimensioning.

Optimized design saves resources and costs and improves the CO2 balance – an aspect that is becoming increasingly important in the current environment and can offer a competitive advantage. Load spectrum calculations are also important for replacing complex time and cost-intensive experiments by simulating test rig damage tests.

PRODUCT NEWS | 2022-12-21

NORD Displays Cost-Effective Solutions at IPPE 2023

NORD DRIVESYSTEMS will be showcasing their innovative meat and poultry drive solutions at the International Production & Processing Expo (IPPE) January 24th – 26th in Atlanta, GA. NORD’s food processing and packaging solutions focus on precise, dynamic control for conveyor systems, reliable performance, and compliance with strict hygiene standards for washdown environments.

INDUSTRY NEWS | 2022-12-08

eAssistant & GearEngineer Support Interactive Learning Tool for Kids

GWJ Technology GmbH, based in Braunschweig, Germany, is a leading manufacturer and provider of calculation solutions for mechanical and gear engineering. With its web-based software eAssistant as well as the special software GearEngineer, GWJ supports GaliGear—an interactive learning tool for children. 

INDUSTRY NEWS | 2022-11-28

Salim Reelected EUROTRANS President

EUROTRANS recently announced the reelection of Haffar Salim as president of their organization during the International Drive Conference that took place online November 17, 2022. 

PRODUCT NEWS | 2022-11-07

NORD Offers Reliable Drive Solutions for Demanding Bulk Material Handling Environments

Many applications in the bulk goods and material handling industry include abrasive environments with large temperature fluctuations and rough operating conditions. To meet these formidable challenges, NORD DRIVESYSTEMS has engineered solutions that are robust, reliable, and easy to service. Their modular product system includes heavy-duty industrial gear units, high-efficiency electric motors with hazard protection features, and variable frequency drives with flexible functionality.

TECHNICAL ARTICLES | 2022-09-30

Reliable, User-Friendly Planetary Gear Unit Design

Stöber Antriebstechnik GmbH + Co. KG rely on the FVA-Workbench for dimensioning and verification of their drives. The calculation and simulation software allows Stöber engineers to develop their innovative gear unit solutions more quickly and efficiently. The result: higher quality products.

REVOLUTIONS | 2022-09-26

Software Bits 2022

What's the latest in software design and simulation in the power transmission market? Here's a recap of some of the latest software solutions for bearings, gears, drivetrains and e-mobility applications.

EVENTS | 2021-12-01

Calendar

Calendar of early 2022 events
REVOLUTIONS | 2021-09-27

The Packaging Perspective 2021

Pack Expo Las Vegas and Healthcare Packaging Expo offers more than 1,500 exhibitors to showcase the latest new materials, technologies and solution...
INDUSTRY NEWS | 2021-03-01

Industry News

The complete Industry News section from the March 2021 issue of Power Transmission Engineering.
FEATURE ARTICLES | 2021-03-01

The Influence of Bevel Pinion Retractability on Casing Design

The intuitive modeling techniques in the FVA-Workbench guarantee consistent, valid, and manufacturable gears every time.
TECHNICAL ARTICLES | 2021-02-01

Consideration of Dynamic Excitation Effects in the Gear Design Process of Two-Stage Gearboxes for E-Mobility

Consideration of dynamic excitation effects in the gear design of two-stage gearboxes for e-mobility.
| 2020-10-15

2020 and Beyond with Bonfiglioli

Company offers new geared motor platform while navigating unusual business environment

What’s a product launch look like during a pandemi...
| 2020-08-12

I-MAK Examines Causes of Gearbox Failure

In a world of optimization and digitization where factories are trying to reduce costs and downtime, the demand for identification of basic gearbox...
TECHNICAL ARTICLES | 2020-06-01

Combining Gear Design with Manufacturing Process Decisions

The integration of manufacturing information into gear design software reduces cost during the design process by avoiding time-consuming back and forth between the design and manufacturing departments. The challenging task for such software is ensuring the design engineer does not need specific manufacturing expertise. Otherwise he or she would be overwhelmed and not use such a feature.
TECHNICAL ARTICLES | 2019-03-01

Optimization of Power Density by Local Gear Failure Modeling

Power density is a key factor in gear design. Increasing the power density enables engineers to use smaller gears for their applications which lead to smaller and lighter gear boxes. The benefit for example for the automotive industry is less moving load in the vehicles and therefor a reduction of fuel consumption and subsequently a reduction of CO2 emission. The limiting factor for the increase in power density of gears is the material strength in regard to the critical failure mode.
| 2018-02-01

Nord Drivesystems Optimizes Baggage Handling System

One baggage handling system OEM came to greatly appr...
TECHNICAL ARTICLES | 2017-12-01

Progress in Rolling Bearing Technology for Refrigerant Compressors

Various surface treatment and bearing technology solutions are explored to solve challenging lubrication regimes.
| 2017-09-07

Meter Bearings Upgrades System Analytics

A global organization, Meter Bearings comprises offices and production centers in China, Germany, and the United States, with their headquarters in...
| 2017-09-05

Buying Gear Drives? Try Gear Expo

Gear Expo is right around the corner, and that means that pretty soon all things gearing will be squarely in the spotlight. Custom gear manufacturi...
| 2017-05-23

There Must Be 50 Ways to Reduce a Duty Cycle (Part 2)

Welcome to Part 2 of our duty cycle journey. In the first part, we reviewed how to take a duty cycle or one block of a duty cycle and reduce it to ...
ASK THE EXPERT | 2017-03-01

ISO-AGMA Standards: Specific Sliding Defined

Does the definition of specific sliding mean the same between ISO 21771:2007 and AGMA 917-B97? In ISO, specific sliding is the ratio of the sliding speed to the speed of a transverse profile in the direction of the tangent to the profile. In AGMA, specific sliding is ratio of gear tooth sliding velocity to its rolling velocity.
ASK THE EXPERT | 2016-10-01

Determining Diametral Pitch, Center Distance

I need help determining the diametral pitch needed to achieve the closest center-to-center distance for 2 spur gears. The 1st gear is a 34-tooth and the 2nd gear is a 28-tooth. The center-to-center distance between the gears needs to be as close to 2 1/8" as possible.
FIELD NOTES | 2016-04-01

Preventing Downtime for Hanger Bearings

Dale Renner, CBS and sales representative at Bearing Headquarters Co., explains how his bearing expertise helped solve a customer’s problem and saved significant downtime and cost.
TECHNICAL ARTICLES | 2016-04-01

Rating of Asymmetric Tooth Gears

Asymmetric tooth gears and their rating are not described by existing gear design standards. Presented is a rating approach for asymmetric tooth gears by their bending and contact stress levels, in comparison with symmetric tooth gears, whose rating are defined by standards. This approach applies finite element analysis (FEA) for bending stress definition and the Hertzian equation for contact stress definition. It defines equivalency factors for practical asymmetric tooth gear design and rating. This paper illustrates the rating of asymmetric tooth gears with numerical examples.
TECHNICAL ARTICLES | 2016-02-01

Homogeneous Geometry Calculation of Arbitrary Tooth Shapes: Mathematical Approach and Practical Applications

This paper provides a mathematical framework and its implementation for calculating the tooth geometry of arbitrary gear types, based on the basic law of gear kinematics. The rack or gear geometry can be generated in two different ways: by calculating the conjugate geometry and the line of contact of a gear to the given geometric shape of a known geometry (e.g., a cutting hob), or by prescribing the surface of action of two gears in contact and calculating the correspondent flank shapes.
MARKET UPDATE | 2015-09-01

Global Industrial Outlook: Game Changer

The number one question today is: are the current low oil prices a near-term or structural development?
FEATURE ARTICLES | 2015-09-01

Mutiple Gearset-Type Calculation Software

Is there a gear software package out there that will calculate the design of spur, helical, worm, and planetary gearsets? Also, we would like a program that calculates stresses and material selection. Finally, we would like to have the program calculate bearings loads, too. Thank you for your help.
TECHNICAL ARTICLES | 2015-08-01

Effects of Contact Ratios on Mesh Stiffness of Helical Gears for Lower Noise Design

In this paper, the influences of various gear parameters on the mesh stiffness are systematically investigated by using the finite element method. The comprehensive analysis shows that contact ratios are the key factors affecting the fluctuation value of mesh stiffness.
TECHNICAL ARTICLES | 2015-08-01

A New Geometrically Adaptive Approach for Tooth Contact Analysis of Gear Drives

Tooth contact analysis (TCA) is an important tool directed to the determination of contact patterns, contact paths, and transmission errors in gear drives. In this work, a new general approach that is applicable to any kind of gear geometry is proposed.
TECHNICAL ARTICLES | 2015-04-01

High Contact Ratio Gearing: A Technology Ready for Implementation

Today’s competitive industrial gear marketplace demands products with excellent reliability, high capacity and low noise. Surface-hardened, ground tooth gearing predominates, but the legacy tooth forms handicap further improvements in capacity and noise generation. Vehicle and aircraft equipment use tooth forms not found in the standard tables to achieve better performance — with little or no increase in cost. This paper will propose adopting these high-contact ratio forms to industrial use.
FEATURE ARTICLES | 2015-04-01

Diametral Pitch Calculation

Circular pitch gives me the size of the teeth in my mind, but diametral pitch does not. What is the purpose of the diametral pitch concept? Does it merely avoid pi in calculation?
| 2015-02-20

Aluminum Housing Series: Cup Distortion after Installation

The next step in our aluminum housing series is to determine where the cup interference is going. If we press a cup with 100µm interference into a ...
ASK THE EXPERT | 2014-09-01

TLC Still Needed for New Axles

A reader asks: I have heard that new axles no longer need a break-in period. True or false?
TECHNICAL ARTICLES | 2014-09-01

Evolution of Worm Gear Standards and their Consequences on Load Capacity Calculation Approach

Beginning with a brief summary and update of the latest advances in the calculation methods for worm gears, the author then presents the detailed approach to worm gear geometry found in the revised ISO TR 10828. With that information, and by presenting examples, these new methods are explained, as are their possibilities for addressing the geometrical particularities of worm gears and their impact upon the behavior and load capacity of a gearset under working conditions based on ISO TR 14521 — Methods B and C. The author also highlights the new possibilities offered on that basis for the further evolution of load capacity calculation of a worm gearset based on load and contact pressure distribution.
TECHNICAL ARTICLES | 2014-08-01

Testing of Alternative Spiral Bevel and Hypoid Gear Theory

Following is a presentation of a gear design based upon a theoretically perfect gear technology, for which an overview is offered for consideration. What follows is a report on the design's testing and subsequent manufacture of a hypoid gear pair for a 1999 Ford Mustang.
MARKET UPDATE | 2014-08-01

Das (Human) Kapital

Columnist Brian Langenberg provides a current outlook update, key findings from a recent energy sector conference, and takes another look at education and employment.
FEATURE ARTICLES | 2013-12-01

Napoleon Engineering Services: Rigged for Success

For design engineers and purchasing agents alike, bearings can sometimes be like family. Oh, you know - can't live with 'em, can’t live without 'em.
FEATURE ARTICLES | 2013-12-01

The Efficient Drive System

It's a fact that drive systems wouldn't function properly or efficiently without couplings. They quietly go about their business of transferring motion from one drive element to the next. In the PT market today, couplings have the unique challenge of satisfying a variety of customer needs including tighter tolerances, higher speeds and a more versatile selection process.
TECHNICAL ARTICLES | 2013-12-01

How To Use a Hand-Held Micrometer to Measure Miniature and Instrument Ball Bearings

For the most accurate measurements, miniature and instrument ball bearing dimensions should be measured with a calibrated air gauge. A good second option is a calibrated optical comparator. On occasion, it may be necessary to use a calibrated, hand-held micrometer to double-check a measurement or for simple verification while working in the field.
TECHNICAL ARTICLES | 2013-12-01

Crowning Spur Teeth - Ask the Expert - December 2013 PTE

When designing spur teeth, is there a formula/guideline/design guide for determining the amount of crowning?
FEATURE ARTICLES | 2013-11-01

VIPS - Very Important Products and Services

Very important gear industry suppliers are featured here.
TECHNICAL ARTICLES | 2013-06-01

Alloying Strategy Boosts Powertrain Performance

The development of a new, gas-carburized gear steel, necessitated by a customer-driven specification, has not only increased the power density in an existing gearbox design, but has done so without requiring any significant change to production processes or heat treatment equipment.
MARKET UPDATE | 2013-04-01

As Risk Recedes, Market Rises

The S&P 500 has rallied six percent since our last review...here's analyst Brian Langenberg's take on what's next for the industrial economy.
FEATURE ARTICLES | 2013-02-01

Gear Design Software

When it comes to gear design software, the learning curve never ends. The leading vendors offer various training programs to keep their users well-informed.
ASK THE EXPERT | 2013-02-01

Ball Screws Revisited - Ask the Expert

A reader asks for clarification on last issue's Ask the Expert column about ball screw sizing.
TECHNICAL ARTICLES | 2013-02-01

Considering Energy-Efficient Motors: Don't Forget the Gearbox

The mechanical components of your drive system play a major role in overall system efficiency. Don't cut corners.
EVENTS | 2012-12-01

PTDA Wraps Up 2012 with Successful Industry Summit

The PTDA Industry Summit, held on October 18-20, 2012 in Dallas, Texas, featured more than 700 participants for two-and-a-half days of networking opportunities and good old-fashioned Texas-style fun.
POWER PLAY | 2011-10-01

Shape-Shifters at Cal Tech Work at Perfecting Metallic Glass

There are no alchemists at the California Institute of Technology, but a team of research scientists at the Pasadena-based institution is doing some pretty remarkable things "transforming something common into something special."
TECHNICAL ARTICLES | 2011-08-01

Gear Drive Selection Process for the Parcel Handling Industry

This article is designed to help describe the selection process of a reducer to be used in the parcel handling industry. It will go over the different applications for which gearboxes are used throughout parcel handling facilities such as UPS, FedEx and DHL.
TECHNICAL ARTICLES | 2011-08-01

Radial Play (Internal Clearance in Ball Bearings)

At first glance, ball bearings are relatively simple mechanisms. However, an analysis of their internal geometries reveals that they are quite complex. For example, the ball to raceway conformity, the radial play, and the number of balls all impact the ability of a ball bearing to support loads under a variety of conditions.
FEATURE ARTICLES | 2009-12-01

Start, Design and Market Your Engines

Honeywell and SAE team up for a unique middle school initiative.
EVENTS | 2009-12-01

Michigan Eyes Investment at AWEA Small and Community Wind Conference

The first trade show dedicated specifically to small and community wind took place in Detroit, Michigan November 3–5. Denise Bode, American Wind Energy Association (AWEA) CEO, was pleased with the turnout for the event and the increasing potential for this segment of the wind energy market.
TECHNICAL ARTICLES | 2008-10-01

Gear- or Actuator-Driven, These Bots Are Cutting-Edge

Robots are everywhere these days— bots in the factory, bots in space, bots at the airport, bots in the movies and much, much more. But robots in the operating room?
FEATURE ARTICLES | 1984-05-01

Gear Design

A gear can be defined as a toothed wheel which, when meshed with another toothed wheel with similar configuration, will transmit rotation from one shaft to another. Depending upon the type and accuracy of motion desired, the gears and the profiles of the gear teeth can be of almost any form.
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