A good understanding of individual failure modes and the failure scenarios that led to the actual system failure is an essential skill to designing gear/bearing systems that will operate properly for their full design life. In this course, we will define and explain the nature of many gear and bearing failures and we will also discuss and describe various actual failure scenarios. In addition, a detailed primer on bearing technology prefaces the failure scenario discussions. You will gain a better understanding of various types of gears and bearings. Learn about the limitation and capabilities of rolling element bearings and the gears that they support. Grasp an understanding of how to properly apply the best gear-bearing combination to any gearbox from simple to complex.

In this course we will examine each of these questions and the interrelation of each with a primary focus on how this information can be used to define the actions required to keep the gearbox running properly and to allow maintenance planning. There are many parameters that provide information about the condition of an operating gearbox, some are lubrication centric while others are operationally centric. Each parameter, individually and in combination, can provide insight into the condition of the gearbox and its individual components. There are a variety of ways we can collect the data required to estimate remaining operational time and risk of premature failure. Even more importantly, however, our discussion of the “how” will address the relation of the function of the gearbox and the risks associated with parameters evaluated.

This half-day online seminar is intended to provide you with a thorough understanding of the information contained within a typical gear inspection report. Specifically, we will look at the contents and meaning of the information contained within the gear charts, as well as the techniques used by the gear measurement system to assess gear quality. An explanation of basic gear measurement techniques, how measurement equipment and test machines implement these techniques, and how to interpret the results from these basic measurements will be covered. We will also discuss how to interpret the results and what corrective actions may be considered if the quality of a particular gear is unsatisfactory.

This half-day online seminar is intended to provide you with a thorough understanding of the information contained within a typical gear inspection report. Specifically, we will look at the contents and meaning of the information contained within the gear charts, as well as the techniques used by the gear measurement system to assess gear quality. An explanation of basic gear measurement techniques, how measurement equipment and test machines implement these techniques, and how to interpret the results from these basic measurements will be covered. We will also discuss how to interpret the results and what corrective actions may be considered if the quality of a particular gear is unsatisfactory.

The need for noise control and its relation to gear drive design will be discussed. The general nature of noise and its measurement will be examined, with particular emphasis on terminology standards, and units of measurement appropriate to gear technology. Gear noise, per se, is seldom heard by and observer. The mechanism by which observer noticed noise is generated and transmitted will be defined, described, discussed. Before attempting to solve a noise problem with an existing unit or beginning the design of a new unit, the nature of the noise must be defined. Both experimental and analytical methods will be covered, with particular emphasis on application rather than theory.The many factors that influence the noise produced by a gear system will be discussed. The relative effects of each factor will be studied qualitatively. Factors to be considered include gear tooth geometry and accuracy, speed, materials, housing design, bearing type, gear type, air entrapment, root clearance, interference alignment, surface finish, and phasing. Although, ideally, the designer should solve noise problems on the drawing board, in the real world this sometimes does not occur. Various techniques that can reduce the noise level of existing gear systems without requiring major hardware replacement will be presented and discussed. Included in the discussion will be enclosures, absorbers, dissipative dampers, isolators (gearbox and gear blank), and impulse phasing.

Explore gear failure analysis in this hands-on seminar where students not only see slides of failed gears but can hold and examine over 130 specimens with the same failure modes covered in the seminar. Approximately half of the course time consists of students in groups identifying failure modes on failed gears and working on a case study. Microscopes are available to examine failed specimens.

Learn the fundamentals of gear manufacturing in this hands-on course. Gain an understanding of gearing and nomenclature, principles of inspection, gear manufacturing methods, and hobbing and shaping. Utilizing manual machines, develop a deeper breadth of perspective and understanding of the process and physics of making a gear as well as the ability to apply this knowledge in working with CNC equipment commonly in use.

Learn how to develop and understand customer gear drive application specifications and target performance expectations. Review, calculate and select basic gear terminology variables and design parameters which define tooth bending and contact rating safety factors on two real-life examples. Learn how to optimize gear fatigue Safety Factors for a given target design life and fit new gear designs and ratios into existing center distance using profile shift. Use commercially available software to develop gear geometry factors, calculate and optimize gear set power density and performance. Review common gear failure modes if the design or final accuracy does not meet application requirements. Discuss time and cost of more than 20 other gear drive component functions and drive development steps through prototypes to shipment of compliant assembled production drives. There will be an opportunity to discuss gear design challenges which may be unique to participant industries.

This course will provide a solid foundation for anyone going into gear inspection. Learn the common, current and basics of the tools and techniques used to measure and inspect gears. Understand the four main categories by which a gear is evaluated and classified. Gain proficiency in understanding gear quality by learning the numerical scale on which gear design, manufacture and inspection are based, and more.

Reverse engineering a gear system is a not too unusual task and in many, but not all, cases the process goes fairly well, thus it is easy to become complacent. It is important, however, to fully understand the process and the best practice procedure for reverse engineering a gear system. Failure to fully follow best practice can result, at best, in an unhappy gear user, but in the worst case it can lead to very expensive, time consuming and reputation damaging litigation. We will discuss the basic types of reverse engineering projects (e.g. upgrading an existing system to increase power or extend operating life or improve noise level; replacing gear that has simply reached the end of its otherwise successful useful life; emergency, short term, interim gear replacement resulting from an unexpected failure; responding to a system that is not providing acceptable performance, etc.). The need for understanding the operation of the system in which the gears will be used, the conditions that led to the need for the project and especially, the specific nature of the failure that occurred, if that is the reason for the project, are key, often ignored, elements of the process. In some cases, no drawings are available at all thus a design must be developed that will yield gears that provide equivalent load capacity, life, noise performance and smoothness of operation. This scenario will be discussed with recommended analyses resented. In other cases, where no drawings are available, the correct procedures to follow in developing a reverse engineered gear that truly meets the system requirements will be discussed in detail with cautionary procedures outlined. The concept of applying the AVO (avoid verbal orders) process to the overall reverse engineering process will be discussed with fact based but names and identifying details eliminated case studies to emphasize the importance of this concept. The “amnesia” issue will also be addressed in this context. The author’s experience in serving as an Expert Witness provides first-hand information that will aid in avoiding this aspect of a reverse engineering project completely…. if followed!