Gain a basic understanding of steel and its properties. Learn to make use of steel properties in an application and understand the potential that different steel and heat treatment options can offer. Explore how performance of the material depends on how the steel is produced.

This course is an introduction to the methodology of analytical gear inspection and the evaluation and interpretation of the resulting data. The application of this information to identify and correct manufacturing errors will begin to be explored. Additionally, it reviews chart interpretation and applies inspection data to understand the causes and cures of manufacturing errors. Many chart examples are used to understand cause and effect.

Evaluation of loaded tooth contact and development of tooth modifications using commercially available software to improve Khb and optimize power density.  Two real life gearing examples will be presented in the course, one will have a cantilever mounted pinion, the other a shaft pinion straddled non-symmetrically by bearings.  Both examples demonstrate component deflections under load which significantly reduce tooth mesh contact which is then corrected with developed helix and profile modifications.

Learn how to develop and understand gear drive application specifications and target performance expectations. Review, select and calculate basic gear terminology variables and design parameters which define tooth bending and contact rating safety factors. Learn how to fit new gear design and ratio into existing center distance. Use commercially available software to calculate and optimize gear set power density through application of profile shift, accuracy, material and heat treatment. Review other gear design related factors of operating noise level, efficiency, lubrication, micro-pitting.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!

Learn and understand fundamentals of gear manufacturing. Acquire knowledge and understanding of gear nomenclature, hobbing and shaping of spur and helical gears, and splines. Learn and understand hobber and shaper machine set-up, as well as gear tooth element inspection. Understand the manufacturing process before gear tooth cutting, as well as post cutting processes. Apply concepts to further finishing processes, I.e. heat treat, gear tooth shaving and grinding and/or skiving. Gain knowledge to establish a solid foundation for all basic gear manufacturing.

Gain a solid and fundamental understanding of gear geometry, types and arrangements, and design principles. Starting with the basic definitions of gears, conjugate motion, and the Laws of Gearing, learn the tools needed to understand the inter-relation and coordinated motion operating within gear pairs and multi-gear trains. Basic gear system design process and gear measurement and inspection techniques will also be explained. In addition, the fundamentals of understanding the step-wise process of working through the iterative design process required to generate a gear pair will be reviewed. Learn the steps and issues involved in design refinement and some manufacturing considerations. 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 also be covered.

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!

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.

This webinar intends to demonstrate how, using the advantages of open die forging combined with the near-net shape capability of closed die forging, the forging process can be tailored to optimize time and cost savings for the gearing industry.

This course provides a solid and fundamental understanding of gear geometry, types and arrangements, and design principles. Starting with the basic definitions of gears, conjugate motion, and the Laws of Gearing, those attending will be given the tools needed to understand the inter-relation and coordinated motion operating within gear pairs and multi-gear trains. Basic gear system design process and gear measurement and inspection techniques will also be explained. In addition, the fundamentals of understanding the step-wise process of working through the iterative design process required to generate a gear pair will be reviewed, and attendees will also briefly discuss the steps and issues involved in design refinement and some manufacturing considerations. Also, 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.