Gear Stress Analysis, Design and Specification

Computer generated image of gear testingWe use a holistic approach to gear design, analysis and specification. Good design and stress analysis requires detailed knowledge of materials, heat treatment processes, finishing processes, gear manufacturing capability, measurement technology and a detailed understanding of what the gear analysis standards will and wont do. We understand the importance of controlling manufacturing costs, though life product costs, minimising risk, improving competitiveness though good design and optimising design for minimum noise and dynamic loads. Our test rigs give us a unique opportunity to design, make and break gears so we know where the limits are.

The Design Unit has 40 years successful experience in the design, stress analysis, review and trouble shooting of gears and gearboxes for:

  • Automotive gearboxes for cars, off-road vehicles, buses, HGVs, quarry equipment, tractors, earth moving equipment and MOD applications.
  • Wind turbine (ISO/IEC 61400-4) and power generation applications.
  • Engine timing gears, PTO, ancillary and pump drives.
  • Industrial drives including mining, quarrying, steel plant, ball mills, cement plants, chemical plant, agitators and pump applications.
  • Marine propulsion and PTOs including Naval applications
  • Rail traction drives.
  • Control and servo drives for automotive, machine tools, printing machinery and material handling applications.

Analysis work will usually involve:

  • Review and/or specification of gearbox and shaft tolerances and gear accuracy to estimate the random manufacturing errors.
  • Quantify elastic deflections, which may be compensated or considered as part of the gear analysis.
  • Stress analysis in accordance with ISO 6336 'Calculation of load capacity of spur and helical gears'. Scuffing analysis to ISO 13989-1 and ISO 13989-2 (Flash temperature and integral temperature methods).
  • Gear optimisation (GATES), an FE based TCA used to optimise the micro geometry (helix and profile corrections) of gears to minimise stresses and noise.
  • Mesh friction loss, if important for function.
  • Windage and churning losses, if important for function.