Project: From theoretical modifications to practical lifetime

Small changes, big effect

Project: From theoretical modifications to practical lifetime | MDESIGN Consulting Services

Problem definition

Analytical verification methods are normally subject to application limits and are nevertheless generally recognized calculation tools for the constructive design of gear tooth systems. In the practical application in the field of highly loaded, multi-stage industrial gears for the transmission of torques beyond 10,000 kNm, additional effects only partially dealt with in standards appear as safety-relevant quantities, which seem negligible in other orders of magnitude. The damage cases that occur in the field cannot be verified mathematically in accordance with the standard procedures and, in addition to spare parts costs and legal questions, also entail uncertainties in the elimination of faults.

In order to generate a solution for the elimination of the repeatedly occurring gear damage in the field, the boundary conditions of the present bevel - helical gearbox have to be compared with the application areas of the standardizations in order to realize technical solutions by using digital and practical tools.


The present gears and gearboxes should be preserved in their constructive form in order to avoid resources and costs of a new production. Based on the occurring damage patterns, a calculation model has to be set up, so that the quality of the product can be increased by gear modifications on already manufactured single parts.
By analyzing the gearbox environment and its influence on the gearing contacts due to the high forces and associated deformations of the gearbox elements such as housing, shafts, bearings and gear body itself, a computational model is to be created which will be qualitatively validated with test bench runs.



In addition to the transmission information digitized to the current state of the art, the calculation model was able to confirm the transmission damage simulated as a digital twin. In the application of the model, flank geometries were subsequently optimized computationally to compensate for the interaction of the transmission elements.
In practical application, all series parts already manufactured can be retained after reworking, and new developments can be specifically optimized in production. Practical tests on test rigs show expected good load-bearing properties of the gears and an average increase in service life of 100%.