Elektrik/Elektronik Nutzfahrzeuge 2016

Registration

Common welcome and opening of the

• International Conference on Gears 2017
• International Conference on High Performance Plastic Gears 2017
• International Conference on Gear Production 2017

by

• Prof. Dr.-Ing. Karsten Stahl, FZG, Technische Universität München (TUM), Garching, Germany
• Prof. i.R. Dr.-Ing. Bernd-Robert Höhn, TUM emeritus of excellence, FZG, Technische Universität München (TUM), Garching, Germany
• Dr.-Ing. Bernhard Bouché, Director of Research and Development Mechanics, Getriebebau NORD GmbH & Co. KG, Bargteheide, Germany

Panel Discussion

The future of gears - a high-tech product? 

"With modern gearing technologies, different materials and manufacturing processes can be combined for tailored gear design to meet the demands regarding cost, power density, NVH-behavior and efficiency. The potentials and challenges of conventional gears, powder metal gears, plastic gears and gears cut on universal 5-axis-CNC-machines are going to be discussed by corresponding senior experts."

Moderation: Prof. Dr.-Ing. Karsten Stahl, FZG, Technische Universität München (TUM), Garching, Germany

Participants:

Andrew Dempsey, Vice President – Powder Metal Division, Stackpole International, Ancaster, Canada

George Diaz, General Manager, Gleason Plastic Gears, Rochester, New York, USA

Claude Gosselin, Ph.D., P.Eng., President Involute Simulation Softwares Inc., Quebec, Canada

Dr.-Ing. Burkhard Pinnekamp, Head of Central Technology, Renk AG, Augsburg, Germany

Lunch break and visit to the exhibition and poster presentations

Possibilities and potentials of plastic gear applications

Moderation: Robert Seidler, ZF Friedrichshafen AG, Germany

Chances and Challenges of High Performance Plastic Gears –  Three Experts, three Perspectives

• Prof. Dr.-Ing Karsten Stahl, FZG, Technische Universität München (TUM), Garching, Germany Dr.-Ing. Ulrich Kissling, President, KISSsoft AG, Hombrechtikon, Switzerland
• Dr.-Ing. Andreas Langheinrich, Development Drive Technology, Horst Scholz GmbH & Co. KG, Kronach, Germany

Performance improvements of spur gears using internal/external material modifications following VDI 2736

• Material modification of polymer spur gears
• External and internal modification
• Tribological behaviour
• Possible Applications Dipl.-Ing. Bernhard Gierl, Project Manager, Tribology and Machine Elements, Research Institute of Polymer Technology, LKT, Erlangen, Germany

Design of plastic micro gear teeth for mass production with high manufacturing tolerances for a medical devices

• Optimized tooth profile for micro gear wheels with less than  2mm diameter
• Plastic micro gears in mass production
• Challenges due to high manufacturing tolerances
• New evaluation criteria for micro gears
• Drive for a wearable drug delivery device

Dipl.-Ing. Jürgen Strüber, Development Engineer, Research and Development, Bühler Motor GmbH, Nürnberg, Germany

Novel precision plastic gear applications in various industries

• Weight and noise reduction in mobility applications
• Feasibility evaluation of metal to plastic gear replacement in an aerospace application
• Robotics and Pick and Place applications
• Several high temperature involving bearings and actuators in automotive

George Diaz, General Manager, Brian Stringer, Gear Design Engineer, Gleason Plastic Gears / Rochester Institute of Technology, Rochester, New York, USA

Coffee break and visit to the exhibition and poster presentations

Tribology of Plastic Gears

Moderation: Dr.-Ing. Ulrich Kissling, KISSsoft AG, Hombrechtikon, Switzerland

Lubrication of plastic worm gears

• Efficiency of grease lubricated gears under various loads
• Investigations on thickener concentration (NLGI class) and baseoil viscosity
• Effect of baseoil and thickener type

Dr. André Bormuth, Polymer Tribologist, Klüber Lubrication München SE & Co. KG, Munich, Germany

Characterization of  thermo-elastohydrodynamically lubricated (TEHL) Contacts of Thermoplastic Gears

• Comparison of thermoplastic-steel and steel-steel TEHL contacts • Friction and film thickness prediction
• Analysis of heat Management

Enzo Maier M.Sc., Research Associate

M.Sc. Thomas Lohner, Head of Department EHL-Tribological-Contact and Efficiency

Prof. Dr.-Ing. Karsten Stahl, Full Professor, Institute of Machine Elements, Director, Gear Research Centre (FZG), Technische Universität München (TUM), Garching, Germany

Lubricant – Polymer Interactions of Plastic Gears

• A short overview about the tribology of plastic gears
• The interaction of polar and non-polar lubricants with polymer surfaces
• The interdependence of wetting and friction
• The role of roughness with respect to friction, wear and lubricant behavior

Prof. Dr.-Ing. Matthias Scherge, Business Unit Leader Trybology, Mikro Tribologie Centrum μTC, Fraunhofer Institute for Mechanics of Materials IWM, Karlsruhe, Germany

Relevant tribological testing method for high performance plastic gears

• High performance plastic gears
• Sliding wear test setup (disc to disc) plastic – plastic contact
• Test conditions representative for plastic gear applications
• Correlation of test results with gear wear measurements

Dr. Ir. Marc Kanters, Scientist

MSc. Benjamin van Wissen, Associate Scientist

Dr.-Ing. Reimo Nickel, Application Development Manager, DSM Engineering Plastics Research & Technology B.V., Geleen, Netherlands

Organized bus transfer to the evening reception

Get-together

Evening reception at the „Hofbräuhaus München” At the end of the first conference day we cordially invite you to our evening reception at the „Hofbräuhaus München”, a traditional Bavarian brewery with deep roots in Munich.

Enhance your personal network and use the relaxed and informal atmosphere for deeper-going discussions with other participants and speakers.

Dinner speech:

Dipl.-Ing. Oliver Zipse, Member of the Board of Management,  Production, BMW AG, Munich, Germany

NVH of Plastic Gears

Moderation: Prof. Dr.-Ing. Dietmar Drummer, LKT, Erlangen, Germany

Product requirements and opportunities: Customer’s expectations and designer’s and manufacturer’s opportunities – Three experts, three perspectives

Dr.-Ing. Armin Kunz, Senior Vice President, Chassis Systems Control, Project Modular Braking Systems, Robert Bosch GmbH, Abstatt, Germany

Dipl.-Ing. Robert Seidler, Director, Corporate Research and Development, Gear Development, ZF Friedrichshafen AG, Germany

Prof. Dr.-Ing. Dietmar Drummer, University Professor, LKT, Friedrich- Alexander Universität Erlangen-Nürnberg, Erlangen, Germany
 

Design investigations and indications for acoustical optimized gear meshes using plastic gears

• Differences between metal and plastic gear meshes
• Indications how a noise optimized toothing including plastic might look like
• Presentation of test rig results and the comparison with FEA regarding acoustics

Dipl.-Ing. (FH) Matthias Koop, Senior Project Engineer

BSc. Egor Melnikov, Project Engineer

BEng. Volker Merz, Test Lab, R&D Components,  IMS Gear SE & Co. KGaA, Donaueschingen, Germany

A contribution to the NVH behavior of plastic gears in automotive applications

• Fabrication of meso-gears of brass using wire-electric discharge machining
• Study the effects of process parameters on gear quality
• Investigations on micro-geometry and surface roughness of meso-gears
• Optimization for high functional performance and long service life

Dr.-Ing. Jens Fechler, Senior Manager, R&D Actuators 

M.Eng. Maximilian Böhm, R&D Actuators

Dipl.-Ing. (FH) S. Aberle,  R&D Actuators, IMS Gear SE&Co. KGaA, Donaueschingen, Germany

Coffee break and visit to the exhibition and poster presentations

Comparison of Typical and Future Materials

Moderation: Dr.-Ing. Armin Kunz, Robert Bosch GmbH, Abstatt, Germany

Measuring permissible root/flank stress of plastic gears according to the VDI 2736-4

• Test rig and testing procedure
• Measuring permissible root/flank stresses
• Statistical evaluation of measured data

Dr. Aljaz Pogacnik, Development Engineer,

Dr. Stefan Beermann, CEO, KISSsoft AG, Bubikon, Switzerland

Material data for advanced plastic gear simulation

• Thermoplastic Materials for Gears
• SABIC’s predictive engineering workflow
• Material data characterization for gear simulation
• Plastic-plastic spur gear wear Simulation

Dr.-Ing. Julien Cathelin, Sr. Scientist, Ing.,

Rob Janssen, Technical  development engineer, Technology & Innovation, SABIC B.V., Geleen, The Netherlands

Adoption of Polymer Gears – Challenges and Solutions

• Automotive megatrends and the motivation for polymer gears
• Efforts to cross the adoption chasm
• Automotive focus areas and initial successes
• Future key challenges

Dipl.-Ing. Ralf Weidig, Global Program Manager Gears, Victrex Europa GmbH, Hofheim am Taunus, Germany

High Performance Polymers for future tribological application

• High performance plastic material for gear parts
• Development strategies for gear parts
• Tribological behavior
• Success stories for gear application

Dipl.-Ing. Frank Lorenz, Director Components – Automotive & Mobility, Evonik Resource Efficiency GmbH, Marl, Germany & Engineering Plastics Research & Technology B.V., Geleen, Netherlands

Lunch break and visit to the exhibition and poster presentations

NVH of Plastic Gears

Moderation: Dr.-Ing. Andreas Langheinrich, Horst Scholz GmbH & Co. KG, Kronach, Germany

Advanced Modeling and Experimental Techniques for Fatigue Life Prediction of Plastic Gears

• A powerful computational design tool for plastic gears’ fatigue analysis
• Provides realistic simulation of plastic gears’ lifetime, durability, and load sharing
• Creep, surface finish, humidity, aging, self-heating and frequency effects on fatigue lifetime of plastic gears can be considered

Amir Kian Shojaei, Ph.Dr., Mechanical Engineering Consultant

Dr. Pieter Volgers, Senior Consultant & Global CAE-ACE Leader, DuPont, Wilmington, USA

Mike Casada, Gear Engineering Manager, Winzeler Gear, Harwood Heights, USA

Influence of the Tooth Flank Shape on thermal Load of the Gear

• Involute versus S-Gear, essential differences
• Polymer Gears – friction and sliding
• Dedendum – addendum length and differences
• Cylindrical gear pairs – effect of the thermal load

Dr.-Ing. Gorazd Hlebanja, Faculty of Systems and Technologies, Higher Education Centre Novo Mesto

Dr.-Ing. Simon Kulovec, Research and development, Podkriznik, d.o.o.

Damijan Zorko,  Mag.-Ing., LECAD – University of Ljubljana, Slovenia

Theoretical and Experimental Investigations on the Load Carrying Capacity of small sized Crown Gears

• Different material pairings (POM-steel and steel-steel)
• Load carrying capacity considering stiffness
• Wear on crown gear flanks
• Load distribution on crown gear flanks

Dipl.-Ing. Markus Baar, Development Engineer for Gear Calculation, Car Powertrain Technology, Business Unit Axle Drives,  ZF Friedrichshafen AG, Thyrnau

Dr.-Ing. Peter Oster, Senior Engineer

Prof. Dr.-Ing Karsten Stahl, Full Professor, Institute of Machine Elements, Director, Gear Research Centre (FZG), Technische Universität München (TUM), Garching, Germany

Coffee break and visit to the exhibition and poster presentations

Load Carrying Capacity of Plastic Gears

Moderation: Prof. Dr.-Ing. Karsten Stahl, Technische Universität München (TUM), Garching, Germany

Semi-analytical method for the prediction of the flank temperatures of polymer gears during running

• Finite element analysis of the mechanical response during polymer gear meshing
• Decomposition between flash and bulk temperature on the gear tooth
• Semi-analytical thermal analysis based on computed mechanical behavior
• Experimental validation of the computed thermal Response

Mag. Ing. Borut Černe, Research assistant

Mag. Ing. Damijan Zorko, Research assistant

Prof. Dr. Jože  Duhovnik, Head of department, Faculty of Mechanical Engineering, University of Ljubljana, Slovenia

Experimental Investigations of Polymer Gear Performance

• Unique test facilities for polymer composite gears
• Study the effects of misaligned polymer composite gear performance
• Investigations on reinforced polymer gear wear

Dr. Ken Mao, Associate Professor, School of Engineering, Warwick University, Coventry, Great Britain

Wear and fatigue behaviour of polymer gears under controlled temperature conditions

• Load and temperature depended lifetime of polyacetal (POM)/ steel gear pairs
• Assumption: “room temperature (25 °C)” tests run actually at 46-64 °C.
• Reducation of the fatigue life by increasing temperature x
• Importance of temperature control in plastic gear tribology

Prof. Mitjan Kalin, Head of Laboratory for tribology and interface nanotechnology

Dr. Alja Kupec, Researcher, Faculty of Mechanical Engineering, University of Ljubljana, Slovenia

Bending strength of cylindrical plastic gears

• Load-induced increase in actual contact ratio
• Back-to-back testing of injection molded POM test gears
• Influence of resonance ratio on bending strength
• Modified bending strength calculation based on VDI 2736

Dipl.-Ing. Christian Hasl, Research Associate

Dr.-Ing. Thomas Tobie, Head of Department

Prof. Dr.-Ing. Karsten Stahl, Full Professor, Institute of Machine Elements, Director, Gear Research Centre (FZG), Technische Universität München (TUM), Garching, Germany

Get-together

At the end of the second conference day we kindly invite you to our evening reception. Enhance your personal network and use the relaxed and informal atmosphere for deepening talks with other participants and speakers.

Dinner Speech: Matthew E. Croson, President, American Gear Manufacturers  Association (AGMA), Alexandria, USA