Electric vehicles could represent up to 70% of all cars by 2050. To ensure the acceptance of their vibrational and acoustical characteristics, profound NVH analyses are the key to minimize vehicle excitations caused by specific e-drive transmission designs. KISSsoft AG & FunctionBay GmbH present a common and continuous solution to design, analyze and optimize the NVH behavior of a gearbox used in an e-drive system.

We present stand-alone solutions for gear chamfer cutting processes including the highly efficient chamfer hobbing technology. We focus on the comparison and benefits of chamfer hobbing and fly cutter chamfering regarding efficiency, flexibility, tool cost and cost-per-piece. Finally, we recommend typical applications for both technologies. 

In this Gear Trainer Webinar, we demonstrate basic functions of robot programming, explain the user interface, and show setup and use of a typical machine tending robot. Together, we will program a simple robotic motion. This webinar is intended to demonstrate the simplicity and flexibility of robots to automate your manufacturing equipment and cells.

“Flexfit” is the modular retrofit solution for condition-based overhaul and modernization of large machines. Worn parts and assemblies are replaced by new parts or pre-installed and tested kits, at customers’ premises. FlexFit includes options for additional hardware and software upgrades to increase machine productivity and performance. 

This webinar provides beginners and existing users with an overview of current dressing processes for threaded wheel grinding of gears. We look at different dressing processes and the corresponding dressing tools and show the advantages of the different processes for specific applications using real-life production examples. This webinar is presented in English language.

An army of actuators simplifies our life and provides comfort in cars, kitchen appliances, office equipment and medical devices. Whenever high volumes with technical features like high ratio, self-locking, right angle axes or high torque are required, thermoplastic crossed axis helical gears are the solution of choice. Yet, few design guidelines are available for the optimization of such gears. The webinar sheds light on strategies and techniques based on experience of numerous engineering projects completed. This webinar is presented in English language.

This webinar illustrates the next Generation in Bevel Gear Engineering and Manufacturing. The new Gleason GEMS^® software platform provides highly desirable gear design and analysis capabilities,  seamlessly connects with all your existing Gleason design software – and helps optimize the complete bevel gear manufacturing process.

Gear noise has become a challenge in automotive e-drives and other applications with extremely demanding gear characteristics. Understanding gear noise in general is the foundation for tracing critical noise sources as a base for counter measures. This presentation provides a basic understanding of the origin of gear noise, as well as the possibilities of analytical measurement and NVH roll testing of cylindrical gears with special software and hardware technologies.

E-drive transmissions are different than conventional transmissions, creating new challenges for manufacturing processes. This presentation showcases processes for soft and hard finishing of typical gears in e-drive transmissions. Featured processes include hobbing, chamfer cutting, shaping, Power Skiving, gear honing and threaded wheel grinding, including the appropriate tool technology.

High rpm’s, reversal of load direction, low vibration excitation, high contact ratios, increased risk of scuffing, deformed housings ... the design, optimization and service life calculation of gears for e-drives is a world of its own. The presentation shows how individual requirements can be covered by the choice and variation of gear geometry. Parameters such as material selection or heat treatment are deliberately ignored to concentrate on gear geometry optimization, which is readily accessible to the designer. Three dimensions are addressed: macro geometry, modifications and manufacturing deviations. This presentation is rounded off with the peculiarities of strength calculation in case of frequent changes in torque direction with torque-time series measured from test rigs.

E-drive transmissions are different than conventional transmissions, creating new challenges for the manufacturing and inspection process. This Gear Trainer Webinar showcases processes for soft and hard finishing as well as inspection of typical gears in today’s e-drive transmissions. This webinar is presented by Gottfried Klein and Dr. Antoine Türich, Directors of Product Management for Soft and Hard Finishing Solutions.

This webinar provides an overview of the basics of gear hobbing and the parameters that influence gear quality and process efficiency. We will present key criteria for tool life and hobbing processes and show how specific choices can affect hobbing results. 

This Gear Trainer Webinar focuses on the advantages of expanding mandrels for exertional accuracy and repeatability in metrology and grinding applications. We explore key design elements enabling excellent datum control and demonstrate the correct use of expanding mandrels. Finally, we show the benefits of expanding mandrels in metrology, grinding and general clamping applications.

This webinar shows the benefits of Hard Power Skiving with carbide cutters including machine-integrated cutter resharpening. We demonstrate the functioning of the sharpening unit in a continuous production cycle, explaining relations between sharpening frequency, stock removal amount, grinding time and cutting edge integrity. We explain benefits of constant quality throughout the cutter life, minimum cutter changes and setups, as well as the exceptional cost saving potential for cutter inventory, handling and logistics, resulting in minimum tool-cost-per-piece.

In this session we discuss the use of carbide and PM-HSS hobs including real-life examples to demonstrate the cost-benefit ratio of both solutions. We explain the effects of different materials and how these can influence performance. This new Gear Trainer Webinar suggests potentials for productivity optimization based on key performance indicators. The webinar is presented by Manuel Schlumpberger, Director Sales Tooling Europe.

In this Gear Trainer Webinar we show the modeling of the kinematics of a two stage electric vehicle transmission in KISSsys. The webinar will include the geometric definition of the gears, shafts and bearings, strength calculation of the components in the system considering a load spectrum, as well as checking efficiency and thermal analysis of the transmission for a given application.

If you have not participated in the previous webinar “My First Gear”, we highly recommend to stream this first webinar to get a headstart into the topic. My First Gear

Learn more about the many possibilities and benefits of automation solutions with a focus on the use of robotic part handling and cart-loaded automation. We discuss advantages and benefits of both systems, making recommendations for each systems’ use and operation.

The presentation is accompanies by real production life examples for both options. Gleason offers standard and tailor-made automation solutions for bevel, cylindrical and metrology machines as well as non-gear systems. This webinar is presented by Christian Sterner, Director of Automation Solutions at Gleason Corporation.

If you are looking for a new metrology system or if you are thinking about upgrading your existing Gleason Sigma or GMM System’s capabilities, then this webinar is for you: GAMA 3.2 provides a simple way to enter gear data and inspect gears as fast as possible - all in a Windows 10 environment.

This webinar updates you on new applications of GAMA 3.2 following the previous webinar, held in 2020, which you can watch here to enter the topic.

In this new Gear Trainer Webinar we are introducing gear designers to the basic functions of KISSsoft, describing the user interface, its structure and how easily it works: Together, we will design the first stage of an e-drive gearbox. This process includes the determination of key data, such as center distance and module based on the requested performance specifications. Finally, we will optimize the selected gear design regarding efficiency, weight and other criteria.

Even machines have a fingerprint, but it is of mechanical nature. This mechanical fingerprint is unique and shows the actual condition of a machine and its assemblies. By comparing the current status with the installation status, necessary adjustments and service actions can be made preventively. Learn how Fingerprint and other digital service solutions change the way machines are maintained and significantly reduce long-term maintenance costs.

This webinar covers the efficient production of large gears up to a diameter of 6,000 mm. Using application examples, we explain the most important production technologies and process components to ensure a cost-effective and high-quality result. Depending on machine availability, we will switch live to a cutting or grinding process of a large gear.

In this Gear Trainer Webinar session we update gear manufacturers on cutting technologies for medium-sized bevel gears in truck and bus transmission industries. We present state-of-the-art cutting technologies with manual or automated loading, showing specific application examples. This webinar will showcase the brand-new 500C Bevel Gear Cutting Machine employing the Pentac^® Ecoblade Tool System for the highly efficient production of large quantities of gears.

In this webinar we introduce you to the challenge of manufacturing worms efficiently with high precision. We take a look at the main characteristics of the workpiece and the immanent requirements for suitable manufacturing equipment, tooling and tools. We show work samples for milling single and multi-start worms on a P90WM Worm Milling Machine with integrated deburring, designed specifically for worm shaft production. In addition we discuss correction possibilities to make sure your worm quality lives up to expectations.

This webinar illustrates the next generation in bevel gear cutter head building, delivering highly sophisticated build, truing and inspection of stick-blade type bevel gear cutters. Automated blade positioning, inspection and clamping combine to reduce overall cutter build time and render consistent quality results. This Gear Trainer Webinar is presented by Uwe Gaiser, Director Product Management Bevel Gear Solutions.

This webinar presents the latest development in gear metrology: up to 100% in-process gear inspection during hard finishing becomes reality. Laser technology with double flank roll testing, Closed Loop technology and integrated Waviness Analysis provide for the detection of potential gear noise. This webinar is presented by Dr. Antoine Türich, Director Product Management, Hard Finishing Solutions and Klaus Deininger, International Sales Manager Metrology.

This Gear Trainer Webinar provides an update on chamfer hobbing technology. While previous chamfer hobbing solutions were limited to diameters of roughly 200 mm, we introduce the new 280HCD hobbing and chamfer hobbing machine to extend the range of this highly efficient chamfer cutting process to gears of up to 280 mm in diameter.

Rack-pinion systems are widely used to transfer rotary into linear movements. In this Gear Trainer Webinar session we explain important requirements and solutions for efficient rack manufacture including design, cutting, grinding and measuring.

This webinar explains the main differences between threaded wheel grinding and gear honing. We show specific advantages and typical characteristics of each process. Finally, we discuss whether one or the other process is better suited for specific applications. This live webinar was presented by Dr. Antoine Türich, Director Product Management for Hard Finishing Solutions.

This webinar is specifically aimed at contract gear shops / job shoppers who need to manufacture geared workpieces flexibly and efficiently. We show possible approaches and specific cutting strategies to open up hidden productivity and quality potentials. If you manufacture small and medium lot sizes and your workpieces are diverse, such as various involute and non-involute gears, shafts with gears and splines, beveloid and oval gears, worms and other geared workpieces, then you have come to the right place.

While your machine tool is running, make use of the idle robot in your automated cell to complete additional operations in your manufacturing process including picking, orienting, cleaning, marking, inspection and packing. In this webinar we will discuss how to analyze your process to find opportunities, identify constraints and provide practical concepts to maximize the utilization of your robot.

Twist is a general phenomenon when grinding helical gears with lead modifications. This webinar presents the latest possibilities to analyse twist effects already in the gear design phase and explains comprehensive methods to compensate or generate a desired twist.

This webinar provides an overview of the continuous developments and improvements on CNC-testing of bevel and cylindrical gears. The Gleason 360T CNC Testing Machine provides state-of-the-art roll testing, single flank and structure-borne noise testing capabilities to suite every customers specific CNC testing requirements. This webinar is presented in English language.

This webinar explains the basics of the gear shaving process, the related tooling and introduces the latest shaving machine solutions. This webinar was transmitted live from the home office of Gottfried Klein, Director Product Management Hobbing, Chamfering, Shaving and Rack Solutions. This webinar is presented in English language.

Combi Honing allows the finishing of two gears on one workpiece in a single setup. Combi Honing also allows the finishing of a gear in one setup with two different honing rings, tailored for roughing and finishing, which results in an excellent high quality surface finish. This webinar was transmitted live from the home office of Dr. Antoine Türich, Director Product Management Hard Finishing Solutions. This webinar is presented in English language.

This webinar provides the basics of hobs, shaper cutters and power skiving cutters. Key elements like current materials, coatings and tool design are presented and discussed. This webinar was transmitted live from the home office of Gottfried Klein, Director Product Management Hobbing, Chamfering, Shaving and Rack Manufacturing Solutions during COVID-19 restrictions. This webinar is presented in English language.

This webinar provides an overview of the basics of gear hobbing and the parameters that influence gear quality and process efficiency. We will present key criteria for tool life and hobbing processes and show how specific choices can affect hobbing results. This webinar was transmitted from the home office of Gottfried Klein, Director Product Management Hobbing, Chamfering, Shaving and Rack Solutions during COVID-19 restrictions. This webinar is presented in English language.

The loaded tooth contact analysis LTCA is the tool of choice for reducing the vibration excitation in gear sets and transmissions. A LTCA takes into account the housing, bearing, shaft and gear body deformations and to some extent manufacturing errors. It allows for optimization of the flank design in terms of macro- and microgeometry and ensuring minimized vibration excitation while keeping other performance parameters like efficiency, life and manufacturability at the required level. In this webinar gear the design expert of KISSsoft AG demonstrate the functioning of this very important tool to reduce vibrations in gear sets and transmissions.

From an economic point of view it is not always necessary or possible to completely swap older controls. There are smarter solutions to digitalize older equipment to benefit from latest digital networking and 4.0 solutions. In this webinar Gleason’s Global Services Expert with Field Service Experience explains retrofit options for gear manufacturing and metrology machines. You will learn how you can update or upgrade your equipment with minimum effort. This webinar has been established for customers with installed Gleason machinery.

Dr. Antoine Türich, Director Product Management Hard Finishing Solutions, talks about the Gleason Closed Loop which allows the direct exchange of measurement data between a Gleason GMS Metrology System and a grinding machine with auto-correction functions.

Dr. Antoine Türich, Director Product Management Hard Finishing Solutions, talks about Gleason Twist-Controlled Grinding. With twist-controlled grinding different amounts of twist on the left and right flank can be achieved in double flank grinding mode without impacting cycle and dressing time.

Dr. Antoine Türich, Director Product Management Hard Finishing Solutions, talks about the fast and extremely easy setup process including grinding wheel, dressing tool, workholding and automation adaption change with one single tool.

Tim Zenoski, Product Manager Workholding, talks about workholding solutions for clamping and centering larger gears including solutions for external and internal applications, manual and automated loading.

Prof. Dr. Hermann J. Stadtfeld, Vice President Bevel Gear Technology and R&D provides an update regarding the Pentac^® Plus-RT, the world's first stick blade cutter system with radial and axial blade adjustability.