technical

Performance of Gears Manufactured

by 5-Axis Milling
Julian Staudt, Cristoph Löpenhaus and Fritz Klocke
Free form milling of gears becomes more and more important as a flexible machining process for gears. Reasons for that
are high degrees of freedom as the usage of universal tool geometry and machine tools is possible. This allows flexible
machining of various gear types and sizes with one manufacturing system. This paper deals with manufacturing, quality and
performance of gears made by free form milling. The focus is set on specific process properties of the parts. The potential
of free form milling is investigated in cutting tests of a common standard gear. The component properties are analyzed and
flank load-carrying capacity of the gears is derived by running trials on back-to-back test benches. Hereby the characteristics
of gears made by free form milling and capability in comparison with conventionally manufactured gears will be shown.

Motivation, Objective and

Approach
Due to several advantages in matters of
flexibility and degrees of freedom in gear
and process design, 5-axis milling has
established itself as an accepted manu-
facturing technology for the gear mak-
ing industry (Refs. 1; 2; 11; 12; 3; and 26).
Beyond the pure academic application
in fundamental research, there are three
main areas of application in the industry
for this technology, i.e. — prototyping,
single part production, and repair/spare
parts; application areas for this technol-
ogy are summarized (Fig. 1).
Because of the high flexibility, small Figure 1 Area of application for free-form milling of gears.
batch sizes and various other gear types
can be economically realized. Combining
soft and hard machining on one single
machine tool creates advantages over
conventional process chains — even for
manufacturing of very big gears and sin-
gle part production. Furthermore, short
delivery periods are one of the major
aspects in the production of spare parts.
Due to the usage of a universal machine
tool and universal milling tools, delivery
times for special hobbing tools can be Figure 2 Objective and approach.
eliminated and the duration of the pro-
duction cycle for spare parts is reduced With use of standard milling tools, the ogy the performance of the parts — in
massively. application area of gear types and sizes comparison with conventionally ground
Five-axis gear milling finally provides is virtually unrestricted. With this pro- gears — must be analyzed.
the opportunity for additional degrees cess all conventional gear types and tooth This paper deals with the potential
of freedom in gear and part design, in geometries can be realized. Furthermore, of 5-axis milling for gears, based upon
comparison to conventional gear making the technology is flexible concerning new years-long comprehensive and scientific
technologies. Now, the microgeometry gear types. work on the free form milling of gears.
of tooth flank and tooth root can be opti- Note that as the technology is not as (Refs. 15–18; 19; 30–31). The objective
mized freely. In addition, the minimal yet available (Refs. 12; 24; 22; 34; 11; 35), of this paper and the approach concern-
run-out of the tool and the accessibility to there is no scientific analysis available ing the related investigations are shown
the cutting area can be used for construc- concerning the potential of this process in Figure 2.
tional improvements to the entire gear- regarding gear quality. In order to uti- The process terminology and process
box and its arrangement of the gears. lize the full potential of this technol- characteristics — as machining strat-

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egy and process specific surface struc-
ture — are explained. The potential of gear
manufacture with free form milling is
investigated in cutting tests of a common
standard gear type C; therefore the gear
geometry and the surface were analyzed.
Gear quality is compared to requirements
of conventionally machined gears.

Process Definition — Terminology

of Free Form Milling of Gears
According to DIN standard, manufactur-
ing of gears on universal machine tools
is located in the area of NC form mill-
ing (Ref. 4). The manufacturing process
regarding machine tool and control unit Figure 3 Process characterization.
is comparable to manufacture of molds
and dies (due to similar materials, hard-
ness and accuracies) and to the manu-
facture of impellers and turbo machinery
components (due to similar geometries).
Beyond this general definition of free
form milling, process specific parameters
for the manufacturing of gears have to be
characterized. The process description
includes the definition of process param-
eters, the tool selection and the genera-
tion of input data (Fig. 3).
A portion from the full description
of the process characteristics of the free
form milling of gears contains: Tool selec-
tion, generation of input data and, par-
ticularly, machining strategy; these three
aspects will be discussed in the following. Figure 4 CAx process chain.
Characteristics beyond that are defined
by terminology of gear manufacturing chosen machining strategy is essential for gear measurement and generation of NC
and NC free form milling and will be these contact conditions and for restric- code. Depending on the correction meth-
adapted. tions of tool selection. od, different steps of the CAx process
Selection of milling tools. The selec- Generation of machine input data. chain are necessary for the compensation
tion of milling tools is divided into soft In contrast to manufacturing of gears (Fig. 4, right).
machining and hard machining. Because on conventional gear manufacturing Machining strategy. The machining
of different requirements rough and fine machines, free form gear milling requires strategy includes three major aspects of
cutting steps are met with different tools. a defined geometry in the form of coor- the definition of the manufacturing pro-
For the machining of tooth root, a tool dinates. Figure 4 shows the CAx process cess, i.e. — the lineness, trajectory and cut-
change can be necessary, too; standard chain necessary for the generation of the ting strategy; Figure 5 provides an over-
milling tools are characterized by the NC code. view of the machining strategy.
parameters shown (Fig. 3, left). After gear design, the gear data is sent The trajectory defines the path of the
For stability reasons a large as possible to the CAx process chain. In the first step tool in machining relative to the tooth
tool diameter is chosen; tool length is the gear data is transferred into the gear flank. The lineness is the term for the
chosen as short as possible. Tool size, as geometry. The creation of gear geometry quantity of required tool paths for the
well as blade radius, is restricted by the can be done analytically or by a manufac- machining of one tooth flank and for
gear geometry. turing simulation, and includes a defined the space between the lines. The index-
Different types of milling tools are geometry of flanks and tooth root. In the ing procedure describes the systemat-
sorted into groups by their blade geome- next step the gear geometry is converted ics of machining all gaps successively.
try. Possible tool geometries are full radi- into NC code. This includes manufacturing order and
us, torus and shaft cutter. Depending on Deviation of geometry resulting from movement of all axes during indexing
the type of tool, there is a point or line the manufacturing process can be offset between two teeth. All three components
contact between tool and gear flank. The by closed loop between manufacturing, of machining strategy will be defined and

March/April 2017 | GEAR TECHNOLOGY 59

 technical

described in the following. defines the schema how tool paths are face requirements can be accounted for
Trajectory. The definition of the trajec- located on the tooth flank; there are three during configuration of the milling pro-
tory is based on technological require- possibilities that can be seen in the mid- cess.
ments for the running behavior of the dle of Figure 5. Cutting strategy. The cutting strategy
gears. Furthermore, the trajectory has First, tool feed can be equidistant for is divided into two categories — indexing
a significant influence on processing each tool path. That leads to a changing and cut distribution. The centering of the
effort and process kinematics. Different structure all over the tooth flank. The gap for hard machining can be realized
trajectories are shown on the left hand second possibility is to define tool feed by measuring equipment on the machine
side of Figure 5. The trajectory can be depending on gear geometry in order to tool. The indexing strategy can be steady
defined in direction of tooth width, pro- keep the space between two paths on the or unsteady. During steady indexing the
file direction or diagonal on tooth flank. gear flank constant. Surface structures proximate gap is located next to the cur-
Furthermore, common structures can be at tip and tooth root are the same. The rent one. The advantages are short move-
imitated (gear honing or gear finish hob- last shown possibility is an independent ments of tool and part during machining,
bing) and new structures can be realized. definition of line spaces in tool feed and as shorter machining times can be real-
From the manufacturing point of view, tooth profile direction. Here the struc- ized. Errors in part rotation and ther-
there are no technological restrictions. In ture can be defined freely and the flank mic influences are accumulated dur-
terms of economical process design, the surface can be realized based upon stress ing machining so that the pitch devia-
complexity of trajectories must be taken deviation for the whole flank. Thus the tion between first and last tooth is high.
into account because complex trajectories effort for process configuration is, in this During unsteady indexing the gaps are
require additional axes and movements of case, very intense. machined/evenly distributed all over the
the tool. The space between tooth paths defines gear. Errors are not accumulated in this
Lineness. Lineness in part defines the the kinematic surface roughness (Ref. 13). case; the peak of pitch deviation can be
number of tool paths that significantly The kinematic surface roughness can be avoided. Machining time will be higher
influence machining time. Also, lineness described geometrically so that the sur- than with steady indexing because more
movements are necessary.
The distribution of cuts depends on
the hard finishing allowance; single- or
multi-cut strategies can be realized in
order to finish the gear after heat treat-
ment. The single-cut strategy leads to
short manufacturing times and high chip
volumes. Multi-cutting includes pre-fin-
ishing steps so that hardening distor-
tions are equalized before the final cut is
applied. In this case the chip volumes can
become very small and the thermal influ-
ence on the part increases.

Scope of the Investigation and

Experimental Setup
Figure 5 Definition of manufacturing strategy for free-form milling of gears.
Using the given process definition for the
free form milling of gears, fatigue tests
were begun. The gear quality, further part
properties, and the running behavior of
the gears made by free form milling are
analyzed; Figure 6 provides an overview
of the experimental setup.
The used gear type is a standard test
gear type C (Refs. 8; 21; 34). For anal-
ysis of the manufacturing technology
and running behavior, only the pinion
(z1 = 16) was made by free form milling.
The wheel (z2 = 24) was conventionally
profile ground.
Four different machining setups were
chosen; (top, right) Figure 6 shows all
used process parameters. The test gears
were manufactured in single-cut strat-
Figure 6 Scope of investigations.

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egy (ae = 20μm) and multi-cut strategy
(ae = 120μm). Furthermore, the theoretic
process-specific surface deviation was
varied from Rth = 1μm up to Rth = 15μm.
Defined test conditions are related to
FVA No. 0/5 and shown (Fig. 6, bottom
right) and (Ref. 9). Flank load carrying
capacity for all variants was derived. In
addition, conventionally ground gears
were tested and a reference S/N-curve
derived.

Integrity of Gears Machined by

Free Form Milling
The first analysis aims for a compre-
hensive analysis of all gear properties.
Figure 7 Gear quality.
Therefore the gear quality, the process-
specific surface structure, and the charac-
teristics of the surface near (near surface)
material structure are analyzed.
Gear quality. The gear quality of all
four variants is shown (Fig. 7). The first
three variants were made by a multi-cut
strategy. The process-specific surface
structure was varied by the lineness. The
fourth part was realized by the same line-
ness as the third one, but hard finishing
was done in a single-cut. The last of the
shown parts is the reference gear, which
is profile-ground.
All gears match the requirements of IT
5 concerning pitch and quality in lead
direction. The quality in profile direc-
Figure 8 Process-specific surface structure.
tion is pre-defined by the chosen line-
ness. Because of that the first part — with chosen machining strategy (e.g., trajec- in the middle and compromises between
Rth = 15μm — has a profile quality of IT 8, tory and lineness). high surface deviations (like the vari-
which is directly related to the lineness The resulting surface structure meets ant with Rth = 15μm) and high machining
and the resulting profile form deviation the existing definition (Refs. 15–16; times (like the variant with Rth = 1μm).
ffα = 15μm. All in all, it is clearly visible 29). The actual value of the deviation The change of the cut distribution from
that all variants have a sufficiently geo- Rth,ist = 9.3μm is smaller than Rth = 15μm multi-cut strategy (ae II = 20μm) to sin-
metrical gear quality. The chosen manu- because the number of trajectories gle-cut strategy (ae = 120μm) leads to an
facturing strategy affects the resulting gear must be an integer and the deviation increasing surface roughness. The dif-
geometry; thus the resulting gear quality Rth = 15μm may not be exceeded. In the ference is explained by the increase of
becomes predictable and can be specified shown case the difference between Rth,ist chip volume and resulting increase of the
during manufacturing process design. and Rth can be high because the number cutting force that affects dynamic tool
Process-specific surface structure. The of trajectories, N = 10, is small. deflection and leads to a wavy surface
gear quality measurements show a profile The microscopic geometry of the sur- structure in the machining direction.
form deviation that is directly related to face structure complies with the theo- Characteristics of surface-near area.
the chosen lineness; therefore the focus retical penetration between tool and part The flank load capacity of gears is highly
of the surface analysis initially is on the (Fig. 8). The change of the lineness must affected by the conditions of the surface-
process-specific surface structure. The affect this structure directly. The results near area of the parts (Ref. 24); therefore
tactile 3-D measurement of the variant of the variation of the lineneness are negative effects of hard machining on the
Rth = 15μm is shown (Fig. 8). The surface- shown (Fig. 9). material structure must be avoided. Thus
specific surface structure is divided into By increasing the number of lines, the micrographs, residual stresses and the full
the amount of the deviation Rth and the deviation is reduced. The variant with width at half-maximum (FWHM) must
spacing of the structure RW (Refs. 15–16; R th = 1μm finally leads to a good sur- be analyzed.
19). Both parameters are driven by the face quality that is equal to the refer- Material structure. There was no
tool alignment, tool geometry, and the ence. The variant with Rth = 5μm sticks grinding burn or negatively affected

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 technical

material structure detected by nital etch-

ing of the hard machined parts. In order
to prove even small influences, additional
metallographic investigations were con-
ducted; micrographs of all variants are
shown (Fig. 10).
The material structure of both variants
with Rth = 15μm and 5μm has no visible
influence on the microstructure due to
the hard machining. In contrast, the vari-
ant with Rth = 1μm and ae = 20μm (with
multi-cut strategy) shows a slight anneal-
ing of the material at the outer surface,
which correlates with the reduction of
the chipping volume and much higher
machining time. In this way the amount
Figure 9 Surface quality.
of thermal energy led into the part is
increased. The variant with Rth = 1μm and
ae = 120μm (with single-cut strategy) also
has no negatively influenced surface near
area. This indicates that only the com-
bination of higher machining time and
small chip volumes lead to an exceeding
of the critical level of thermal capacity of
the material.
The profile grinding has a relatively
small influence on the material structure
of the reference part. The microstructure
of the reference part is equal to material
structures due to profile grinding known
from literature (Refs. 7 and 27); thus no
defect is detectable at the reference parts.
Depth profile of residual stresses. By
Figure 10 Material structure.
measurement of the depth profile of
residual stresses a closer look at the prop-
erties of the surface near area is possible.
Influences of the 5-axis milling process
and the chosen machining parameters on
the properties can be quantified this way.
Therefore the initial condition after heat
treatment and the profile ground refer-
ence were analyzed as well. Figure 11 dis-
plays an overview of all measured depth
profiles; the residual stresses of all parts
were measured in tangential (profile)
direction and in axial (lead) direction.
The direction of tool feed is in lead
direction and equal for all machined
parts. Hard machining parameters seem
to have a relatively small influence on the
Figure 11 Depth profile of residual stresses.
depth profile in axial direction. Beneath
an edge distance of T = 30μm, all residual
stress profiles are equal.
In tangential (profile) direction there
are bigger effects on the residual stresses
at the gear surface. The variant with min-
imal chip volume (Rth = 1μm, ae = 20μm,
f z = 13μm) leads to σ tangential = –630 MPa

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directly at the surface. High chip volume
(Rth = 1μm, ae = 120μm, fz = 40μm) is barely
affecting the residual stresses.
Mechanical loads lead to an increase
of compressive residual stresses, whereas
thermal load reduces compressive resid-
ual stresses (Ref. 31). Because of this,
grinding burn is usually detected by a
local reduction of compressive residual
stresses (Refs. 7; 27; 35; 26).
The small influence of microstructure
(Fig. 10) was not detectable by analysis
of the depth profile of the residual stress
measurements (Fig. 11); even nital etch-
ing did not reveal any affected surface
near area. This is why micro-residual Figure 12 FWHM of residual stress measurement.
stress also must be taken into account.
FWHM of residual stress measure-
ment. Influences of the hard machining
process on micro-residual stresses and
homogeneity of material structure can
be detected by analysis of the full width
at half maximum (FWHM). Literature
shows a correlation between reduction of
part durability and a drop of FWHM by
10% (Refs. 1 and 32).
The depth profiles of FWHM of all
5-axis-milled variants are shown
(Fig. 12). In addition, the profile ground
reference is shown as a solid black line.
The FWHM of the two variants with
the smallest chip volumes (R th = 1μm
and 5μm, ae = 20μm) are affected by the Figure 13 Tooth flank load capacity dependent upon processing strategy.
machining process at a depth down to
T = 10μm. This is the same area where Nr. 0/5 (Ref. 9). Therefore pinions of the seems to massively exceed the expec-
the annealing of the surface near area was standard test gear type C were used as tation. In contrast, the third vari-
detected in the micrographs (Fig. 10). the test part. The gear was convention- ant — machined with R th = 1μm and
The variants with higher chip vol- ally profile ground. The tests were carried ae = 20μm — misses the expectation. The
umes are not affected in case of FWHM out on back-to-back test rigs according to second variant (R th = 5μm, a e = 20μm)
by the machining process. This can be DIN ISO 14635 (Ref. 5). Additionally, a meets the calculated value, whereas the
confirmed by the analysis of the micro- Woehler curve for 50% probability of fail- last variant actually exceeds the durability
graphs, which also show no negatively ure was derived from the profile ground of the profile ground reference.
influenced material structure. This cor- gears as a reference for all tests. Based The differences in the durability of the
relation between the reduction of FWHM upon this reference, flank load carrying gears cannot be based upon differences
and the resulting part durability must capacity can be calculated according to of surface structure; this means that a
be confirmed by conducting flank load ISO 6336-2 for 50% probability of failure. closer look at wear behavior of the parts
capacity tests. The tests were proceeded at ML = 372 is required. Therefore the occurrence of
Nm load. Figure 13 shows the resulting micropittings after 20 hours of testing
Flank Load Carrying Capacity of performance of all variants for 10%, 50% and number of pitting defects on one
Gears Made by Free Form Milling and 90% probability of failure as a bar single gear during the complete test were
To prove the usability of 5-axis milling as chart. According to ISO 6336-2, cycles- analyzed; results are shown (Fig. 14).
a technology for industrial applications, to-failure were calculated theoretical- High process-specific surface deviations
the applicability of the ISO 6336 standard ly, based on the results of the Woehler lead to bigger areas of micropitting. Thus,
must be verified (Ref. 10). Concerning curve, for the specific flank deviations the variant Rth = 15μm shows a 50% area of
this, the effects of the process-specific ffα caused by the process-specific surface micropitting on the flanks. At the variants
characteristics of gears made by 5-axis- structure of the specific variants. Rth = 5μm and Rth = 1μm (both multi-cut-
milling on the performance of the gears It can be observed that the first 5-axis- strategy), a nearly equal amount of micro-
was validated in tests according to FVA milled variant (R th = 15μm, a e = 20μm) pitting occurs. This cannot be explained

March/April 2017 | GEAR TECHNOLOGY 63

 technical

at half-maximum) of the measurement of

residual stresses was derived as an appro-
priate value for the quantification of the
thermal impairment. The reduction of
FWHM at depth T = 10μm led to a nega-
tive effect on the function of the gears.
The performance of gears made by free
form milling was proven and document-
ed by this investigation. The tests showed
a significant influence of the process-spe-
cific surface structure on the lifetime of
the gears and the resulting wear behav-
ior during application. It was shown that
gears made by free form milling will pro-
vide the same performance as conven-
Figure 14 Wear behavior dependent upon processing strategy. tional, profile-ground gears — part integ-
rity being equal. Large process-specific
by the surface alone, as the surface qual- Summary and Outlook deviations lead to unconventional wear
ity of both variants is different. The vari- The capabilities of five-axis milling of behavior that is not describable by exist-
ant Rth = 1μm and ae = 120μm (single-cut gears are becoming increasingly impor- ing criteria (damage of 4% of the flank by
strategy) has the best result concerning the tant, as this process is a flexible manu- pitting, for example).
micropitting area. As in the case of load facturing technology for the machining If the machining strategy leads to a
cycles, micropitting behavior is even better of small batch sizes and single parts. And gear and surface quality that is compa-
than the reference. since there was no comprehensive knowl- rable to conventionally machined gears,
In addition, pitting frequency at the edge available regarding the resulting free form-milled gears will have the
end of each test run was analyzed. The function of 5-axis-milled parts (Refs. 21; same performance. Unfavorable choice
distribution of the number of pittings for 28), the aim of this paper was to describe of machining parameters leads to an
each variant is shown (Fig. 14, right). The the influence of 5-axis milling on the impairment of the surface near micro-
reference usually has no more than one properties of the part and the resulting structure and so to a lack of performance.
or two pittings on each gear. This fail- function of the gears in application. In this way the positive effects of a good
ure characteristic is well known from lit- The influence of the manufacturing surface or gear quality can be reversed
erature for case hardened gears (Refs. 10; strategy and chosen parameters on part (Ref. 30).
24). All variants with higher process- integrity is important in predicting load- Further investigation is needed in order
specific surface structures (R th 15μm carrying capacity, and is decisive for to establish the transferability of outcomes
and 5μm) have a much higher number industry application of 5-axis milling. of this research from standard test gears
of pittings. The variant R th = 1μm and Based on standard test gears, machining to actual application scenarios in industry.
ae = 20μm with the big area of micropit- and running tests were carried out. From Especially, additional challenges concern-
ting, and the annealing of the material that R&D fundamental knowledge of the ing tool wear and realization of complex
structure, leads to a high number of pit- general process design for 5-axis milling geometries — such as bevel gears — must
tings as well. of gears was derived (Ref. 30). be faced in order to utilize 5-axis milling
In summary, failure behavior of gears The machining strategy for free form as a process for hard machining of gears
made by free form milling depends milling of gears was defined based on for industrial applications.
directly on the chosen manufacturing existing definitions (Refs. 15; 18; 29). Acknowledgement. The investigations
parameters. The higher the chip vol- The process-specific surface structure described in this present paper were con-
ume, the better the gears performed in was predicted, and from here on can be ducted as part of the projects (IGF 17890)
case of micropitting and pitting behavior addressed during manufacturing pro- sponsored by Forschungsvereinigung
(Fig. 14). As known from literature, good cess design. The surface near properties Antriebstechnik FVA e.V. and the
surface quality results in better running of the microstructure were influenced by German Federation of Industrial
behavior. Too high process-specific sur- the chosen manufacturing parameters. Research Associations (AiF).
face structures affect micropitting and, Number of trajectories, cutting strate-
finally, cause damage by pitting. The vari- gy and tool feed can lead to unfavor- References
ant Rth = 1μm and ae = 120μm (single-cut able small cutting volumes; therefore an 1. Batista, A., A. Dias, J. Lebrun, J. Le Flour and
G. Inglebert. “Contact Fatigue of Automotive
strategy) has the best result and shows impairment of the function by tempering Gears: Evolution and Effects of Residual Stresses
the same behavior of failure as state-of- occurs. This impairment is small in com- Introduced by Surface Treatments,” from
the-art gears. Hereby, the expectation of parison to grinding burn in conventional “Fatigue and Fracture of Engineering Materials
and Structures” 23, 2000, S. 214–228.
an ideal process strategy for free form gear profile grinding, and so it is not pos- 2. Baxmann, M. “Innovative Komplettbearbeitung
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64 GEAR TECHNOLOGY | March/April 2017

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3. Bieker, R. “Herausforderungen beim Technologische Herausforderungen bei der
5-Achsfräsen von Kegelrädern,” Hartbearbeitung,” Tagungsband zu: Seminar Dr.-Ing. Dipl.-Wirt.Ing. Julian Staudt in
Tagungsunterlagen zum Seminar Innovation “Feinbearbeitung von Zahnrädern,” Aachen, 2016 completed his doctoral thesis in production
rund ums Kegelrad,” Aachen, 12.-13. März 3./4., November Aachen, WZL der RWTH engineering — “Function-
2014. Aachen, 2015. Oriented Machining of Gears by
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Begriffe, Einteilung 2003. Zahnradprüfstand und in Pra-xisgetrieben,” Staudt was a research assistant
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zur Getriebeproduktion, Würzburg, 2013. “Innovationen rund ums Kegelrad,” Aachen, continuing his studies, Staudt
7. Gorgels, C. “Entstehung und Vermeidung 13–14. April 2010. (2007–2012) was a student worker at Laboratory
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Zahnflankenprofilschleifen,” Dissertation, Fertigungsverfahren auf die Grauflecken- densification of P/M gears; condition monitoring
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8. Grossl, A. “Einfluss von PVD- TU München, 2004. cutting processes. While in the midst of his studies,
Beschichtungen auf die Flanken- und Fuß- 24. Moser, S. “Der Name Hermle zieht auch in Staudt served (2004–2005) performed military
Tragfähigkeit Einsatzgehärteter Stirnräder,” harten Zeiten,” Produktion Mai, 2009.
service in the German Air Force. He currently
Diss. TU München, 2006. 25. Niemann, G. and H. Winter.
works for Saint-Gobain Sekurit — a supplier to the
9. Hösel, T. and J. Goebbelet. “Empfehlung Maschinenelemente Band 2. 2. Aufl. Berlin,
zur Vereinheitlichung von Flanken- Springer, 2003. automotive industry.
Tragfähigkeitsversuchen an Vergüteten und 26. Potts, M. “Hoch Beanspruchte Dr.-Ing. Dipl.-Wirt.-Ing. Christoph
Gehärteten Zylinderrädern,” FVA-Merkblatt Kegelradverzahnungen in Schiffsantrieben,” Löpenhaus is a 2010 industrial engineering
Nr. 0/5, 1979. Tagungsunterlagen zum Seminar “Innovation graduate of RWTH Aachen; he
10. Norm ISO 6336. Tragfähigkeitsberechnung rund ums Kegelrad,” Aachen, 12.-13. März received his Ph.D. (local strength
von Gerad- und Schrägverzahn-ten 2014. and friction models for gears)
Stirnrädern, 2003. 27. Reimann, J. “Randzonenbeeinflussung in 2015. Upon graduation he
11. Jaster, M. “Multifunctional Advancements,” beim Kontinuierlichen Wälzschleifen von worked as a research assistant
Gear Technology 01/02.2012. Stirnradverzahnungen,” Dissertation, RWTH
in the gear testing group of the
12. Klein, A. “Integrierte Kegelradbearbeitung Aachen, 2014.
Laboratory for Machine Tools
auf Drehfräs- Fräs- und Fräsdrehmaschi- 28. Schlattmeier, H. “Diskontinuierliches
(WZL) of RWTH Aachen and in
nen, Tagungsband zum, Seminar Zahnflankenprofilschleifen mit Korund,”
“Innovationen rund ums Kegelrad,” Aachen, Dissertation, RWTH Aachen, 2003. 2011 was named the group’s team
12–13. März 2008, Aachen, WZL Forum, 29. Stadtfeld, H. “Wozu noch Spezialmaschinen? leader. Lopenhaus has since 2014 worked as chief
2008. – Aspekte aus Sicht des Establishments, engineer of the department for gear technology at
13. Klocke, F. and W. König. Tagungsband zur Innovationen Rund ums WZL.
“Fertigungsverfahren 1. Drehen, Fräsen, Kegelrad,” Aachen, 13.-14. April 2010. Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c.
Bohren. 8. Aufl. Berlin: Springer, 2008. Aachen: WZL Forum, 2010. Fritz Klocke began his distinguished career
14. Klocke, F., M. Brumm and M. Kampka. 30. Staudt, J., F. Klocke and C. Löpenhaus. (1970–1973) as an apprenticed toolmaker while
“Ressourceneffizienz Alternativer “Compensation of Geometric Deviations in
at the same time pursuing his
Fertigungsverfahren durch Charakterisie- 5-Axis-Milling of Gears – First Part Right
production engineering studies
rung von Oberflächenstrukturen – Strategy for Gear Milling on Universal
at Lemgo/Lippe Polytechnic, and
Forschungsvorhaben Nr. 669 I., FVA- Machine Tools,” Proceedings of International
Forschungsheft Nr. 1105, 2012. VDI Conference on Gear Production, later (1973–1976) at Technical
15. Klocke, F., M. Brumm and M. Kampka. München, 5.-6. Oktober 2015, München: University Berlin. He then
“Ressourceneffizienz Alternativer VDI Verlag, 2015, S. 1495–1504. (1977–1981) went on to serve
Fertigungsverfahren durch Charakterisie- 31. Staudt, J. “Funktionsgerechte Bearbeitung as Assistant at the Institute for
rung von Oberflächenstrukturen – von Verzahnungen durch Freiformfräsen,” Machine Tools and Production
Forschungsvorhaben Nr. 669 I., FVA- Dissertation, RWTH Aachen, 2016. Engineering, Technical University
Forschungsheft Nr. 1105, 2012. 32. Totten, G., M. Howes and T. Inoue. Berlin. Starting in 1981, Klocke achieved or
16. Klocke, F., M. Brumm and J. Staudt. Handbook of Residual Stress and Steel received the following academic credentials
“Potentiale des Freiformfräsens von Deformation, Ohio ASM International, 2002. and awards: Chief Engineer; (1982)Doctorate in
Verzahnungen,” Tagungsband zur 33. Vielma, A., V. Llaneza and F. Belzunce. engineering; (1984–1994)employed at Ernst Winter
54, Arbeitstagung “Zahnrad –und “Effect of Coverage and Double Peening & Sohn GmbH & Co., Norderstedt; (1984) Head of
Getriebeuntersu-chung,” 15/16 Mai 2013, Treatments on the Fatigue Life of a Process Monitoring; (1985) Technical Director,
Aachen, WZL der RWTH Aachen. Quenched and Tempered Structural Steel,” Mechanical Engineering Department; (1985)
17. Klocke, F., M. Brumm and J. Staudt. Surface and Coatings Technology 249, 2014, Awarded Otto Kienzle Medal by the Universities
“Wirtschaftliche Zahnfußbearbeitung S. 75–83. Production Engineering Group; (1995) Director
durch Freiformfräsen,” Tagungsband 34. Weser, G. “Freiformfräsen Erobert die of the Chair of Manufacturing Technology at
zur 55, Arbeitstagung “Zahnrad –und Zahnradindustrie,” Werkstatt und Betrieb Nr. the Institute for Machine Tools and Production
Getriebeuntersu-chung,” 14/15 Mai 2014 in 06, 2011. Engineering (WZL) of the RWTH Aachen, and
Aachen, WZL der RWTH Aachen. 35. Weser, G. “Zahnradherstellung mittels director of the Fraunhofer Institute for Production
18. 18a. Klocke, F., C. Löpenhaus and J. Staudt. Freiformfräsen: Möglichkeiten, Lösungen Technology, Aachen; (2001–2002) Dean of the
“Bauteileigenschaften 5-Achs-gefräster und Erfahrungen,” Tagungsband zu
Faculty for Mechanical Engineering; (2006)
Zahnräder,” Tagungsband zur, “GETPRO” “Innovationen rund ums Kegelrad,” Aachen,
Honorary Ph.D. by the University of Hannover;
5, Kongress zur Getriebeproduktion, 14.-15. März 2012. Aachen: WZL Forum,
Würzburg, 25.-26. März 2015, Frankfurt: 2012. (2007–2008) President of the International Academy
Eigendruck Forschungsvereinigung 36. Weßels, N. “Flexibles Kegelradschleifen mit for Production Engineering (CIRP); (2009) Honorary
Antriebstechnik e.V., 2015. Korund in variantenreicher Serienfertigung,” Ph.D. by the University of Thessaloniki; (2010)
19. 18b. Klocke, F., C. Löpenhaus Dissertation RWTH Aachen, 2009. Honorary Ph.D. by the Keio University; Award of
and J. Staudt. “5-Achs-Fräsen von Fraunhofer Medal; (2012) Fellow of the Society of
Leistungsverzahnungen,” Tagungsband Manufacturing Engineers (SME); (2014) Eli Whitney
zur 56, Arbeitstagung “Zahnrad- und Productivity Award (SME); and (2014) Fellow of
For Related Articles Search RWTH Aachen University.
Getriebeuntersu-chungen,” 20./21., Mai 2015
in Aachen, WZL der RWTH Aachen, 2015.
20. 18c. Klocke, F., C. Löpenhaus and J. Staudt. 5-axis
“5-Achs-Fräsen von Verzahnungen, at www.geartechnology.com

March/April 2017 | GEAR TECHNOLOGY 65