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  • 1.
    Botkina, Darya
    et al.
    KTH.
    Hedlind, Mikael
    Olsson, Bengt
    Henser, Jannik
    KTH, School of Industrial Engineering and Management (ITM).
    Lundholm, Thomas
    KTH, School of Industrial Engineering and Management (ITM).
    Digital Twin of a Cutting Tool2018In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 72, p. 215-218Article in journal (Refereed)
    Abstract [en]

    This paper focuses on a digital twin of a cutting tool as a digital replica of a physical tool, its data format and structure, information flows and data management, as well as possibilities for further applications and analysis of productivity. Data are collected throughout the production lifecycle in an accurate way, using the international standard ISO 13399 and messaging based on the previously developed event-driven line information system architecture (LISA) with IoT functionality. The digital twin is tweeted to be stored, refined and propagated to the process planning for an optimized machining solution.

  • 2. Brecher, Christian
    et al.
    Brumm, Markus
    Henser, Jannik
    Calculation of the Tooth Root Load Carrying Capacity of Beveloid Gears2014In: Gear Technology, Vol. 31, no 4, p. 52-61Article in journal (Other (popular science, discussion, etc.))
  • 3. Brecher, Christian
    et al.
    Brumm, Markus
    Henser, Jannik
    Calculation of the Tooth Root Load Carrying Capacity of Beveloid Gears2013Conference paper (Refereed)
  • 4. Brecher, Christian
    et al.
    Brumm, Markus
    Henser, Jannik
    Validation of the tooth root load carrying capacity calculation of beveloid gears with parallel axes2014In: INTERNATIONAL GEAR CONFERENCE 2014 / [ed] Velex, Philippe, Woodhead Publishing Limited, 2014, p. 1038-1048Conference paper (Refereed)
    Abstract [en]

    Beveloid gears are conical involute gears which are used to transmit torque and rotation between crossing, skew or parallel axes. This paper describes the validation of two tooth root load carrying capacity calculation methods for beveloid gears with parallel axes. Fatigue tests are presented and the correlation between the test results and the two described calculation methods is shown. By analyzing the different endurance limits and the fracture surfaces it is shown that effects like a specific load distribution or a varying root fillet geometry of beveloids are affecting the load state and that these effects are covered by the developed calculation methods.

  • 5. Brecher, Christian
    et al.
    Löpenhaus, Christoph
    WZL RWTH Aachen, Germany.
    Brimmers, Jens
    Henser, Jannik
    KTH, School of Industrial Engineering and Management (ITM).
    Influence of the defect size on the tooth root load carrying capacity2016In: AGMA 2016 - Fall Technical Meeting, AGMA American Gear Manufacturers Association , 2016Conference paper (Refereed)
    Abstract [en]

    In order to increase the power density of gears, a high level of information concerning the load carrying capacity is necessary. Calculation methods for the flank and tooth root load carrying capacity are well-established in the industry and are an important tool for the gear design engineer. The existing methods cover various types of gears, such as cylindrical, bevel, or beveloid gears. Calculating the flank and tooth root load carrying capacity for various gear types relies either on analytical formulae (Hertzian theory, fixed beam) or on results of FE-based tooth contact analysis software. The existing calculation methods for the tooth root load carrying capacity derive the material strength either from fatigue limit tables, that are based on test rig results, or from the calculation of local material data (e.g. based on hardness, residual stress, and oxidation) by means of empirical formulae. The research of the influence of material defects, such as pores or inclusions, in the context of weakest-link models, has shown that the material fatigue depends on the distribution of defect size within the material. Models for the consideration of the defect size on the tooth root strength, such as the model according to Murakami, have not been applied in fatigue models for gears yet and are focused on in this report. Therefore, the objective of this work is to introduce a method for the calculation of the tooth root load carrying capacity for gears, under consideration of the influence of the defect size on the endurance fatigue strength of the tooth root. The theoretical basis of this method is presented in this paper as well as the validation in running tests of helical and beveloid gears with different material batches, regarding the size distribution of inclusions. The torque level for a 50 percent failure probability of the gears is evaluated on the test rig and then compared to the results of the simulation. The simulative method allows for a performance of the staircase method that is usually performed physically in the back-to-back tests for endurance strength, as the statistical influence of the material properties is considered in the calculation model. The comparison between simulation and tests shows a high level of accordance. Copyright © 2016 American Gear Manufacturers Association.

  • 6. Brecher, Christian
    et al.
    Löpenhaus, Christoph
    Brimmers, Jens
    Henser, Jannik
    Influence of the Defect Size on the Tooth Root Load Carrying Capacity2017In: Gear Technology, p. 92-100Article in journal (Other academic)
  • 7. Brecher, Christian
    et al.
    Löpenhaus, Christoph
    Henser, Jannik
    KTH, School of Industrial Engineering and Management (ITM).
    Brimmers, Jens
    Stahlschnecke : kupfer- und zinnfreie Schneckenradgetriebe hoher Effizienz und Leistungsdichte - technologische Substitution von Bronze durch Stahl: Abschlussbericht : Bewilligungszeitraum: 01.03.2013 bis 31.08.2016, Berichtszeitraum: 01.03.2013 bis 31.08.20162017Report (Other academic)
  • 8. Cramer, Tim
    et al.
    Henser, Jannik
    Heidgen, Melanie
    Pollaschek, Jonas
    Brumm, Markus
    an Mey, Dieter
    Müller, Matthias
    Brecher, Christian
    Praxisgerechte Strategien und Methoden zur effizienten FE-Berechnung des Zahnkontakts2014Conference paper (Other academic)
  • 9. Flodin, Anders
    et al.
    Brecher, Christian
    Gorgels, Christof
    Röthlingshöfer, Tobias
    Henser, Jannik
    Designing Powder Metal Gears2011In: Gear Solutions, ISSN 1933-7507, Vol. 9, no 101, p. 26-35Article in journal (Other academic)
  • 10. Henser, Jannik
    Auslegung von Beveloidzahnrädern unter Zuhilfenahme von Fertigungssimulation und FE-basierter Zahnkontaktanalyse2011In: / [ed] Forschungsvereinigung Antriebstechnik, 2011Conference paper (Other academic)
  • 11. Henser, Jannik
    Berechnung der Zahnfußspannungen von Beveloidverzahnungen2015Doctoral thesis, monograph (Other academic)
    Abstract [en]

    Beveloid gears are conical gears which are derived from cylindrical involute gears to transmit torque and rotation for parallel, intersecting or skew axes. While defined by the same data as cylindrical involute gears, the addendum modification factor, however, changes linearly to the tooth width. This results in the characteristic conical geometry of beveloid gears. Therefore, beveloid gears are also referred to as conical involute gears.

    Typical applications for beveloid gears are marine transmissions and automotive four-wheel drives. For marine transmissions beveloid gears are used to transmit power from a horizontally mounted motor positioned above the water surface to the propeller below the water surface. For this, propeller shaft and motor shaft are mounted with a moderate axis angle. For automotive four-wheel drives, beveloid gears transmit power from the transmission output shaft to the front axis differential. The use of a beveloid gear enables the transmission design to have the front axle shaft mounted inside the transmission tunnel. This leads to reduced space requirements compared to conventional four-wheel drive concepts. Another application for beveloid gears are robot gears. Here, the beveloid gears are mounted with parallel axes, meaning that the cones have the same angle and the gears are mounted with opposite orientations. This concept allows a precise adjustment of the backlash by shifting the gears axially.

    Generally, beveloid gears are used when small crossing angles are to be realized. For smaller crossing angles beveloid gears should be used due to advantages in the manufacturing technology. For bigger crossing angels, bevel gears are preferred as beveloid gears tend to unfavorable contact conditions in these cases.

    Unlike bevel gears or cylindrical gears, there are no existing calculation methods for the tooth root load carrying capacity of beveloid gears. This, however, is an essential requirement for ensuring the beveloid gear does not suffer any root damage during operation without over dimensioning it in the design stage.

    Therefore, two methods for calculating the tooth root load carrying capacity for beveloid gears are developed in this thesis. First, a calculation method based on local calculation methods is presented and validated by fatigue tests. By means of this calculation method, an analytic-empiric calculation method for tooth root load carrying capacity of beveloid gears with parallel axes and an explanatory model for the tooth root load carrying capacity for beveloid gears with intersecting axes are developed.

  • 12. Henser, Jannik
    Berücksichtigung von Fertigungseinflüssen bei der Auslegung von Beveloidzahnrädern2011In: / [ed] Feldhusen, Jörg; Grote, Karl-Heinrich; Brökel, Klaus; Rieg, Frank; Stelzer, Ralph, 2011Conference paper (Other academic)
  • 13. Henser, Jannik
    Innovative Production and Possibilities for the industry2016Conference paper (Other (popular science, discussion, etc.))
  • 14. Henser, Jannik
    Research and development trends in powertrain manufacturing for heavy vehicles2016Conference paper (Other (popular science, discussion, etc.))
  • 15.
    Henser, Jannik
    KTH, School of Industrial Engineering and Management (ITM).
    Trends und Innovationen bei der Fertigung von Nutzfahrzeugen2018In: Aktuelle Entwicklungen beim Vorverzahnen / [ed] Thomas Bergs, Christian Brecher, Aachen: Eigendruck WZL Forum , 2018, article id V02Conference paper (Other academic)
  • 16. Henser, Jannik
    et al.
    Brumm, Markus
    Brecher, Christian
    Analytisch-empirischer Ansatz zur Berechnung der Zahnfußtragfähigkeit von Beveloids2013In: / [ed] Klocke, Fritz; Brecher, Christian, 2013, p. 5-1-5-35Conference paper (Other academic)
  • 17. Henser, Jannik
    et al.
    Brumm, Markus
    Brecher, Christian
    Berechnung der Zahnfußspannungen von Beveloidverzahnungen2011Conference paper (Other academic)
  • 18. Henser, Jannik
    et al.
    Brumm, Markus
    Brecher, Christian
    Comparison of Local Approaches for the Evaluation of Tooth Root Load Carrying Capacity of Beveloid Gears2013Conference paper (Refereed)
  • 19. Henser, Jannik
    et al.
    Brumm, Markus
    Brecher, Christian
    Local Approach for the Evaluation of Tooth Root Load Carrying Capacity of Beveloid Gears2012In: / [ed] Klocke, Fritz; Brecher, Christian, 2012, p. 7-1-7-21Conference paper (Other academic)
  • 20. Henser, Jannik
    et al.
    Brumm, Markus
    Brecher, Christian
    Simulation von Beveloidverzahnungen - Berechnung der Zahnfußspannungen2011In: / [ed] Institut für Maschinenelemente und Maschinenkonstruktion Dresden / Lehrstuhl für, Maschinenelemente, Dresden: TUDpress, 2011Conference paper (Other academic)
  • 21. Henser, Jannik
    et al.
    Brumm, Markus
    Brecher, Christian
    Using the .vtk-Standard for Stress Visualization of Special Gears2013Conference paper (Other academic)
  • 22. Henser, Jannik
    et al.
    Brumm, Markus
    Brecher, Christian
    Vergleich lokaler Berechnungsansätze zur Berechnung der Zahnfußtragfähigkeit von Beveloids2012In: 53. Arbeitstagung "Zahnrad- und Getriebeuntersuchungen" des WZL / [ed] Klocke, Fritz; Brecher, Christian, 2012, p. 16-1-16-41Conference paper (Other academic)
  • 23. Henser, Jannik
    et al.
    Brumm, Markus
    Hübner, Florian
    Brecher, Christian
    Influence of the manufacturing method on the running behavior of beveloid gears2013In: Production Engineering, ISSN 0944-6524, E-ISSN 1863-7353, Vol. 7, no 2-3, p. 265-274Article in journal (Refereed)
    Abstract [en]

    Beveloid gears, also known as conical involute gears, gain more and more importance in industrial practice. They are based on cylindrical gears, but have a variable profile shift along their tooth width. For some time, beveloid gears have been applied to marine transmissions (Winkler 2002; Zhu et al. in Chin J Mech Eng 25:328-337, 2012), but in the last years they have been used increasingly in the automotive industry (Börner et al. in Gear Technol 6:28-35, 2005; Alxneit 2010). A crucial step of the manufacturing process is the grinding process that is necessary to achieve high load carrying capacity and low noise vibration harshness (NVH). During the grinding process the micro-geometry of the tooth flanks can be modified in order to increase the gear quality. For the generation grinding process of beveloids, two types of machine kinematics and two tool concepts are known. The different machine kinematics and tool concepts may lead to unintentional changes in micro-geometry of the flanks which has an impact on load carrying capacity and NVH qualities of the gear. Up to now, no research has been made to quantify the influence of the machine kinematics and the tool concept on load carrying capacity and NVH. Therefore, these influences are analyzed in this work by simulating the gear manufacturing with the help of the two known machine kinematics as well as the two known tool concepts and by meshing the simulated gears in an FE-based tooth contact analysis (TCA). The results of the TCA are parameters regarding the running behavior which are analyzed and compared for the four aforementioned manufacturing concepts.

  • 24. Henser, Jannik
    et al.
    Gorgels, Christoph
    Brecher, Christian
    Optimierung der Mikrogeometrie von PM-Zahnrädern2011In: / [ed] Forschungsvereinigung Antriebstechnik, 2011, Vol. 1Conference paper (Other academic)
  • 25. Henser, Jannik
    et al.
    Gorgels, Christoph
    Kauffmann, Philipp
    Röthlingshöfer, Tobias
    Flodin, Anders
    Brecher, Christian
    ZaKo3D – Simulation Possibilities for PM Gears2010Conference paper (Other academic)
  • 26. Henser, Jannik
    et al.
    Gorgels, Christoph
    Röthlingshöfer, Tobias
    Brecher, Christian
    Design Aspects of Powder Metal Gears2010In: / [ed] VDI-Society for Product and Process Design, 2010Conference paper (Refereed)
  • 27. Henser, Jannik
    et al.
    Lindberg, Bengt
    Industri 4.0 - den sista forskningen2017Conference paper (Other (popular science, discussion, etc.))
1 - 27 of 27
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