Berechnungsprogramme der Abteilung Getriebeberechnung und Simulation


The program GearGenerator simulates continuous generation grinding of gears. It excels in short calculating times and in regarding numerous effects that can occur during continuous generation grinding. This way, it is possible to model flank twists of crowned gears due to the generation grinding process. Furthermore, asymmetrical and modified gears can be simulated with the help of the GearGenerator.

GearGenerator - Flyer (PDF)


Cutting is a part of preprocessing in the framework of the classic production chain of bevel gears. For this, a multitude of processes can be implemented. These processes apply extremely complicated kinematics that allow to generate the tooth geometry as well as modifications of the flank topography.
With the help of KegelSpan it is possible to analyze the occuring load during bevel gear manufacturing for the first time. This is carried out by analyzing the obtained parameters for the chip formation, which are determined by a penetration calculation.

Kegelspan - Flyer (PDF)

Force Coupling Element

The design of gearset requires to consider not only the static nominal loading conditions but also additional dynamic forces under realistic operating conditions. These dynamic forces can lead to intolerable noise emission and reduced fatigue life. Reasons for the dynamic excitation forces can be found in the gear mesh and increase significantly in the neighborhood of resonance frequencies. A possibility to reduce the dynamic forces and therefore noise and fatigue can be achieved by reducing the excitation amplitudes. By analyzing the force spectrum critical frequencies and conclusions for reducing the excitation can be drawn. The force coupling element is a powerful tool for evaluation and optimization of a gearset dynamic excitation behavior under these circumstances. Due to the fact, that the three dimensional tooth contact analysis is utilized an application to nearly every gear type is possible.

Force Coupling Element


SPARTApro is a software which has been developed to assist the user in the designing of gear hobbing processes. A geometrical process simulation based on penetration calculations provides the information to compute the undeformed chip geometries, characteristic values and cutting forces. Furthermore the inbuilt multi factor variants calculation of SPARTApro enables the user to determine a tool design which is economically optimized by the given restrictions.

SPARTAPro - Flyer (PDF)


In modern gearboxes after the design of the macro geometry the design of the micro geometry of the tooth flanks is needed. For the calculation of the macro geometry calculation methods based on the calculation standards DIN / ISO, AGMA, etc. are available. In addition to the macro geometry the micro geometry significantly affects the load distribution and running behavior of the gears.
The software system FE-Stirnradkette (STIRAK) allows the calculation of internal and external spur gears based on the finite element method. The gears can be analyzed in terms of the expected load and running behavior and are subsequently optimized using micro geometry corrections. The gear profile can be designed using asymmetrical cutter profiles as well.
The development of the simulation system is sponsored by the Forschungsvereinigung Antriebstechnik e.V. (FVA)

STIRAK - Flyer (PDF)

Knowledge-based Gear Design

Using a knowledge-based expert system can support you with the design and optimization of gear geometry. The software uses databases that utilizes experiences from former gear designs. Furthermore, existing expert knowledge can be incorporated. Multi-stage cylindrical gear stages, planetary gear stages as well as bevel gear stages can be designed automatically based on a specification of requirements.
In the second step of the design process the defined gear geometry can be optimized regarding fatigue life and noise excitation. Furthermore, cylindrical gear stages can be optimized regarding a minimum of gearbox weight and volume. Tooth flank modifications are dimensioned in lead and profile direction. In the last step the design gear transmission is evaluated and verified with regard to the fatigue life according to DIN 3990 or ISO 6336.

Knowledge-based Gear Design

WZL Gear Toolbox

The „WZL Gear Toolbox“ is an unified and unique graphical user interface for the gear manufacturing simulation “GearGenerator”, the manufacturing process simulations “SPARTApro” and “KegelSpan” and the gear contact analysis software “ZaKo3D”. The graphical user interface provides tools and solutions for a comfortable input definition, simulation control and result postprocessing. For instance, the operating behavior of beveloid gears can incorporate manufacturing deviations, that are predicted by the manufacturing simulation of generating grinding, in the tooth contact analysis.

Long term objective of this development project for a graphical user interface is a simulation tool for the entire process chain of gear design and development.

WZL Gear Toolbox - Flyer (PDF)
WZL Gear Toolbox - Handbuch (PDF)

GearGenerator - Flyer (PDF)
Kegelspan - Flyer (PDF)
SPARTAPro - Flyer (PDF)
ZaKo - Flyer (PDF)


Through the development of new processes and products a need for special transmissions and gears arises constantly. They are mostly characterized by complex kinematics and geometries. These transmissions and gears can usually not be analyzed using standard software. Either the contact characteristics are modeled in commercial FE-software, which costs a lot of effort. Or software for this special case has to be developed. Sometimes this results in strong simplifications to enable standard gear software to analyze the parts. In order to overcome this barrier for special transmissions and gears (e.g. beveloids), the general tooth contact analysis software ZaKo3D can be used. It enables the user to analyze special gears as well as common gears.

ZaKo - Flyer (PDF)



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