The GearEngineer is a powerful and intelligent software for the calculation of various types of gears. Its main focus is on calculating and generating the precise 3D tooth geometry of complex gearings, which serves as a basis for alternative manufacturing methods, such as producing gears on universal multi-axis machining centers. In addition, calculation methods according to DIN and ISO standards are available for assessing the load capacity of gears. A tooth contact analysis is also integrated.
GearEngineer is recognized as one of the world’s leading software solutions in this field and has been honored with the MM Award.
Quick Overview
The GearEngineer enables the calculation of involute cylindrical gears, including:
- External and internal gears
- Spur or helical gears
- Involute splines
Spur gears as well as involute splines (shaft and hub) can be manufactured based on the accurate gear tooth form. The manufacturing of double helical and herringbone gears (with and without space in the center) is also possible.
Various types of bevel gears can also be calculated, such as:
- Straight and helical bevel gears with different forms of tooth depth
- Spiral bevel gears
3D tooth geometry calculation and export is available for straight and helical bevel gears with constant or tapered tooth depth. For spiral bevel gears, the Klingelnberg Zyklo-Palloid® system is currently supported. The 3D gear geometry can be exported in STEP and IGES formats.
Calculation results can be documented with reports in HTML and PDF format. The software is available in both German and English.
Advantages and New Capabilities
Manufacturing gears on CNC machining centers offers the following benefits:
- Greater design flexibility: freely selectable module, customizable 20° pressure angles, special gear types such as full-depth or stub-tooth gears, double helical and herringbone gears (with or without a center gap), and bevel gears
- More compact components, as tool runout (e.g., from hobbing) is not required
- Optimized tooling, reducing the number of tools needed by using standard cutting tools
- Complex parts in a single setup, including components with internal and external gears
- No gear cutting machines are necessary
- Larger parts and module ranges, e.g., external spur gears up to 16,000 mm, internal gears up to 3,000 mm, and bevel gears up to 4,000 mm (depending on the machining center)
- Dry processing
- Soft and hard cutting supported
- Ideal for single-part and small-batch production, typically from module 3 or 4 and upwards
- High productivity and competitive lead times, often matching or exceeding traditional manufacturing, especially for larger modules
- High-quality gears, achieving DIN 4 or better, with surface finishes comparable to grinding