BGA KNOWLEDGE TRANSFER

PROGRAMME

SEP 2019– JUN 2020

From introductory classes to more in-depth specialist training

here at the BGA we have all of your gear training needs

covered. Our courses are suitable for all sections of the

Gearing community, from students and apprentices starting

out in their careers to seasoned gear experts looking to hone

their skills or get up to date with latest developments.

BGA training is CPD Accredited contributing to

your professional development.

WWW.BGA.ORG.UK

GEAR FOUNDATION DAY

An Introduction to Gears Part 1:

Gear Fundamentals.

Law of Gearing; The Involute Form; Power

Transmission; Motion Control; Gear Types –

Features and Benefits.

An Introduction to Gears Part 2:

Noise & Load.

Modes of Failure (Bending, Pitting, Micro-

Pitting, Scuffing, Wear) Gear Rating methods;

Application Factors; Gear Lubrication; Noise &

Vibration basics; Transmission Error.

An Introduction to Gears Part 3:

Gear Manufacture.

Gear Material Specification; Gear

Manufacturing Methods (Forming, Moulding,

Machining; Hobbing, Shaping, Shaving, Honing,

INTRODUCTION TO

GEAR CUTTING AND

MEASUREMENT · Basic involute gear theory, terms and

definitions for spur and helical gears including:

· Gear terms and definitions.

· Introduction to the involute form and its

construction / tables.

· Calculations on the above.

Practical work on the measurement of gears

including calculations on the following:

· Chordal tooth settings for gear tooth Vernier.

· Constant chord settings to gear tooth Vernier.

· Base tangent micrometer settings.

· Distance over rollers measurement.

· Basic principles of gear hobbing and shaping.

Selection of index and feed change gears.

GEAR NOISE & TRANSMISSION ERROR MEASUREMENT Introduction.

·The sources of Gear Noise

·Definition of Transmission Error (TE)

Gear Design for Low Noise.

·TE spur gears & TE and helical gears

·The relation of TE to contact ratios and

the concept of integer contact ratio

·Effect of misalignment on tooth contact

·Practical approaches to designing gears

for low TE

·TE in planetary gears (theory of

factorising and non-factorising)

Noise Signals.

·Tooth passing frequencies

·Gear pairs

·Planetary gears

·Run out ; generation of side bands

·Ghost frequencies and their origin

Noise measurement.

The practical aspects of noise

measurement will be considered where in

order to correctly diagnose the cause/

source of the noise, it is necessary to

correctly identify the frequency. Reference

will be made back to the section on “Noise

Signals.”

GEARBOX SYSTEMS: PROBLEMS & SOLUTIONS.

• Tackling Unexplained Bearing and Gear Element Failures.

• The Dynamics of Gearbox Systems.

• Gearbox Noise and Vibration.

• Problem Solving using State of the Art Data Acquisition &Analysis Techniques.

• Wind Turbine Gearboxes: Type Testing, Instrumentation &Early Stage

Troubleshooting.

• Gear Alignment Instrumentation (KHβ, Kϒ). • In-Service Unattended Load (Torque) Data Collection Techniques.

• Case Studies in Rail, Marine Propulsion, Renewables, Automotive and Heavy Industries.

GEAR WEAR AND FAILURE RECOGNITION. The seminar gives delegates an insight into the appearance and underlying causes of gear

failure modes. No prior gear knowledge is required. It provides gear manufacturers and

users with the necessary skills to examine, assess and recognise common gear failure

modes. The seminar content is applicable to gear designers, gear service personnel,

operators and users of valuable equipment, inspection and certification bodies who need to

confidently examine gears and gearboxes and those new to the gear industry.

The Seminar will cover:

• How gears work and how they fail and wear.

• Failure recognition strategy.

• An introduction to the common investigation methods and equipment used to establish

the root cause of a failure.

• An introduction to the ISO 10825 failure modes standard and supporting ISO

standards o Case studies.

• Failure recognition- a chance to test your failure recognition skills with 20 failed gear

samples.

Key skills and knowledge:

• At the end of the seminar you will be able to recognise the common failure modes,

understand their causes and you will be able to confidently examine failed gears. You will

appreciate what is considered normal wear and what could potentially be a problem and

know the appropriate action to take.

AN INTRODUCTION TO GEAR MANUFACTURE.

• Summary introduction of the range of gear production methods.

• Summary of heat treatment and surface treatment methods.

• Overview of process capability, selection and tooling requirements.

• Detailed overview of the gear cutting and finishing processes of cylindrical gears.

HEAT TREATMENT

FOR GEAR STEELS.

• Introduction to steel heat treatment

metallurgical principles; hardening &

tempering.

• Carburising.

• Introduction to nitriding, nitro-

carburising & other surface treatments.

• Laser & Electron Beam Hardening.

• Induction & flame hardening.

• Problem solving – low/high hardness; case

-depth.

• Controlling distortion.

Wind TurbinE

Gearbox

Technology.

• Gear loading; failure analysis.

• Bearings - Selection and application

in wind turbines; life calculation.

• Lubrication - Gearbox lubrication

and system cleanliness.

• Condition Monitoring - Methods and

interpretation including vibration,

oil and bearings.

• Maintenance Issues.

• Standards.

INTRODUCTION TO GEAR DESIGN & GEOMETRY THE SEMINAR WILL COVER • How involute gears work.

• An introduction to the involute gear geometry standard ISO21771, BGA Code of

Practice 07 and gear terms and symbols.

• The basic rack, cutting tools and basic gear sums relating to spur and helical gears.

• Gear pairs, centre distance, working pressure angles, tooth thickness and backlash.

• Non-standard geometry, contact ratios and start of active profile calculations.

• Plenty of examples to work through.

Gear Stress Analysis. • Provide a brief introduction as to how gears work and fail.

• Provide an overview of how the ISO 6336 standard works, its key influence factors,

what it will do and more importantly, what it won’t do.

• Discuss the calculation of tooth bending and contact stresses in a given set of cylindrical

gears.

• Show how we can increase power density and reduce manufacturing costs.

• Discuss what the safety factors actually mean.

• Use examples to highlight key features and limitations of the ISO 6336 method.

• Optimization models.

GEAR MEASUREMENT • How gears work and why we need to measure them.

• ISO terms, symbols and measured parameters.

• An introduction to the common measurement methods and equipment.

• Use and application of gear accuracy standards (DIN 3962, ISO1328 etc.).

• Good measurement practice- lab demonstration/discussion.

• Interpreting lead, profile and pitch measurement results to identify the cause of

manufacturing errors from common processes.

• Methods of calibrating measuring machines- quantifying measurement uncertainty.

• Minimising measuring errors; how to improve measurement performance.

• An introduction to estimating the measurement uncertainty using ISO 18653 and

BEARINGS AND CONDITION MONITORING Bearings.

• Types and applications (ISO 15).

• Selection & life calculation.

• Wear & failure modes (ISO 15243).

Condition Monitoring.

• Comparison and applicability of methods (Vibration; Acoustic Emission; Oil Debris

Analysis).

• Remote CM techniques.

• Case histories including bearing and gearbox damage in wind turbines and other

applications. CPD ACCREDITATION The majority of BGA seminars are officially recognised as complying

with universally accepted principles of Continual Professional

Development (CPD).

CPD certification means that the content and structure of the

courses have been independently assessed and approved for multi-

disciplinary and industry-wide continuing personal and professional

development purposes.

To book training please go to the BGA website at www.bga.org.uk.

Date Seminar

11th Sep Gear Foundation Day

18th Sep Gear Noise & Transmission Error Measurement

24th-28th Sep Introduction to Gear Cutting & Measurement

1st Oct Gearbox Systems Problems & Solutions

20th Nov Heat Treatment of Gear Steels

4th & 5th Dec Wind Turbine Gear Box Technology

5th February Gear Foundation Day

25th February Introduction Gear Design & Geometry

3rd March Gear Wear & Failure

7th & 8th April Gear Stress Analysis

29th April Bearings & Condition Monitoring

6th & 7th May Gear Measurement

12th-15th May Introduction Gear Cutting & Measurement

27th May Introduction Gear Manufacture

28th May Designing for Gear Manufacture

KNOWLEDGE TRANSFER

PROGRAMME

SEP 2019– JUN 2020

To book training please go to the BGA website at www.bga.org.uk or contact the

BGA Office on admin@bga.org.uk / 0191 208 6160