“Lopsided” gear flanks for high torque

This animation shows how the Reishauer continuous generating gear grinding process can also produce asymmetric gears efficiently.

To date, most gear designs feature symmetrical gear flanks. In other words, the left and right gear flanks are identical. Although, in the real world, gear teeth are not subject to equal loads on both the drive and the coast flanks. If one of the tooth flanks is subjected to higher force in the direction of the applied torque, the tooth meshing can be optimized by using an asymmetrical tooth flank geometry. Typical examples of a preferred direction of applied torque are tractor and truck transmissions. In all these examples, the highest torque load acts in the same direction.

Automotive gears are also subjected to unidirectional torque loads. Concrete examples of asymmetrically designed dual-clutch transmissions, the gears of which have been manufactured on Reishauer machine for a customer project, have delivered a proven increase of around 25 percent higher torque load, without any increase in their design space.

Moreover, automotive gear manufacturing is subject to enormous economic pressures. Gears must be manufactured both in high volume and at low cost, and the Reishauer continuous generating process meets these challenges for asymmetric gear design, too. Additionally, the Reishauer process allows the combined grinding and polishing of asymmetric gears in one clamping operation.

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