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Variation of cylindrical gear stage geometry

This functionality provides assistance with quickly and clearly optimizing the primary geometry of cylindrical gear stages with regard to their load capacity, efficiency, and weight.

Specification of the parameters to be varied

Select the stage parameters to be varied by activating their respective checkboxes on the first page. Start and end values as well as the step size for the variation of these parameters can be entered on the next page. The selection and values are saved and can be used for subsequent variation calculations. Once all required input fields have been completed and the individual parameters align, the total number of variations is shown.

Fixed center distance: The number of teeth cannot be varied; it is internally assigned so that the specified center distance can still be achieved when the rest of the parameters are varied. The addendum modification coefficient of Gear 2 is also determined internally and cannot be varied.

Allow automatic addendum reduction: This checkbox specifies whether tip easing should be performed if the minimum tooth tip thickness or bottom clearance is not reached.

Click the "next" button to start the variation calculation.

Filter criteria

In the second window of the cylindrical gear variation, a progress bar is displayed as the calculation is running. The number of variants calculated and the estimated remaining calculation time are also shown. Once the calculation is complete, the following additional information is also displayed:

  • Total number of variations,

  • Number of variants for which a valid geometry cannot be calculated with the combination of varied parameters,

  • Number of variants for which a valid geometry can be determined.

Activate the respective checkboxes to control the variation parameters and result values to be shown in the representation of the individual variants in the next window. A value range can also be defined for the selected parameters and result values, which limits the number of displayed parameters. This is optional.

Show plot of gear engagement activates visualization of the tooth contour for the selected variant.

Click next to show the calculated variants in the next window.


In the third window of the cylindrical gear variation, the results of all calculated variants that meet the specified filter criteria are shown in the form of both a table and a parallel coordinate diagram.

The order of the values can be changed via "drag & drop" of the individual columns or axis headers. Click on a column head to sort the variants in ascending or descending order. The curves are also color-coded according to the sorting order. If a variant is selected in the table, it is highlighted in blue. Multiple curves can be selected in the diagram by marking a range on an axis. The selection is marked accordingly in the table. Click on the diagram to remove the selection.

The variant marked in the table can be saved as a model snapshot in the current Workbench model, which makes it possible to make detailed comparisons between multiple variants in the Report Manager. The current model is not overwritten. Clicking "apply" transfers a selected variant into the Workbench model, replacing the previous gear geometry.

The following must be taken into consideration when transferring to the model, but can be also be adjusted later:

  • The new gear profile is defined by the specification of the gear reference profile. Any existing tools are no longer considered,

  • The gear reference profile does not include any protuberance,

  • Only one manufacturing step can be considered (not rough and fine machining).