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Machine Elements
Calculation, simulation and experimental analysis of gears, synchronizers, clutches and rolling element bearings
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The Institute of Machine Elements (FZG) focuses on the development of methods and tools for
reliable determination of fatigue life, efficiency, friction and vibration characteristics of gears and
transmission elements.
The Institute of Machine Elements, also known as ‘Gear
Research Centre’ (FZG), is an internationally renowned
research centre for gears and transmissions. The primary
focus of research activities at FZG is the development of
methods and tools for reliable determination of fatigue
life, efficiency and vibration characteristics of gears and
transmission elements. FZG has state-of-the-art facilities
for the examination and testing of different machine
elements – such as gears, synchronizers, clutches and
rolling element bearings.
The research projects of FZG range from theory-oriented
fundamental research to application-related work. The
projects are financed and supported by different organ-
isations. A large number of these projects are initiated,
financed and supervised by the Forschungsvereinigung
Antriebstechnik e.V. (FVA), usually together with the
Arbeitsgemeinschaft industrieller Forschungsvereinigun-
gen (AiF). Other important research partners include the
Deutsche Forschungsgemeinschaft (DFG), the federal
ministry for economic affairs and energy (BMWi), the
Deutsche Wissenschaftliche Gesellschaft für Erdöl, Erdgas
und Kohle e.V. (DGMK), the FVV or the Stahlforschung. In
addition, many application-oriented projects are requested
and commissioned directly by industry.
Our education lecture series and exercises in machine ele-
ments represent the basic training of mechanical engineer-
ing. In the lectures, students learn to select machines and
machine elements properly, to design them and to calculate
their properties. This knowledge is then applied practically
to design and calculation examples within the lecture-re-
lated exercises. A very important aspect of this is that the
students learn to communicate in the ‘engineer’s language’
– with sketches and drawings. Practical relevance and
topicality are also an important criteria for lectures with spe-
cial subjects. Last but not least, this is ensured by lectures
given by executives from industry.
Research on the load-carrying capacity of gear drives is
one of the main research areas of the institute. Further
important aspects of research in automotive applications
have evolved, such as synchromesh systems, multidisc
clutches and rolling element bearings. The consideration
of fatigue life, efficiency friction and vibration behavior of
gears and transmission elements is in the foreground of
research activity at FZG.
A large number of the research topics deals with the
load-carrying capacity of the components cylindrical,
bevel, hypoid and worm gears, as well as multidisc
clutches, synchronizers and rolling element bearings. The
results of many research projects at FZG are gained from
theoretical and experimental investigations carried out
simultaneously. These validated methods are often pro-
grammed as application software and thereby comfortably
accessible for pratical application. For the development of
a method, simulation models for the load case are usually
developed and validated by extensive tests with samples.
The following selected projects give an exemplary insight
into the research activities of FZG.
Innovative High-Speed Powertrain Concept
for Highly Efficient Electric Vehicles
Due to its high power density and lightweight design,
high-speed powertrain concepts are increasingly used in
electrified vehicles. Because of the high input speeds, new
design challenges arise in terms of efficiency, lubrication,
load capacity and NVH behavior, which were investigated
in the BMWi joint research project ‘Speed2E’. Within this
project, a new powertrain layout based on two identical
electrical machines and one joint gearbox was developed
and investigated.
In order to determine the power requirements of the
electromechanical powertrain, a reference vehicle of the
C segment, which includes compact-class vehicles for
suburban use, was defined. Based on this reference, a
compact powertrain based on a front-wheel drive was
designed resulting in a maximum vehicle velocity of up
Design of sub-transmissions I and II