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MANUNET CALL EOI TEMPLATE

PROJECT TITLE: Development of a new cost-effective gear shaping (cutting) and measuring technology for face gears to be used i

CALL IDENTIFIER: 2008 CONTACT DATA

AGENCY Enterprise Estonia / Estonia Organization name Feanor OU
DATE 13/03/2008 Project manager Luca Giorgio Bochese
Phone number +3726207825
Fax number +3726207825
Address Faehlmanni 1-3, 10125 Tallinn ESTONIA
Web address www.feanor.com
Email address info@feanor.com
Region Estonia
Country Estonia
Acronym FACEGEAR

TOPIC & INDUSTRY CLASSIFICATION

Please select 3 choices out of TOPIC and other 3 from SECTOR

TOPIC 1st CHOICE High performance manufacturing technologies

2st CHOICE High manufacturing efficiency
3st CHOICE

In case you choose “other (specify)”

please specify your topic here

SECTOR 1st CHOICE Manufacture of Aeronautical / Aerospace products (and m

2st CHOICE Manufacture of motor vehicles components
3st CHOICE

In case you choose “other (specify)”

please specify your topic here

AIM OF THE PROPOSED WORK

Aim of the project is to facilitate use of face gears in aviation industry, through a new cost-effective
manufacturing technology, based on shaping technology with a special software on CNC horizontal
shaping machine. Face gears have been known and studied for many years, and have been extensively
used for low power and low speed. With the advent of high torque and speed requirements, face gears
have been driven out by conventional bevel gears, which are easier to be manufactured. Face gears can
have important applications in transmissions of helicopters, especially for two reasons: 1. the face gear
coupling proved to be effective also with insufficient lubrication, thus increasing the reliability of the
aircraft; 2. the face gear coupling works also with imperfect misalignment between pinion and the rotor
gear. In case of damage of the gearbox, helicopters using transmission systems based on face gears
have thus a higher safety and survivability. Face gears have some other natural advantages, compared

EXPECTED RESULTS OF THE PROPOSED WORK

 survivability.....(continued from above). Actual application in military aircrafts: Facegears are used in
military helicopters, where higher manufacturing costs are driven out by need of helicopter reliability and
survivability. As far as we know, face gears are not used on civil helicopters.
Potential benefits for partners: All the partners are involved in gear technology design (Feanor), gear
manufacturing (GRA/AVIAG) and gear measuring (STRO) will have benefit if the project will be
completed. Importance of face gears on aviation industry has been pointed out here, but all
manufacturers of gearboxes and transmission are potentially interested in the possible applications of
face gears (in automotive, building, steel processing, mills and wind-mills, …) if this technology will be
succesful. It is impossible to evaluate impact on all these areas, but it is certainly impressive.

ACTIVITIES TO ACHIEVE THE PROPOSED WORK

WP 1 - Identification of industry needs with focus on aviation industry; WP 2 - Design, manufacturing of

the shaper cutter; WP 3 - Manufacturing of the sample face gear; WP 4 - Development of the software
for face gear measurement; WP 5 - Project co-ordination
Partners tasks and contribution to WP
WP 1 - Feanor; WP 2 - Feanor, GRA/AVIAG; WP 3 - GRA/AVIAG; WP 4 - STRO, Feanor; WP 5 - Feanor.
Timing: WP 1 - month 3; WP 2 - month 9; WP 3 - month 15; WP 4 - month 21; WP 5 - monh 1 to 24.
Milestones: D1 - Report on possible applications of face gears, with focus on aerospace applications -
month 3; D2 - Description and prototype of the gear shaping tool - month 9; D3 - Manufacturing of the
prototype of face gear transmission - month 15
D4 - Software module for measurement of face gears on standard 4 axis GMM - month 21

EXPERTISE NEEDED

Please select 3 choices out of TOPIC and other 3 from SECTOR

TOPIC 1st CHOICE High manufacturing efficiency

2st CHOICE other (specify)
3st CHOICE

This technology represent a spin-off from military technology into civilian aircraft technology.
In case you choose “other (specify)”
please specify your topic here

SECTOR 1st CHOICE Manufacture of Aeronautical / Aerospace products (and m

2st CHOICE
3st CHOICE

In case you choose “other (specify)”

please specify your topic here

REMARKS
Tasks: STRO will be responsible for the measurement technology, adapting existing hardware of
standard gear measuring machines (GMM) and designing new software for measurement and evaluation
of face gears.
STRO has locations in Slowak (Manunet region)
PIEDMONT (Italy) GRA is a large gear manufacturer in Piedmont. As alternative another manufacturer in
Piedmont (AVIAG) has more experience in aircraft engine technology.

CONSORTIUM DESCRIPTION

Estonia+Piedmont+Slowak
ESTONIA - Feanor OÜ is a SME located in Tallinn (Estonia), active in length metrology consulting,
software programming, cutting tool design and research since 1998.
Tasks: Feanor will coordinate the project, perform marketing research, develop technical manuals,
manage all translations, design the gear shaper cutter, develop part of the software module for face gear
profile, helix, pitch and deviation analysis, and assist in testing the shaper cutter and the measuring
equipment. Feanor has already participated succesfully to FP4 SMT program (1998-2001) with the PTB
Physikalisch Technische Bundesanstalt in Braunschweig (Department of length Measuring Machines),
Helios (Germany) and Danfoss (Denmark).
SLOWAK REPUBLIC- STRO is a manufacturer of standard and special gear measuring equipment and