Flank Fracture

Damage Patterns - Spur Gear Simulation

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Advanced Seminar




09:30-16:30 CET


Parkring 6
85748 Garching bei München





Price (excl. VAT)

Standard : 1,550.00 €
FVA Members : 1,150.00 €
VDMA Members : 1,150.00 €



The load carrying capacity of the tooth flank and root are crucial gear dimensioning parameters. Optimized design and continuous improvements to the simulation process have made it possible to largely avoid the "classic" fatigue damage symptoms of pitting and tooth root fracture as well as to increase the load carrying capacity limits of gears. However, this leads to an increased risk of damage due to the formation of cracks at great component depths. Flank fracture is characterized by cracks originating beneath the surface of the tooth flank. Damage due to flank fracture generally occurs suddenly and unexpectedly due to growth of the crack within the material. The consequences are generally serious and often result in complete failure of the affected gear stage. Outages due to flank fracture therefore lead to high repair and downtime costs. To avoid damage due to flank fracture, it is important to know and understand the underlying mechanisms and influencing factors.

Target Audience

Employees from companies and specialist departments for spur and bevel gear units: design and operating engineers, maintenance and repair specialists, experts.

Main Topics

The following topics will be covered:

  • Flank fracture damage patterns - basics and damage characteristics
  • Flank fracture mechanisms and and influencing factors
  • Basics of simulation of flank fracture on spur gears
  • Flank fracture on bevel gears
  • Advanced analysis and interpretation of results
  • Overview of ISO/TS 6336-4
  • Calculation options using FVA's RIKOR software


The goal of the seminar is to provide a deeper understanding of the mechanisms, influencing factors, and simulation processes for flank fracture on gears:

  • Reliable detection and assessment of damage to spur, bevel, and hypoid gears due to flank fracture
  • Knowledge of the essential mechanisms and relevant influencing factors of damage due to flank fracture
  • Knowledge of calculation methods for a quantitative evaluation of the risk of flank fracture
  • Understanding of the advanced interpretation of calculation results for qualitative and quantitative estimation of the possibilities for avoiding flank fracture


Dr. Michael Otto

Technical University of Munich, Institute of Machine Elements, Gear Research Centre (FZG)


Dr. Thomas Tobie

Technical University of Munich, Gear Research Centre (Forschungsstelle für Zahnräder und Getriebebau, or FZG)