Home EN atualizada

August 13th and 14th, 2025 in São José dos Campos – SP/Brazil

the Event

About the Event

The Brazilian Gear Conference ITA-WZL appears as a response to the potential demands for technological solutions and innovation research for gears, as one of the initiatives of the partnership between CCM-ITA (Brazil) and WZL-RWTH Aachen (Germany).

The event addresses topics related to manufacturing technologies, product development, and testing of gears, organized into thematic blocks covering the following areas of knowledge: Surface Integrity, Design for Manufacturing, Additive Manufacturing, and Power Density.

The technical seminars address the global state-of-the-art and successful case studies of academic-industry partnerships in gears and power transmission systems. Internationally renowned special guests from the industrial sector will participate in the event’s discussion panels. At the end of the first day, an immersive Product Development Journey will take place at CCM-ITA’s facilities, with a limited number of participants, followed by a cocktail reception. The second day will conclude with the CCM-ITA Open Doors.

The Brazilian Gear Conference ITA-WZL 2025 (BGC 25) will take place on August 13 and 14, 2025, at Parque de Inovação Tecnológica São José dos Campos, in the city of São José dos Campos, São Paulo, Brazil.

Hosts

Prof. Dr. Ronnie
Rodrigo Rego

Prof. Dr.-Ing.
Christian Brecher

M.Sc. Christian
Westphal

Prof. Dr.-Ing.
Thomas Bergs

Special Guests

André Thuswaldner

President at EUROTRANS

Baydu Al

Director at BGA

Christian Kunze

Deputy Managing Director at FVA

Dr. Elbia Gannoum

CEO at ABEEólica

Erica Daumichen

Vice President of Operations at Mercedes-Benz

Friedrich Wölfel

Head of Machine Sales at KAPP NILES

Hanspeter Dinner

Managing Director at KISSsoft

John Oneil

Engineering Manager at Star Su

Prof. Dr.-Ing. Karsten Stahl

Head of FZG at TUM

Dr.-Ing. Nico Tross

Head of Technical Sales at Gleason Switzerland AG

Prof. Dr.-Ing. Oliver Koch

Head of MEGT at RPTU

Dr.-Ing. Oliver Winkel

Head of Application Technology at Liebherr

Pablo Benedini Ferreira

CEO at Transmiservice

Rafael Bachini Werneck

Director of Engineering – Mobility Group South America

Todd Praneis

Vice President, Technical Division American Gear Manufacturers Association

Schedule

08:00 - 08:30

Registration

08:30 - 08:40

Welcome | Prof. Dr. Antonio Guilherme Lorenzi (ITA / Rector)

08:40 - 09:20

Prof. Dr. Ronnie
Rodrigo Rego

09:20 - 09:50

Dr. Marcelo Prim

09:50 - 10:20

Coffee Break

10:20 - 10:50

Prof. Dr. Jefferson de Oliveira Gomes

10:50 - 11:40

Moderator:
Prof. Dr. Ronnie Rego

André
Thuswaldner

Baydu Al

Erica
Daumichen

Rafael Bachini
Werneck

Todd
Praneis

11:40 - 12:25

Benjamin Abert

Dennis Tazir

From Concept to Detailed Analysis: Efficient Gearbox Development with the FVA-Workbench
This presentation demonstrates how to efficiently develop a gearbox from the initial concept to detailed analysis using the FVA-Workbench. Taking a bevel-spur gearbox as an example, the full capabilities of the software are showcased, from creating a first design in just a few steps to refining and analyzing it down to the smallest detail. The FVA-Workbench combines a highly user-friendly interface with the latest state-of-the-art technology and research, enabling engineers to develop and validate gearboxes quickly, accurately, and with scientific precision.

12:25 - 13:40

Lunch

13:40 - 14:10

M.Sc. Gilberto Martins

Eng. André Santana

This presentation will contextualize the challenges of gear design for the agricultural market and explore potential optimization strategies to increase torque density. It will also present results on surface integrity and fatigue life enhancement using the Shot Peening and Superfinishing processes. Finally, it will discuss the gear manufacturing chain incorporating the superfinishing process, which may extend to the rolling contact fatigue on gears.

14:10 - 14:40

Mr. Gerrit Hellenbrand M.Sc

At WZL, a lifetime prediction model for the tooth root was developed considers crack growth rate with the Nasgro equation. The model uses local material properties such as hardness, residual stresses, fracture toughness and the stress intensity threshold to calculate fatigue life from crack initiation to fracture. The first validations of the model were carried out with pulsator tests, further investigations are being carried out on the WZL high-performance back-to-back test rig.

14:40 - 15:10

M.Sc. Izabel Criscuolo

M.Sc. Miguel Danelon

The presentation will focus on investigating the influence of both substrate residual stress state and topography on Nb and Ti doped MoS2 coatings for low-friction gear durability

15:10 - 15:40

Coffee Break

15:40 - 16:10

M.Sc. Caio Gomes

M.Sc. Guilherme Guimarães

As gear standards underestimate the residual stress effects in the fatigue lifetime, a strategy was developed to employ this knowledge in the design phase. A case study is presented, where the joint effect of residual and actuating stresses were considered to downsize a gear while keeping its tooth bending fatigue lifetime. Indirect economical benefits regarding manufacturing time and energy consumption, besides mass/volume reduction, are highlighted.

16:10 - 16:40

Mr. Christian Westphal M.Sc.

The aim of the report is to investigate the effects of waviness on the acoustics behaviour of gear pairs. In this paper, an analytical model is used to explain the effects in theory. Afterwards, the FE-based tooth contact analysis software ZaKo3D is used to calculate the behaviour in detail. Key takeaways are that a difference between β_ᴮ and β_ᵂ does not immediately lead to a reduction of the amplitude of the waviness order. The effect depends on the wavelength and the tooth width. Also, it is shown that there are cross influences between width crowning and waviness.

16:40 - 17:30

Moderator:
Christian Kunze

Friedrich
Wölfel

John
Oneil

Prof. Dr.-Ing.
Karsten Stahl

Dr.-Ing.
Nico Tross

Dr.-Ing.
Oliver Winkel

19:00 - 22:00

After a full day of technical discussions, a special evening is offered to BGC25 participants at a cocktail party. The event will take place at Golden Bar, located at: Av. Cassiano Ricardo, 70 – Parque Residencial Aquarius, São José dos Campos – SP, 12246-870.

*The schedule is subject to change

08:30 - 08:50

Welcome | Prof. Dr.-Ing. Christian Brecher (WZL)

08:50 - 09:20

M.Sc. Guilherme Guimarães

Mr. Emil-Elias Breuer M.Eng.

The performance of Binder Jetting and Laser Powder Bed Fusion Gears were compared to conventionally manufactured gears. The performance evaluation was carried out through Bending Fatigue, Contact Fatigue and NVH assesment

09:20 - 09:50

M.Sc. Matheus Rubik

Additive manufacturing processes such as Binder Jetting introduce porosity and surface integrity concerns in gears. This presentation examines how a dual approach to shot peening, combining densification and the induction of compressive residual stresses, can mitigate these issues and enhance fatigue performance.

09:50 - 10:20

Coffee Break

10:20 - 10:50

M.Sc. Felipe de Sá

Dipl.-Ing. Daniel Hinzmann

Powder metallurgy poses particular challenges for the surface integrity of gears. This presentation explores how experimental and simulation tools can optimize the decision for the finishing manufacturing chain to enable high performance applications.

10:50 - 11:20

M.Sc. Matheus Fernandes

Eng. Josevaldo Fernandez

Improved NVH performance and lightweight designs are increasingly demanded for electrified gearboxes. This study explores the design freedom of Powder Metallurgy to develop an optimized gear body and increase the structural damping for improved vibration absorption through polymer infiltration.

11:20 - 11:50

M.Sc. Carla Cunha

Residual stresses are a key factor in the performance of mechanical components such as gears. However, in-situ measurement and control remain challenging for the manufacturing industry. This presentation introduces a neural network-based approach to predict grinding-induced residual stresses, highlighting consistent results that demonstrate its potential for real-time application.

11:50 - 13:05

Lunch

13:05 - 13:35

Mr. Emil-Elias Breuer M.Eng.

The aim of productive manufacturing is to ensure workpiece quality while minimizing manufacturing costs, whereby tool wear influences both workpiece quality and manufacturing costs. In this paper, an algorithm for detecting and quantifying tool wear on gear cutting tools using computer vision methods is presented. For this, the suitability of traditional and deep learning-based computer vision methods for tool wear detection is compared. Overall, good agreement is achieved between the algorithm-generated and manually measured wear curves with an average absolute difference of ΔVB_max = 7.99 µm for bevel cutting and ΔVB_max = 19.95 µm for gear hobbing.

13:35 - 14:05

M.Sc. Bruno Cardozo

Eng. Jader Geremia

As gearboxes are downsized, thermal dissipation becomes a challenge. This presentation explores a method to evaluate heat distribution and quantify oil churning through Computer Vision techniques.

14:05 - 14:55

Moderator:
M.Sc. Christian Westphal

Prof. Dr.-Ing.
Oliver Koch

Hanspeter
Dinner

Drª. Elbia
Gannoum

Pablo Benedini
Ferreira

15:55

The visit will feature newly installed equipment: Zirtec Shot Peening Station, a L-PBF Additive Manufacturing Machine from Omnitek, a KAPP NILES Gear Profile Grinding Machine, and a Binder Jetting Additive Manufacturing Machine from Markforged, which now join the existing infrastructure at CCM, further strengthening the laboratory’s capacity for applied research and innovation in the gear industry.

*The schedule is subject to change

MAKE YOUR PRE-REGISTRATION

SUPPORTERS

DA VINCI

LEWIS

Partners

SOCIAL MEDIA

CCM-ITA:

WZL-RWTH:

BGC 25:

CONTACT

E-mail: bgc25@ccm-ita.org.br