Highlighting best practice
Dontyne works with partners
such as Renishaw plc and Mazak
Inc to demonstrate integration of
design and production data for
more efficient and accurate gear
production at Gear Expo 2017 Dontyne applies Industry 4.0 principles to rejuvenate ancient
technology. In 2006, Dontyne Systems created the Gear
Production Suite software program to provide a platform
for integrating design and manufacturing processes for more
efficient production. The export and import of data to machine
tools and measuring devices was essential to reduce potential
errors. Dontyne Gears was formed by DrMike Fish in 2013 to
address a requirement in the gear industry to facilitate small
testing programs for large and small specialist companies. This
would utilise all modern techniques for both CAD and production
equipment as well as provide a testing program if necessary.
The principles of gearing have been well understood for thousands of years and
it is therefore easy to assume, even by companies involved in mechanical power
transmission, that there is nowhere left to go with this technology. Gear and
gearbox manufacturers are under a lot of pressure to meet stringent demands
in gear quality, efficiency and conformance to exacting design standards.
Fortunately,we are at a crucial time in the industry when technology can permit a
step change in capability to improve product and performance.
New CAD and CAM technology can produce beneficial tooth forms to reduce
gear box size with consequential reductions in machine time and transport
costs. Research has shown it is possible to get dramatic improvement in power
density, meaning the same power with a smaller unit or more power through the
same-size unit, with obvious benefits in savings for company resources and the
environment. Dontyne can design, analyse, and prove new gear forms prior to
»Founders: Dr Mike Fish and
DrDavid Palmer
»Established in 2006
»Based in Newcastle upon Tyne
»Services: Design and
analysis of geared systems,
prototyping, and testing
»No. of employees: 6
»Over 150 customers in 15
countries worldwide
Dontyne Systems
production. Some new tooth forms
can, in certain applications, give up to
50 per cent better power density than
In 2006, Dr Mike Fish and Dr David
Palmer set out to develop and globally
market intuitively designed, user-
friendly gear software with a heavy
focus on making it easier for design
and production to communicate. This
was started from offices in Newcastle
upon Tyne and Melbourne, Australia.
The concept was to not only provide
recognised standards to reduce
calculation time but also to model
machining processes at the design stage
to allow engineers to investigate the
effects of tooling selection and machine
methods on performance and to identify
likely faults before productionbegins.
The information can be returned to the
design parameters for more efficient
production. There is now a convenient
term for this called Industry 4.0. The
resulting Gear Production Suite (GPS)
software now has over 150 installations
in 15 countries with UK, Japan and USA
the biggest markets, and has an annual
turnover of around £0.75million.
Dontyne has benefited from the internet
and high-speed data flow, which
support the software from our offices,
thereby improving support and reducing
costs for us and the customer. This
was all achieved with six personnel and,
given that there is a $36billion annual
turnover in the gear industry, there is a
great deal yet to tap into. It is interesting
to note that Europe was found to be
the most difficult market to break into
Dontyne’s plans for development will
not be greatly affected in the short or
medium term by the Brexit process.
Gearbox Model calculates deflections
in housing, shafts and components
such that detailed analysis of each
tooth contact can be made for noise
and vibration, stress, and efficiency.
Detailed macro and micro geometry
can be established for each gear pair,
and analysis of surfaces under load can
be made for transmission error, stress,
and efficiency to determine optimum
form before moving to manufacture.
Tool designs can be produced for
various process and manufacturing
simulations carried out to validate the
form, including macro geometry, are
being accurately generated. Errors in
break-out or chamfer position, which
would lead to errors in contact during
operation, can be identified and
corrected before material is cut.
There is a direct link between the gear
design and loaded tooth contact analysis
tools to automate selection. Tool design
and simulations of manufacturing
processes ensure machining
accuracy and resulting performance
characteristics such as strength, stress
and noise can all be assessed before
cutting metal. Engineers can also
make choices based on priority for
production such as minimum machine
time, maximum strength or power and
tool life. The system promises dramatic
savings in production time and cost.
The GPS has in recent years made it
possible to further close the gap in
gear manufacture by enabling a flexible
alternative to dedicated gear equipment
that utilises multi-axis CNCs for small to
medium batch, R&D or one-off gears
that may be cost and space prohibitive
to justify large capital investment in
dedicated equipment. Dontyne also
integrates software with inspection
Gearbox Model
deflections in
housing, shafts
and components
such that
detailed analysis
of each tooth
contact can be
made for noise
and vibration,
stress, and
This example shows
reduced material
required for same power
transmission (20 per cent
less) using new tooth
Highlighting best practice
equipment to provide real-time
inspection, reducing waste and time
costs in mass production.
Collaboration between industrial
partners has enabled gear
manufacturers to take a fresh look
at how gears are designed, analysed,
machined and measured. Development
of bespoke software with machine
manufacturers has enabled companies
to migrate from expensive dedicated
equipment to flexible machine centres
and inspection platforms.
Dontyne Gears can assist with
the design and development of
your gearing system with proven
performance and, if required, help
implement a turnkey solution to
reproduce this for our customers.
There are four parts to our company:
»Design and analysis service
»Manufacture and inspection
»Testing and validation
There are three ways our design
services can help our clients:
»Improvement of existing designs
»Creation of new designs using
standard techniques
»Research and development of novel
The major obstacle to taking
advantage of modern CAD and
machine tools for this technology
in this is human inertia; many new
ideas that work in theory have not
translated into good practice. There is
therefore a need for extensive real-
world testing. Since its inception,
Dontyne has associated itself with
recognised industrial institutions such
as the British Gear Association (BGA)
and the American Gear Manufacturers
Association (AGMA), thus ensuring
consistency in its calculations. DrFish
and Dr Palmer also contribute to
several ISO committees relevant to
gear production and have represented
the UK at these meetings on occasion.
Dontyne feels this is important not
only for consistency but also to drive
development of these standards with
new developments. The developments
can be shaped by results from Dontyne
testing programs but also from
research and development centres
within the UK. Dontyne is partnered
with Design Unit (DU), Advanced
Manufacturing Research Centre
(AMRC), and Advanced Forming
Research Centre (AFRC) – very valuable
assets to the UK, which keep Britain at
the forefront of the mechanical power
transmission industry.
partners has
enabled gear
to take a fresh
look at how
gears are
machined and
Latest from Dontyne Systems for IMTS – Closed-loop
manufacturing on 5 Axis
Spiral Bevel Design – Quick design of spur, helical, bevel,
and spline pairs geometry with loaded tooth contact
Definition of process – Definition of 4 or 5 axis machine
and cutting procedure including tooling, rough and/or
finish cut, variable cutting options for optimum process
Export CNC Path as G-Code Calculation and export of
the G-code for CNC machines completed within seconds
Dontyne provides
simulations of machine
tools and inspection
to check accuracy and
identify problems before
cutting metal