Gear Engineer

Contributed to engineering since ****:

**+ years of engineering work for major aerospace, automotive, marine, oil and gas companies. 6 design patents (1986-2011), 16 technical articles, 3 presentations on international engineering conferences, 1 book, 3 engineering educational web sites.

Sold personally initiated engineering projects to Boeing, DOD, DOE, TACOM, Moog, Curtiss-Wright, Terex, Rolls-Royce, GM, GE, DMG, MAZAK, Breton, Remacontrols, Boeing, Delphi Automotive, Chrysler, Formula One teams, New Venture Gear, Metso Minerals, National Oil Varco, Brad Foote Gear Works, Overton Gear, Volvo. Customers in USA, Japan, Germany, Italy, South Africa, India, China, Belgium, Finland, Nederland, UK, Canada, Turkey.

In aerospace gear design and manufacturing personally covered all stages: gear cutting machine setup, shop supervision, design, R&D, testing, transition into production, deployment, support, warranty, repairs. Won multiple design competitions. Proposed, developed, and sold a number of different software tools for gear design, manufacturing, and inspection. Initiated several gear design, manufacturing, and inspection methods that are currently common around the world: Direct Digital Simulation, 3,4,5-axis CNC gear cutting, CMM gear tooth inspection with contact pattern simulation, and other innovations.

Researched, developed and consulted on marine power transmission gears with VOLVO PENTA, WARTSALA, OVERTON GEAR, Rolls-Royce. Up to 100”Dia spiral bevel gears. Developed software for digital simulation of rolling/sliding and driving efficiency on the gear tooth for spiral bevel, hypoid, worm, helical and other gears. Researched and developed new marine gear systems. Investigated gear failure for large hard cut spiral bevels by computer reverse simulation of the tooth contact pattern from clouds of CMM points on the tooth surface. Catalyzed 3,4,5-axis CNC manufacturing methods for 40”-90" Dia case hardened spiral bevel gears in the US in 2007-2009 with MAZAK, DMG, NOV, Overton, Brad Foote, and Spiral Bevel Co.

Acted as a lead expert during start up and promotion of large (up to 100"Dia) case hardened industrial spiral bevel and hypoid gears manufacturing on 3-axis CNC for mineral, marine and oil/gas drilling industries in 2008-2010. Managed technical proposals and customer relations. Developed and put into production a new CNC cutting method of spiral bevel gears and other gears with Spiral Bevel Co in 2009. Developed software and manufacturing methods for large worm face gears for oil pipeline actuators.

Achieved world-wide recognition for development of productive tooth contact pattern simulation modeling algorithms on different gears. Suggested and tested novel ideas for increase of load capacity and driving efficiency of spiral bevel and hypoid gear drives for automotive drive axles, marine propulsion, oil/gas rotary tables, and for aerospace. Reduction of noise 6 Db and transmission error 50% have been recorded by VOLVO in 2003. Developed algorithms for specific CAD, FEA gear software. Assisted to GM and Chrysler by CAD gear software development for Ultra Globoid Gear design. Developed CAD software tools for variable ratio steering rack and pinion design for GM, TRW, and for Formula One teams with the most accurate variable ratio rack geometry calculation. Developed design improvements for higher ratio gain. Proposed alternative drive axle gears with simplified pinion design interchangeable with different ratio crown gears. Proposed and prototyped a new fiber reinforced composite drive axle differential housing. Personally built a few prototypes with use of carbon fiber and Aramid™ fibers with cost reduction and reduction of the moment of inertia for racing application and for high performance cars. Proposed idea and developed small diameter (2”) high temperature (350C-500C) electric motor for deep down hole compressors for oil and gas production.

Pro/E Creo, UG NX6, AutoCAD, Inventor, Solid Works, CATIA V5, ANSYS, FEA, UTS, KissSoft, Fortran, VB, VBA, C, Java Scripts, Visual Studio, Fortran, AutoLISP, HTML, MS Office, Fluent CFD, CNC, PLC, FEA, COSMOS, NASTRAN, ANSYS.

Work Experience

Sr. Mechanical Engineer

Goodrich Actuation Systems

February 2012 to Present

Propose, concept and develop electromechanical systems for aerospace: landing gears, flight controls, accessory actuators. Acting as a key expert in transmission gears and bearings.

Sr. Mechanical Engineer

Calnetix Technologies - Cerritos, CA

November 2010 to January 2012

Participated in team effort on design and development of high speed (up to 130000rpm) electric generators and motors with magnetic bearings.

Designed, developed and customer support of dynamic high speed machines. Conducted development of new products. High temperature (350+C) small diameter electric motor to fit into down hole oil production tubing. Carbon fiber reinforced composite high speed (150000RPM) rotor sleeves. Proposed and tested a new method of hop stress measurement on magnet retention sleeves. Proposed and tested a new method of manufacturing of carbon fiber reinforced composite sleeves with use of low temperature prepregs for achieving extra high hoop stress. Proposed and tested a novel high temperature (600C) stator coil design with significantly increased of conductor fill factor for increase motor power. Developed mathematical models to simulated operation of high temperature down hole oil and gas pumps. Proposed a lower cost approach in conducting of chemical compatibility study in developing of ORC machines with corrosive working fluids: Cyclohexane and Toluene. Wrote concept, designed tools and conducted test study to produce the methodology for selecting of dielectric materials for design of high speed electric machines with magnetic bearings. Successfully completed $2mil earn-out technology transfer project for GE. Two award for invention disclosures.

Sr. Mechanical Engineer. Geared dynamic systems.

The Boeing Company - Irvine, CA

December 2006 to October 2010

Primary contact on mechanical systems of A160, HALE(Phantom Eye)

Designed and developed helicopter driveline gear systems, transmissions, and electromechanical flight controls actuators. Developed, tested, improved, deployed, and transition into production helicopter and airplane gearboxes. Wrote reports and proposals to DARPA, external Boeing customer. Conducted investigations of bearing and gear failure. Verified and examined continuing design effort in relation to gears, bearings and other rotating components. Participated in helicopter testing. Inspected Boeing gear suppliers. Inspected incoming gears. Won internal design competition for HALE main gearbox resulted in $5mil extra revenue. The competition was between three Boeing divisions: Irvine, Mesa, and Philadelphia. My Irvine division won the competition thanks to my idea of high driving efficiency and low cost gearbox. 2 patents.

Sr. Mechanical Engineer. Geared electro mechanical actuators.

Curtiss-Wright Controls - Gastonia, NC

January 2006 to August 2006

Responsible for selection of gears and gear stress calculation in development of aerospace electromechanical gear actuators for cargo door, hoists and for weapon bay doors. Reviewed gear manufacturing process and suggested improvements. Reviewed design work of the team from gear prospective. Proposed a new flight control actuator design with 20% cost saving and 40% potential weight reduction. Designed and personally built prototypes of new lower weight and reduced cost actuator components for 747. Participated in proposals for Boeing 737 High Lift actuation system. Submitted 8 provisional patent applications.

Sr. Design Engineer. Gears.

Moog - Torrance, CA

February 2005 to December 2005

Responsible for selection of gears and gear stress calculation in development of aerospace electromechanical gear actuators for high lift systems and for weapon bay doors. F-22, F35, X-45. Participated in gear manufacturing process and suggested improvements. Proposed a new process of gear manufacturing with use of fiber reinforce composite materials with 20% cost saving and 30% potential weight reduction. Designed and built prototypes of new lower weight and reduced cost actuator components for F-22. Selected suppliers for fiber reinforced composite gear manufacturing. Participated in F-35 proposals. Identified the problem and proposed solution for wing folding actuation system for F-35 VTOL. Acted as a key technical expert in Moog’s effort in protection of intellectual property. 1 Patent.

Principal Specialist

Volvo Penta of the Americas - Chesapeake, VA

April 1999 to August 2004

Responsible for spiral bevel gear transmissions for marine applications. Lead development effort of marine driveline gear systems. Acted as a key expert in spiral bevel gears, and in hydrodynamics. Reported to VOLVO Global Engineering Board on the current developments in the USA. Represented VOLVO on four International power transmission gear conferences. Developed multiple simulation methods for improving of gear design. More specifically, developed tooth contact simulation software for spiral bevel gears with different tooth profiles including but not limited to Wildhaber-Novikov tooth profile. Designed novel gears with not traditional tooth form and tested with successful result of significant noise reduction. Developed a method of transmission error reduction of gear transmissions by tooth profile modification. Proposed net shape cold rotary forming method for manufacturing of spiral bevel gears and selected suppliers for machinery. Made recommendations on gear manufacturing equipment purchasing. Selected gear suppliers. Represented American division of Volvo on Volvo Global gear engineering meetings. Proposed novel method of hydrofoil installation for reduction of fuel consumption. Proposed, built and tested a new propeller design with undisclosed hydrodynamic efficiency improvement. Submitted multiple invention disclosures. Promoted to Principal Specialist.

Mechanical Engineer

General Motors Corporation - Saginaw, MI

April 1998 to April 1999

Responsible in electric power steering system development, transitioning into production, and manufacturing.

Key gear expert in development of electromechanical actuators for electric power steering system for automobiles. Acted as a gear engineer within a team of 4 engineers in development of steering gear actuators for cars. Designed gears, produced production drawings, visited suppliers, inspected parts, assembled and tested gear systems. Identified methods for critical improvements in gear design thanks to innovative mathematical way of computer modeling that allowed more accurate calculation of the resulting gear tooth surface. Wrote software for design, gear cutting simulations and CMM inspection of the finished gear tooth surface. Worked with Spiroid, Worm Face, worm, Globoid, and High Ratio gears. Primary role in development of corporate gear software library. Received 2 money awards for critical innovations in gear development for electromechanical steering gear actuator.

Chief Engineer

Glas-Tec Inc - Tucson, AZ

April 1995 to January 1997

Responsible for design, manufacturing and sale of fiber reinforced composite products for aerospace, automotive, sport, marine, mining, industrial and residential applications. Started as a fiberglass laminator at Glas-Tec Inc, where, soon, was named the most skilled composite laminator on the South- West. Personally designed, built tools and sold multiple fiber reinforced composite projects including airplane components, high speed cars, and bikes. Personally laminated over 100,000lbs of fiberglass with different fibers and resins including corrosion resistant epoxy and fire resistant phenolic resins. The largest project, 200-foot long and 16-foot tall, was chemically resistant fiber reinforced composite duct for a copper mine in Globe, AZ. Wrote software for design and stress calculation for composite structures. Designed and built manufacturing machines and tools for filament winding. When promoted to a Chief Engineer at AKS Skillcraft, supervised one engineer and 16 shop workers. Supported customers on $200K-$2mil purchases.

Manufacturing Engineer

Mil Helicopter – Moscow, Russia

April 1986 to December 1994

Helicopter drive line gear systems production and deployment.

Supervised manufacturing of helicopter gearboxes. Acted as key gear expert. 4 gear patents.

Education

Ph.D. in Computer Simulation of Geared Mechanical Systems. Direct Digital Simulation.

M.S. in Applied Mathematics

M.Eng. in Aerospace Engineering

Diploma in Physics and Mathematics

Awards

Delphi Automotive

July 1998

2 money awards from two different development teams for key contribution into development of design and manufacturing methods of Spiroid steering gear for cars. I developed a computer program to calculate the 3d tooth geometry of Spiroid gear and pinion and to simulate the tooth contact with different misalignments of the shafts. The computer program allowed to develop tools for injection molding of the Spiroid face gear and selection of correct tooth lead and profile modifications in order to account for possible misalignments in assembly.

IHPVA International competition in Milwaukee, WI

May 1989

Received multiple awards during 1986-1991 for development of high speed (80mph) human powered vehicles bikes. The first recognition was a gold medal on a trade show (VDNX) in Moscow, Russia in 1987 for design and building a prototype of the first high speed bike, “Gold Fish” with a new front wheel drive transmission. Other multiple recognitions and money awards have been concealed in USA, Switzerland, Holland, and in Germany. The highest award was $300,000.00 for design and production of 4 “ZAK” bikes.

Calnetix Technologies

January 2011

2 money award for inventions. The inventions proposed novel design for high speed and high temperature electric motors.

Mil Helicopter

January 1987

6 money awards for multiple inventions related to design and manufacturing of power transmission gears.

The Boeing Company

February 2009

2 money awards for inventions related to power transmission gears for helicopters.

Glas-Tec, Inc. Tucson, AZ

May 1995

Multiple money awards for innovations and product development in fiber reinforced composite plastics. The most significant recognition has been received for design, prototyping and transitioning into production of light weight and high speed hybrid bike that I designed and built entirely out of fiber reinforced composite materials.

Patents

Split torque geared power transmissions with composite output shafts(#7896287)

http://www.google.com/patents?id=3-wcAQAAEBAJ&printsec=frontcover&dq=stepan+lunin&hl=en&sa=X&ei=FgNlT9ShGu6CsgLCwJm3Dw&ved=0CDQQ6AEwAA

August 2007

A light weight, split torque, geared power transmission having a reduced number of gears and useful for, e.g., transmitting power from an engine to the main rotor of a rotorcraft, includes a ring gear having a pair of oppositely facing angular bevel gears respectively formed on opposite sides of a medial plane thereof, and a first pinion having an elongated drive shaft extending through the medial plane of the ring gear and disposed at an oblique angle relative thereto. The first pinion includes a pair of cylindrical gears mounted coaxially on the drive shaft and respectively disposed in conjugate meshing engagement with respective ones of the bevel gears of the ring gear. An elongated annular output shaft made of a strong, light weight composite material is coupled to a circumferential periphery of the ring gear.

COMPOSITE GEAR AND METHOD OF FORMING SAME(#7861411)

http://www.google.com/patents?id=7iiwAAAAEBAJ&printsec=frontcover&dq=stepan+lunin&hl=en&sa=X&ei=FgNlT9ShGu6CsgLCwJm3Dw&ved=0CDcQ6AEwAQ

May 2007

A composite gear and method of making same. In one embodiment the gear includes a body portion having a plurality of teeth. The gear is formed by placing it in a suitable tool such that a compressive stress is exerted on the teeth adjacent the root portion of each tooth. A portion of the gear adjacent the teeth is wrapped with a resin fibrous material that is allowed to cure while the compressive stress is maintained on the gear. When the resin fibrous material has at least substantially cured and the gear is removed from the tool, a permanent compressive stress is formed at the root portion adjacent each tooth. The compressive stress counteracts the tension stress that is experienced at the root portions of the teeth when the gear is in use, thus significantly strengthening (i.e., toughening) the gear and increasing its fatigue life.

Composite ring gear with metallic gear insert, and method of forming same(#8118958)

http://www.google.com/patents/US8118958?dq=stepan+lunin&ei=FgNlT9ShGu6CsgLCwJm3Dw

April 2007

A composite ring gear (10) with a metallic gear insert (30) has at least one filament (34) wound about the gear insert and an eyelet (32) a plurality of times. The filament is adapted to withstand a portion of a tensile load transmitted between the insert and the eyelet. The insert, eyelet and filament are then embedded in a composite material

SECTIONAL GEAR(#SU1762058 (A1))

http://worldwide.espacenet.com/publicationDetails/biblio?DB=EPODOC&II=0&ND=3&adjacent=true&locale=en_EP&FT=D&date=19920915&CC=SU&NR=1762058A1&KC=A1

September 1992

This invention allows to avoid axial load and, in the same time, get advantage of helical gear design such as smooth transmission and higher load capacity. There are multiple authors. My contribution was an idea how to design and manufacture the sections for higher accuracy angular alignment of the sectors.

VEHICLE(#SU1717454 (A1))

http://worldwide.espacenet.com/publicationDetails/biblio?DB=EPODOC&II=4&ND=3&adjacent=true&locale=en_EP&FT=D&date=19920307&CC=SU&NR=1717454A1&KC=A1

March 1992

This invention has been used in practice for design of high speed bikes. I have patented this invention while building a high speed bike out of carbon fiber. The bike received multiple design awards in Europe and in the USA in 1988-1991 and set a record in 1hr race.

COMPOSITE GEAR WHEEL(#SU1566123 (A1))

http://worldwide.espacenet.com/publicationDetails/biblio?DB=EPODOC&II=7&ND=3&adjacent=true&locale=en_EP&FT=D&date=19900523&CC=SU&NR=1566123A1&KC=A1

May 1990

This is another invention of how to avoid axial forces on cylindrical gears and achieve performance of a helical gear with high contact ratio. My participation in this invention was to develop an inspection method for a not involute tooth profile.

Selected publications:

1. V.I. Goldfarb, S.V. Lunin, E.S. Trubchev. “Direct Digital Simulations for Gears” Volume 1, Izhevsk 2004, ISBN 5-7526-0196-7, Published in Russia. English translation available at http://www.stepanlunin.com/book1.html

2. Stepan V. Lunin, “Direct Digital Simulation Modeling” Gear Solutions magazine, May 2004, pages 32-38

3. Stepan Lunin, Front page cover, Image of the month: 3-dimentional model of orthogonal spiral bevel gear set with special tooth profile. Gear Technology magazine, May/Jun 2002

4. Goldfarb, Lunin, Trubachev. “Advanced computer modeling technique in gear engineering” 2003 ASME Design Engineering Technical Conferences. September 2-6, 2003, Chicago, Illinois

5. Goldfarb, Lunin, Trubachev. “Novel computer modeling technique in gear engineering” 2004 IFTMM Congress, China, Beijing, April 2004.

6. Stepan V. Lunin ”New method of gear geometry calculation” International Congress on Gears, Fukuoka, Japan, 2002

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