Prof. Dr.-Ing. Karsten Stahl

Prof. Dr. Karsten Stahl is Chair, Machine Elements, Mechanical Engineering, at Technische Universität München. He conducts research in the area of mechanical drive systems. His main research interests are drive components, such as gears, synchronization systems, multi-disc clutches and rolling bearings, and electromechanical drive systems. The focus of his investigations is on load capacity, efficiency, dynamic behaviour and EHD tribocontact. The knowledge acquired through this research is transferred to industrial practice by incorporating the results into standardization processes and the development of calculation programs. Stahl studied mechanical engineering at TUM and performed his doctoral studies from 1994 to 2000 in the Machine Elements Department. In 2001, he joined BMW, first as a gear development engineer, then as the manager of gear development in Dingolfing. In 2006 he transferred to the MINI plant in Oxford where he was initially quality manager for transmissions, then quality manager for powertrains and suspensions. In 2009 he took over responsibility for the initial development and innovation management of powertrain and vehicle dynamics systems at BMW in Munich. Since 2011, Stahl has been a full professor in the Machine Elements Department and scientific director of the Research Institute for Gears and Transmissions. (Bio last updated 2017-06-01 Contact Randy Stott, Managing Editor, with changes.)

Articles by Karsten Stahl

  • Ground and Hobbed Globoidal Worm Sets (June 2017)
    A reader wants to know: Are profile ground and hobbed globoidal worm sets better than multi-axis CNC generated globoidal worm gear sets for reduction of noise and vibration?
  • Increased Tooth Bending Strength and Pitting Load Capacity of Fine-Module Gears (September/October 2016)
    The common calculation methods according to DIN 3990 and ISO 6336 are based on a comparison of occurring stress and allowable stress. The influence of gear size on the load-carrying capacity is considered with the size factors YX (tooth root bending) and ZX (pitting), but there are further influences, which should be considered. In the following, major influences of gear size on the load factors as well as on the permissible tooth root bending and contact stress will be discussed.
  • Influences on Failure Modes and Load-Carrying Capacity of Grease-Lubricated Gears (January/February 2016)
    In order to properly select a grease for a particular application, a sound knowledge of the influence of different grease components and operating conditions on the lubrication supply mechanism and on different failure modes is of great benefit.
  • Gear Noise Prediction in Automotive Transmissions (August 2015)
    Due to increasing requirements regarding the vibrational behavior of automotive transmissions, it is necessary to develop reliable methods for noise evaluation and design optimization. Continuous research led to the development of an elaborate method for gear noise evaluation. The presented methodology enables the gear engineer to optimize the microgeometry with respect to robust manufacturing.
  • Tooth Flank Fracture - Basic Principles and Calculation Model for a Sub-Surface-Initiated Fatigue Failure Mode of Case-Hardened Gears (August 2015)
    Cracks initiated at the surface of case-hardened gears may lead to typical life-limiting fatigue failure modes such as pitting and tooth root breakage. Furthermore, the contact load on the flank surface induces stresses in greater material depth that may lead to crack initiation below the surface if the local material strength is exceeded. Over time the sub-surface crack propagation may lead to gear failure referred to as “tooth flank fracture” (also referred to as “tooth flank breakage”). This paper explains the mechanism of this subsurface fatigue failure mode and its decisive influence factors, and presents an overview of a newly developed calculation model.