Stepan V. Lunin, M.Sc., M.Eng.,
Ph.D.
Web
site: www.stepanlunin.com
EDUCATION
Ph.D.
- Izhevsk State University, 2000. Applied
CAD/CAM technology.
M.Sc. - Moscow State University, 1989. Applied
mathematics.
M.Eng. - Moscow Aviation Institute, 1986. Manufacturing
engineer-mechanics.
Diploma
– School of physics and mathematics, 1980.
SUMMARY
20+
years experience in power transmission gears, fiber reinforced composite
plastics, engineering software development, mechanical design in aerospace and
automotive. Expert in 3-dimentional CAD gear modeling. Inventor
of Direct Digital Simulation
method for gear design and manufacturing. 15 years experience in
engineering software development related to tooth contact analyses and gear
manufacturing for spiral bevel,
hypoid, globoid, worm face, crown face, helical gears and variable ratio rack
and pinion drive. Experience includes: 15 years in composite gear
design and fabrication, 7 years in helicopter transmissions, 8 years in
automotive power trains and activators, 5 years in marine drives. Familiar with
gear manufacturing: hobbing, shaving, honning, cutting, grinding, CNC dressing, tooth surface
modification, crowning, shaping, forging, tip and root relief, face milling
(GLEASON), face hobbing (OERLIKON), palloid (KLINGELNBERG), not involute
tooth, Wildhaver-Novikov tooth form, whirling, CBN
grinding, CMM inspection, gear machine summary calculation, heat treatment.
Design experience with: Pro/Engineer, AutoCAD and Mechanical Desktop. Familiar
with composite manufacturing: filament winding, resin transfer, injection
molding, vacuum molding, spray applications with chopped fibers, hand laminate,
bounding between metal and composite plastic, structural carbon and glass
fibers. Software development experience in Windows environment with: FORTRAN,
Visual Basic, C, Java, 3-d Studio Max, OpenGL, FEA, CFD, NURBS, IGES, HTML.
Have an extended experience with design and manufacturing of light weight and
non corrosive power transmission gears incorporated with composite plastic
structural elements for boats, helicopters, airplanes, automobiles
and racing vehicles. Proposed and
developed practical solutions for improving driving efficiency of gears for
increasing of fuel economy and reducing noise of cars and trucks, increasing
power to weight ratio on helicopter transmissions and activators, and
increasing efficiency of marine propulsion systems. Proposed new solutions for
mechanical mating components with different surface geometry for lower friction
and improved lubrication. Designed novel cutting, grinding, shaving,
forging and molding tools. Have numerous engineering awards, inventions and
publications.
2006 - Current Senior Design
Engineer. Boeing,
Conceptual
design, helicopter gearboxes, electromechanical actuators. Proposed the winning concept of HALE gearbox.
2006 Senior Design
Engineer. Curtiss Wright
Controls.
Conceptual
design, IR&D, prototyping and manufacturing of gears, rotary actuators, and
fiber reinforced composite plastic elements. Initiated new research
and development projects.
2005 Senior Design Engineer. Moog Aircraft.
Conceptual
design, IR&D, prototyping and manufacturing of gears, rotary actuators, and
fiber reinforced composite plastic elements. Initiated new research
and development projects. Click here for more.
1999 - 2004. Chief Engineer. ZAKGEAR.
US representative. Manufacturing and consulting on power transmission gear
related products. Design, evaluation, software development
and manufacturing. Developed design and manufacturing gear software for
different gears, racks and ball screws. Served the following
companies: Delphi Automotive (MI), New Venture Gear (MI), UTS (IL), Libwil Technology (
Developed 3-dimentional engineering design and manufacturing
software tools for: worm and helical gears, worm pinion, screw, variable ratio
rack and pinion drive, ball screw and ball nut. Simulation of
tooth geometry and tooth contact, stress, driving efficiency, cutting,
grinding, CMM inspection. Simulation of tooth contact analyses with
misalignments.
Achievement:
Primary gears software vendor for Delphi Automotive. Developed
an innovative mathematical solution to help with design, product development
and manufacturing of a fiber reinforced plastic composite gear for an automotive
steering electromechanical rotary actuator.
4/99-2003. Principal Specialist. Volvo.
Lead
in design and development of innovative gears for Volvo Penta
Ocean Series XDP patented composite gear drive. Proposed a new gear tooth form
with low sensitivity to misalignments in order to incorporate with higher
deviations within carbon fiber reinforces composite gear exterior. Design and
development of carbon fiber reinforced composite propellers blades.
Proposed
number of different designs for electromechanical rotary and linear actuators
for tilt and steering to incorporate in to the Award winning composite gear
stern drive.
Proposed
an improvement for composite and metal marine propellers for up to 30%
improvement of fuel economy.
Achievements.
On
behalf of VOLVO did presentations on International power transmission conferences.
Published
a number of gear engineering papers.
Submitted 25 invention disclosures.
Advanced in position from a Senior Design Engineer to the
Principal Specialist.
1/97-4/99 Manufacturing engineer. Delphi Automotive.
Acted as a member of a new product development engineering
team in designand development of a new electromechanical
rotary gear actuator with fiber composite plastic gear. Developed a CAD method
for evaluation of different design options: simple planetary, compound
planetary, high ratio hypoid, worm face and worm gears. Developed CAD
models of the gear tooth geometry and recommended the gear tooth manufacturing
processes. Participated in purchasing of gear manufacturing
equipment from GLEASON, HOEFFLER and Leistritz.
Did mathematical evaluations of the manufacturing equipment
capabilities by simulation of the process on computer models. Did mathematical
modeling for CAD design of molding tools for plastic composite gears including
load test of interface between the fiber reinforced plastic and the metal ring.
Achievements:
Received two awards from manufacturing and product
development teams.
Submitted 5 inventions.
4/95-4/97. Chief Engineer. AKS Skillcraft and Glas-Tec,
Supervised
23 people at a manufacturing plant producing wide spectrum of fiber reinforced
plastic composite products. Chopped fiberglass applications, filament winding,
hand laminate, vacuum molding. Designed and developed expendable production
gears for filament winding. Produced different products from airfoils for
flight controls to 16x200 feet exhaust ducts for chemical plants. Developed new methods and new tools for improving of filament
winding methods around ring shape and rectangular composite tools. True
hands-on experience includes design and fabrication (metal cutting and aluminum)
welding of cylindrical metal inserts sized from 4 inches to 48 inches for using
in filament winding production. Designed and fabricated tooling for racing
vehicles. True hands-n experience with integration composite materials and
metal structural gears: integration with aluminum, PVC, steel and
polycarbonate. Polyester, epoxy, phenolic and corrosion
resistant resins.
In
the same time worked on Ph.D. program: invented and developed new CAD/CAM
method for gears. Practically created and developed a new method of simulation
of gear manufacturing: Direct Digital Simulation. The method is now well
recognized around the world as the most effective method for manufacturing
simulation of the complex tooth surfaces. The ideas were presented to General
Motors that leaded to a very successful joint work after 1997.
4/86-12/91. Manufacturing
engineer. MIL-HELICOPTER.
Responsible
for manufacturing, research and development of helicopter transmission gears. Supervised 6 production workers manufacturing helicopter power
trains and accessory gear-boxes. Wrote step-by-step manufacturing
procedures for helicopter transmission components including shafts, bearings,
housings, splines, spiral bevel, helical, spur and
oil pump gears. Calculated machine setting and summary for
Gleason, Oerlikon, MAAG gear cutting and grinding
machines. Did general gear manufacturing calculations like dimensions
over pins, tooth span, tooth thickness, root and tip relief. Designed gear hobs
and gear cutters. Performed tooth contact analyses (TCA). Inspected gears for:
lead, profile, tooth thickness, transmission error. Proposed new manufacturing
method of helical gears incorporated topological tooth surface modifications.
Developed and build a machine fixture for MAAG tooth grinder to make gear
prototypes. Proposed new calculation method for more accurate
calculation of the tooth surface deviation after heat treatment of carbonized
gears. Proposed a solution for inspection of a helical
gear with high level of tooth profile modification on the existed MAAG involute testing machine. Wrote FORTRAN program for
basic summary calculations for GLEASON gear cutting and grinding machines. Closely involved with complexity of helicopter spiral bevel gears
with different shaft angles. Gear durability testing.
Evaluation of tooth failure. Gear manufacturing
processes: face milling, face hobbing, cutting,
grinding, shaving, honing, shaping. Gleason cutters face and relief grinding.
Familiar with mechanical Gleason spiral bevel cutting and grinding machines.
Designed work piece fixture, calculated summary and set up the machine for
complex tooth surface generation incorporated sliding base, helical motion,
modified roll and cutter tilt. Used CBN plated grinding wheels to grind teeth
out of solid blank for higher accuracy. Setup special cams
for dressing grinding wheels for special tooth modification.
Manufactured spiral bevel and helical/spur gears with root protuberance and
with ground protuberance. Did final gear inspection.
Inspected contact pattern on spiral bevel gears with V,H
and Alpha deviations on Gleason roller tester and transmission error on
KLINGELNBERG. Conducted chemical inspection of tooth burning
after grinding. Modified roll gears on MAAG tooth grinding machine for
making topological tooth modification on 50” diameter helicopter helical gear.
4/91-12/94. Project engineer. Mosinvest.
Responsible
for design and fabrication of sport related racing gears. Proposed
a new concept of using a composite exterior for supporting interior power
transmission elements on high speed racing bicycles. Designed a built
the first composite racing bicycle with all the interior metal gears supported
by bounding to the exterior composite shell. The innovative composite-metal
design received the award for the design in 1988 in
1981-1985 Part time student job at manufacturing
lab at University.
Worked on different research projects including ultrasonic
wire cutting.
Designed electronic schematics and soldered together electric controls for
variable speed wire transporter. Operated hobbing,
shaving, shaping, milling, grinding and turning
machines. Composite materials design and fabrication at
1978-1980 Manufacturing classes at high school.
Introduction
to manufacturing: metal cutting and composite material fabrication. Gear cutting, turning and milling. Built
motorcycles, hang gliders, windsurfers and high speed bicycles.
MANAGEMENT and TEACHING EXPERIENCE
1980-1983:
Teaching physics and mathematics at Moscow Aviation Institute.
1986-1994:
Supervised gear cutting area at MIL Helicopter in
1988-1993:
Team leader and director of government supported project with budget of
$500,000.00 and 6 engineers. The successful result of the project was design
and manufacturing of four composite high speed human powered vehicles with an
innovative transmission.
1995-1997:
Teaching and supervision of composite production workers at AKS Skillcraft in Tucson AZ. 3 engineers and 20 production
workers.
1999-2004:
Director and chief engineer of the
RELATED 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
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,
5.
Goldfarb, Lunin, Trubachev. “Novel
computer modeling technique in gear engineering” 2004 IFTMM
6.
Stepan V. Lunin ”New method of gear geometry
calculation” International Congress on Gears,