SHOW PREVIEW - Gear Solutions

Your Resource for Machines, Services, and Tooling for the Gear Industry AUGUST 2016

gearsolutions.com

COMPANY PROFILE:KHK USA

GEAR SOLUTION

S MAGAZIN

E PRE-IM

TS SHOW

PREVIEW

AUGUST 2016

PRE-IMTS SHOW PREVIEW

http://gearsolutions.com

KAPP Technologies2870 Wilderness Place Boulder, CO 80301Phone: (303) 447-1130 Fax: (303) 447-1131www.kapp-niles.com [email protected]

Generating Grinding 8mm- 1,250mm

BOOTHN-7036

Question 1:

What do you want? A machine that will grind your parts perfectly and efficiently, so you can go home and be with your family.

Question 2:

What do we have? See answer to question 1.

A QUIZ

See the ZE 800 and KX100 in our booth at IMTS.

Profile Grinding 8mm- 8,000mmProfile Grinding 8mm- 8,000mm

Family friendly machines.

KAPPAd_July_2016.indd 1 6/19/2016 9:11:21 PM

http://www.kapp-niles.com

mailto:[email protected]?subject=Referred by Gear Solutions

http://www.toolink-eng.com

HCB VBL SSQ EQ MIQIQ

THE MENTOREXTERNALQUENCH

INTERNALQUENCH

SOLARSUPER QUENCH

VERTICALBOTTOM LOADING

HORIZONTALCAR BOTTOM

T H E B R I G H T E S T S O L U T I O N S T H R O U G H I N G E N U I T Y

PROUDLY MADE IN THE USA

P 267.384.5040

W solarmfg.comGive us a call to learn more about our vacuum furnace ingenuity.

Get fast, forceful gas cooling with Solar Manufacturing’s SSQ seriesof vacuum carburizing furnaces. Its high performance internalquench system with direct-exit, sliding radiation baffles is the leastrestricted gas flow path on the market for superior hardening at quenchpressures up to 20 bar.

SSQ-IQ SERIES

20 BAR QUENCHVACUUM FURNACE

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AUGUST 2016 3

KHK USAOffering one of the largest selections of metric-dimensioned power transmission gearing in North

America as a distributor for Kohara Gear Industry, KHK USA services its customers by providing off-the-shelf gears with fast lead times.

FEATURES

32

44 A New Class of Industrial Gear Oil By David B. Gray, René Koschabek, and Aidan Rose A new class of industrial gear lubricants based on alternative synthetic materials has been developed to satisfy critical market performance expectations, ensure global supply chain security, and address economic and performance challenges.

50 Analysis and Optimization of Asymmetric Epicyclic Gears By Alexander L. KapelevichFollowing the Direct Gear Design approach to asymmetric epicyclic gear stages with singular and compound planet gears, methods of optimization of the tooth flank asymmetry factor and root fillet profile are considered.

40 Case Study #2: Tracey Gear, Drake Manufacturing, and Norton AbrasivesBy Phil PlainteWith a unique approach to grinding threads from solid, Tracey Gear utilizes Drake machine technology and Norton wheel technology to achieve impressive metal removal rates.

36 Case Study #1: Erwin Junker Machinery and Komet of America Inc.When KOMET of America Inc. sought to produce multi-step tools more efficiently, investing in the Lean Selection Allround machine from JUNKER brought a cost-effective upgrade in technology together with dramatically decreased setup times.

HCB VBL SSQ EQ MIQIQ

PROUDLY MADE IN THE USA

P 267.384.5040

W solarmfg.comGive us a call to learn more about our vacuum furnace ingenuity.

Get fast, forceful gas cooling with Solar Manufacturing’s SSQ seriesof vacuum carburizing furnaces. Its high performance internalquench system with direct-exit, sliding radiation baffles is the leastrestricted gas flow path on the market for superior hardening at quenchpressures up to 20 bar.

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Call 530-885-1939 or visit www.broachmasters.com

1605 Industrial DriveAuburn, CA 95603Phone: (530) 885-1939Fax: (530) 885-8157

and Universal Gear Company

http://www.broachmasters.com

AUGUST 2016 5

Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway, Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210, Pelham, AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek, Richmond Hill, ON L4B4R6. Copyright®© 2006 by Media Solutions, Inc. All rights reserved.

No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without permission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All “Industry News” material has either been submitted by the subject company or pulled directly from their corporate web site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to [email protected].

American Gear ManufacturersAssociation

In this section, the premier supporter of gear manufacturing in the United States and beyond shares news of the organization’s activities, upcoming educational and

training opportunities, technical meetings and seminars, standards development, and the actions of AGMA councils and committees. 19

David SenkforPresidentTopGun Consulting LLC

AUGUST 2016VOLUME 14 / NO. 08

Cover Photo: KHK USA

Zoller Features Products at IMTS 2016 Klingelnberg To Present Products and Services at IMTS 2016

DEPARTMENTS

24 MATERIALS MATTERMartin McCormickMICROPITTINGMicropitting is a unique gear failure mode that can be eliminated by isotropic superfinishing.

56 PRODUCTSHOWCASE

64 Q&A

26 TOOTH TIPSMatt Mondek RECRUITING MILLENNIALSWhen recruiting to fill a gear design position, you need to be able to understand and manage from the perspective of the millennials, as well as understand the generational dissimilarities.

28 TREND TALKSKenneth CarterCOST SAVINGSA good company is always looking for ways to save itself money, but a great company looks for ways to pass those savings on to its customers.

08 INDUSTRYNEWS

Reports, data, and developments to keep you aware of what’s happening with your colleagues in the gear-manufacturing industry around the country and world.

30 HOT SEATSteve KowalskiWORKFORCE DEVELOPMENTThere are many reasons why we all need to invest more in human capital, especially in the heat treating industry.

Call 530-885-1939 or visit www.broachmasters.com

1605 Industrial DriveAuburn, CA 95603Phone: (530) 885-1939Fax: (530) 885-8157

and Universal Gear Company


6 gearsolutions.com

EDITOR'SLETTER

The 2016 International Manufacturing Technology Show (IMTS) is just around the cor-ner on September 12-17 in Chicago, Illinois. We know that everyone is getting prepared for the event, and to start planning, we’ve included a plethora of product announcements, new technology releases, and scheduled demonstrations in our Industry News and Product Showcase sections in this issue, and of course, there will be more to follow — to be posted on our social media pages and in our next issue of Gear Solutions magazine. I hope you find the information helpful to stay informed of the latest IMTS news. And if you are attending IMTS, I look forward to seeing you there. For me, it’s a chance to meet (face-to-face) those of you I’ve had the pleasure of working with in the past year and a chance to catch up with those of you I met at last year’s Gear Expo. This will be my first time to attend IMTS, and I hear that rollerblades might be in order if I want to check out every corner of the show. If you are an IMTS pro and have a surefire game plan, I would love to hear from you. Please remember to put Gear Solutions Booth #N-7225 on your list of stops, and say hello to us.

There will be so much to see at IMTS — with increased productivity, new technology, and cost efficiency on everyone’s mind. To align with that theme, for this issue, we’ve dedicated several pages to articles that show how companies can help its customers do just that. In our Trend Talks column, our new associate editor, Kenneth Carter, discusses cost savings from the perspective of a few different companies, and we continue the trend in two case studies focusing on improved productivity. These are specific examples that you might be able to glean some ideas to consider and implement in your business.

You’ll also read in this issue a technical paper on newly developed synthetic industrial gear oils by David B. Gray of Evonik Industries. In-depth research specific to wind turbine gearbox applications is presented, explaining that the wind turbine gear oil market is helping to drive the rapid development and evolution of industrial gear oils. He demonstrates that synthetic fluids offer significant improvements in critical performance areas and provide enhanced in-service reliability and extended fluid lifetimes. Certainly, increasing wind turbine performance is a plus for the wind energy industry.

Alex Kapelevich of AKGears presents an analysis and optimization of asymmetric epicyclic gears, and our company profile this issue is on KHK USA, the North American distribu-tor for Kohara Gear Industry. The Materials Matter column discusses possible solutions to micropitting through isotropic finishing, and this issue’s Q&A is with David Senkfor of TopGun Consulting who gives some tips on attending IMTS.

Lastly, I would like to thank Steve Kowalski of Kowalski Heat Treating for his first-time contribution to the Hot Seat column. As a business owner, he shares his point-of-view regard-ing the need for a more skilled workforce and some ways that can help improve this issue.

As always, thanks for reading!Molly J. Rogers

EditorGear Solutions magazine

[email protected](800) 366-2185 x205

PUBLISHED BY MEDIA SOLUTIONS, INC.P. O. BOX 1987 • PELHAM, AL 35124

(800) 366-2185 • (205) 380-1580 FAX

Teresa CooperOPERATIONS

David C. CooperPRESIDENT

Chad MorrisonVICE PRESIDENT

Coop wants to use this one for the website

Vertical Logo Horizontal Logo

David C. CooperPUBLISHER

Chad MorrisonASSOCIATE PUBLISHER

EDITORIALMolly J. Rogers

EDITOR

Kenneth CarterASSOCIATE EDITOR

SALESChad Morrison

ASSOCIATE PUBLISHER

Dave GomezREGIONAL SALES MANAGER

CIRCULATIONTeresa Cooper

MANAGER

Jamie WillettASSISTANT

ARTShane Bell

CREATIVE DIRECTOR

Michele HallGRAPHIC DESIGNER

CONTRIBUTING WRITERSDAVID B. GRAY

ALEXANDER L. KAPELEVICH RENÉ KOSCHABEK STEVE KOWALSKI

MARTIN MCCORMICKMATT MONDEK PHIL PLAINTEAIDAN ROSE

Welcome to our pre-IMTS issue of Gear Solutions!

New England Gear 343 John Downey Dr.

New Britain, CT 06051 p. 860-223-7778 • f. 860-223-7776 www.newenglandgear.com

20-4

CUSTOM Fanuc Controller

OPTIONS5” Stroke6” StrokeSWING AWAY Center SupportOTHER Risers Available

We have the World’s largest stock of used late model Fellows Gear Shapers. We do it all! Our machines are equipped with Fanuc 1,2, 3,4 & 6 axis controls.

We have a Full Inventory of parts in stock and ready for delivery so come visit us at www.newenglandgear.com

and start shaping now!

We own what we sell, and

we know what we’re selling.

New England Gear has Fellows 20-4 Gear Shapers

R E M A N U F A C T U R E D • R E T R O F I T T I N G • C U S T O M M A C H I N E S

IN STOCKRemanufactured in 2014

NEG_Ad final_03.14.pdf 1 4/11/14 10:19 AM



New England Gear 343 John Downey Dr.

New Britain, CT 06051 p. 860-223-7778 • f. 860-223-7776 www.newenglandgear.com

20-4

CUSTOM Fanuc Controller

OPTIONS5” Stroke6” StrokeSWING AWAY Center SupportOTHER Risers Available

We have the World’s largest stock of used late model Fellows Gear Shapers. We do it all! Our machines are equipped with Fanuc 1,2, 3,4 & 6 axis controls.

We have a Full Inventory of parts in stock and ready for delivery so come visit us at www.newenglandgear.com

and start shaping now!

We own what we sell, and

we know what we’re selling.

New England Gear has Fellows 20-4 Gear Shapers

R E M A N U F A C T U R E D • R E T R O F I T T I N G • C U S T O M M A C H I N E S

IN STOCKRemanufactured in 2014

NEG_Ad final_03.14.pdf 1 4/11/14 10:19 AM

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8 gearsolutions.com

INDUSTRYNEWS

NEW PRODUCTS, TRENDS, SERVICES, AND DEVELOPMENTS

Companies wishing to submit materials for inclusion in Industry News should contact the editor, Molly J. Rogers, at [email protected]. Releases accompanied by color images will be given first consideration.

Emag To Display Machine Tools at IMTS 2016

Emag, a leading supplier to the North American market, will be presenting machine tools and related manufacturing equipment at IMTS 2016 in Chicago, Illinois, September 12-17, Booth #N-6834, in the Gear Pavilion located in the North Hall.

The company will present its family of turning centers, gear genera-tion machines, grinding, milling, vertical turning, and boring equip-ment, plus advanced electro-chemical and laser-welding machines, as well as heat treatment. A variety of machines will be on display, running under power, plus experts in all the various technologies will be available for discussions.

Emag is a family of global machine companies that includes the proprietary-branded and popular vertical turning machines, as well as Eldec, Naxos-Union, Koepfer, Reinecker, Lasertec, ECM, Kopp, and Karstens. The company often integrates a variety of machines into work-cell arrangements at major automotive, off-highway, and other power-transmission component suppliers.

Displayed machines include: • The VL 4 is a modular vertical lathe with integrated automation,

designed for maximum production at low cost per piece with a small footprint. A pick-up spindle moves in the X- and Z-axes with 12 driven tools on a turret to cut and index parts up to 200 millimeters (7.87 inches) in the shortest time possible. The pass-through rotary conveyor keeps blanks incoming and machined

parts outgoing. Machines can be equipped with a Y-axis for more complex geometries.

• The VM 9 combines turning, milling, and drilling into a single machine for large-part production. With the workpiece spindle in the bottom of the cutting theater, the VM 9 offers a turning diameter of 450 millimeters (17.71 inches), a max workpiece height of 300 millimeters (11.81 inches), and a max workpiece weight to 300 kilograms (660 pounds).

• The VT 2-4 performs dual-sided shaft machining in high-produc-tion mode with dual 11-position tool turrets for fixed or driven tools — workpieces to 200 millimeters (7.87 inches) in diameter and 630 millimeters (24.8 inches) in length.

• The Eldec Mind-M 250 is a compact hardening system for basic heat treatment of chucked parts and shafts, provided by the Eldec group of Emag. Heat treatment tasks are performed at 30 kW in high-frequency applications and 100 kW in medium frequency — workpieces to 10 kilograms (22 pounds).

The Emag booth also will feature a blisk (bladed disk) display to demonstrate the precision electro-chemical machining (PECM) tech-nology offered to the aerospace, pump, and power-generation markets.

In-depth technical videos will be shown at the booth to present some of the other technologies available at Emag, including laser-welding technology.

FOR MORE INFORMATION: emag.com

Zoller Features Products at IMTS 2016

Zoller presents its extensive product range, from tool presetting, measuring, inspection, and automation to software solutions at IMTS 2016 in the West Building, Booth #W-2022. Zoller is known for innovative solutions, and IMTS will give visitors the opportunity to see numerous innovations and further developments.

Software Module for Inspection Device ”PomBasic” “ReGrind” The new Zoller software module for wear measurements finally enables economical regrinding processes. The Zoller tool inspection device PomBasic was introduced in 2013 and is now successfully being used all over the world. Due to this new regrinding module, it also can be used as an electronic caliper gauge for any precision tools to be reground.

Automation Solution “RoboSet 2” The version RoboSet 2 of the automation solution for tool mea-surement, RoboSet, now features a significantly more compact and space-saving design. Due to a multi-pallet system and the associated larger number of tools, this smart automation solution

is capable of covering even larger series in unmanned quality assurance or production processes, while its new double gripper makes it faster at the same time.



http://www.emag.com

AUGUST 2016 9

KISSsoft Highlights● Optimized 3D modeling in KISSsys● Enhanced evaluation of planet carrier deformation● FE calculation of the gear body● Updated VDI 2737 (2016)● Bevel gear contact analysis with shaft influence● And many more ...

Get your free trial version atwww.KISSsoft.com

KISSsoft USA, LLC3719 N. Spring Grove Road

Johnsburg, Illinois 60051Phone (815) 363 8823

[email protected]

Release 03/2016

NEW

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Precision Gear ProductsSTOCK : HOBS : HSS & CARBIDE

STOCK : SHAPERS : Disc & ShankSTOCK : MASTER GEARS

RFQ on specials gear tools welcomeDiametral Pitch 12 and finer

STOCK AVAILABLE

RUSSELL,HOLBROOK&HENDERSON, INC.25 E Spring Valley Ave., Maywood, New Jersey 07607P: 201-226-9000 F: 201-226-9004 E: [email protected]

CELEBRATING 100 YEARS IN BUSINESS

Zoller TMS Tool Management Solutions for Grinding WheelsThe new grinding-wheel management package enables systematic and efficient management as well as measurement of grinding wheels. This ensures not only precise measurements but also seamless provision of any grinding-wheel data required in the manufacturing process. The structure of a grinding-wheel package is reproducibly documented in a parts list.

Measurement macros for the individual grinding-wheel types according to the FEPA standard are included by default. Availability is visible at any time due to connected storage systems.

Every Tool Must Have a Digital TwinUsers of Zoller products are well-equipped for future developments. For smart manu-facturing, also known as Industry 4.0, to reach the shop f loor, manufacturing

plants not only need top-notch physical tools in the machines but also their digital twins for work preparation. Therefore, Zoller offers solutions for generating digi-tal twins according to DIN 4000 with the new software module “DigitalTwin.” This enables tool manufacturers as well as grinding and sharpening companies to offer their customers genuine added value, while ensuring they are prepared for the requirements of tomorrow.

FOR MORE INFORMATION: zoller-usa.com

New Norton Centerless Grinding Technology at IMTS 2016

Norton Saint-Gobain will feature Norton Century45™at IMTS, Booth #N-7051.

The newly developed Norton Century45 centerless bond platform features an exclu-sive chemistry that greatly improves grain retention in the wheel. Better grain reten-tion means wheels are constructed with more porosity for a given hardness. This translates into wheels having a hard grade with the performance of a softer grade, providing a range of benefits.

Norton Century45 wheels are available with ceramic, aluminum oxide, silicon car-bide grain, and abrasive blends to maximize user grinding safety and efficiency. These wheels reduce cycle times by up to 50 percent, improve stock removal by more than 30 per-cent, and increase wheel life from 30 percent to 100 percent versus standard products on the market.

Norton Century45 provides a continually sharp wheel face that achieves more than 30


http://www.KISSsoft.com


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http://www.zoller-usa.com

10 gearsolutions.com

Throughout the manufacturing process, heat treatment is consistently viewed as a critical step for adding value to the parts produced. A part expensively manufactured by melting, hot rolling or forging, annealing, rough machining, teeth cutting and grinding is essentially useless and of little to no value without heat treatment. In addition, without reliable and repeatable heat treatment, it is impossible to achieve competitive overall manufacturing costs.

Amazingly, the cost for a manufacturing step that adds such a high value is only a fraction of the total production costs – generally in the range of no more than 5%. This percentage, however, increases to roughly 15% of the cost per part if all further post-treatment process steps inherent with, or caused by, heat treatment – such as cleaning, blasting, straightening and/or grinding – are taken into account. Therefore, a noticeable reduction of manufacturing costs is only possible by minimizing the distortion of parts. For this, all the influencing parameters like steel melting, forming of the parts, uniformity of microstructure and hardenability, as well as ...

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percent more stock removal, reducing grind-ing times through fewer passes to achieve optimal results.

Operators will generate more parts through reduced production cycle times when using Norton Century45 wheels.

Norton Century45 centerless grinding wheels also can decrease grinding noise levels by as much as 23.2 decibels, even when grinding hard-to-grind alloys such as Inconel 718, thus increasing operator safety.

To put this noise reduction in context, many commercially available foam ear plugs offer noise reduction ratings in the range of 25 to 28 decibels.

Norton Century45 is ideal for bar grinding, fastener and tool grinding, automotive, or aerospace components, as well as bearing appli-cations. Whether in a high-production grind-ing facility or job shop, Norton Century45 can significantly reduce grinding costs while increasing safety and production throughput.

FOR MORE INFORMATION: nortonindustrial.com

www.zoller-usa.com

MAX.PRODUCTIVITYwith the universal tool inspection machines incombination with the smart automation solution»roboSet« for efficient tool measurement - 24/7!

See the video! ZOLLER live: Booth W-2022

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Röhm To Feature Workholding Technologies at IMTS 2016

Röhm Products of America will show its strength as a one-stop clamping-and-grip-ping supplier by presenting a wide range of workholding innovations in Booth #W-2528 at IMTS 2016. Among the products on display will be two of the company’s new-est solutions that fulfill industry demands for increased efficiency, ergonomics, weight reduction, and convenience.

Manufacturers in search of new ways to maximize the potential of their milling and turning machines will want to see the Duro-TA XT key bar chuck. Röhm engineered this manual chuck with weight reduction, work-piece accessibility, and application flexibility in mind. Up to 75 percent lighter than competitive designs, the Duro-TA XT features extended and easily detachable guideways that allow for an unmatched clamping range and the quick conversion between small and large workpieces.

Additionally, through the direct mount on the base body, these guideways provide high rigidity, stability, and protection against dirt and dust.

Another highlight in Röhm’s booth at IMTS will be the Power-Grip modular, zero-point clamping system that meets manufac-turers’ demands for customizable solutions to maximize machine utilization. A user-friend-ly palletization system, Power-Grip reduces both the number of setups required per part and allows setup to take place outside of the machine, thus eliminating downtime due to workpiece clamping. Moreover, Power-Grip can be seamlessly incorporated with a mul-titude of Röhm standard clamping devices, allowing for easy and flexible integration.

Booth visitors are welcome to discuss spe-cific workholding challenges. Application specialists will be on-hand to address these challenges as well as show how Röhm’s work-holding and automation technology can help increase productivity through lights-out and just-in-time manufacturing.

FOR MORE INFORMATION: rohmproducts.com

Klingelnberg To Present Products and Services at IMTS 2016

Klingelnberg will present its versatile machine lineup in operation at Booth #N-6837 at IMTS 2016. This year’s focus will be “solu-

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tions for the automotive industry” and “solu-tions for small-batch gear manufacturers.”

Every day, manufacturers in the automotive industry are faced with challenges for which appropriate solutions must be found while continually improving power consumption and significantly lowering exhaust emissions. Not only do engines for passenger vehicles and commercial vehicles have to meet strin-gent environmental standards, they must also maintain the defined performance standard or even increase it in the best case. To achieve these goals, Klingelnberg offers an extensive portfolio of appropriate solutions.

Bevel Gear Cutting Machine C 30 — Leading-Edge Technology for Optimal Flexibility and Maximum Productivity In cars, spiral bevel gears are used in all-wheel-drive systems and rear-wheel-drive sys-tems to transmit torque from the transmission to the road. Due to increasing performance requirements, these drives sometimes must transmit outputs of more than 300 kW. The bevel gears they use must be efficient, smooth running, and low maintenance.

Due to ongoing advancement of the verti-cal concept, the Oerlikon bevel gear cut-ting machine C 30 sets new standards in dry processing. All machines in this series are equipped with a thermostable, vibration-damping machine bed. An optimized axis arrangement also ensures reduced approach paths and thus significantly less load on the drive components — and a more rigid design of the overall system. Moreover, an integrated deburring tool enables maximum productiv-ity and utmost process safety through the use of the Pulsar method.

Precision Measuring Center P 40 — Cutting-Edge Technology for Maximum Safety and Precision, Featuring a New Graphical User InterfaceThe fully automatic CNC-controlled preci-sion measuring center is designed as a com-pact unit for the workpiece diameter range up to 400 millimeters. At the heart of the P 40 is an accurate, durable rotary table. Configured as a measuring axis (C axis), it provides con-centric seating of the workpieces to be tested.

All precision measuring centers are equipped with new versions of the calibra-tion software and an advanced graphical user interface. The new Windows user interface, soon to be established on the market under the “EasyStart” brand, allows the machine operator to operate the machine in a manner that is both significantly easier and target-oriented. A clearly structured user interface, displayed by a tiled layout with appropriate symbols for the specific measuring appli-cation, ensures a quick-and-easy program start on the gear-measuring machine. Most machine operators already will be familiar with this type of application from the current general Windows system interface.

Optimized Small Batch ProductionThe industrial gear unit sector comprises many different applications, all of which place great demands on the reliability of gear wheels. The cylindrical gears for these sectors often are produced by companies specializing in small batch sizes and a variety of products.




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AUGUST 2016 13

A stiff machine design and flexible, cost-effective tool systems are the keys to success for ranking among the market leaders in these sectors. With the Viper 500 machine vari-ants, Klingelnberg has developed a modular technology platform that gives contract gear manufacturers in particular a leg up on the competition due to maximum process effi-ciency and unparalleled production quality.

Cylindrical Gear Grinding Machine Viper 500 WThe Viper 500 W cylindrical gear grinding machine is designed for component diam-eters up to 500 millimeters and specifically for small- to medium-sized batches. To suit individual requirements, the machine is avail-able in three different configurations: profile grinding, small grinding wheels for custom jobs, and multiple-wheel technology (K) as well as generation grinding (W). The Viper 500 W configuration allows both profile grinding and continuous generation grinding on the same machine with minimal retool-ing time.

On all variants, the optional internal gear grinding arm allows retooling from external to internal gearing. Moreover, the special machine-axis arrangement is a contributing factor in the machine’s precision and consis-tent quality, as well as flexibility.

The highly dynamic axes allow opti-mized 5-axis machining of an entire range of modifications in the shortest possible grinding time.

FOR MORE INFORMATION: klingelnberg.com

Sandvik Coromant Offers Connectivity to Customers at IMTS 2016

In an era of digital transformation in machin-ing operations, Sandvik Coromant will reveal for the first time at IMTS 2016 new con-nectivity-based solutions designed to help manufacturers optimize their machining and decision-making process.

The new solutions have been developed to improve every aspect, from design, produc-tion planning, and through machining to post-process analysis and intelligence.

Digitalization within manufacturing is increasingly important for the success of machine shops the world over; however, embarking on this transformational journey also brings challenges and complexities. To

EnginEEring & DEsignQuality Above and Beyond Our Customer’s Expectations Our experienced engineering staff coupled with our skilled manufacturing technicians will partner with you to produce your product. View our Online catalog of standard components www.nordex.com.

prosthEsis Over 32,400 Standard ComponentsFrom prototype to production. Manufacturing, engineering, assembly, testing, custom machining, and gears for every application. Offering a full line of mechanical components: gears, pulleys, racks, shafts, and related products.

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help manufacturers overcome them, Sandvik Coromant has devised digital solutions that support those looking to take steps toward a connected future.

“Sandvik Coromant has a long heritage of bringing new technology developments to the metal-cutting industry, each of which is based on the values that our customers hold highest, such as greater productivity and profitabil-ity,” said Magnus Ekbäck, vice president of business development at Sandvik Coromant. “Connected software and hardware does the same thing but in a different way. At IMTS, visitors will discover how advancements such

as data exchange and machining intelligence will improve efficiency and optimize produc-tion processes. New technologies open new possibilities, and we are keen to share our knowledge and help customers take the lead in digital machining.”

The data collected at each step of the digital machining processes combined with Sandvik Coromant’s competence in inter-preting and optimizing them will provide manufacturers with better insight about their machining environment and help them increase their overall profitability. For those wanting to discuss how best to

benefit from digital advances — such as connectivity, digital machining, and big data as well as the latest machining trends — leading experts from Sandvik Coromant will be available at IMTS 2016 to address specific inquiries. A wide selection of tools also will be at the exhibition, and some will be used in live demonstrations.

Sandvik Coromant has two booths at IMTS, #W-1500 (West Building) and #NC-509 (North Building, Hall C).

FOR MORE INFORMATION: sandvik.coromant.com

Star SU To Unveil Dry Grinding Technology and Cutting Tool Advancements at IMTS 2016

Star SU will showcase its product range of machine tool, cutting tool, and tool services at IMTS 2016. It will have two booths — one in the Gear Pavilion in the North Hall and another in the West Hall showcasing its cutting tool technology.

In Booth #N-6924, visitors will see product overviews, video displays, and a new interac-tive customer application guide solution tool for Star SU’s full line of product and technol-ogy offerings. A Star SU representative guide will be available to guide visitors through its complete machine tool, cutting tool, and tool services offerings. Brands represented include: Star Cutter Company, Samputensili, Bourn & Koch, SICMAT, Profilator/GMTA, FFG Werke (Huller Hille, Hessapp, Modul, VDF Boehringer), H.B. Carbide, and Sandvik Coromant.

Samputensili SG 160 Sky Grind Gear Dry Grinding MachineStar SU offers the Samputensili SG 160, the first gear dry grinding machine that can grind gears without using coolant. This extraordi-nary evolution of the gear-generating grind-ing process ensures short cycle times, even less than the traditional machines (less than 2 seconds).

DMG MORI is coming to the nation’s largest manufacturing show. Join our experts at IMTS in Chicago to

explore the Path of Productivity, and learn how technology can solve your challenges before they exist.

Visit DMG MORI at IMTS.

BOOTH S-8900

"We challenge our customers to redefine possible."

– Dr. Thorsten Schmidt CEO, DMG MORI USA

+ 26 machines on display

+ Customized automation solutions

+ Exclusive Technology Cycles for

increased productivity

+ New Direct Sales and Service

structure

BOOTH HIGHLIGHTS U.S. PREMIERES DMG MORI EXPERT SPEAKERS

See your future in action. Learn more and schedule an appointment at imts.dmgmori.com.

DMGMORI @dmgmoriusa

+ Sprint 32|8 automatic lathe

+ ULTRASONIC 20 linear

+ Additive Manufacturing Conference,

McCormick Place

New Approaches to

Additive Manufacturing

Dr. Greg Hyatt

Tuesday, September 13th

+ IMTS Conference, McCormick Place

Art of Hybrid Manufacturing

Mike Panzarella

Wednesday, September 14th

Visit our booth at IMTS to win a trip to Germany!*

*Exclusions apply. Visit imts.dmgmori.com for trip details.

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Grinding fluids tooptimize productivty,economic efficiencyand machining quality.

Blaser Swisslube Inc. Goshen, New York Phone 845-294-3200 [email protected] www.blaser.com

Our specialists support you to get the best out of your machines and tools with the Liquid Tool. Please contact us for your local distributor.

When the coolant becomes a liquid tool.

Our specialists support you to get the best out of your machines and tools with the Liquid Tool. Please contact us for your local distributor.

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http://www.sandvik.coromant.com

DMG MORI is coming to the nation’s largest manufacturing show. Join our experts at IMTS in Chicago to

explore the Path of Productivity, and learn how technology can solve your challenges before they exist.

Visit DMG MORI at IMTS.

BOOTH S-8900

"We challenge our customers to redefine possible."

– Dr. Thorsten Schmidt CEO, DMG MORI USA

+ 26 machines on display

+ Customized automation solutions

+ Exclusive Technology Cycles for

increased productivity

+ New Direct Sales and Service

structure

BOOTH HIGHLIGHTS U.S. PREMIERES DMG MORI EXPERT SPEAKERS

See your future in action. Learn more and schedule an appointment at imts.dmgmori.com.

DMGMORI @dmgmoriusa

+ Sprint 32|8 automatic lathe

+ ULTRASONIC 20 linear

+ Additive Manufacturing Conference,

McCormick Place

New Approaches to

Additive Manufacturing

Dr. Greg Hyatt

Tuesday, September 13th

+ IMTS Conference, McCormick Place

Art of Hybrid Manufacturing

Mike Panzarella

Wednesday, September 14th

Visit our booth at IMTS to win a trip to Germany!*

*Exclusions apply. Visit imts.dmgmori.com for trip details.

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W-1426

Star XTG Tool and Cutter GrinderThe XTG 575 showcases the latest in technology offered by Star. This state-of-the-art, five-axis linear tool and cutter grinder was engineered to regrind and manufacture complex cutting tools in both high- and low-volume applications. With 575 millimeters of Z-axis travel, this machine has impressive long-tool capability. Design features include a mineral cast base for increased damping and thermal stability performance, 1,000 rpm work head, and a four-station HSK wheel changer. The machine is ideal for high-mix, low-volume jobs due to its quick setup and stability. Partnered with Numroto software, the XTG 575 is ready for anything from the daily grind to cutting-edge prototypes. The XTG 575 is engineered and made in the U.S.

Bourn & Koch 400 H CNC Horizontal Hobbing MachineBourn & Koch 400H 7-axis CNC horizontal gear hobber features Fanuc CNC control and industry exclusive point-to-point array hobbing capability. The machine is ideal for longer spline shafts and spur and helical gears up to 400 millimeters in diameter, 6.4 max module.

FFG Werke Modul H200 vertical hobbing machineThe H 80/100/130/160/200 series is the latest version of Star SU’s hobbing machine line for small automotive applications, specially engineered for automotive applications. These machines have been designed for dry-cutting applications in particular, although using oil or emulsion is not a problem. Chips are conveyed cleanly from the work area by means of a chute, which is steep and smooth in design to prevent any buildup. The hob head is housed within the tool column, which is tightly fastened to the sturdy machine bed. The tailstock is on the tool column above the hob head, leaving the work area free for workpiece loading and unloading operations.

Gear Cutting Tool SolutionsStar SU not only carries a variety of new gear cutting tools, but it also offers precision tool re-sharpening services and advanced coatings, including Oerlikon Balzer’s New Balanit® Altensa, the high-speed coating solution that realizes productivity gains and efficiency.

Star SU will also feature Scudding® cutters in conjunction with GMTA and Profilator manufactured to produce gear and spline teeth for reduced cycle times and tool costs.

In Booth #W-2258 (Tool Technology Hall) visitors will see the following:Gundrills — Star SU carries a full line of gundrills and deep hole drills, including single-

flute gundrills, solid carbide single flute gundrills, two-flute two-hole gundrills, double jet gundrills, double crimp gundrills, and bi-tip gundrills.

Solid and Brazed Construction Carbide Drills & Reamers — Star SU offers a range of precision solid carbide drills and reamers, including solid and braze construction carbide drills and reamers, core drills, Super Round Tool (SRT) reamers, valve guide reamers, multi-diameter cavity machining tools, and cryogenic machining cutting tools.

Carbide Blanks and Preforms — Star SU offers a variety of tungsten carbide blanks and preforms from H.B. Carbide. Using only the highest quality raw materials and employing state-of-the-art, computer-controlled vacuum furnaces and vacuum Sinter-Hipping furnaces, these cemented carbide preforms can be used for cutting tools, dies, and wear parts in a variety of specialized applications.

FOR MORE INFORMATION: star-su.com

Liebherr To Demonstrate New Single Table Gear Grinding Machine At IMTS 2016

With a one-table design and a new-design grinding head, the new Liebherr LGG 280 gear grinding machine greatly reduces grinding times for twist-free profile and generating grind-ing of workpieces to 280 millimeters in diameter.

Presented for the first time in North America in the Liebherr Booth #N-6930 at IMTS 2016, the machine is the second in the LGG series and is designed to deliver consistent high large-scale production quality in automotive applications, including conical gearing. With it, manufacturers can produce smaller gears with greater load-carrying capability.

“With this series of space-saving machines, vehicle manufacturers can develop a complete pro-duction line, in which all gearing components for a passenger vehicle transmission can be ground:



http://www.star-su.com

AUGUST 2016 17

Mytec Hydraclamp introduces workholding Solutions for high force applications

This new Product Line from MyTEC, world leading innovator and manufacturer of hydraulic clamping tools, features:Stainless steel

constructionExtreme accuracy,

similar to hydraulic expansion tools

High expansion rates (up to .010” or greater)

Custom Solutions for the inspection of gears & splines

Frenco’s 30 years of expertise includes bench and in-process inspection of splines and gears. Products include spline gages, master gears, profiled clamping systems, double flank gear rolling devices

and rotation inspection systems. Frenco also offers gear and spline calculation software, consulting and seminars.

Euro-Tech Corporation is the exclusive North American distributor of the Frenco and MyTEC Product lines

262.781.6777 | [email protected]

we find solutions!

VISIT US IN BOOTH W-2453 AT IMTS

planetary and sun gears, bore-type gears, as well as drive and pinion shafts with lengths up to 500 millimeters,” a Liebherr spokesman said.

The advantage to the one-table solution is higher quality through-out the entire production. There is one clamping fixture, one geom-etry. Every machined part is manufactured under the same conditions for the highest reproducibility. The one-table approach provides the statistical capability and reliability in continuously producing controlled micron-range finish quality for gear noise optimization.

The new grinding head allows for rotation speeds up to 10,000 rpm and has spindle power of 35 kW. With this performance data, the head enables high cutting speeds and high feed rates.

The new grinding machine can exploit the considerable potential of the innovative 3M abrasive Cubitron II. Changing the grinding arbor with HSK-C 100 toolholder is a fast and simple process. Also available is a second grinding head featuring a small worm diameter for collision-critical parts.

The machine will enable undulations to be applied specifically to gear wheel flanks for noise optimization purposes for the first time. The ability to produce sub-micron range waviness cost-effectively gives designers a whole new range of optimization options.

The touch-screen user interface on the machine control permits easier, intuitive programming and machine operation and incorporates an inte-grated webcam. The control also can incorporate substantial additional documentation, such as fixture layouts and tool mounting instructions.

The LGG machines are easily coupled with Liebherr automation solutions to create a fully automated production line for the highest quality gears in the least possible cycle times.

FOR MORE INFORMATION: liebherr.com


http://www.eurotechcorp.com

http://www.liebherr.com

The new Genesis® GX Series takes high-volume, high-quality gear grinding to an entirely new level, including fast, easy setup with just one tool and integrated automation – all from a single source.

www.gleason.com/GX

Finish First

© Gleason Corporation. All rights reserved.

Booth N-7000

http://www.gleason.com/GX

AUGUST 2016 19

American Gear ManufacturersAssociation

Amir AboutalebVice President, Technical DivisionAGMA

AGMA’s 2016 Fall Technical Meeting in October Will Present Current Industry ResearchAGMA goes back to its roots this fall by holding the Fall Technical Meeting (FTM) in Pittsburgh, Pennsylvania, on October 2–4. From a historic perspective, this event marks the 100th year of AGMA meetings where technical papers will be presented on the subject of gearing. The first technical papers were presented during the 1916 Annual Meeting, which also was held in Pittsburgh.

AGMA’s expertise in understanding the technical intricacies of power transmission and delivering timely solutions has been demon-strated by technical presentations and in the development of AGMA standards over the last century. The presentations at this year’s FTM promise to follow on this tradition by providing insight into current state-of-the-art research on the future of our industry and recom-mendations that are immediately actionable for our FTM attendees. This year, as an attendee, you will listen to 23 presentations arranged into five sessions: Manufacturing, Inspection, and Quality Control; Materials & Heat Treatment; Application and Design & Rating; Efficiency, Lubrication, Noise, and Vibration; and Gear Wear & Failure. You will have the opportunity to talk with the presenters who come from various sectors of the industry from across the globe.

For your review, we have provided the titles and shortened abstracts in this edition of Gear Solutions. Even if you are not an engineer, I encourage you to review these abstracts and attend this event. Within these presentations, so many of our members have found insights that they have taken back and imple-mented to save time in a production technique or tweak something for better efficiency.

Come hear about advanced engi-neering steels; new possibilities of modifications with the continuous generating grinding method; new synthetic lubricant formulations; a new approach to repair large indus-trial gears; new methods for design-ing and specifying gear teeth; and so much more.

In addition to the 23 presenta-tions, AGMA has arranged for two special presentations. During Session 3, the chairperson of the Helical Gear Rating Committee will provide a status report on AGMA 925-BXX “Method to

Predict Micropitting, Wear, and Scuffing.” Two years ago, AGMA formed a sub-committee to review and revise AGMA 925-A03, with the specific goal of adding a method to predict the risk of micropitting to the Information Sheet. This presentation will cover conclusions to date, proposed changes, and the status of the Information Sheet.

Our second special presentation will be included in Session 5. Norbert Haefke of FVA GmbH will present “Standardization Based on Innovations from the German Drive Technology Industry Network.”

Presenters will be coming from several countries and from a wide variety of work and research settings. There will be opportunities to ask questions at the end of each session, as well as opportunities for networking. Come discover how others in the industry are finding successes in techniques in our field. Make new connections. Gain insights into how others look at similar problems that you face.

I encourage you to attend this event. And I would also like to take a moment to thank our more than 50 reviewers who took time out of their busy schedules to assist AGMA in providing this robust lineup.

The 2016 Fall Technical Meeting will also be the backdrop for the AGMA centennial event that closes our centennial year. A reception, open to all, will take place on the evening of Monday, October 3. This event is included in the full registration for the FTM, but individual tickets are also available for $75 on www.agma.org.

The new Genesis® GX Series takes high-volume, high-quality gear grinding to an entirely new level, including fast, easy setup with just one tool and integrated automation – all from a single source.

www.gleason.com/GX

Finish First

© Gleason Corporation. All rights reserved.

Booth N-7000

http://www.agma.org

AGMA Fall Technical Meeting — Presentation Lineup

SESSION 1 – MANUFACTURING, INSPECTION, AND QUALITY CONTROLEffi cient Hard Finishing of Asymmetric Tooth Profi les and Topological Modifi cations by Generating GrindingAndreas Mehr, Liebherr-Verzahntechnik GmbH

New possibilities of modifications with the con-

tinuous generating grinding method will be pre-

sented, such as Deviation Free Topological grind-

ing (DFT), Generated End Relief (GER), Noise

Excitation Optimized modification (NEO), and

hard finishing of asymmetric gears. The focus is

on the explanation of the technical challenges,

their solutions, and the principal function of the

dressing and grinding processes.

The Whirling Process in a Company that Produces Worm Gear DrivesMassimiliano Turci, Eng, Studio Tecnico Turci

This paper looks at the benefits that can be real-

ized with the introduction of a whirling machine

into the worm gear manufacturing facility. The

benefits include time and cost savings, especially

in regard to the need for grinding, increased

quality, and environmental considerations due

to not needing cutting oils.

Worm Screws High-Speed ManufacturingJean-Laurent Feutren, Affolter Technologies SA

The conventional setup of a gear hobbing

machine for the production of helical gears has

the hob axis perpendicular (±30°) to the work-

piece. This setup does not allow for conventional

manufacturing of worm gears. To solve this prob-

lem, a high-speed method will be presented that

reverses the axis between the workpiece and tool

and utilizes a high-speed spindle (up to 16,000

rpm). This method can produce worm gears

eight times faster than conventional methods.

Twist Control Grinding (TCG) Walter Graf, Reishauer AG

This paper introduces the latest process devel-

opments for the hard finishing of gears in regards

to controlling flank twist. Flank twist occurs as a

matter of course when machining helical gears

that feature lead modifications and is brought

about by the geometries and kinematics inherent

in the continuous generating grinding of helical

gears. Controlling the flank twist on gears using

twist control grinding (TCG), can either eliminate

twist completely or introduce a counter-twist to

counteract the deformation of gears under load.

SESSION 2 – MATERIALS & HEAT TREATMENTReview of Microstructure and Properties of Non-Ferrous Alloys for Worm Application and Advantages of Centrifugally Cast Bi-Metal Gear BlanksGiri Rajendran, MCC International

This paper reviews the microstructure and properties of tin

bronze, manganese bronze, and aluminum bronze materials

that make them suitable for specific worm gear applications. The

advantages of centrifugally cast bi-metal gear blanks and some

common causes of worm gear failures are discussed.

Pre-Nitriding: A Means of Signifi cantly Increasing Carburizing ThroughputThomas Hart, Seco/Warwick Corporation

Higher carburizing temperatures allow end users to use shorter

cycle times and significantly increase production rates but can

lead to grain growth. Pre-nitriding is a relatively new technology that

addresses grain growth and allows carburizing end users to carburize

at higher temperatures. Real-life case studies show how carburizing

productivity has doubled, and sometimes tripled, using pre-nitriding.

Performance and Machining of Advanced Engineering Steels in Power Transmission Applications – Continued DevelopmentsLily Kamjou, MSc, Ovako AB

This paper discusses the potential gain for the power transmission

industry by making use of the material properties of advanced

engineering steels to support more demanding applications.

Machining the advanced engineering steels is discussed based on

a number of recent studies. All studies indicate that by optimizing

machining parameters and tools, the productivity and efficiency

of these processes can be maintained or even improved.

Gear Design Relevant Steel Cleanness MetricsE. Buddy Damm, TimkenSteel Corporation

This paper describes the methods used to characterize premium

quality clean steels through the use of statistics of extreme values

(SEV) and the use of these data to perform gear design relevant

engineering analysis of the potential for a gear failure due to

bending fatigue in the root or flank. Literature evaluation, model-

ing results, and experimental results are presented in order to

validate the approach.

Development of High-Hardness Cast Gears for High-Power Applications in the Mining IndustryFabrice Wavelet, Ferry-Capitain

Multiple solutions are available to increase the transmissible

power of girth gears, including using a larger module, increasing

the gear diameter, enlarging the face width, and increasing the

hardness of the base material. Base material hardness, the only

parameter that is not limited by cutting machine size, is being

increased to meet higher power needs. This paper will review the

related design and manufacturing impact of the high-hardness

gears needed to meet today’s industry demands.

SESSION 3 – APPLICATION AND DESIGN & RATINGComputerized Design of Straight Bevel Gears with Optimized Profi les for Forging, Molding, or 3D PrintingAlfonso Fuentes, Rochester Institute of Technology

Research will be presented on whether there is

a reference profile that will yield the same advan-

tages for bevel gears as the involute for cylindrical

gears. The spherical involute and octoidal profiles

will be studied, and the virtual generation of bevel

gears with the different profiles will be developed

and simulated using advanced tools such as tooth

contact analysis and finite element analysis.

Contact Fatigue Characterization of Through-Hardened Steel for Low-Speed Applications Like HoistingMichel Octrue, CETIM

Lubrication by grease is often employed on open

gears that transmit power at low speeds. The rating

methods found in ISO 6336 have shown that ISO

is very conservative for grease-lubricated, through-

hardened steel gears running with case-hardened

pinions, specifically when considering service life.

Fatigue SN curves resulting from tests will be

compared and discussed with values given in ISO

and AGMA gear rating standards.

Determination of Load Distributions on Double Helical Geared Planetary GearboxesTobias Schulze, DriveConcepts GmbH

The optimization and effective utilization of plan-

etary gearbox designs require a detailed con-

sideration of the loads on the gears. This paper

presents a computer-aided calculation method

that has been developed for planetary gearboxes

with spur and helical gears and considers the most

important influences on the load distribution. Using

this information, a detailed load distribution is pos-

sible to reach the maximum capability of the gears.

Designing Very Strong Gear Teeth by Means of High-Pressure AnglesRick Miller, Innovative Drive Solutions LLC

This paper will show a method of designing and

specifying gear teeth with much higher bend-

ing and surface contact strength than that of

conventional gear teeth. The primary means of

achieving this is by specifying gear teeth with

significantly higher pressure angles. This paper

will show calculation procedures, mathematical

solutions, and the theoretical background and

equations to achieve this.

SESSION 4 – EFFICIENCY, LUBRICATION, NOISE, AND VIBRATIONImpact of Surface Condition and Lubricant on Effective Gear Tooth Friction Coeffi cientAaron Isaacson, Gear Research Institute

Using a four-square, power re-circulating gear test rig with high-accuracy torque

transducers, losses due to operating speed, surface roughness, and torque level,

including two different lubricants, were compared. Measurements of the effective

coefficient of friction at the gear tooth flanks are provided. This paper summarizes

the results obtained.

Surface Structure Shift for Ground Bevel GearsSebastian Strunk, MSc, The Gleason Works

A process is presented that improves the excitation behavior of a ground bevel

gear set by altering the surface structure of a generated member along the path

of contact from slot to slot. This process addresses this objectionable harmonic

excitation by influencing each axis position in each line of the axis position table

with small predetermined or random amounts.

Developing an Energy-Effi cient Industrial Gear OilShubhamita Basu and Mr. Dan Wilkerson, The Lubrizol Corporation

This paper describes a laboratory test rig, test procedure, and results that are

focused on quantifying increased operating efficiency with various synthetic

lubricant formulations. Fluid evaluations were conducted in an industrial-scale

worm gear efficiency rig. Operating under a wide range of speeds and loads, the

rig produced sharp differentiation among fluids for their impact on power loss and

operating temperature.

Analysis of Excitation Behavior of a Two-Stage Gearbox Based on a Validated Simulation ModelMarius Schroers, MSc, Laboratory for Machine Tools and Production Engineering (WZL) of RWTH

Aachen University

In order to reduce development and production costs of a gearbox, simulation

models have been set up to predict the noise and vibration behavior of a gear-

box before the prototype phase. A simulation model, verified by experimental

results, is presented that is able to calculate the dynamic excitation behavior of

a two-stage gearbox.

An Experimental and Analytical Comparison of the Noise Generated by Gears of Both Austempered Ductile Iron (ADI) and SteelDonald Houser, The Ohio State University – Gear and Power Transmission Research Laboratory

Many have made claims concerning the relative noise performance of austempered

ductile iron (ADI) versus steel as a gearing material. Predictions based on measured

tooth topographies of the transmission error and “sum of forces” gear noise metrics

show that the iron gears should be slightly quieter than the steel gears at loads

beneath the transmission error optimization “notch” torque and slightly louder above

this torque. This paper presents results from a systematic experimental study to

ascertain these differences.

SESSION 5 – GEAR WEAR & FAILURENumerical Thermal 3D Model to Predict the Surface and Body Temperature of Spur and Helical Polymer GearsNiranjan Raghuraman, MS, Romax Technology

Tooth surface wear is an important failure mode in plastic gears, and this is primarily

caused by the surface temperature increasing to a value close to the melting point

of the material. Thus, it is critical to compute the temperature of the gear pair in

an accurate fashion. This paper will focus on the prediction of gear temperature

of plastic gears using a numerical heat transfer model based on 3D finite differ-

ence method.

Infl uence of the Defect Size on the Tooth Root Load-Carrying CapacityJens Brimmers, MSc, Laboratory for Machine Tools and Production Engineering (WZL) of RWTH

Aachen University

Conventional calculation methods for the flank and tooth root load-carrying capac-

ity are well-established, but models that consider the defect size on the tooth root

strength have not yet been applied in fatigue models for gears. This paper will

introduce a method for calculating the tooth root load-carrying capacity for gears

while considering the influence of the defect size on the endurance fatigue strength

of the tooth root.

Infl uence of Contact Conditions on the Onset of Micropitting in Rolling-Sliding Contacts Pertinent to Gear ApplicationsAmir Kadiric, Imperial College London

Recently, increased sliding has been one of the factors suggested to be responsible

for the onset of micropitting, with the proposed underlying mechanism being the

potential reduction of film thickness through increased sliding speed. This paper

attempts to shed light on the tribological conditions that may lead to the onset of

micropitting in lubricated, concentrated contacts representative of those occurring

between gear teeth. In particular, the effect of slide-roll-ratio, surface roughness,

and film thickness is studied.

Comparison of TIFF Load Capacity to Standardized Gear Failure Modes Using Boundary Conditions from an Effi cient and Accurate Loaded Tooth Contact AnalysisBaydu Al, MEng, Smart Manufacturing Technology Ltd.

This study aims to improve the existing understanding of Tooth Interior Fatigue

Fracture (TIFF) load capacity and compare calculated load capacity to the allow-

able loading conditions for bending and pitting fatigue failure, based on standard

calculation procedures. Possible methods that could be used to mitigate TIFF risk

are presented, and the effect of these methods on the performance with respect

to the other failure modes are quantified.

A New Approach to Repair Large Industrial Gears Damaged by Surface Degradation – The Refurbishment Using the Modifi cation of Both the Profi le Shift Coeffi cient and the Pressure AngleHoracio Albertini, HASA – Horacio Albertini Ltda

Superficial degradation of industrial gears, and a lack of approaches to repair them,

have resulted in many gears being discarded prematurely. This paper presents a

computer program and method for repairing industrial gears, enabled by the recent

advances in multi-axis CNC machine centers and gear grinding, that considers the

modification of both the profile shift coefficient and the pressure angle.American Gear ManufacturersAssociation 1001 N. Fairfax Street, Suite 500 • Alexandria, VA 22314

(703) 684-0211 • www.agma.org

http://www.agma.org

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BO

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CTO

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Dean Burrows: ChairmanPresident, Gear Motions Inc.

Jim Bregi: TreasurerPresident, Doppler Gear Company

John Cross: Chairman, BMECASI Technologies Inc.

Thomas Maiuri: Chairman, TDECThe Gleason Works

Lou Ertel: Chairman EmeritusOverton Chicago Gear CorporationE

XE

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Joe Franklin, Jr.: President

Amir Aboutaleb: Vice President, Technical Division

Jenny Blackford: Vice President, Marketing

Jill Johnson: Director, Member Services

STA

FF

General requests: [email protected] | Membership questions: [email protected] | Gear Expo information: [email protected]

Technical/Standards information: [email protected] | AGMA Foundation: [email protected]

AGMA LEADERSHIP

CALENDAR OF EVENTSWhether you’re looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, AGMA has something to offer you. If you would like more information on any of the following events, visit www.agma.org or send an email to [email protected].

Events are open to AGMA members only. Not a member? Send an email to [email protected].

AU

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Computer Programming Committee Meeting — August 29, 2016 WebExLubrication Committee Meeting — August 30, 2016 WebExFlexible Couplings Committee Meeting — August 31, 2016 WebExVehicle Gearing Committee Meeting — August 31, 2016 WebEx

Wormgearing Committee Meeting — September 7, 2016 WebExSound & Vibration Committee Meeting — September 8, 2016 WebExBevel Gearing Committee Meeting — September 8, 2016 WebExFine Pitch Gearing Committee Meeting — September 13, 2016 WebExAccuracy Committee Meeting — September 14, 2016 WebExLubrication Committee Meeting — September 15, 2016 WebExBasic Training for Gear Manufacturing — September 19-23, 2016 Chicago, IllinoisGear Failure Analysis — September 19-21, 2016 Big Sky, MontanaAerospace Gearing Committee Meeting — September 19-20, 2016 Cincinnati, OhioMill Gearing Committee Meeting — September 22, 2016 WebExNomenclature Committee Meeting — September 27, 2016 WebExHelical Gear Rating Committee Meeting — September 29, 2016 WebEx

Fall Technical Meeting — October 2-4, 2016 Pittsburgh, PennsylvaniaSound and Vibration Committee Meeting — October 5-7, 2016 Pittsburgh, PennsylvaniaHelical Gear Rating Committee Meeting Subcommittee 925 — October 11, 2016 WebExPlastics Gearing Committee — October 12-13, 2016 Detroit, MichiganMarketing & Forecasting Conference — October 19-20, 2016 Chicago, IllinoisAccuracy Committee Meeting — October 21, 2016 WebEx

Nitin Chaphalkar: DMG Mori USA

Kenneth J. Flowers: Machine Tool Builders, Inc.

William Gornicki: ALD-Holcroft Vacuum Technologies Co., Inc.

John E. Grazia: GearTec Inc.

Aarnout Kant: Siemens AG, Mechanical Drives - Winergy

David Long: Chalmers & Kubeck Inc.

Don Michael: Martin Sprocket & Gear

Carl D. Rapp: The Timken Company

Tania Sabados: Rapid Gear

Andrea Scanavini: Somaschini North America

Brian Schultz: Great Lakes Industry, Inc.

George Thomas: Bison Gear & Engineering Corp.

Hastings Wyman: Klingelnberg America, Inc.

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Leistritz Polymat

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Computer Programming Committee Meeting — August 29, 2016 WebExLubrication Committee Meeting — August 30, 2016 WebExFlexible Couplings Committee Meeting — August 31, 2016 WebExVehicle Gearing Committee Meeting — August 31, 2016 WebEx

Wormgearing Committee Meeting — September 7, 2016 WebExSound & Vibration Committee Meeting — September 8, 2016 WebExBevel Gearing Committee Meeting — September 8, 2016 WebExFine Pitch Gearing Committee Meeting — September 13, 2016 WebExAccuracy Committee Meeting — September 14, 2016 WebExLubrication Committee Meeting — September 15, 2016 WebExBasic Training for Gear Manufacturing — September 19-23, 2016 Chicago, IllinoisGear Failure Analysis — September 19-21, 2016 Big Sky, MontanaAerospace Gearing Committee Meeting — September 19-20, 2016 Cincinnati, OhioMill Gearing Committee Meeting — September 22, 2016 WebExNomenclature Committee Meeting — September 27, 2016 WebExHelical Gear Rating Committee Meeting — September 29, 2016 WebEx

Fall Technical Meeting — October 2-4, 2016 Pittsburgh, PennsylvaniaSound and Vibration Committee Meeting — October 5-7, 2016 Pittsburgh, PennsylvaniaHelical Gear Rating Committee Meeting Subcommittee 925 — October 11, 2016 WebExPlastics Gearing Committee — October 12-13, 2016 Detroit, MichiganMarketing & Forecasting Conference — October 19-20, 2016 Chicago, IllinoisAccuracy Committee Meeting — October 21, 2016 WebEx



Leistritz Polymat

and Polyjet

machines have

the features

to improve

quality, shorten

cycletimes and

minimize set-ups.

Polymat series of

CNC keyseating

machine



www.leistritzcorp.com



Leistritz Polymat

and Polyjet

machines have

the features

to improve

quality, shorten

cycletimes and

minimize set-ups.

Polymat series of

CNC keyseating

machine



www.leistritzcorp.com N-7061

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MATERIALSMATTER

MICROPITTINGMicropitting is a unique gear failure mode that can be eliminated by isotropic superfinishing.

MARTIN MCCORMICKTECHNICAL SALES REM SURFACE ENGINEERING

MICROPITTING IS A GEAR FAILURE MODE THAT TYPICALLY occurs when higher contact stresses are applied to hardened gear teeth. Unlike most other failure modes, micropitting does not always proceed to component failure if left unaddressed. However, the direction that micropitting will take cannot be reliably predicted except with frequent inspections [1], and, as a result, steps must be taken to avoid its development.

WHAT IS MICROPITTINGMicropitting is a contact fatigue phenomenon that occurs in rolling/sliding contact environments. When micropitting begins to occur, the surface exhibits microscopic pits that are too small to be detected by the naked eye. As noted, micropitting can be progressive, leading to growth of micropits in size and prevalence. Once the progression is sufficient to be observed without magnification, the affected area will take on a gray appearance. This stage of micropitting is commonly referred as “gray staining.”

WHY DOES MICROPITTING OCCURMicropitting occurs most commonly with case-carburized steels that experience high loads and are operating in a mixed–film elastohydrodynamic lubrication (EHL) environment. Under these conditions, the relative roughness of the mating surfaces and the oil thickness are of the same order, and, as a result, the mating surfaces operating load is shared by the lubricant and the peak surface asperities. In a rolling/sliding contact environment, direct contact of the peak asperities leads to a sharp rise in contact pres-sure at the asperity level, significantly above that predicated by Hertzian contact theory. This pressure causes plastic deformation at the surface of the material, which has the effect of reducing the peak asperity height, acting akin to a “running-in” mechanism. The plastically deformed surface is highly stressed and is liable to crack under repeated cyclic loading and unloading. The cracks that form start at the peak asperities where the deformation occurs and lead to the generation of micropits.

The growth of the micropits is theorized to be the result of crack propagation caused by lubricant generated hydraulic pres-

sure or “hydraulic pressure propagation” [2]. In short, this theory postulates that lubricant becomes temporarily trapped in surface cracks due to the plastic deformation of peak asperities resulting in a sharp rise in lubricant pressure and, ultimately, the expansion of the crack itself.

ISSUES CAUSED BY MICROPITTINGMicropitting can cause several problems for engineered components. Progressive micropitting causes a loss of component geometry, which can manifest as increased noise, vibration, and loss of efficiency. Additionally, as micropitting grows, the micropits will combine to form a macropit. Macropits are much larger and can undermine the strength of the hardened casing, which, if not caught, will lead to tooth breakage. Even prior to the formation of macropits, it is pos-sible for the micropitting itself to lead to bending fatigue by acting as a failure initiation site.

As noted, not all micropitting will progress to component failure. Micropitting can self-arrest leading to only minor modifications to the component’s geometry or profile — effectively a “run-in” step serving to correct minor manufacturing or design errors. The problem is that there is no economical way of predicting which path micropit-ting will take, so a solution must be sought.

ISO 15144ISO Technical Report 15144 developed a safety factor calculation for micropitting. This report looked at a number of factors and determined that having a minimum specific lubricant film thick-ness in the contact area greater than the permissible lubricant film thickness is critical to avoiding micropitting and should therefore have a defined ratio:

Equation 1

where: Sλ — safety factor against micropitting λGF, min — minimum specific lubricant film thickness in the

contact area λGFP — permissible specific lubricant film thickness Sλ, min — minimum safety factor

The minimum specific film thickness in the contact area is derived from the local film thickness and the surface roughness:

Equation 2

where: λGF,Y — local specific lubricant film thickness hY — local lubricant film thickness Ra — the effective arithmetic mean roughness value

Figure 1: Example of “gray staining” in the dedendum of a gear tooth


AUGUST 2016 25

Based on these formulas, it is clear that there are two primary factors that must be considered in order to eliminate micropitting: lubricant film thickness and surface roughness. As discussed in the March 2016 Materials Matter column, increasing lubricant viscosity detrimentally impacts system efficiency. Lubricant additive packages (a third potential factor) have their own risks and have not been shown to be a universal solution. Therefore, improving surface roughness would seem to be the optimal solution to micropitting.

FZG TESTING METHODOLOGYFZG micropitting gear testing is an accepted pro-cedure for evaluating micropitting. This testing uses a back-to-back gear test rig with a tooth profile designed to show micropitting relatively quickly and involves two test phases. The first phase is a sequential load stage test where the gears are inspected after each load stage for evidence of micropitting. Failure is defined as profile deviation greater than 7.5 µm. The second phase is an endurance test designed to see the progression of micropitting over time. It is run at the highest load stages to give an accelerated picture. Failure is defined as the point at which profile deviation exceeds 20 µm.

A SOLUTION TO MICROPITTINGIn an effort to find a solution to micropitting, a study was conducted by REM Surface Engineering, Winergy AG, and the University of Bochum using the FZG testing methods previously described. The testing compared components with a ground surface finish against components with an isotropic superfinish — obtained using REM’s ISF® Process [3]. As shown in Figure 2, the isotropi-cally superfinished gears exhibited no micropitting and almost no profile deviation through both test methodologies. In comparison, the baseline ground gears failed the first testing phase at load stage eight and the second testing phase at the third full endurance stage. The results of the isotropically superfinished gears are even more impressive from the perspective that the profile of FZG micropit-ting test gears is specifically designed to induce micropitting. The total profile deviation of the ISF gears was only 0.5 µm, and no micropitting was generated.

CONCLUSIONMicropitting is a gear failure mode that, while not always inducing failure, must be treated as an unacceptable occurrence given the inability to economically or effectively predict its progression. Per ISO, lubricant film thickness and surface roughness are the critical parameters that influence micropitting. Modification of lubricant viscosity has unattractive consequences and is not a root cause solu-tion to micropitting. Reduction of surface roughness via isotropic superfinishing is a tested and verified root cause solution to the problem of micropitting.

REFERENCES1. B. Pinnekamp, T. Weiss, and G. Steinberger, “Micropitting – A

Serious Damage? Testing, Standards and Practical Experience, “ AGMA Fall Technical Meeting, Cincinnati, OH, 2011, 11FTM15

2. Robert Errichello, “Morphology of Micropitting,” AGMA Fall Technical Meeting, Cincinnati, OH, 2011, 11FTM17.

3. L .

Winkelmann, O. El-Saeed, and M. Bell, “The Effect of Superfinishing on Gear Micropitting, Part II, “AGMA Fall Technical Meeting, Milwaukee, WI, 2010, 08FTM10.

ABOUT THE AUTHOR: Martin McCormick has been with REM Surface Engineering since 2008 through REM’s European office in the United Kingdom. He has worked in a number of departments and currently holds a technical sales role focusing on supporting new and existing business. McCormick has an honorary master’s degree in chemistry from Hull University. He can be reached by email at [email protected].

Figure 2: FZG testing results of isotropically superfinished versus ground gears

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MATT MONDEKPRESIDENTMONDEK SOLUTIONS

TOOTHTIPS

RECRUITING MILLENNIALSWhen recruiting to fill a gear design position, you need to be able to understand and manage from the perspective of the millennials, as well as understand the generational dissimilarities.

IF YOU’VE ATTENDED ANY INDUSTRY FUNCTION LATELY, YOU’VE noticed that conversations invariably include discussions about the shortage of skilled gear designers and the difficulty to hire or retain the needed talent. This problem is not new; however, for the organizations that comprehend the generational differences and tailor their recruit-ing strategies, they will be well-positioned ahead of their competitors.

BACKGROUND AND STATISTICSAs the baby boomers’ rate of retiring accelerates and Generation X moves deeper into management, the hiring of Generation Y (or the millennials) becomes a growing necessity. The specialty skills of gear design compounded by the unique characteristics of the millennials can make filling a position seem impossible at times.

Today, more than one in three American workers are millenni-als (adults ages 18 to 35), and they have surpassed Generation X to become the largest share of the American workforce (see Figure 1). The U.S. Bureau of Labor Statistics predicts that millennials will make up approximately 75 percent of the workforce by 2030.

In order to design an effective hiring strategy, a look at the gen-erational characteristics will help you appreciate the values and differences of each generation. The table below is a brief overview.

Millennials, especially engineers and designers, look for a col-laborative team-setting where everyone works toward a common goal within a respectful environment. Common traits include: they embrace innovation, utilize technology, look for interesting compa-

nies, thrive on flexibility in their workweek, have significant student debt, are usually under-employed (highly educated, in general), and have a high expectation or entitlement of the workplace. They will also change jobs if they feel it doesn’t fit with their values, and typical tenure is one to three years.

Understanding how millennials communicate is also important. Most do not own a landline and would rather text than make a call. According to a report from the U.S. Chamber of Commerce Foundation, millennials check their devices over 40 times each day, and 80 percent sleep near their phones.

Generation Baby Boomers Generation X Millennials

Birth Year 1946-1964 1965-1980 1981-2000

Core Values Anti-war, anti-government Equal rightsOptimistsSpend now, worry laterTeam-orientedWorkPersonal growth

BalanceDiversityFunIndependentNo company loyaltyPracticalGlobal thinkers

Technically connectedHave funCompetitiveWant it nowOptimistsSelf-centeredSelf-confident

Work Ethic DrivenWorkaholics, 60-hour weeksQualityLive to work

BalanceWork smart, not longWant structure and direction

AmbitiousWant the next thingPersistenceEntrepreneurialWork to live

Technology Learned Adapted Essential

View on Workplace Work long and hard, gain visibility Paid to get the job done The job is a placeholder between weekends

View on Work Life Balance Work comes before family, fear of losing the job

Balance work and family, less fear of losing job

Balance of work, family, and commu-nity, flextime and customized perks

Communication Media Touch-tone phones Call me anytime

Cell phones Call me only at work

Internet Smartphones Text

Excerpts from “Generational Differences” by Dennis Gaylord and “Generational Differences” by WMFP, The Silent Generation; born from mid-1920s through early 1940s

Figure 1


AUGUST 2016 27

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This generation is digitally connected and dependent; therefore, your company must be tuned in to how they think. Here are some do’s and don’ts to consider:

Do:• Embrace multiple digital channels such as Facebook, LinkedIn,

YouTube, Instagram, and Twitter. It’s also important to monitor your social media presence to make sure your feedback is favorable — more than 90 percent of millennials are active on social media.

• Make it easy to apply online, and be sure your message is formatted for all forms of mobile devices, especially smartphones.

• Be receptive to having a highly flexible workplace. Flexible hours, generous telecommute policies, and comp time are becoming more expected. Millennials assume a work-life balance from day one.

• Design venues for the millennials to contribute and be heard. • Have a structured onboarding procedure that assigns a skilled and

experienced mentor.• Design opportunities to keep millennials technologically current and

competitive. They value online learning opportunities that can be accomplished off-site or during a commute.

• Because millennials are eager to advance in the organization, consider more frequent, but smaller promotional opportunities with commensurate levels of responsibility and raises. A clear advancement path is essential.

• Be sure that middle managers provide more frequent feedback and mentoring — as millennials require a need for this in their work.

• Create opportunities to diversify their work experiences and exposure. Consider rotational learning opportunities within the company and abroad if you have global locations.

• Create teams with a mix of generations to provide learning opportuni-ties within your company.

• Expose your gear designers and engineers to challenging projects that allow them to hone their skills and develop ownership.

Don’t:• Use formats that are not compatible with mobile devices to commu-

nicate your message, brand, and opportunities.• Neglect managing your online presence, referrals, and feedback on

social sites.• Underestimate the power of work-life balance.• Offer traditional perks with an unbalanced emphasis on salary, or

neglect to tailor and promote custom perks.• Restrict off-site and variable work-hour options.• Separate your design teams generationally.

CONCLUSIONMillennials are becoming the largest portion of the workforce while the demand for gear designers continues to grow. In order to capitalize on the limited supply of talent, it is essential that your company understands the values of millennials and what drives them. Developing strategies tailored to this generation is critical to the continued growth of your company.

ABOUT THE AUTHOR: Matt Mondek is the president of Mondek Solutions, a consulting business providing resources and solutions that drive the success of manufacturers through “common sense” implementation of best practices and problem resolution. He has over 38 years of experience in P and L, executive level leadership, operational effectiveness, and quality and product design. For more information, contact Mondek at [email protected] or 815-382-1987, or visit www.mondeksolutions.com.


http://www.forkardt.com


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KENNETH CARTERASSOCIATE EDITOR GEAR SOLUTIONS

TRENDTALKS

COST SAVINGSA good company is always looking for ways to save itself money, but a great company looks for ways to pass those savings on to its customers.

FOR MANY CUSTOMERS, SAVING MONEY ISN’T JUST A LUXURY, it’s a necessity. So when companies can offer options that can cut costs as a result, that translates into a service that will keep customers happy. And happy customers mean repeat customers.

But cost savings aren’t necessarily defined as discounts. Savings often can be found in a myriad of options. And those options eventu-ally and ultimately can mean good things to a customer’s bottom line.

Marposs S.P.A. — a leader in precision equipment for measurement and control in the production environment — supplies precision gauging equipment to industries all over the world. Its customers include machine-tool manufacturers, the automotive industry and its subcontractors, and aerospace companies. It is committed to offering top-quality products that can help customers cut costs.

Unlike processes where absolute information such as tool breakage or missing tool is sufficient, gear hobbing requires continuous monitoring, which ensures tool wear is held strictly within specified tolerances.

Marposs has developed a new feature for its Artis machine monitor-ing system to optimize the gear-hobbing process. It uses the milling spindle torque measurement to obtain information about the condi-tion of the tool. The torque curve for a known good tool is “taught” once, and then compared with the actual machining process.

The result is displayed as a curve with the area below the curve representing the acceptable value for the operation.

Tool breakage will show up as an anomalous “spike” in signal intensity. Normal wear can be tracked as well and displayed for the operator. By setting experience-based limits on the tool’s “signature,” it is possible to reliably predict the remaining life of the tool. This reduces downtime and allows maintenance and re-sharpening to be done based on actual tool condition rather than on a time- or part-based schedule.

“Tool-cost savings can add up to five-figure sums within a few months,” said Jorge Pena, Marposs Machine Monitoring Solutions product manager.

The Artis system has been installed in many high-production gear-manufacturing applications worldwide, according to Pena. Increased hob life of 40 percent to 60 percent is possible in many cases. The system also is able to optimize cycle time by monitoring the load during the cut and maintaining the highest practical metal removal rates compatible with machine capabilities and the life of the tool.

Another example of how customers can save on costly manufac-turing errors is by using gear inspection machines, such as United Tool’s Unite-A-Matic™. United Tool Supply, located in Cincinnati, Ohio, has been manufacturing the Unite-A-Matic, a series of flexible gear inspection gauges for the global market, for more than 30 years.

“We are able to help our customers cut costs on the front end and increase profit and productivity on the back end,” said Curtis Criswell, head of Business Development. “The Unite-A-Matic is the

most cost-effective gauging solution at a fraction of the cost of a CMM. Being a family-owned business, we know how important every dollar is. Our competitive price point makes our product affordable for small and large companies alike.”

With the Unite-A-Matic, basic operator training is all that’s needed.“In most cases, our gauge can be set up within a few minutes and

takes only seconds to gauge a part,” Criswell said. “Ease of use, com-bined with the efficiency of our Unite-A-Matic, gives our customers the ability to check parts at a higher frequency while maintaining a robust production schedule and an increase in gauging confidence.” Manufacturing errors are discovered much quicker with more part checks. This means less scrap parts, which leads to higher profit and productivity while keeping a high level of productivity intact.

United Tool Supply continues to offer OD & ID gear inspection gauges fitting requirements up to 400 mm, with custom builds avail-able, while expanding their footprint with additional products and improved global support.

New England Gear is another company that helps its customers save money by offering remanufactured machines as an option to purchasing a new machine. According to the company’s president, Jeff Barnes, the remanufactured machines from New England Gear provide the same quality standards as a new one. On top of cost savings, customers can get a remanufactured machine a lot quicker than a new one as well.

“A New England Gear remanufactured machine is 60 percent the cost of a new machine, and deliveries are 12 weeks instead of eight months,” Barnes said.

To further help its customers save costs, New England Gear offers remanufactured Fellows machines with special options that allow a smaller machine to cut a larger part. For example, New England Gear’s Fellows 10-4 with a throated riser will allow a customer to cut a part with a 13-inch pitch diameter while also having the ability to swing a 35-inch-diameter flange. With this remanufactured machine option, the customer can use a smaller, less expensive Fellows 10-4 machine to do the cutting of a larger Fellows 20-4 —without the 20-4 price tag.

Another option for both the Fellows 10-4 and the 20-4 is the swing away center support. This option will allow the customer to cut parts on centers and then immediately switch over to cut internal gears just by swinging the center support out of the way.

“The savings is in the changeover time, which is minimal —less than two minutes,” Barnes said.

Just from these three examples, it’s easy to see that companies can help their customers with cost-saving measures in a variety of ways. And many times those costs savings are born from time savings.

The old adage, “Time is money,” may be a cliché, but in the gear industry, it can also a truism.

ABOUT THE AUTHOR: Contact Kenneth Carter, the associate editor of Gear Solutions, at 800-366-2185 ext. 204.


Never settle for close when you can have precision fit.

When it comes to the mechanical components you count on, close just doesn’t cut it. Common sense says a poor fit and premature wear will eventually lead to failure. And no one has time for that. At Schafer, we specialize in custom, precision-fit products designed to keep equipment moving. Simply put, our service, quality and on-time delivery are second to none. Reliability is our trademark and it has helped us grow from Schafer Gear to Schafer Industries. These days, our expertise doesn’t end with gears. Now we’re leading the way in driveline, axle and brake applications as well. So whether you’re in the automotive, truck, marine, off-road leisure, heavy equipment or aviation industry, look no further than Schafer. For more information visit us online.

SchaferIndustries.com

http://schaferindustries.com


HOTSEAT

WORKFORCE DEVELOPMENTThere are many reasons why we all need to invest more in human capital, especially in the heat treating industry.

STEVE KOWALSKIPRESIDENTKOWALSKI HEAT TREATING COMPANY

HOW MANY TIMES HAVE WE HEARD, “OUR COMPANY IS ONLY as good as our people.” Yet more often than not, the majority of the today’s business conversations are centered around hard initiatives — new technologies, new systems, new production lines, new equipment, or learning to leverage the Internet of Things (IoT). What about new and improved human capital?

As a small-business owner, I know the value of my human capital. Closely tied to every employee, I “feel it” when someone does not show up for work, struggles on a new production job, or is a bit off their game. I see it in the numbers and know when something is off kilter. Years of reinvesting in improved equipment, production time studies, and endless employee training, I’ve found the human part of my operations is the difference between average and out-standing. And in the hyper-competitive world of challenging jobs, average just won’t do.

Back in the 1960s, economist Theodore Schultz invented the term “human capital” to reflect the value of human capacities. He believed human capital was like any other type of hard capital — something to be invested in through continuous education, training, team building, and other enhanced benefits that would directly lead to improvement in manufacturing quality, production output, and competitiveness. In business terms, human capital is a measure of the economic value of an employee’s skill set. If we could capture and repeat the basic production input of labor, where all labor is equal (think repetitive assembly line), we could more easily predict outcomes. Yet the concept of human capital recognizes that not all labor is equal, or always predictable, and must be constantly nurtured and improved upon by investing in education, experience measures, training, team building, results, and rewards.

Too often, systems are put into place with the express purpose of improving quality, reliability, and perfor-mance, and unfortunately we forget, or simply ignore, human innovation. As business owners and leaders, we need to foster an environment that enables all of us to ask questions, such as “what happens if” or “why can’t we.” We all need to continually reinvest in the workforce to keep the shop floor, and balance sheet, humming. Our best technology investments can be flattened if we don’t keep investing in our human capital.

Here in Cleveland, we are rapidly coming to the end of summer, the Indians are in first place, and some of my younger folks will be heading back to school. Part of me worries that so much of their energy won’t have the proper guidance upon graduation. Studies show

U.S. schools are graduating less than 5,000 material science engineers per year, but over 25,000 mechanical engineers. Where will all of these young people find the answers to problems they are tasked to solve? Who will take the time to mentor them? Most importantly, how will they even know what questions to ask? And how can we ensure human capital success?

One option is technical societies. As the current president of the ASM – Heat Treating Society (HTS), I can attest to the valuable efforts being made to capture the collective knowledge of HTS members. The Society offers a venue for workers to network with our experts, share insights, and build lifelong friendships. HTS members also serve as mentors to young academicians, engineers, and practi-tioners, laying the foundation for future generations. Participation in the Society affords the opportunity to both share and gain knowledge at no additional cost. HTS is also working to develop collaborative relationships with other organizations to retain and expand the exten-sive knowledge base needed to assist the rapidly changing workplace. Learn more at www.asminternational.org.

So what does all this training and sharing have to do with lean manufacturing, the Internet of Things, LPC processing, automation, and root and pitch dimensions? Actually, it’s quite simple. Without talented, engaged, highly skilled, and trained employees, all of the automation and technology investments will be meaningless with-out dedicated employees to carry them forward. Together, we must constantly encourage, enable, and cajole the industry to continually improve — one second, one inch, one degree at a time. This is where and how the quantum leaps of improvement will most likely occur. Our people are, and will continue to be, the next big thing.

ABOUT THE AUTHOR: Stephen Kowalski is the president of Kowalski Heat Treating Company in Cleveland, Ohio, a second-generation commercial heat treating firm “specializing in those PIA (pain in the @%$) jobs.” He is also the current president of the ASM-HTS (Heat Treating Society) and can be reached at [email protected] or 888-548-4328. Visit www.khtheat.com for more information.

Whatever clean technologies the future brings, lubricants will continue to play a key role. For innovative industrial lubricants that extend service life and enhance performance, look to lubricants formulated with NUFLUX™ technology from Evonik.

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Whatever clean technologies the future brings, lubricants will continue to play a key role. For innovative industrial lubricants that extend service life and enhance performance, look to lubricants formulated with NUFLUX™ technology from Evonik.

Aim high — Let it flow.

To learn more, scan the QR code or visit evonik.com/oil-additives.

Fresh air.

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32 gearsolutions.com32 gearsolutions.com32 gearsolutions.com

KHK USA

COMPANYPROFILE

AUGUST 2016 33

Offering one of the largest selections of metric-dimensioned power transmission gearing in North America as a distributor for Kohara Gear Industry, KHK USA services its customers by providing off-the-shelf gears with fast lead times.

KHK USA INC. IS A WHOLLY OWNED SUBSIDIARY OF Kohara Gear Industry of Kawaguchi, Japan. Founded as Kohara Haguruma Factory in 1935, the company, under the leadership of its founder Tomizo Kohara, developed from a single lathe machine to that of a world-renowned gear manufacturer. After supply-ing materials to the Japanese government during the second World War, Kohara realized that there was a need for replacement gears for lathe machines, and in 1954, began in earnest to be the supplier that Japanese industrials could turn to for stock gears. In 1973, the company trademarked the brand name “KHK” and began to sell its gears internationally.

Always a forward-thinking organization, in 1996, Kohara Gear Industry was the first Japanese stock gear company to seek and obtain ISO:9000 certifica-tion. Kohara introduced his family to the business, and all three of his sons took leadership roles within the organization. In the early 2000s, the third genera-tion of Koharas took leadership of the company when Tomizo’s grandson Toshiharu Kohara became CEO and president of Kohara Gear Industry. Since then, Kohara Gear Industry has obtained ISO:14000 certification, has completely modernized its Kawaguchi headquarters and factory to meet the latest seismic codes, and has expanded its Noda factory to three buildings. It has also introduced the concept of Haguruma-Kobo (a concept of using existing stock gears to produce pre-planned custom modifications on demand), and has reconfigured all of the products offered such that all KHK gears are RoHS compliant.

In 2015, Kohara Gear Industry decided that in order to grow within North America, it needed a direct sales team. This team is KHK USA Inc. based in Mineola, New York, as the factory-direct, stocking distributor of KHK gears. KHK USA Inc. stocks approximately 4,500 of the 15,000 SKUs produced by Kohara Gear and has an engineering team on-site with over 25 years of gearing experience.

Kohara Gear Industry has approximately 215 employ-ees throughout Japan. KHK USA has three employees based in a 5,000-square-foot warehouse in its New York location. The export division of Kohara Gear services 23 distributors worldwide including KHK USA, which covers all of North America.

KHK USA seeks to meet the needs of the industrial automation designer. It offers one of the largest selections of metric-dimensioned power transmission gearing in North America. Its products are used in gantry systems, packaging equipment, gearboxes, and almost anywhere that motion needs to be provided in an industrial environment.

KHK USA offers a broad selection of stock metric gearing components and over 175 different styles of gears including stock metric spur gears; helical gears; internal ring gears; gear racks; straight and spiral tooth miter gears; straight, spiral, hypoid, and Zerol bevel gears; screw gears; worms and wormwheels; ratchets and pawls; gear couplings; involute spline shafts and bushings; and right-angle gearboxes.

Using the Haguruma-Kobo concept, KHK USA is able to offer over 15,000 configurations of gearing either from stock or within three business days. It offers gears with minimum plain bore for custom configuration and finished gears with keyways, hardened teeth, and tapped holes. To assist the design engineer, KHK USA also offers downloadable 3D CAD models of each product.


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“Our expedited service gets the product to our customers within three business days for the same price as overnighting the shipment from our U.S.-based warehouse,” said Brian Dengel, general manager for KHK USA.

Kohara Gear Industry owns two Gleason Phoenix 275 Coniflex generators, a Gleason Phoenix 275 bevel grinder, multiple auto-mated Gleason 104 Conif lex generators,

CNC rack milling machines, CNC rack grinding machines, multiple Mazak CNC turning centers, and multiple Okuma 4-axis turning centers.

Kohara Gear marks all of its stock gears with the identifying logo “KHK” and the part num-ber, typically being engraved on the hub diam-eter. Another unique characteristic of Kohara Gear products is that all carbon steel products are black-oxide coated. Kohara Gear performs all of its induction hardening in-house, but outsources any case hardening.

According to Dengel, what sets KHK USA apart in the industry are its three core assets: quality, availability, and offering metric-dimensioned products.

“In the U.S. marketplace, we see a chal-lenge of a slow roll-out of metrification from the U.S.,” said Dengel. “AGMA is celebrat-ing its 100th anniversary this year, and the U.S. gear industry is still predominantly inch-dimensioned. The process of globaliza-tion has finally started to take root in the U.S. as most multinationals are now design-ing in metric, but the U.S. is the only coun-try in the entire world that is not metric.”

For these companies that build in the U.S. and export worldwide, or import equipment to the U.S. that is produced elsewhere, met-ric gearing is becoming more prevalent in their designs.

“With our broad selection of products, our vast expertise in production, and our world-renowned quality, KHK is poised to capture this demand,” Dengel said.

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CASESTUDY

Erwin Junker Machinery and Komet of America Inc.

Having only one simple setup to grind each part complete has significantly increased Komet’s productivity

TWO CASE STUDIES ARE PRESENTED HERE TO SHOW SPECIFIC EXAMPLES OF HOW COMPANIES CAN WORK TOGETHER TO FIND SOLUTIONS FOR BETTER PRODUCTIVITY.

#1

AUGUST 2016 37

When KOMET of America Inc. sought to produce multi-step tools more efficiently, investing in the Lean Selection Allround machine from JUNKER brought a cost-effective upgrade in technology together with dramatically decreased setup times.

IN ORDER TO STAY COMPETITIVE IN THEIR INDUSTRIES, manufacturers must always be on the lookout for new ways to provide value while keeping cost at a minimum. Nobody knows this better than David Zurowski, Komet’s Dihart® carbide group leader, who understands the impor-tance of finding the most optimal cost-effective solution for his customers. With this in mind, Komet, the success-ful whole-line tool supplier from Schaumburg, Illinois, has continued to hold tight to the company’s core values of being ambitious, attractive, creative, exemplary, and supportive — constantly searching for ways to improve.

Established in 1918, The Komet Group is a global technology leader and a full-line supplier of drilling, bor-ing, reaming, threading, and milling tools. With a total workforce of 1,600, the privately held company manu-factures reamers, cutting rings, and rapid set heads with carbine and cermet blades. The focus of the company is on solution-oriented development, manufacture and sale of machining tools, and future-oriented services. Led by its president and CEO Jan Pflugfelder, Komet of America and its 140 employees are dedicated to the design and manufacturing of special indexable tools, PCD tools, and reamers.

THE CHALLENGEWith a growing demand for complex tools, Komet of America was facing the challenge of manufacturing at higher production rates without sacrificing quality. It was determined that the existing grinders could no longer keep up, and a new solution would be essential to produce multi-step tools effectively. The major bottleneck in pro-duction was for tools with a flat diameter and a backtaper, as the existing grinders required an extra setup to adjust the table to match the angle. Paramount in the search was to remove this extra setup, grind the tools in one clamping, and simplify the process for operators. Further complicating the search was Komet of America’s need for a short machine delivery time and need for a machine that could handle a diamond grinding wheel.

THE SOLUTIONTo meet the necessary requirements, Komet of America searched for a CNC grinding machine with a freely program-mable B-axis that could accurately and efficiently grind its parts while offering flexibility. Despite the various options available to the tool supplier, one grinding machine stood out among the rest. Junker’s Lean Selection Allround universal cylindri-cal grinding machine offered a B-axis with a resolution of 0.0001° — rigid and capable of grinding all tapers that Komet needs to

manufacture. Along with the crucial B-axis, the Lean Selection Allround machine’s flexibility set Junker apart from the competition.

“One of the options that we selected was a choice of a two spindle wheel,” Zurowski said. “We believe that we will have fewer limitations having one wheel per side and more clearance for our complex tools.”

In addition to the technological benefits of the Junker Lean Selection Allround, the machine came with a short delivery time and appealing price point.

Along with the proper mechanical features, Komet sought a custom-designed grinding program in order to reduce the amount of “air grinding.” The carbide inserts ground on each reamer are set at common intervals along the diameter, meaning an interrupted grinding surface. After several discussions about the problem, Junker offered the solution of using its gap detection acoustic sensor to control the workhead speed. Now, when the grinding spindle detects air grinding, the workhead rotates quickly until detecting the next carbide insert. At each insert, the workhead slows to the grind setting, ensuring top quality, and then speeds up again when finished grinding the insert to the air setting, ensuring the best cycle time.

In April 2015, the Junker Lean Selection Allround arrived at Komet of America and was up and running shortly thereafter. With machine operation in full swing, Komet immediately noticed significant time savings in its production times.

“Setting back the taper with the B-axis has been easier, hassle-free, and faster for operators,” Zurowski said. “In setup, we save around 30-35 minutes.”

The Junker Lean Selection Allround’s economical and flexible design not only provides significant savings in setup time, but it also cuts down Komet’s running time by 5-10 minutes per part. The freely programmable B-axis allows the operator to grind continuously without having to change out the grinding wheel.

Junker JUWOP/LS graphical and conversational programming page


Despite the improved run time and setup time, a final inefficiency was detected after installation. Komet’s high mix of parts requires frequent wheel changeovers, which cause long changeover times and can cause quality issues if the new wheels are not properly mounted. As a solution, Komet will be implementing Junker’s patented three-point grinding wheel mounting system that reduces wheel change-over times to an absolute minimum and guar-antees a wheel concentricity of under 2 µm. When the system is installed, Komet expects a further reduction in setup times, improved grinding times, and even better part quality.

CONCLUSIONNot only has the Junker Lean Selection Allround provided Komet with greater effi-ciency in its setup and run time, but it has also been able to produce the same high-quality product that Komet expects from its machines.

“From our experience in grinding reamers and the way we set up and run Junker, our finished product is the same quality despite a reduction in production time, which is what we were looking for,” Zurowski said.

The tool supplier is able to use the same grinding wheels as before but with a simpler setup, faster changeover, better grind time, and improved operator experience. The machine comes standard with the JUWOP/LS programming system that allows the user to program the machine quickly and efficiently. Due to graphically supported data entry and to-scale representation on the screen, programming is easy and requires little or no training.

Today, Komet of America produces high-quality reamers with greater efficiency and at highly competitive costs for a quality/value proposition. Improved productivity and sustained accuracy allow the tool sup-plier to provide its customers with the best product possible and cement its position as an industry leader in drilling, boring, reaming, threading, and milling tools. The economical and flexible Junker Lean Selection Allround allows the tool supplier the freedom to manufacture a wide range of parts with high quality and precision as it aggressively seeks to expand its markets and provide new applications to its customers.

Junker’s customized gap detection software was developed to grind Dihart reamers (shown here in the rough state)

(Pictured left to right) David Zurowski, Komet’s Dihart carbide group leader; Jan Pflugfelder, president/CEO of Komet of America; and Kevin Padden, regional sales manager at Erwin Junker Machinery Inc. They are standing in front of the Junker Lean Selection Allround.

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GMTA_AD5030_Gear Solutions_January 2015

GMTA brings a wide variety of high quality machine tools for component production, plus laser welding technology, robotics, advanced automation, tooling, and parts washers to your door, backed by application engineering, onsite commissioning, local service and after-sale support. We’re not all things to all people, but we’re getting closer, every day.

What this means to your production is actually quite simple…a single source, with all its advantages, those productive and those financial, who can solve your output and workflow challenges, because they’ve seen and solved similar ones for many companies like yours.

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CASESTUDY

Tracey Gear, Drake Manufacturing, and Norton AbrasivesBy Phil Plainte

TWO CASE STUDIES ARE PRESENTED HERE TO SHOW SPECIFIC EXAMPLES OF HOW COMPANIES CAN WORK TOGETHER TO FIND SOLUTIONS FOR BETTER PRODUCTIVITY.

#2

AUGUST 2016 41

With a unique approach to grinding threads from solid, Tracey Gear utilizes Drake machine technology and Norton wheel technology to achieve impressive metal removal rates.

THE WORLDWIDE USE OF GRINDING WHEELS FOR grinding a thread form into a precision workpiece is a common process. However, in this case study, the thread grinding operation is unique in that the threads were ground from solid to finish tolerance, eliminating the need for the rough cutting operation, the cutting machine, and complementary cutting tools. Advancements in wheel technology, coolant, coolant delivery, and machine technology have made this approach economically viable.

BENEFITS OF GRINDING THREADS FROM SOLIDGrinding threads from solid can provide a quicker response to customer needs, competitive cycle times, and the elimi-nation of the traditional milling and turning tooling lead times. It also reduces tooling cost — to change the form, simply redress the wheel — and it reduces tooling inven-tory and cutter costs and logistics. This approach offers additional design freedom to allow thread form modifica-tions to improve strength or fit a custom application, and it eliminates capital equipment cost, as there’s no need for a thread milling or turning machine.

Those who could benefit from the operation of grind-ing threads from solid include job shops, shops that have large varieties of products manufactured in small batches, or worm reducer manufacturers with aging and inefficient thread milling machines.

Economics play a major factor where a job shop sup-ports a large mix of products that have short lead times. With a rush job, they can’t wait for special cutting tools, or the products they manufacture are so varied that the cost to hold tooling to support their jobs is cost prohibi-tive. Producers of small to medium size lots are the best candidates for grinding from solid. Tracey Gear is one such company that has successfully embraced the new Drake grinding machine technology and the new Norton wheel technology.

COOLANT NEEDED TO GRIND THREADS FROM SOLIDFor coolant, oil is the best option — premium ester-based high-performance grinding oil for multiple metals with a high flash point. Coolant velocity matches wheel velocity. For an untested grind cycle, use 25 GPM/inch of form width. If power is known, use 1.5–2.0 GPM/HP.

A coolant nozzle should help provide a solid jet flow of coolant. This means the coolant coming out of the nozzle looks like a solid bar, void of any air entrapment. This is accomplished through correctly sized supply pipes and limit bends in the coolant lines. Lastly, a properly designed coherent jet nozzle will help to reduce turbulence and air entrapment. See Figure 1.

Figure 1

Coolant should be maintained at ambient temperature whenever possible. Tank size should be able to satisfy coolant flow without interruption of coolant during a continuous grind cycle and, ideally, provide for 8-10 min-utes of settling time for degassing. Filtration is necessary to eliminate reprocessing grinding swarf.

GRINDING WHEEL SELECTION FOR DEEP CUT GRINDINGThe makeup of a grinding wheel is:

Grain + Bond + Porosity = Wheel

For all but very fine pitch threads (Drake uses the prod-uct to grind medium to coarse pitch threads), the wheel makeup is (see Figure 2):

High-Performance Ceramic Grain + Strong Bond + High Porosity

Figure 2

The self-sharpening grain technology, stronger glass bonds, and porosity of the wheel enhanced by the shape of the grain help to remove material in a rapid, efficient process. Wheel specifications are customized to suit the applications. The high unit material removal rates (Q’ to 25 mm3/mm sec.) keep high unit pressure on the ceramic grains to force self-sharpening from micro-fracturing.

High-quality dressing rolls are required to condition the wheel. Quality hand-set diamond rolls with synthetic CVD reinforcing logs are best. The roll and wheels should run in the same direction at the point of contact — uni-directional. For peak sharpness of the wheel, run the diamond roll at 80 percent of the grinding wheel speed measured in SFPM. On this particular operation, travers-ing the diamond roll across the wheel at 6–12 IPM would provide a sharp aggressive wheel. The dress depth should not exceed 0.0007" (0.015 mm). See Figure 3.

TG2 Grain Vitrium Bond Porosity


Figure 3

Figure 4

Figure 5

THREAD GRINDING MACHINE Machine stiffness and accuracy is critical to the success of grinding threads from solid. In this case study, the test machine is a Drake GS:TE 200 external thread grinder equipped with a 12 kW vari-able speed grinding spindle motor. It is a rigid machine with high static and dynamic stiffness and linear motors on linear ways. It has micron-scale feedback with a Fanuc CNC controller and a dia-mond dressing roll. The machine is equipped with a high-volume, high-pressure coolant system with engineered coolant nozzles. Furthermore, software and a typical interactive screen make for easy operation. See Figure 4.

RESULTSAt Tracey Gear, the thread was ground using two metal removal rates (MRR). MRR is the term used to quantify the amount of material removed in a given time period. The first 50 percent of the cut had an MRR of 4.3 cubic inches per minute. The last 50 percent of the cut had a reduced MRR of 2.7 cubic inches per minute with one light cleanup pass. The effort produced promising results. In this test, the customer was able to remove up to 4.3 cubic inches of steel per minute, resulting in very short processing times for these particular parts. See Figures 5 and 6.

CONCLUSIONGrinding from solid, referred to as machining to grinding (MTG) at Norton, is a more efficient process that can provide additional

opportunities for manufacturers to be more f lexible and com-petitive. Tracey Gear is one of those companies that is thinking outside the box and achieving its goals by using this approach.

ABOUT THE AUTHOR: Phil Plainte is a senior applications engineer who has been in manufacturing for 40 years. With 37 years at Norton, he is an expert in challenging technical manufacturing applications with a focus on centerless and gear grinding.

Figure 6: Grinding versus cutting

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AUGUST 2016 45

A New Class of Industrial Gear Oil By David B. Gray, René Koschabek, and Aidan Rose

A new class of industrial gear lubricants based on alternative synthetic materials has been developed to satisfy critical market performance expectations, ensure global supply chain security, and address economic and performance challenges.

IN 2013, THE GLOBAL LUBRICANT MARKET WAS just over 40 million tons, comprised of 58-percent automo-tive lubricants and 42-percent industrial lubricants. The industrial lubricant portion of 16.9 million tons was made up of three major segments — namely hydraulic oils, engine oils, and gear oils — which account for just under 50 per-cent of the market. The remainder includes process oils, metalworking fluids, turbine and circulating oils, grease, refrigerating oils, compressor oils, and transformer oils.

While industrial gear oils have not traditionally been the leading focus for lubricant development, the strong recent growth of wind turbines and field service perfor-mance has shifted the focus significantly.

The challenging application for gearboxes in wind turbines has created a demand for new, high-performance synthetic gear oils that provide both good equipment protection and longer drain intervals. Within the indus-trial oil market, the global growth of synthetic industrial gear oils exceeds that of the total growth of the entire industrial gear oil market.

DRIVERS FOR GROWTH OF SYNTHETIC INDUSTRIAL GEAR OILS The rapid growth of synthetic industrial gear oils is being driven by more severe operating environments and higher performance expectations. Smaller sump sizes are lead-ing to higher stress on oils, while modern machines are running at higher loads, higher speeds, and increased operating temperatures.

This is coupled with an expectation of longer drain intervals while maintaining and even improving upon machine efficiency. As such, today’s industrial gear oils must have increased bearing protection, a low tendency for micropitting, increased resistance to oxidation, and enhanced low-temperature performance. Synthetic indus-trial gear oils have been proven to address all of these concerns, and polyalphaolefin (PAO)-based lubricants are predominant within the category.

WIND TURBINE GEAR OILS Wind turbine oils currently represent only 2 to 3 percent of the current industrial gear oil market, with the major-ity of these oils being synthetic. While this does not represent a significant proportion of the market, a large amount of research and development is being focused on wind turbines and wind turbine gear oils. As such,

the wind turbine gear oil market is helping to drive the rapid development and evolution of industrial gear oils.

Wind turbine gear oils are typically at the higher end of the performance spectrum, with in-service reli-ability being a critical factor in determining relative performance. Typically, wind turbine gear oils place an increased emphasis on bearing protection, have a low tendency for micropitting, provide superior oxidation performance, and must demonstrate excellent low-tem-perature properties.

SYNTHETIC INDUSTRIAL GEAR OIL COMPOSITION A conventional industrial gear oil is formulated to include a performance additive package treated at approximately 2 to 5 percent by weight, with the balance comprising of a blend of conventional mineral base oils.

In a typical industrial gear oil, the performance addi-tive package provides protection from fatigue and wear to the gearbox hardware, in addition to providing thermal stability, rust protection, anti-foaming, demulsibility, and seal protection. The mineral base oil in these formula-tions provides solubility to the performance additives and contributes to the typically high viscosity of these fluids. While mineral oils have been shown to provide a good fluid film to protect the gears and bearings of the gearbox, in severe applications, the need for enhanced oxidative and thermal stability, as well as relatively poor cold-temperature performance, can lead to reliability concerns.

In typical synthetic industrial gear oils, the mineral base oil is replaced with polyalphaolefins, polyglycols, esters, and Group III base oils. When combined with the correct performance additives, these synthetic base oils improve thermal resistance, can lower operating temperatures to enhance lubricant service lifetimes, and can improve fluid films for greater bearing protection, in addition to provid-ing a greater operating range of temperature. An added benefit of synthetic base oils is that they provide inherently lower volatility loses and a higher flash point.

One of the more critical advantages of synthetic base oils is an improvement in the viscosity/temperature behav-ior of the fluid. This behavior is characterized as the lubri-cant’s viscosity index, or VI, and is typically expressed by plotting the log-log of viscosity versus temperature.

In Figure 1, the log-log viscosity of two fluids versus temperature has been compared. In comparison to the

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear Manufacturers Association (AGMA). This paper was presented October 2015 at the AGMA Fall Technical Meeting in Detroit, Michigan. 15FTM22.


mineral fluid, the synthetic fluid shows lower viscosity at lower temperatures and higher viscosity at higher temperatures, thereby has a higher viscosity index.

The reduced viscosity at lower temperatures provides better mechanical efficiency due to a reduction in churning losses and fluid drag, while the increased viscosity at higher temperatures provides better equipment protection by maintaining stronger lubricant films. Conventional mineral fluids have been proven to have significantly weaker fluid films at higher temperatures, which can lead to metal-to-metal contact, premature wear, and in-service failure.

While synthetic base oils provide significant advantages over con-ventional mineral base oils, they have some disadvantages. They are poor solvents, which means that in order to ensure that the perfor-mance additives are kept in solution, compatibilizers such as esters or alkylated naphthalenes must be added to the synthetic formulations. In addition, synthetic fluids are significantly more expensive than conventional base oils.

A NEW CLASS OF NON-CONVENTIONAL BASE FLUIDS Methacrylates are a recently developed, highly viscous synthetic base fluid. (See Figure 2.) They can be used to formulate a wide variety of lubricants, but due to their high viscosity, they are particularly well-suited to synthetic industrial gear oil applications.

In addition to a high viscosity index, they offer excellent low-temperature performance and are good solvents, eliminating the need for compatibilizing additives in lubricant formulations. Additionally, lubricants formulated with methacrylates have been shown to improve fluid films, providing improved bearing and gear protection. When used in combination with hydro-processed Group III base oils, synthetic industrial gear oils can be readily formulated.

It has been demonstrated that the combination of high-quality Group III base oils with methacrylate base fluids shows many of the advantages of the PAO-based fluids and addresses the potential disadvantages.

In the example shown in Figure 3, two synthetic industrial gear oils have been formulated to meet ISO viscosity grade 220 and ISO viscosity grade 320. These ISO viscosity grades are typical of those used in industrial gearboxes.

While the physical properties of the two fluids are very similar, there are significant differences in their composition. The meth-acrylate formulation does not use PAO and does not require the use of ester for compatibility with the performance additives.

PERFORMANCE TESTING OF SYNTHETIC INDUSTRIAL GEAR OIL FLUIDS In order to examine the relative performance of synthetic industrial gear oil fluids formulated with a variety of base oils, a range of per-formance tests has been completed.

In this section, the primary performance requirements associated with wind turbine gear oils are addressed — as they represent one of the most severe applications.

The following performance attributes are investigated: • Bearing wear• Tendency for micropitting• Scuffing protection of gears and gearboxes• Load-carrying capacity• Gearbox efficiency

BEARING WEAR The FE8 roller bearing wear test is a widely used bench test that predicts in-service bearing wear and has passing limits set by the

bearing manufacturer. In Figure 4, the performance of various ISO viscosity grade 320 lubricants are compared. All lubricants were formulated with the same commercially available performance additive package.

It can be seen that while there is significant variation in per-formance, both the PAO/ester formulation and the methacrylate formulation exhibit strong performances.

Figure 1: Viscosity versus temperature, high VI versus low VI

Figure 2: Methacrylate

Figure 3: Examples of ISO VG 220 and 320 industrial gear oil formulations

Figure 4: FE8 roller bearing wear test comparison


AUGUST 2016 47

MICROPITTING PROTECTION FOR GEARS Micropitting is an often-seen phenomenon in hardened steel gears that can result in catastrophic failure of the gears, and subsequently, failure of the gearbox. Failures occur on the flanks of highly loaded gears and consist of very small cracks and pores on the tooth surface. In modern gearboxes, gears are often highly loaded and run under conditions of mixed lubrication, in which the flanks of the gears are not fully separated by the fluid film.

In order to prevent these failures, lubricants must provide and maintain a strong fluid film and utilize performance additives specifically designed to protect the tooth flanks from micropitting. Additionally, good gear design and attention to surface finishing can further reduce the risk.

However, a very effective method of reducing risk of gear failure due to micropitting and extending the life of the fluid and the gearbox is to maintain a good fluid film.

One way of measuring the effectiveness of a fluid in reducing the tendency for micropitting is the micropitting test, run in accordance with FVA 54/7 on the conventional FZG apparatus.

The test is run at 1,500 rpm with an increasing load using FZG type C hardened gears. (See Figure 5.)

The test is run in two phases: first, for 96 hours in 16-hour cycles with increasing load (the step test), and then for 400 hours in five 80-hour cycles (the high-load endurance test). The entire process is run first at 60°C and then is repeated at 90°C.

In Figure 6, an industrial gear oil ISO VG 320 lubricant formulated with a methacrylate was tested in both the step and the endurance phases of the test with an oil temperature of 60°C. The required passing limits to indicate satisfactory field performance, listed for both phases, are indicated on the chart. The formulation containing methacrylate provided very good micropitting protection to the gears and was clas-sified by the test institute as “highest level of micropitting protection.”

In Figure 7, the same fluid was similarly tested at 90°C and again provided very good micropitting protection.

LOAD-CARRYING CAPACITY The load-carrying capacity of three fully formulated ISO VG 320 industrial gear oils was compared using the FZG scuffing test. The test differs from the micropitting tests in that it uses different type A gears, which are more sensitive to scuffing. All lubricants were for-mulated using the same commercially available performance additive package and methacrylate base fluid. (See Figure 8.)

When scuffing occurs, the contacting surfaces of the gears instan-taneously weld together for a short time. This welded joint is quickly broken by the high sliding velocity of the contact surfaces. The result of this broken weld is scuffing and scoring to the flanks of the gear tooth. Scuffing is very sudden damage, which can be caused by a single overload, and often leads to total destruction of the tooth flanks. Industrial gear oil lubricants are expected to provide the gears protec-tion from scuffing.

In this standard scuffing test, the pre-load on the gears is increased in stages, and after each stage, the gears are inspected for signs of scuffing or wear. In this particular test, the temperatures of the lubricants were recorded.

All lubricants provided good protection from scuffing, but it is evident that both the PAO and methacrylate formulations experi-ence a significant reduction in temperature at the higher load stages. A reduction in temperature in a lubricant, while protecting heavily loaded gears, will result in reduced internal losses and higher effi-ciency, while continuing to provide excellent gear protection.

Figure 6: Micropitting test (FVA 54/7) at 60°C with methacrylate base fluid

Figure 7: Micropitting test (FVA 54/7) at 90°C with methacrylate base fluid

Figure 8: FZG scuffing test comparing ISO VG 320 industrial gear oils

Figure 5: FZG gear test rig

1 Test Pinion2 Test Wheel3 Slave Gear4 Load Clutch

5 Locking Pin6 Load Lever and Weights7 Torque Measuring Clutch8 Temperature Sensor


EFFICIENCY TEST Three ISO 320 VG industrial gear oils were formulated using the same commercially available performance additive package and compared in another variant of the FZG test apparatus. The test was run in accordance with test method PV 1456 at 30°C and 60°C. The test rig is equipped with a torque meter, and it is possible to record the difference between the applied and the transmitted torque across a range of torque values.

As shown in Figure 9, at 30°C, the formula-tions containing PAO and the methacrylate/Group III were observed to have reduced loss of torque when compared to the mineral oil formulation. While the formulation contain-ing a complex ester and Group III base oil had the highest torque loss of the group, the meth-acrylate/Group III formulation had the lowest.

As shown in Figure 10, at 60°C at higher loads, the formulations containing methac-rylate and PAO both showed a reduction in torque versus the mineral oil formulation.

ADDITIONAL PERFORMANCE TESTING Synthetic industrial gear oils formulated with the methacrylate base fluid have been tested with respect to their foam behavior, filter-ability, rust and corrosion protection, seal compatibility, and coating compatibility [6].

The results of this testing confirmed that synthetic industrial gear oils formulated with methacrylates perform well, comparing very favorably to conventional synthetic formula-tions, such as those utilizing polyalphaolefins. In all cases, the formulations with methacrylates met and often exceeded industry standards.

In all cases, the performance was superior to that of mineral oil-based industrial gear oils.

IN-SERVICE PERFORMANCE EVALUATIONS After successful bench test evaluations of the performance of synthetic industrial gear oils formulated with methacrylates and Group III base oils, in-service evaluations are now under-way. These in-service evaluations are ongoing, and it is expected that the results of these evaluations will be shared in future papers.

CONCLUSIONWhile the market for industrial gear oils grows at a very moderate rate, the use of synthetic industrial gear oils is increasing rapidly. One of the main drivers for the growth of these synthetic fluids is the need for improved in-service performance of wind turbine gear oils.

When compared to mineral oil-based fluids, synthetic fluids offer significant improvements

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in critical performance areas and provide the user with enhanced in-service reliability and extended fluid lifetimes.

In a wide variety of industry-standard testing, a new class of synthetic gear oils utilizing methacrylates and Group III base oils has demonstrated performance advantages comparable to the polyalphaolefin-based synthetic fluids when compared to mineral oil-based gear oils.

In some bench tests, the methacrylate/Group III base oil for-mulations have demonstrated some performance advantages.

As an alternative to fluids formulated with polyalphaolefins, methacrylate/Group III base oil-formulated industrial gear oils have the potential to offer increased flexibility for the lubricant formulator.

REFERENCES 1. Industrial Gear Oils – An Example of

How Supply Chain Considerations Trigger New Technical Developments. Dr. Rene Koschabek, Evonik Industries AG, Darmstadt, Germany.

2. Micropitting Fundamentals and Performance Relevant Testing. Lavern D. Wedeven, Wedeven Associates.

3. Main Shaft Arrangements, Failure Modes and Enhancements. Rich Brooks, Timken Bearings.

4. Lubricants and Lubrication, Second Edition, Theo Mang and Wilfried Dressel.

5. Oil Additives Can Prevent Micropitting – Michael Hochman and Herman Siebert, Klüber Lubrication, München.

6. “New approaches to Wind Turbine Gear Oil formulation.” Rene Koschabek, Michael Müller, Christoph Wincierz (Evonik Oil Additives); Mika Kettunen, Sebastian Dörr (NESTE Oil Corporation.) 18th International Colloquium Tribology – Industrial and Automotive Lubrication, January 2012. Stuttgart/Ostfildern, Germany.

ABOUT THE AUTHOR: David B. Gray is the North American OEM liaison manager for Evonik Industries. A 28-year veteran in the industry, he started his career with a focus in engine oils, residing in both the United Kingdom and the United States. He began working with Evonik in 2008 as a technical service manager at Evonik’s global headquarters near Frankfurt, Germany. In 2010, Gray returned to the United States, where his role at Evonik later developed into his current position. His main responsibilities include working with automotive and industrial gear oil and heavy-duty diesel original equipment manufacturers. He holds U.S. and EU patents for off-highway transmission lubricants and fuel-efficient engine oils. Gray attended Portsmouth University in the United Kingdom, where he graduated with an honors degree in mechanical engineering. In addition to his current responsibilities, he is a proud staff member of the successful Evonik Technical University.

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Analysis and Optimization of Asymmetric Epicyclic Gears By Alexander L. Kapelevich

Following the Direct Gear Design approach to asymmetric epicyclic gear stages with singular and compound planet gears, methods of optimization of the tooth flank asymmetry factor and root fillet profile are considered.

THE DESIGN OBJECTIVE OF ASYMMETRIC TOOTH gears is to improve performance of the primary drive flank profiles at the expense of the opposite coast profiles’ performance. The coast flanks are unloaded or lightly loaded during a relatively short work period. Such gears should be used for unidirectional or mostly unidirectional load transmission when the coast flanks are unloaded or lightly loaded during relatively short work time.

In a simple epicycling gear stage, the singular planet gear transmits the same load by both tooth flanks. However, the convex planet gear tooth flanks are in simultaneous meshes with the convex sun gear tooth flanks and the concave ring gear tooth flanks resulting in very different contact stress values in those meshes.

In epicycling gear drives with compound planet gears, one portion of the planet gear is in mesh with the sun gear and other one with the ring gear. In this case, the coast tooth flanks are used only when the gear drive works in a reversed load direction.

This paper describes a gear geometry analysis and the asymmetry factor and tooth root fillet optimization of epicycling stages with singular and compound planet gears. This allows for a considerable increase in power transmission density, increase in load capacity, and reduc-tion in the size and weight of asymmetric epicyclic gear drives.

BASIC ASYMMETRIC EPICYCLIC GEAR STAGESEpicyclic gear stages provide high load capacity and compactness to gear drives. There is a huge variety of different combinations of planetary gear arrangements. Although some of them are quite complicated, they typi-cally contain simple epicyclic stages with singular planet gears (see Figure 1) or epicyclic stages with compound planet gears (see Figure 2). For an epicyclic planetary stage with singular planet gears where the ring gear is stationary, the practical gear ratio varies from 3:1 to 9:1; for an epicyclic planetary stage with compound planet gears, the practical gear ratio varies from 8:1 to 30:1 [1].

The gear ratio of an epicyclic gear stage depends on its arrangement. The most common arrangements are the solar stage with the stationary carrier, the planetary stage with the stationary ring gear, and the differential stage where the carrier and ring gear are rotating with the same rpm but in opposite directions. Table 1 presents the gear ratio equations for different epicyclic arrangements.

ASYMMETRY FACTOR OPTIMIZATION

Epicyclic Stage with Singular Planet Gears In an epicyclic stage with singular planet gears (see Figure 3), opposite flanks of the planet gear are in simultaneous contact with the sun and ring gears. In this case, the goal

Figure 1: Epicyclic stage with singular planet gears; numbers of teeth: z1 — sun gear, z2 — planet gear, and z3 — ring gear

Table 1

Figure 2: Epicyclic stage with compound planet gears; numbers of teeth: z1, — sun gear, z2’ — planet gear portion engaged with sun gear, z2” — planet gear portion engaged with ring gear, and z3 — ring gear


of asymmetry factor optimization is equalization of the contact stress safety factors in the external mesh of the sun and planet gears and the internal mesh of the planet and ring gears.

The flank contact stress safety factor is:

Equation 1

where σHP12 and σHP23 are permissible contact stress in the sun/planet gear mesh and the planet/ring gear mesh, and σH12 and σH23 are maximum operating contact stress in the sun/planet gear mesh and the planet/ring gear mesh.

Equation 1 can be converted into the operating contact stress ratio:

Equation 2

In order to simplify the asymmetry factor optimization, the maxi-mum contact stresses in the sun/planet and planet/ring gear meshes are replaced with the contact stress at the pitch points. The operating contact stresses at the pitch points (in the sun/planet gear mesh) are:

Equation 3

where ZE — elastic factor (material property factors), u12 = z2/z1 — sun/planet mesh gear ratio, bw12 — contact face width, αwd12 — drive flank pressure angle, Td1 — sun gear driving torque (in the sun/planet gear mesh):

Equation 4

where u23 = z3/z2 — planet/ring mesh gear ratio, bw23 — contact face width, αwd23 — drive flank pressure angle.

Assuming all gears are made from the same material and inserting Equations 3 and 4 into Equation 2, the coefficient A is equal to:

Equation 5

According to Reference [2], “The permissible stress at limited

service life or the safety factor in the limited life stress range is deter-mined using life factor ZNT.” This allows replacing the permissible contact stresses in Equation 18 with life factors:

Equation 6

where zNT12 and zNT23 are the life factors in the sun/planet and planet/ring gear meshes respectively. These life factors can be defined by numbers of load cycles. The load cycle number ratio in an epicyclic stage with singular planet gears is:

Equation 7

where N12 and N23 are the numbers of load cycles in the sun/planet and planet/ring gear meshes respectively. Then, the asymmetry fac-tor [3] is:

Equation 8

For example: The sun gear number of teeth is n1 = 37, the planet gear number of teeth is n2 = 32, the output gear number of teeth is n3 = 101, the contact face width ratio is bw12/bw23 = 1.4, the number of load cycles in the sun/planet gear mesh is n12 = 109, the number of load cycles in the planet/ring gear mesh is n23 = n12 x z1/z3 = 3.7 x 108. This makes the life factors for nitrocarburized steel ZNT12 = 0.89 and ZNT23 = 0.90, and the factor A = 0.672. If the selected sun/planet gear mesh drive pressure angle αwd12 = 36°, the asymmetry coefficient is K = 1.16 and the planet/ring gear mesh drive pressure angle is αwd23 = 19.8°.

Epicyclic Stage with Compound Planet GearsIn an epicyclic stage with compound planet gears (see Figure 2), one portion of the planet gear is in mesh with the sun gear and the other with the ring gear. In this case, the coast tooth flanks are used only when the gear drive works in a reversed load direction. The goal of asymmetry factor optimization is equalization of the contact stress safety factors in the main drive and opposite reversed load transmission directions.

Figure 3: Epicyclic mesh with singular planet gears

Figure 4: Epicyclic mesh with compound planet gears


AUGUST 2016 53

Then, the flank contact stress safety factor is:

Equation 9

where σHPd and σHPc are permissible contact stress in the main drive and opposite reversed load transmission directions, and σHd and σHc are maximum operating contact stress in the main drive and opposite reversed load transmission directions.

Equation 9 can be converted into the operating contact stress ratio:

Equation 10

In order to simplify the asymmetry factor optimization, maximum contact stresses are replaced with the contact stress at the pitch points. The operating contact stresses at the pitch points (in the main drive load transmission direction) are:

Equation 11

Equation 12

where u12’ = z2’/z1 — sun/planet mesh gear ratio, u2”3 = z3/z2” — planet/ring mesh gear ratio, z2’ — tooth numbers of the planet gear engaged with the sun gear, z2” — tooth numbers of the planet gear engaged with the ring gear, bw12’ and bw2”3 — contact face widths in the sun/planet gear mesh and the planet/ring gear mesh, αwd12’ and αwd2”3 — drive flank pressure angles in the sun/planet and the planet/ring gear meshes respectively, and Td1 — sun gear driving torque (in the main drive load transmission direction):

Equation 13

Equation 14

where αwc12’ and αwc2”3 — coast flank pressure angles in the sun/planet and the planet/ring gear meshes respectively and Tc1 — sun gear reversed torque.

Assuming all gears are made from the same material and insert-ing Equations 11-14 into Equation 10, the coefficient A is equal to:

Equation 15

The permissible contact stresses in Equation 15 can be replaced for life factors:

Equation 16

where ZNTd and ZNTc are the life factors in the main drive and opposite reversed load transmission directions respectively, which are defined by Nd and Nc — the numbers of load cycles in the main drive and opposite reversed load transmission directions.

Then, the asymmetry factors (in the sun/planet gear mesh) are:

Equation 17

and (in the planet/ring gear mesh):

Equation 18

Unlike in the epicyclic asymmetric gear stage with singular planet gears, the optimized asymmetry coefficients depend only on the main driving and reversed torque ratio and numbers of cycles in the main drive and reversed load transmission directions.

For example: Main driving and reversed torque ratio is Td1/Tc1 = 1.5, the number of load cycles in the main drive load transmission direction is Nd = 109, the number of load cycles in the reversed load transmission direction is Nc = 107. This makes the life factors for nitrocarburized steel ZNTd = 0.89 and ZNT23 = 0.97, and the factor A = 0.561. If the selected sun/planet gear mesh drive pressure angle αwd12’ = 36°, its asymmetry coefficient is K12’ = 1.187 and the coast pressure angle in this mesh is αwc12’ = 16.1°. If the selected planet/ring gear mesh drive pressure angle αwd2”3 = 33°, its asymmetry coefficient

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is K2”3 = 1.147 and the coast pressure angle in this mesh is αwc2”3 = 15.4°.

TOOTH ROOT FILLET OPTIMIZATIONIn Direct Gear Design, the tooth fillet is designed after the involute f lank param-eters are completely defined. The goal is to achieve minimal stress concentration in the tooth fillet profile. In other words, the maximum bending stress should be evenly distributed along a large portion of the fil-let. The initial fillet profile is a trajectory of the mating gear tooth tip in a tight (zero backlash) mesh. This allows for an exclusion of interference with the mating gear tooth.

The fillet optimization method that is used in Direct Gear Design was developed by Dr. Yuriy V. Shekhtman [4]. This method utilizes the following calculation processes:• Definition of a set of mathematical

functions that is used to describe the optimized fillet profile. Parameters of these functions are defined during the optimization process.

• Stress is calculated using a 2D finite element analysis (FEA) subroutine that achieves satisfactory optimization results within a reasonable amount of time.

• A random search method is used to define the next step in the multi-parametric itera-tion process of fillet profile optimization.

The fillet optimization method establishes the approximate fillet center (see Figure 5). The first and last finite element nodes of the initial fillet profile located on the form diameter circle cannot be moved during the optimization process. The rest of the initial fillet finite element nodes are moved along straight lines that pass through the fillet center. Bending stresses are calculated for every iteration of the fillet profile con-figuration. Variable parameters of the fil-let profile functions that describe the fillet profile for the next iteration are defined depending on stress calculation results of the previous iteration. If it provided a stress reduction, the optimization process moves fillet nodes in the same direction. If stress was increased, the nodes are moved in the

Figure 5: Tooth root fillet optimization: a — profile shaping technique, b — stress chart; 1 — involute tooth flanks, 2 — initial fillet profile, 3 — fillet center, 4 — optimized fillet profile, dfd, dfc — form circle diameters of the drive and coast tooth flanks

Figure 6: Tooth stress distribution comparison before and after root fillet optimization: a — tooth FEA mesh, b — stress distribution charts, ΔσF — tensile stress reduction, ΔσFC — compressive stress reduction

Figure 7: (a) Asymmetric epicyclic gear stage stress isograms; (b) charts of sun gear, planet gear, and ring gear respectively

Figure 8: (a) TV7-117S gearbox arrangement; (b) first and (c) second stage sections


AUGUST 2016 55

opposite direction. After the specified num-ber of iterations, the optimization process stops, outputting the optimized fillet profile. During the optimization process, the fillet nodes cannot be moved inside the initial fillet profile because this may cause interfer-ence with the mating gear tooth tip.

Figure 6 compares gear tooth stress distribu-tion before and after root fillet optimization.

Asymmetric epicyclic gear stage stress iso-grams and charts are shown in Figure 7.

IMPLEMENTATION OF ASYMMETRIC EPICYCLIC TOOTH GEARSThe first known application of epicyclic gears with asymmetric teeth was for the TV7-117S turboprop engine gearbox. The engine and gearbox were developed by Klimov Corporation (St. Petersburg, Russia) for the commuter airplane Ilyushin Il-114.

The TV7-117S gearbox arrangement is shown in Figure 8. The first planetary-differential stage has three planet gears.

The second solar-type coaxial stage has five planet gears and stationary planet carrier. This arrangement is proved to provide the highest power transmission density for the required gear ratio.

The main parameters and characteristics of this gearbox are described in Reference [3]. The first stage (without the sun gear) and the second stage carrier assembly of the TV7-117S turboprop engine gearbox are shown in Figure 9.

CONCLUSIONThis article outlines the Direct Gear Design approach to asymmetric epicyclic gear stages with the singular and compound planet gears. Methods of optimization of the tooth f lank asymmetry factor and root fillet pro-file are considered, and an example imple-mentation of asymmetric epicyclic gears has been demonstrated.

REFERENCES 1. V.N. Kudriavtsev, Y.N. Kirdiashev,

Planetary Gears. Handbook. Mashinostroenie. Leningrad, 1977.

2. Standard ISO 6336, Calculation of load capacity of spur and helical gears, 2006.

3. A.L. Kapelevich, Direct Gear Design, CRC Press, 2013.

4. A.L. Kapelevich, Y. V. Shekhtman. Tooth Fillet Profile Optimization for Gears with Symmetric and Asymmetric Teeth, Gear Technology, September/October, 2009, 73 – 79.

ABOUT THE AUTHOR: Dr. Alexander L. Kapelevich is the founder and president of the consulting firm AKGears, LLC, a developer of modern Direct Gear Design® methodology and software. He has over 30 years of experience in custom gear transmission development, and he is the author of “Direct Gear Design” and many technical articles. Kapelevich can be reached by email at [email protected].

N-7036

Figure 9: Assemblies of (a) first and (b) second stages of TV7-117S turboprop engine gearbox



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NEW PRODUCTS, TRENDS, SERVICES, AND DEVELOPMENTS

PRODUCTSHOWCASE

GLEASON TO DEMONSTRATE NEW SOLUTIONS FOR ADVANCED GEAR PRODUCTION AT IMTS 2016Gleason will demonstrate brand-new solu-tions in advanced gear manufacturing tech-nology in Booth #N-7000 at IMTS 2016 in Chicago, September 12-17, covering a wide array of processes for the complete produc-tion and inspection of all types of bevel and cylindrical gears.

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Hard Power Skiving – The Breakthrough in Fine Finishing of Internal GearsHard Power Skiving on the Gleason 300PS will be demonstrated for the first time at IMTS. Gleason offers a tailored solution to workpieces, including extraordinarily stiff machines, modular workholding, and the right tools to meet the high requirements of the process. The Gleason Power Skiving Simulation Software depicts the cutting cycle for every cut and ensures that cycle times are minimized and tool life is maximized.

500CB Cutter Build Inspection Machine for Automatic, Accurate, and Repeatable BuildsAnother premiere is the 500CB, shown for the first time outside the Gleason premises. The 500CB delivers more accurate and highly automated build, truing and inspection of all types of stick-blade bevel gear cutters with automated closed-loop blade positioning for better gear quality and maximum tool life. The 500CB also automatically controls the tightening of the blade clamp screws, consistently applying the correct torque without the previously required operator intervention.

Genesis® 400HCD Gear Hobbing/Chamfering with the New GEMS® Software PackageThe newest addition to the Genesis line of hobbing machines features a newly developed time-parallel chamfering process. With this new solution, customers can chamfer medium-sized gears more economically and with greater flexibility. Designed for dry hobbing, the 400HCD has the benefits of the latest cutting tools employing high-speed spindles and a rigid structure. The 400HCD is equipped with the new Gleason operator software package for easy and efficient operation of the machine including many new features.

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New Tool and Servicing Solutions Gleason will present its complete gear manu-facturing tool program including modern tool servicing concepts with integrated connectivity via RFID. Products featured will include tool materials such as G90 and advanced carbides, optimized with the latest wear coatings. Power Skiving tools are now available in solid car-bide and with inserted blades for the Hard Gear Power Skiving process. For bevel gears, Gleason will show the innovative Pentac®Plus RT cutter head, which makes blade setup and checking more reliable and faster. Gleason also will present its latest line of hard finishing tools including dressing tools for grinding and honing applications.

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AUGUST 2016 57

Advanced Workholding SolutionsQuik-Flex® Plus, Gleason’s next generation of modular, quick-change workholding systems requires a single tool, less time, and minimal operator experience. Customers can partici-pate in the Gleason Quik-Flex®Plus Challenge to experience how easy it is to change the modular components.

Gleason will also demonstrate its line of hydraulic workholding solutions. The holding force, extreme accuracy, and contamination-free designs are suited for dry gear processing appli-cations. The new Gleason Stir-Able modular workholding designs allow off-spindle assembly and truing, reducing changeover time as well as the amount of total run-out in the fixture.

Gleason Automation Systems with Modular, Integrated SolutionsGleason Automation Systems specializes in the design and manufacture of factory automa-tion systems serving a variety of customers in the automotive and other industries. Gleason will present the modularity of its automation systems with two different solutions including the compact DS1200 automation unit with integrated secondary processes as an accurate, reliable alternative to costly operator-depen-dent conveyor automation. This compact sys-tem, which is compatible with most machine tools, uses robotic technology for loading and unloading. Its secondary operations capability allows this system to function as a versatile work cell, further enhancing productivity.

Gleason Global Services Shows Its Complete Service OfferingGleason Global Services is the leading source of gear technology knowhow and education.Gleason trainers will be promoting the full range of training classes ranging from beginner levels to the most advanced expert topics. Gleason Global Services will present its range of perfor-mance upgrades, modernization programs, and tooling services, including practical examples.

Gleason Plastic Gears for Stronger, Quieter GearsGleason Plastic Gears will showcase its capa-bilities in plastic gear design and injection molded plastic gears including bevel and cylindrical gears, helical and spur gears, and planetary and internal gears. Gleason Plastic Gears provides customers with the benefit of a plastic gear with no weld-line for a stron-ger, more accurate, and economical drive train, eliminating the additional expense of secondary machining.

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CARBIDE-ROLL BURNISHING TOOLS TO BE FEATURED AT IMTS 2016By Elliott Tool Technologies, carbide-roll burnishing tools, which produce a mirror-like surface finish while eliminating secondary operations, machining setups, and operator labor and cost, will be featured at IMTS 2016, Booth #W-1292. These cost-effective, easy-to-use carbide rolls from Monaghan Tooling Group improve surface irregularities and tool marks, producing optimum surface finishes

The JUNKER Group is the ultimate partner worldwide for all needs related to grinding and air fi ltration technology. Maximum precision and absolute passion for what we do makes us a pioneering technology leader. It is our mission to set new standards and justify the trust placed in us by discerning customers from a vast array of industrial sectors.

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Monaghan Tooling Group provides engineered tooling and services, including application-relat-ed consulting, to solve machining challenges. It has partnered with industry-leading standard and custom-tooling manufacturers including Diatool, UC Tools, RE-AL, MK-Tools, Reamtec, Axis, and Elliot Tool Technologies to address the challenges of precision metal finishing and high-performance cutting.

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GEHRING RELEASES LIFEHONE L630 MODULAR HONING MACHINEGehring L.P. has released the Lifehone L630, the newest in its line of modular honing machines for precision metal components. The Lifehone L630 offers a systematic approach to help ensure an efficient manufacturing pro-cess. Features include standard part applica-tions that can be honed on the Lifehone range from sun gears to connecting rods, hydraulic sleeves, and injector pump components.

Small-bore diameters often place different demands on the production technology than larger ones. The L630 has market-proven components in a modular design. Depending on customer requirements and the product spectrum to be finished, the machine is equipped with matching honing units. The Gehring honing control allows for precision controlled stroke speeds and reversal precision.

© 2016 Smart Manufacturing Technology Ltd. @SmartMTGloballinkedin.smartmt.com

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• Accurately and rapidly design and analyse transmission systems from scratch or troubleshoot exisiting designs• Comprehensively understand the life of a mechanical part over the customer duty cycle• Identify potential failure modes early in the development cycle• Rapidly predict key performance characteristics at the design stage• Easily explore changes in transmission layout, component selection and/or design, materials and manufacturing processes• • Perform full system simulations for any transmission or driveline configuration• Incorporate manufacturing simulation at the design stage to reduce process development time & cost

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AUGUST 2016 59

An optional feature allows the stroke to be executed via a ball screw or a linear motor. The user-friendly and clear graphic interface of the Gehring Operator Panel (GOP), as well as the program assistant, eases machine operation.

The L630 machine is a honing center that can be equipped with one or two honing spindles. Depending on the machining task and the batch size, this type of machine can be equipped with a fixed or rotary table and up to eight workstations. Stations also can be used for measuring or brushing operations. The single-spindle version of the Lifehone series has a compact design and small footprint — an advantage to customers with limited space or those who need to frequently change the type of part that needs to be honed. This flexible two-spindle honing center allows for a two-stage honing process and shorter overall honing processing times.

Gehring will display the Lifehone L630 at IMTS, along with its entire portfolio of honing technologies and services including position and form honing, laser structuring, and contract honing. Gehring also will display

its tooling and abrasives products. Michael Schaefer of Gehring will hold daily technol-ogy briefings at Gehring Booth #N-6740. A technical presentation titled “Advanced Honing Technology Solutions for Modern Manufacturing” by Schaefer is scheduled for September 15 from 11 to noon in Room N-127.

gehring.de

HARDINGE ANNOUNCES RELEASE OF TWO NEW VMCS Hardinge Inc., a leading international pro-vider of advanced metal-cutting solutions, recently announced the release of its new-est vertical machining centers (VMCs), the Bridgeport V480 and V710.

The Bridgeport V480 and V710 machines feature fast rapid rates, high axis and spindle acceleration/deceleration, and a powerful Mitsubishi control packed with many stan-dard features. For job-shop type work to high-production manufacturing, the machines feature heavy-duty cast-iron construction, 8,278-pound machine weight for the V480 and 8,613 pounds for the V710, 10 HP / 7.5 Kw, 33 ft-lb / 47 Nm spindle torque, 20-sta-tion Swing Arm ATC, and manual pulse generator (MPG) at a competitive price.

The Bridgeport V480 and V710 are ideal for a job shop or OEM, and they are designed with flexibility and throughput in mind. The Bridgeport V480 and V710 have quick, small compact footprints yet they are rugged machines and are developed for applications that require a rigid, fast, and accurate setup. The fully digital machines have a rapid tra-verse rate of 1,417 IPM, X, Y, and Z and acceleration rates of X : 6 m/sec² / Y: 4.6 m/sec² / Z: 3.75 m/sec² providing a fast and accurate response.

Axis travels are: • V480 — X: 18.9 inches (480 millimeters),

Y: 15.75 inches (400 millimeters), Z: 16.93 inches (430 millimeters).

• V710 — X: 27.87 inches (708 millimeters) Y: 15.75 inches (400 millimeters) Z: 16.93 inches (430 millimeters).

Standard machine features include a 10.4-inch color LCD, CT40 or BT40 Big Plus spindle, 10,000 rpm direct-coupled greased spindle, circular f lushing ring, coolant chip f lush system, three-color stack light, and 20-tool ATC. The machines are offered with a Mitsubishi M70V type-A control. Navi-Mill and embedded Ethernet are also standard.

Some of the popular available options include 12,000- and 15,000-rpm spindles, CTS-Deublin rotary union, through-spindle coolant, 280 PSI, air blast, chip conveyors, spindle chiller, and fourth-axis prewiring.

“The Bridgeport V480 and V710 machin-ing centers offer a high degree of sophistica-tion and functionality at an attractive price,” said Brooke Sykes, director of sales and service of the turning/milling group.

Hardinge will be at IMTS, Booth #S8738.

hardinge.com

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CONTACT GEAR SOLUTIONS AT 800-366-2185 TO LIST YOUR MACHINERY.MACHINERY

GEAR ACCESSORIES, PARTS & TOOLING

FELLOWS Model #10-4/10-2, All Parts Available REF#105

Tilt Tables for 10-2/10-4, Qty 2 REF#105

FELLOWS Parts Available For All Models REF#106

BARBER-COLMAN – PARTS AVAILABLE FOR ALL MODELS REF#106

G&E – PARTS AVAILABLE FOR ALL MODELS REF#106

GEAR HOBBERS/CUTTERS CNC

PFAUTER #PE-150, 6-Axis CNC, 6” Dia, 5 DP, 6” Face, Fanuc 18MI REF#106

G&E #60 S-2 CNC Gasher/Hobber REF#106

BARBER-COLMAN #16-36, 16” Dia, 4-Axis, 6 DP, 36” Face REF#106

MUIR CNC Gear Hobber, 4-Axis, 118” Dia REF#106

LIEBHERR #L-252 3-Axis, 9.8” Dia, recontrolled 2008 REF#106

LIEBHERR #ET-1802 CNC – 98” Dia Internal, 3-Axis REF#106

G&E #120GH, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42” Face, ‘94 REF#106

PFAUTER P400H, 5-Axis, 18” Dia, 1 DP, Recontrolled ‘03 REF#106

G&E #96GH, CNC, Gasher/Hobber, New ‘09 REF#106

PFAUTER PE 300 AW CNC 6-Axis REF#106

Pfauter PE150, 15MB Fanuc, Chip Conveyor, Auto Load REF#102

Pfauter PE150, Siemens 3M, Magnetic Chip Conveyor, Oil Chiller REF#102

Pfauter PE150, Fanuc 15, with light hob slide 8” REF#102

Pfauter PE80, 15MB Control, Auto Load, Light Curtain REF#102

Liebherr LC82 15M Fanuc Control, Auto Load REF#102

Liebherr LC502, 20”, Fanuc 16im, 2007 REF#102

Liebherr LC380, 440mm W/100mm Hob, 2008 REF#102

GEAR HOBBERS/CUTTERS

TOS OFA Series Conventional Gear Hobbers, 12” & 40” Dia REF#103

TOS OHA Series Conventional Gear Shapers, 12” & 40” Dia REF#103

PFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#105

PFAUTER (1) RS-00 s/n 17593 REF#105

BARBER COLEMAN (1) 16-36 multi cycle s/n 4404 REF#105

BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm and/or Single Thread Worm REF#106

G&E #48H 48” Dia, 18” Face 2 DP, Universal REF#106

G&E #48H, 48” Dia, 35” Face, 3 DP, Gooseneck Attachment REF#106

BARBER-COLMAN #6-16, 6 Multi-Cycle REF#106

G&E #36H Differential, Excellent Condition REF#106

BARBER-COLMAN #14-30, 14” Dia, 30” Face, 3.5DP REF#106

BARBER-COLMAN #14-15, 14” Dia, 15” Face, 1 to 4 Start Worm, Several REF#106

BARBER-COLMAN #16-16, 16” Dia, 16” Face, 6DP REF#106

BARBER-COLMAN #16-36, 24” Dia, C-Frame Style, 4 1/8” Bore REF#106

BARBER-COLMAN #16-56, 16” Dia, 56” Face, Differential REF#106

G&E #24H Universal Head, Infeed, Tailstock, Differential, ‘50’s REF#106

LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New ‘70’s REF#106

G&E #16H Gear Hobber, 16"Dia REF#106

BARBER-COLMAN #6-10, 6” Dia, 10” Face, 16 DP REF#106

KOEPFER #140 , 2.75” DIa, 4” Face REF#106

LANSING #GH-50, 50” Dia, 17.75” Face, 2 DP REF#106

LIEBHERR #L-252, 9.8” Dia, 7.9” Face, 4.2 DP REF#106

BARBER-COLMAN TYPE T REF#106

G&E #36HS 36”Dia, 14” Face 3 DP REF#106

PFAUTER #P-3000, 120” Dia, Single Index REF#106

SCHIESS RFW-10-S 55” Dia REF#106

SCHIESS 1 RF-10, Dia 60” 150” L, .50 DP REF#106

G&E #40TWG, 48” Dia, 18” Face, 3 DP REF#106

G&E #60S, 72” Dia, 14” Face, 1.25 DP REF#106

G&E #72H, 72” Dia, 24” Face, 1 DP REF#106

G&E #96H, 104” Dia, .50 Face, 1.25 DP REF#106

PFAUTER #P-630, 25” Dia REF#106

PFAUTER P250 10” Dia REF#106

GE/Fitchburg Hobber 32” Dia, 72” Face 1.25DP REF#106

JF Reinecker 40” Dia 35” Face REF#106

LIEBHERR L-160-R 6.5” Dia REF#106

MIKRON #102.04 , 4’ Dia, 5” Face REF#106

PFAUTER P-900 36” Dia REF#106

BARBER-COLMAN #25-15 25” Dia, 15” Face, 2.5 DP REF#106

PFAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#106

Lees Bradner 7VH, 8”PD, 10” Face, , Magnetic Chip Conveyor , Hob Shift REF#102

Lees Bradner 7VH, 8”PD, 4PD, Magnetic Chip Conveyor, Hob Shift REF#102

Barber C. 16-15, 4” Hob, Crowning, Differential, Double Cut, 3 DP, 1977 REF#102

G & E 36H, 36”, Hi-Column, Differential, From AEM Toolroom, Excellent REF#102

G & E Model 48HS, 48”PD, 18” Face, 2.5 DP, Hi-Column, Heavy Duty, 8” Hob REF#102

Liebherr L301, 12” Crowning, Double Cut, Differential, Hob Shift REF#102

Liebherr L401, 16”, Differential, 2-Cut Cycle, Chip Conveyor, 7.566” Hob Dia. REF#102

Liebherr L402, 2-Cut, Infeed, Differential, Tangential Feed, 19.3 OD W/4” Hob REF#102

Cleveland 1886, Hi-Helix, Hob Head, Auto Hob Shift, 4-Pitch, 1975 REF#102

GEAR PINION HOBBERS & SPLINE MILLERS

HURTH #KF-32A 15” Dia, 59” Face, ‘67 REF#106

GE/Fitchuburg Pinion Hob 32” Dia, 72” Face REF#106

MICHIGAN Tool #3237 REF#106

FITCHBURG Pinion Hobber 42” Dia, 72” Dia REF#106

GEAR HOB & CUTTER SHARPENERS (INCL CNC)

TOS OHA Series CNC Gear Shapers, 12” & 40” Diameter REF#103

TOS OFA Series CNC Gear Hobbers, 12” & 40” Diameter REF#103

BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, ‘57 REF#106

FELLOWS #6SB, Helical Cutter Sharpener, 6” Dia, up to 50 Degrees REF#106

KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#106

KAPP #AS204GT, 10” Dia, Wet Grinding, CBN Wheels, ‘82 REF#106

REDRING MODEL #SGH "PREIFORwM" SHAVE CUTTER GRINDER/SHARPENER REF#106

STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#106

BARBER-COLMAN 2-2 1/2 , 2.5” Dia REF#106

KAPP #AST-305B, 27.5” Dia, REF#106

KAPP AS-410B REF#106

GLEASON #12 Sharpener, 3-18” Cone REF#106

Red Ring Shaving Cutter sharpener Periform REF#106

Star #6 Gear Cutter Sharpener REF#106

Star 4HS Hob sharpener REF#106

Star HHS Horizontal Hob Sharpener CNC, Max Dia 10” Max length 12” New 1990 REF#106

Barber Colman 10-12, Water Guards, Dresser, Index Plates REF#102

Star 2VHS, 6”x6”, Coolant, Change Gears, REF#102

Star 4 x 4 (G691), 0-7000 Spindle Speeds, Auto Cycle, Coolant REF#102

Barber Colman 4-4, Index Plates, Very Light Use, Excellent REF#102

Gleason 538, 18” Shaper Blades, Makes Blades from Blanks, Light Use, Extras REF#102

Star 2VHS, 6” x 6”, Coolant, Change Gears REF#102

GEAR SHAPERS CNC

36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3 REF#105

FELLOWS #10-4/10-2, Qty 150 REF#105

HYDROSTROKE #50-8, Qty 2 REF#105

HYDROSTROKE #20-8, Qty 5 REF#105

HYDROSTROKE #FS630-125, Qty 1 REF#105

HYDROSTROKE #FS400-90, Qty 2 REF#105

FELLOWS #20-4, Qty 6 REF#105

FELLOWS #48-8Z, Qty 1 REF#105

FELLOWS #FS-180, 3-5 Axis, 7” Dia, 1.25” Face., 6 DP, New ‘88 REF#106

LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#106

LORENZ # LS-180, 4-Axis CNC, 11” OD, 2” Stroke, 5 DP REF#106

LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#106

FELLOWS FS400-125, 16” Dia, 3.5 DP 5” Face REF#106

FELLOWS #10-4 3-Axis (A/B), 10" Dia, 4" Face, 4 DP New .’09 REF#106

FELLOWS #10-4 2-Axis, 10” Dia 4” Face REF#106

FELLOWS #20-4 3-Axis 10” Dia, 4” Face REF#106

FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15.7" REF#106

Fellows 20-8, CNC Gear Shaper, Remanufactured and recontrolled REF#106

Fellows Model Z gear Shaper REF#106

Lorenz SN4 Gear Shaper, Max OD 7”, 2” Face, Max 6 DP with Loader REF#106

GEAR HOBBERS

Barber Colman Model 4-4HRS, Hob Sharpener 4” Max OD, 4” Length REF#106

Fellows FH 200 Gear hobber, universal hobbing Machine REF#106

Barber Colman 6-10, CNC, CRt 5 Axis, 6” Dia, 10.5” travel, 6 DP REF#106

Barber Colman Hobber Type T REF#106

Barber Colman model #14-15 Gear Hobber, horizontal Heavy Duty REF#106

Barber Colman Model #16-36 GearHobber REF#106

Barber Colman Model #16-56, 16” dia, 56” Face, adj. Air Tailstock REF#106

Barber Colman Model 2.5-2 gear hobber, 2” length Manual Dresser REF#106

G&E Model 5.2 CNC Internal Gear gashing head REF#106

Jeil JDH-3, Gear hobber, Max Dia 31.5”, 3DP, 22.8 Table Diameter REF#106

Jeil JDP-2, Gear hobber, Max Dia 26”, 4 DP, 19.5” Table Dia, Differential

and tailstock REF#106

Liebherr ET 1802, Internal Gashing head, Fanuc 16i Control, 98”Max dist 17” Face REF#106

Liebherr L-402 Gear hobbing Machine, New 1977 REF#106

Liebherr LC 752, 6 Axis CNC Hobber, Max OD 29.5”, Max Face width 23.6” REF#106

Micron Model 120.01 w/bevel Cutting Attachment, New 1975, 1.6” dia, 25.4 DP REF#106

Pfauter P900 Reman and Recontrolled, Max OD 120” REF#106

Pfauter Model PE125 CNC Gear hobber REF#106

Pfauter model PE300 CNC, Max OD 12”, Max gear face 15”, 3 DP, 6 Axis REF#106

Reinecker Heavy Duty Gear Hobber REF#106

Scheiss Model RF10 Horizontal Hobber, 60” dia, 144” face, 180”cc, 8 DP REF#106

GEAR SHAPERS

FELLOWS #10-2, (10” Dia), 2” Face REF#105

FELLOWS #10-4, (10” Dia), 4” Face REF#105

FELLOWS (200) 10-4 / 10-2 Shapers REF#105

FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009) REF#105

FEATURED SUPPLIERSGibbs Machinery Company – REF #102Phone: 586-755-5353 Fax: 586-755-0304Email: [email protected]: www.gibbsmachinery.com

Havlik International Machinery, Inc. – REF #103Phone: 519-624-2100 • Fax: 519-624-6994Email: [email protected]: www.havlikinternational.com

General Tool & Engineering Company - REF #107Phone: 501-945-7111 • Fax: 501-945-7111Email: [email protected]

Midwest Gear Corporation – REF #104Phone: 330-425-4419 • Fax: 330-425-8600Email: [email protected]: www.mwgear.com

New England Gear – REF #105Phone: 860-223-7778 • Fax: 860-223-7776Email: [email protected]: www.newenglandgear.com

R. P. Machine Enterprises, Inc. – REF #106Phone: 704-872-8888 • Fax: 704-872-5777Email: [email protected]: www.rpmachine.com


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http://www.rpmachine.com


AUGUST 2016 61

FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009 REF#105

FELLOWS (1) #7 125A Face Gear Machine REF#105

FELLOWS (2) #3 Face Gear Machine REF#105

(1) 4ags with adjustable Helical Guide s/n 30634 REF#105

(1) #7 125A adjustable Helical Guide REF#105

FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009) REF#105

FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#105

FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc

(2009) REF#105

FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#105

FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#105

FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009) REF#105

FELLOWS (1) 48-8Z Shaper w/ 14” throated riser (53” of swing) REF#105

FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#105

FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller

s/n 34326 REF#105

FELLOWS (1) 36-10 Gear Shaper REF#105

FELLOWS (1) 10x6 Horizontal Z Shaper REF#105

FELLOWS (1) 36-6 Gear Shaper w/ 13” riser s/n 27364 REF#105

FELLOWS (1) 10-4 Shaper w/ 3” riser w/ 4 axis 21i Fanuc Controller (2009) REF#105

All Parts for 10-4/10-2 Fellows Gear Shapers REF#105

FELLOWS #36-8, 36” Dia, 8” Face REF#106

FELLOWS #100-8 100” Dia, 8” Face REF#106

FELLOWS #612A, 615A, #645A REF#106

FELLOWS #10-4, 10” Dia, 4” Face, 4 DP REF#106

FELLOWS #4A Versa, 10” Dia, 3” Face, 4 DP, New ‘70’s REF#106

FELLOWS #10-2, 10” Dia, 4” Face, 4 DP REF#106

FELLOWS #20-4, 20” Dia, 4” Face, 4 DP, ‘70’s REF#106

FELLOWS #3-1,/3GS, 3” Max Dia, 1” Face, Pinion Supp, High Precision REF#106

FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#106

MAAG #SH-150, 57" Dia.12.6" Face REF#106

PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#106

FELLOWS #36-6 Max Dia 36” 6” Face, 3 DP REF#106

FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5” REF#106

FELLOWS #4GS & 4AGS, 6” Dia, 2” Face, 4DP, ’68, Ref.# Several REF#106

FELLOWS #624A, 18” Max Dia, 5” Face REF#106

FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7” Dia, 0-12” Risers, Several Avail REF#106

MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#106

FELLOWS Model Z Shaper, 5" Stroke, ‘50’s REF#106

STAEHELY SHS-605, Gear Shaper REF#106

FELLOWS #6, #6A, #61S, From 18”-35” Dia, 0-12” Risers REF#106

FELLOWS #8AGS Vertical Gear Shaper, 8” Dia, 2” Face, 6-7 DP REF#106

GEAR DEBURRING/CHAMFERING/POINTING

CROSS #50 Gear Tooth Chamferer, 18” Dia, Single Spindle REF#106

REDIN #20D, 20” Dia, Twin Spindle, Deburrer/Chamfer REF#106

SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14” Dia, 5” Face, ‘82 REF#106

SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10” Max Dia, (3) New ‘96 REF#106

REDIN #24 CNC Dia 4” Setup Gear Deburring REF#106

CROSS #60 Gear Tooth Chamferer, 10” Dia, Single Spindle REF#106

FELLOWS #100-180/60 CNC Max Dia 180”, Single Spindle REF#106

CIMTEC #50 Finisher REF#106

CROSS #54 Gear Deburrer, 30” Dia, 18” Face REF#106

RED RING #24 Twin Spindle Dia 4” REF#106

GLEASON GTR-250 VG CNC 5-Axis REF#106

Gleason- Hurth Model ZEA 4, Max Dia 250mm, Max Module 5mm REF#106

Redin Model 36 universal Chamfering and Deburring Machine, Max OD 36”, Twin spindle,

Tilt table REF#106

Cross 55 Gear Rounder, 18” Chuck, Hydraulic Unit REF#102

Cross 65, 10” Gear Pointer, Power Cylinder, Cutter, Change Gears REF#102

Cross 85 10” Chamfer, (2) Cutter Heads, Bevel, Spur, Helical REF#102

Samputensili SCT3 13.7”, SM2TA 10”, (5), 2003 REF#102

Samputensili SM2TA, 10”, Max. Face Width 4”, Hyd. Work Clamping, 1983-2003 REF#102

Mitsubishi MA30 CNC, 11”PD, Fanuc Control, Powermate, 1999 (2) REF#102

GEAR HONERS

Kapp #CX120 Coroning 4.7” Dia REF#106

Red Ring GHD-12, 12” Dia, 5.5 Stroke REF#106

Red Ring GHG, 12” Dia, 5.5 Stroke REF#106

Kapp #VAC65 Coroning 10” Dia REF#106

National Broach GHG 18”, Power Stock, Crowning, Variable Speed REF#102

Toyo T465 CNC, 160M Fanuc 5-Axis, Power Stock, Uses Fassler Tooling, REF#102

GEAR GENERATORS

GLEASON #37 Str. Bevel Planer, 6” Dia REF#106

GLEASON #496 Straight.& Spiral. 7.5” Dia REF#106

GLEASON 725-Revacycle, 6” Dia REF#106

GLEASON 726-Revacycle, 5” Dia REF#106

Farrel Sykes Model 12C herringbone max dia 264”, max face width 60” REF#106

Farrel Model 5B herringbone gear generator. REF#106

Gleason 529 gear quench press, Auto cycle 16” Diam, New 1980 REF#106

Gleason 614 hypoid finishing machine, 10.5” pitch, dia 5.25” Max cone dist REF#106

Oerlikon/klingelnburg Model C28, Max dia 320 mm, Max Module 7.5 mm REF#106

Gleason Model 26 Quench press and Hypoid Generator Max OD 16”, Max face Width Air

Cylinder REF#106

Gleason Model 36 Gear Quenching Press, Max Ring 28” OD, 8” Face, Universal REF#106

Gleason Model 450 HC CNC Hypoid Cutter, Face width 2.6”, fanuc 150 Controls REF#106

Gleason 11 Spiral Bevel, 13”, Stock Divider, Hyd. Chucking, Roughers & Finishers REF#102

Gleason 12”, Gears, Gauges Tool Blocks REF#102

Gleason 16 Spiral Bevel, 18”, 2-1/2 DP, Modified Roll, Chip Conveyor REF#102

Gleason 24 Rougher, Gears, Finishing Tool Holder REF#102

Gleason 116 Rougher & Finisher (6) REF#102

Gleason Phoenix 175HC CNC – 1994 REF#102

Gleason 22 Rougher & Finisher (8) REF#102

Gleason 26 Spiral Bevel, 33-36”, Mod. Roll, Stock Divider, Coolant, Change Gears REF#102

Gleason Phoenix 450HC, Spiral Bevel, 150MB Fanuc REF#102

Gleason 610 Combination Rougher & Finisher, 1988 REF#102

Gleason 608 & 609 Rougher & Finisher REF#102

Gleason 645 Spiral Bevel, Helical Motion, Chip Conveyor, Variable Rate of Roll REF#102

Gleason Cutters, 3” to 25” in stock, 1000 REF#102

GEAR GRINDERS

#27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder generating Cams

(2 full sets) REF#105

Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#105

REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#106

GLEASON #463, 15” Dia REF#106

Hofler model Rapid 2000L, CNC Grinder, Max OD 78”, CNC Dressing REF#106

Matrix model 78, Reman CNC Thread grinder, 24” Dia, 86” grind Length, 106 between

centers REF#106

Mitsu Seiki Model GSW-1000 Gear Grinder REF#106

Reishauer RZ 362 AS, CNC Grinder, Max Dia 360mm REF#106

Sundstrand/Arter Model D12 Grinder REF#106

Teledyne-Landis Gear Roll Finishing Machine, 5” Diam, 42k lbs Rolling Force REF#106

Reishauer NZA, 12”, Fassler Dresser, Many Extras, 1994 REF#102

Reishauer RZP, 4-8”, Auto Loading, High Production, Use in Lab REF#102

Reishauer RZ301AS CNC, 13” Measuring System (3) REF#102

Reishauer ZB, 27.5” PD Gears, Coolant REF#102

Gleason 120 Curvic Coupling, 24” Max. Dia., Index Plates, Extras REF#102

Csepel FKP-326, Fassler Dresser, Like A Hogland NZA Reishauer, Super Cond. REF#102

National Broach SGK-24, Max. OD 31”, ID 24”, Spur & Helical, From Aircraft REF#102

Maag SH150, 60”, Change Gears, 2-Pitch, Max. Face 23-1/2”, Navy Surplus REF#102

ZSTZ 800 WMW Niles REF#107

GEAR RACK MILLERS/SHAPERS

MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#106

SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, ‘80 REF#106

GEAR SHAVERS

Red Ring #GCX-24" Shaver, 24” Dia, 33” Stroke REF#106

Red Ring #GCU-12, 12” Dia, 5” Stroke REF#106

Red Ring #GCY-12, 12” Dia, 5” Stroke REF#106

Red Ring GCI 24, 12.75” Dia, 5” Stroke REF#106

Kanzaki model GSP 320 Gear shaver REF#106

Red Ring GCU 12” Crowning, 1956 to 1988 (6) REF#102

Rex Ring GCX 24”, Crowning, 12” Cutter Head, Taper Attachment, Long Table REF#102

Mitsubishi FB30, 12.2 CNC Fanuc, 1997 REF#102

Michigan 870, Crowning, Power Stocks, Very Light Use, Excellent REF#102

National Broach GCY 18”, Crowning, Max. 19=1/2”, Rebuilt or Under Power REF#102

National Broach GFF, Crowning, Heidenhein Scales, Servo Drives, 1993 REF#102

Raso Sicmat 400 CNC, Fanuc 16iM, Chip Separator, 2001 REF#102

GEAR TESTERS/CHECKERS (INCL CNC)

FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#105

FELLOWS (1) 24H Lead Checker s/n 32289 REF#105

GLEASON (1) #14 Tester s/n 31907 REF#105

GLEASON (1) #6 Tester s/n 19316 REF#105

FELLOWS (1) 20 M Roller Checker REF#105

FELLOWS (1) 20 M w/ 30” Swing Roller Checker REF#105

FELLOWS (1) #8 Micaodex s/n 36279 REF#105

David Brown #24 Worm Tester REF#106

Gleason #4, #6, #13 and #17 Testers REF#106

Hofler EMZ-2602 Int/Ext Gear Tester 102” REF#106

Klingelnberg #PFSU-1600 Gear Tester-2001 REF#106

Kapp Hob Checker WM 410 REF#106

Maag #ES-430 Gear Tester REF#106

Maag #SP-130 Lead and Involute Tester REF#106

National Broach Gear Tester GSJ-12 REF#106

Oerlikon #ST2-004 Soft Tester REF#106

Maag #SP-60- Electronic Tester REF#106

Parkson #42N Worm Gear Tester REF#106

Vinco Dividing Head Optical Inspection REF#106

Gleason model 511 Hypoid tester Max Dia 20”, max spindle centerline 3.5” REF#106

Klingelnberg Model PFSU-1600 63” Dia, 1.02 DP, Rebuilt REF#106

MAAG ES401 Pitch tester With Process Computer REF#106

Fellows 24M Involute, Response Electronic Recorder, Hot Pen REF#102

Fellows 36” Space Tester, Hot Pen Guaranteed REF#102

Fellows 8M Redliner, 13 5/8”, Recorder (2) REF#102

Gleason 6, 7-1/2” Indicator Check, Pinion .00015, Gear .00001 REF#102

Gleason 17A Running or Rebuilt Guaranteed REF#102

Gleason 511, 20” Reconditioned in 2010 Guaranteed REF#102

Gleason 502, 10”, Hydraulic Chucking, Automatic Backlash, Eliminator REF#102

Gleason 513 20” Gear, 10’ Pinion Electronic Meter Reading of Sound (3) REF#102

Gleason 515, 24” REF#102

Gleason 520, 30”, Hyd. Chucking, Auto Splash Doors/Backlash, Eliminator REF#102

Gleason 523, 20” Reconditioned, 2010 REF#102

Gleason 528 Cutter Inspection, Proximity Type Gage, 3.5”-25”, Conventional REF#102

Illinois 1731-3C, Hob & Worm Lead Tester, Electronic Recorder, Master Hob REF#102

Illinois 3412B-3C, 12” Involute with 1606 Electronic Recorder, Master Gauge REF#102

Illinois 3824-1-3B Spline & Spur Lead Tester, Max. Centers 52”, 1606 Recorder REF#102

Illinois 3912-3C Lead Tester, 12”, 1607 Electronic Recorder, 1980 REF#102

Klingelnberg PFS600 W/Masters, Recorder, Extras, 23.6”, 0.59-23.6” REF#102

M&M 3015, 15” Gear Analyzer, P2 Computer Software, 12”Mag. Chuck REF#102

GEAR THREAD & WORM, MILLERS/GRINDERS

BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#106

EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#106

EXCELLO #33 Thread Grinder 6” Dia 18” Length REF#106

HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88” REF#106

LEES BRADNER #HT12x102, Extra Large Capacity REF#106

LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#106

LEES BRADNER # LT 8” x 24” 8” Dia REF#106

HOLROYD 5A 24.8 “ Dia REF#106 LEES BRADBER WORM MILLER REF#106

MISCELLANEOUS

WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80” Centers,

12” Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#104

Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#105

GLEASON #529 Quench, 16" Diameter REF#106

Klingelnberg Model LRK-631 Gear Lapper REF#106

TOS SU & SUS Series Conv Lathes REF#103

TOS SUA Series CNC Flat-Bed Lathes REF#103

Gleason: Change Gears, Cutter Heads, Cams, Index Plates, Workholding REF#102

G & E: Change Gears, Arbors REF#102

Barber Colman: Change Gears, Arbors, Parts for All Models REF#102

Liebherr: Change Gears, Parts REF#102

Reishauer: Wheel Mounts REF#102


Manufacturing excellence through quality, integration, materials, maintenance, education, and speed.

MARKETPLACE

KORO for Quality Hob Sharpening Service

Quick Turnaround 2 Day Service Spur Shaper Cutter Sharpening HSS & Carbide Hob with center hole

Koro Sharpen ing Ser vice 95 30 85 t h Ave Nor th

Ma ple Grove , MN 55369 76 3 -425 -5247

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and straight flutes Thin Film Coatings Length up to 7 inches

Diameter up to 5 Inches Precise rake and spacing guaranteed to AGMA standards RUSH SERVICE AVAILABLE

· Custom gear racks in AMERICAN and METRIC standards, STRAIGHT and HELICAL, VARIOUS materials, FINE and COARSE pitch (254 D.P. – 0.5 D.P.; 0.10 Module – 50 Module); hard-cut (up to 60 Rc) and soft-cut (up to 40 Rc); 32” face width; Up to 82” lengths – longer lengths through resetting

· Custom gears in AMERICAN and METRIC standards (3 D.P. – 72 D.P., 10” Diameter)

· Precision Quality up to AGMA 12· Prototype & Production quantities· Breakdown Service Available· Reverse Engineering · Unique Tooth Configurations· Heat Treating· Complete CNC Machining

SHARP HOBSChange Downtime To Productivity

You Need Your Tools Back FAST– Eliminating Downtime &Tuned To Meet or Surpass Original Design Specsand That’s Where We Come In

• Stripping & Re-Coating

• Gear Shaper Sharpening

• Milling Cutter Sharpening

• Gear Tool Certifications

Tel: 216-642-5900 • Fax: 216-642-8837 • 5755 Canal Road • Valley View, OH 44125Email: [email protected] WWW.GALLENCO.COM

SERVICING FELLOWS GEAR SHAPERSOn Site Service: Emergency & ScheduledTechnical Support: Via Telephone, Fax or E-mailTraining: Operator, Set-up & Maintenance (Electrical & Mechanical)Preventive Maintence Plan: Customized to Your NeedsParts: New and/or UsedRetrofi ts - Counters, Servo Controllers, or Single and Multiple Axis CNCHydrostatic Guides: Repair Service or Purchase New

Allen AdamsSHAPER SERVICES, Inc.

98 Winery RoadProctorsville, VT 05153Telephone: 802-226-7891Fax: 802-226-7892E-mail: [email protected]

We’veMoved

Enhance your atmosphere heat treatment operations with the latest technical resources. Read the technical article on recommended best practices for enhancing your carburizing and quenching processes.

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of the Trade


Complete Gear Manufacturing

PHONE: 815-874-3948

www.raycargear.com 1-800-428-6028C-B GEAR & MACHINE, INC.4232 Mooney Road • Houston, Texas 77293

281-449-0777 • Fax: 281-590-9127Email: [email protected]: www.cbgear.com

GEAR MANUFACTURING & MACHININGGEAR GRINDING & CHECKINGGEARBOX REBUILD & REPAIR

SPLINE GAGES

INVO–QUALITYINVO–QUALITYINVO–QUALITY• Spur & Helical Master Gears

with helix up to 45°• Solid-Type and Spline & Serration Gauges

Internal and External Checking• Indicator type ring and plug Gages to .0001”• Precision Gear Grinding• Prototype Gears & Spline Parts Small Lots• Spline Arbors

Invo Spline’s policy of using only the highest quality steel available, along with our own 100% inspection procedures has made us the nation’s leader in ultra-precision master gears and spline gages.

2357 EAST NINE MILE ROAD • WARREN, MI 48091 • (586) 757-8840 • FAX: (586) 757-8849

1-800-959-0884 • [email protected]

WWW.INVOSPLINE.COM

http://www.raycargear.com





http://www.cbgear.com



http://www.gearacks.com

http://www.gallenco.com

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AUGUST 2016 63

ADVERTISERINDEX

CONTENTS PAGE NO.ALD Thermal Treatment Inc.................................................................38

Allen Adams Shaper Services Inc .......................................................62

All Metals & Forge Group ....................................................................59

Blaser Swisslube Inc ...........................................................................14

C-B Gear & Machine Inc .....................................................................62

Circle Gear & Machine Co Inc .............................................................49

DMG/Mori ............................................................................................15

Engineered Tools Corporation .............................................................35

Erwin Junker Machinery Inc ................................................................57

Euro-Tech Corporation ........................................................................17

Evonik Industries .................................................................................31

Federal Broach & Machine Company .................................................34

Forest City Gear ................................................................................IBC

Gleason ...............................................................................................18

GMTA (German Machine Tools of America) ........................................39

Hardinge Inc. Forkardt Division ...........................................................27

Index Technologies..............................................................................62

Innovative Rack & Gear .......................................................................62

Invo Spline Inc .....................................................................................62

Ipsen USA .....................................................................................11, 52

KAPP Technologies ........................................................................... IFC

KISSsoft USA LLC ................................................................................9

Koro Sharpening Service ....................................................................62

Leistritz Corporation ............................................................................23

Luren Precision Chicago Co Ltd .........................................................12

McInnes Rolled Rings .........................................................................48

Mitsubishi Heavy Industries America Inc ...........................................BC

Mitsubishi Materials USA ....................................................................16

New England Gear ................................................................................7

Nordex Inc ...........................................................................................13

Penta Gear Metrology LLC .................................................................55

P & G Machine & Supply Co Inc .........................................................53

Pinson Valley Heat Treating .................................................................25

Raycar Gear & Machine Co ................................................................62

Reishauer ............................................................................................43

Russell Holbrook & Henderson Inc .......................................................9

Schafer Industries ...............................................................................29

SMT – Smart Manufacturing Technology ............................................58

Solar Manufacturing ..............................................................................2

STD Precision Gear & Instrument Inc .................................................63

The Broach Masters Inc ........................................................................4

Toolink Engineering Inc .........................................................................1

United Tool Supply ..............................................................................63

Wickert USA ........................................................................................34

Zoller Inc ..............................................................................................10

GEARING AHEAD TO MEET INDUSTRY'S DEMAND FOR PRECISION– SERVING –

Aircraft • Aerospace • ActuationInstrumentation • Optic

Robotics • Radar • MedicalMarine • Defense • Experimental

Prototype • ProductionHi-Performance Automotive

Precision Gear Products (up to AGMA Q14):Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, Clutch Gears,

Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, Bevel Gears, Miter Gears, Metric Gears, Internal Gears, Idler Gears, Gear Rack & Pinion, Worms, Wormshafts,

Splines, Spline Shafts, Serrated Shafts.

STD Precision Gear & Instrument, Inc.318 Manley St. • W. Bridgewater, MA 02379(888) STD-GEAR or (508) 580-0035

Fax (888) FAX-4STD or (508) 580-0071E-mail [email protected] • Web site: www.stdgear.com

CNC Thread Grinding


http://www.stdgear.com

http://unite-a-matic.com


Q&AEach issue, a Gear Solutions editor talks with experienced leaders from companies across the industry to learn about their offerings, philosophy, technology, processes, and customer relationships.

DAVID SENKFORPRESIDENTTOPGUN CONSULTING LLC

Tell us a little about yourself.I am the president of TopGun Consulting based in Scottsdale, Arizona, as a manufacturing consultant with a focus on helping companies seek new opportunities for business development and quality improvement as well as in crafting aggressive strategies to achieve a competitive advantage. I work with all levels of employees, from shop floor technicians to the CEO, establishing an atmosphere of open communication that can enable change to happen quickly and productively.

Please give us an overview on the upcoming IMTS 2016.If you haven’t considered attending this year’s IMTS (International Manufacturing Technology Show) in Chicago on September 12-17, 2016, it’s not too late.

Over 2,000 exhibitors from 112 countries along with over 100,000 attendees will go to McCormick Place in Chicago to see the state of the art in manufacturing. The show is organized into pavilions that group similar types of machines or technologies together to simplify your search for your needs. There are also other exhibitions occurring at the same time at McCormick Place as well as a full range of seminars and educational opportunities. There is over 1.3 million square feet of exhibitor space. The East and West buildings will be open from 9 a.m. to 5 p.m., and the North, C Hall, and South buildings will be open from 10 a.m. to 6 p.m.

What are the benefits in attending IMTS?Technology is literally changing daily in the manufacturing world. What wasn’t possible yesterday, now is. The exhibitors at IMTS can show you their latest and greatest products from small packaging supplies and techniques to the largest of machine tools.

Some of the reasons to go to the show may not be as obvious as just seeing new machines and services. You might consider the following:• Finalizing a purchase of a machine or service right there at the

show. Many, if not all, of the vendors will attempt to close an open proposal by offering, “show pricing.” This could involve price or freight discounts or even offering to sell machines right off the floor of the show to relieve them from shipping it back to their offices or showrooms.

• Initiate a machine or service purchase by engaging the companies in person to show you are serious about a purchase by coming to their booth instead of just requesting information online.

How long should attendees plan for the show?The show is six days long, and you could spend that entire time walking the show to see everything.

I’d suggest that you narrow your search to a short list of needs. On the show website, there is a planner where you can search for vendors you know and/or search for products by type. Using this planner, you can develop a list of booths and therefore reduce your time walking. I suggest you bring a very comfortable pair of shoes to wear. Your feet will be happier at the end of the day. And food is available at the show.

As for hotel rooms, many of the choice hotels are booked and have been for a long time. However, you should check on the IMTS website when you register and book rooms you’ll need. Taxis are available and provide easy access to the show, hotels, Chicago-area restaurants, and other attractions.

What gear-related machines and services will be exhibited?The show is organized into pavilions based on themes. The Gear Generation pavilion is located in the North Building, Hall B. In looking at the list of exhibitors in this pavilion, you’ll be able to talk with and see most if not all of the major gear machine manufacturers as well as support services. While many of these exhibitors were at Gear Expo 2015, there are some from other countries that will be in Chicago that were not in Detroit.

What tips do you have for attending IMTS?I think it is important to go to a show like IMTS with an open mind and explore technology and systems that may not be what you are cur-rently using. Also, you may want to look at support items or technology that adds to or automates a process that is causing you bottlenecks.

Perhaps you’ve thought of looking for a different way of packag-ing your products for transportation to and from vendors or to your customers. Robotics, ERP, and other software technology will be there on display for you to take a look and start your process to pur-chase these items. Remember, if you are not advancing the way you are producing a product, your competitors will be. While these new technologies may not be inexpensive (some are though), you must find a way to continually improve your process. I recall that during one of my company’s trips to IMTS, we were in desperate need of a drill sharpener and looked around until we found one that frankly was very affordable yet solved a pain-in-the-neck problem.

If you are planning on closing a deal at the show, let your sales-person know you are planning on going to the show, arrange an appointment, and bring a purchase order or PO number. Nothing motivates a salesperson like a PO and telling them you are going to place it with a vendor at this show.

In short, check out the IMTS site for more info, wear a comfortable pair of shoes, and prepare to be amazed.

FOR MORE INFORMATION, go to topgunconsulting.com


http://topgunconsulting.com

We’re Adding StrengthTo Our Sales and Marketing

As a world leader in the production of high-precision gears, with a new high volume production facility, we’ve never been in better shape. But we need a Manager of Sales to make us even stronger.

Good fit?eMail your resume in confidence to:[email protected]

volume production facility, we’ve never been in better shape. But we need a Manager of Sales to make us even stronger.

eMail your resume in confidence to:

11715 Main Street, Roscoe, IL 61073815-623-2168


The Game-Changing Mitsubishi GE Series CNC Gear Hobbing Machines.A quick glance at Mitsubishi’s GE Series Gear hobbing machine doesn’t reveal the truth behind it’s real power. However, when you evaluate the output the full picture is dramatic and clear. With an all new, utlra-effi cient dry cutting design, the GE series machines produce gears up to 50% faster than previous technologies—with all the precision your specifi cations demand. This kind of boost in productivity is sure to help you be more competitive in the marketplace and pump up your profi ts. Experience the world-class performance of the GE series hobbing machines at www.mitsubishigearcenter.com or contact sales at 248-669-6136.GEseries

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