Rev I Stage Ards

MAY
2013
Cutting Tools
Advanced Coating New Manufacturing
Technology Technologies
Benefitting Gleason
Repurposing Machine Tools

Delivering Big Gears Fast
The Gear Research Institute:
Removing Risk from Gear Design
TECHNICAL
OPTIMIZING HIGH-SPEED, NON-

LUBRICATED LOW-CONTACT-
PRESSURE SPUR GEARS
LIGHT-WEIGHT ASSEMBLED GEARS:
GREEN DESIGN SOLUTION FOR
PASSENGER AND COMMERCIAL
VEHICLES
HYBRID GEAR PRELIMINARY
RESULTSAPPLICATION OF
COMPOSITES TO DYNAMIC
MECHANICAL COMPONENTS
ASK THE EXPERT:
PRESSURE ANGLE/OPERATING PRESSURE
www.geartechnology.com ANGLE WHATS THE DIFFERENCE?
THE JOURNAL OF GEAR MANUFACTURING

Solutions for all
your gear cutting
tool needs
Gear cutting tools and services Total tool life cycle management
Star SU offers a wide variety of gear cutting tools Control your tool costs and let Star SU manage your
and services, including: tool room. From new tools to design work to re-
Gear hobs sharpening and recoating, we have the equipment and
Milling cutters resources to help keep your gear cutting operation
Shaper cutters running smoothly.
Shaving cutters
Chamfer and deburring tools
Rack and saw cutters
Master gears
Ring and plug gauges
Advanced coatings including Alcrona Pro
Tool re-sharpening
Phone: 847-649-1450
5200 Prairie Stone Pkwy. Ste. 100 Hoffman Estates IL 60192
Affordable hob sharpening and
in-house tool maintenance
Stars PTG-1 sharpens both straight and spiral gash hob designs
PTG-1 up to 8 OD x 10 OAL. Additionally, it sharpens disk, shank and
helical type shaper cutters and a wide range of round tools,
making it a versatile tool room machine.
Shaving cutter and master gear grinding

Designed to grind shaving cutters and master gears, the GS 400
sets new standards for precision, reliability and ease of use. An
integrated measuring unit automatically checks the quality of the
GS 400 rst tooth ground without unclamping the workpiece.
www.star-su.com
contents
MAY
52 2013
28
features
22 Heavy-Duty Demands
Cutting-edge coatings cut to the quick.
28 Reinventing Cutting Tool Production

at Gleason technical
Gleasons new in-line process for gear cutters
and hobs pays dividends for all. 56 Ask the Expert: Pressure Angle vs.
Operating Pressure Angle
32 Delivering Big GearsFast Whats the difference?
A customer needed custom gears delivered 60 Gear Design Optimization for Low-Contact
in three weeks; heres how Brevini Wind got Temperature of a High-Speed, Non-
it done. Lubricated Spur Gear Pair
Design optimization to reduce tooth contact
temperature/noise excitation of high-speed spur
36 Job Shop Lean gear pair without lubricant.
The Tiger Team hear them roar.
64 Light-Weight Assembled Gears: Green
46 If You (Re)build It, They Will Buy It Design Solution for Passenger and
Commercial Vehicles
Retrofit, re-control, re-build, re-manufacture: Light-weight gear design and manufacture to help
Its all good. comply with imminent CO2 mandates.
52 Gear Research Institute: A Big Part of 72 Hybrid Gear Preliminary Results

Application of Composites to Dynamic
Small World of U.S. Gear Research Mechanical Components
Research lab soldiers on in good times NASA Glenn hybrid design may have dramatic
and bad. effect on drive system weight without
sacrificing strength.
Vol.30, No.3 GEAR TECHNOLOGY, The Journal of Gear Manufacturing (ISSN 0743-6858) is published monthly, except in February, April, July and December by Randall Publications LLC, 1840 Jarvis Avenue, Elk Grove Vil-
lage, IL 60007, (847) 437-6604. Cover price $7.00 U.S. Periodical postage paid at Arlington Heights, IL, and at additional mailing office (USPS No. 749-290). Randall Publications makes every effort to ensure that the processes
described in GEAR TECHNOLOGY conform to sound engineering practice. Neither the authors nor the publisher can be held responsible for injuries sustained while following the procedures described. Postmaster: Send
address changes to GEAR TECHNOLOGY, The Journal of Gear Manufacturing, 1840 Jarvis Avenue, Elk Grove Village, IL, 60007. Contents copyrighted 2013 by RANDALL PUBLICATIONS LLC. No part of this publication may
be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the publisher.
Contents of ads are subject to Publishers approval. Canadian Agreement No. 40038760.
2 GEAR TECHNOLOGY|May 2013

[www.geartechnology.com]
For 87 years Twin Disc has been devel-
oping, engineering, manufacturing and
distributing power transmission products
that make things work. Find out more at:
www.twindisc.com.
The NILES ZX 1000 is operator friendly; easy to set-up, program and run. It has given Twin Disc a consider-
able cost savings through shortened set-up and machining times, and is versatile enough to take on many
custom grinding projects. The ZX 1000 gives us closer tolerances in the precision grinding thats required
to maintain the high quality machining that Twin Disc is known for worldwide. Germany has a good support
team that works closely with us for problem solving. We would recommend the NILES ZX machine to any
company wanting to stay competitive in todays market.
Guy Clementi, Wayne Turek
Twin Disc, Inc.
Customers Say it Best.
KAPP Technologies
2870 Wilderness Place Boulder, CO 80301
Phone: (303) 447-1130 Fax: (303) 447-1131 www.kapp-niles.com [email protected]
contents
SDP ISO9001
R E G I S T E R E D
ISO9001 AS9100
SI REGISTERED
Stock Drive Products / Sterling Instrument
Vol.30, No.3
Quality without compromise!

Precision Gear ManufacturinG
departments
For 50 years Sterling Instrument,
ISO 9001 and AS9100 Registered, has
been designing and manufacturing 06 GT Extras
precision gears and assemblies for defense This-that-and-more
and aerospace applications. Our in-house
capabilities include, but are not limited to,
planetary gearheads, differentials, worm
09 Publishers Page
drives, spur gears, and racks. Coordinating Efforts
Your success is our business;
call todaY! 10 Letters
Battle of the big gears continues: Our readers
have their say
12 Product News
Newest hardware, software, etc.
80 Industry News
Wenzel America Partners with Liebherr Gear
Technology
84 Calendar
Stock Drive Products | Sterling Instrument May 22May 23: AGMA Marketing and
2101 Jericho Turnpike, New Hyde Park, NY 11040
Phone: (800) 819-8900 (516) 328-3300 - Fax: (516) 326-8827
Forecasting Conference
Email: [email protected] - www.sdp-si.com June 36: Gleason Cutting Tools Gear School
Fundamentals
85 Subscriptions
SET4b-Precision Gear Manufacturing.indd 1 4/16/13 8:50 AM
Sign up or renew; its free!
BOBBING FOR BITS OF INFO 86 Advertiser Index
to improve your aging gear-cutting equipment?
Every advertiser in this issue
87 Classifieds
Our products and services marketplace
88 Back-To-Basics
Hardness Scales
Bobbers, bucktails, and shumway seem the same, but an

avid angler knows the slightest difference to entice the
cleverest musky. The same is true in rebuilding. Under-
standing what components are kept and replaced is the
difference of 20 reliable years in production versus a
broken down machine. When youre bobbing for facts,
talk to the gear experts at MTB.
MAY
MTB offers meticulous and quality craftsmanship in 2013

rebuilding and recontrolling gear shapers, hobbers and Cutting Tools
grinders. Advanced Coating
Technology
New Manufacturing
Technologies
Benefitting Gleason
Repurposing Machine Tools

The Gear Research Institute:
Removing Risk from Gear Design
TECHNICAL
OPTIMIZING HIGH-SPEED, NON-

LUBRICATED LOW-CONTACT-
PRESSURE SPUR GEARS
LIGHT-WEIGHT ASSEMBLED GEARS:
GREEN DESIGN SOLUTION FOR
PASSENGER AND COMMERCIAL
VEHICLES
HYBRID GEAR PRELIMINARY
RESULTSAPPLICATION OF
COMPOSITES TO DYNAMIC
MECHANICAL COMPONENTS
ASK THE EXPERT:
PRESSURE ANGLE/OPERATING PRESSURE
Call MTB: 815.636.7502 or visit www.machinetoolbuilders.com

www.geartechnology.com ANGLE WHATS THE DIFFERENCE?
THE JOURNAL OF GEAR MANUFACTURING

Cover Photo courtesy of Sulzer

Precise and productive.
Profile grinding machines LFG 800 - 1250 from Liebherr.
With the new LFG product line a series of machines is now available for hard finishing of gears from
800 1250
250 mm diameter, that is characterized by their productivity and versatility.
Profile-grinding of external- and internal gears
Dressable- and Non-dressable profile grinding discs
NC coolant nozzle for optimum cooling
Sync-Dresser for reduced dressing time
Optional ring loader automation
Modern operator interface / HMI
Liebherr Gear Technology, Inc.

1465 Woodland Drive
Saline, Michigan 48176-1259
Phone.: +1 734 429 72 25
E-mail: [email protected]
www.liebherr.com
The Group
2014-003 Umbau Profilschleifen_216x279_GB.indd 1 22.03.13 14:2

GT extras
THE GEAR INDUSTRYS INFORMATION SOURCE
www.geartechnology.com
Randall Publications LLC

1840 Jarvis Avenue
GT VIDEOS Elk Grove Village, IL 60007
The GT website currently features a video on (847) 437-6604
DMG/Mori Seikis gear milling capabilities. Fax: (847) 437-6618
Gear-milling operations have remained virtually
unchanged for decadesoften requiring
slow, tedious processes, expensive equipment Editorial
and time-consuming setups. DMG/Mori Seiki Publisher & Editor-in-Chief
USA and its partners are shaking things up Michael Goldstein
with creative cutting strategies, standard, [email protected]
multipurpose milling machines, and off-the-
shelf tooling. Associate Publisher & Managing Editor
Randy Stott
To browse the archive visit: www.geartechnology.com/issues
[email protected]
Senior Editor
Jack McGuinn
E-Newsletter [email protected]
Upcoming E-News topics for Gear Technology include the following:
Senior Editor
June Raw Materials Matthew Jaster
July Gear Education and Training [email protected]
August EMO pre-show coverage Editorial Consultant
Contact [email protected] with editorial ideas. Paul R. Goldstein
Technical Editors
William (Bill) Bradley
Robert Errichello
Octave Labath, P.E.
Joseph Mihelick
Kapp-Niles Rocky Mountain Gear Charles D. Schultz, P.E.
Finishing School: This cant miss Robert E. Smith
event will be held October 1618 in
Boulder, Colorado and is designed for design
both classroom and shop floor lessons. Art Director
Visit www.kapp-usa.com or check our David Ropinski
technical calendar for more information. [email protected]
ADVERTISING
Associate Publisher
& Advertising Sales Manager
Brian Langenberg, CFA and PTE con- Dave Friedman
tributor, will occasionally share market [email protected]
information within our social media net- Materials Coordinator
works. Check our GT and PTE LinkedIn Dorothy Fiandaca
Groups as he monitors global insights to [email protected]
support your business (www.langenberg- CIRCULATION
LLC.com). Circulation Manager
Carol Tratar
Stay Connected [email protected]
Ask the Expert
Follow us on Twitter RANDALLSTAFF
Do you have a question about gear twitter.com/#!/Gear_Technology President
design, manufacturing, heat treating, Michael Goldstein
inspection or assembly? Submit your Accounting
questions to our panel of experts at: www. Luann Harrold
Connect with us on LinkedIn
geartechnology.com/asktheexpert.php www.linkedin.com/groups/Gear-
Technology-Magazine-3893880
Subscribe Online
www.geartechnology.com/
subscribe.htm

Hunting For
High Quality Gears?
Forest City Gear Leads the Way
US Navy MH-60S Seahawk helicopters patrolling for mines out ahead of surface vessels use a
powerful and precise Carriage Stream Tow and Recovery System (CSTRS) to quickly raise and
lower mine-hunting and destruction equipment. Very high-precision gears from Forest City Gear
help to ensure that the mission goes as planned. In this and many other aerospace and defense
applications, Forest City Gear is helping customers meet their gear challenges no matter how
difficult to detect.
Dont let gear challenges go undetected.

Visit www.forestcitygear.com.
11715 Main Street, Roscoe, IL 61073

815-623-2168
Our Technologies, Your Tommorow
The Advantage
of Supreme
Productivity
The Game-Changing Mitsubishi GE Series

CNC Gear Hobbing Machines.
A quick glance at Mitsubishis GE Series Gear hobbing machine doesnt
reveal the truth behind its real power. However, when you evaluate the
output the full picture is dramatic and clear. With an all new, utlra-efcient
dry cutting design, the GE series machines produce gears up to 50% faster
than previous technologieswith all the precision your specications
demand. This kind of boost in productivity is sure to help you be more
competitive in the marketplace and pump up your prots. Experience
GE20A
GEseries
the world-class performance of the GE series hobbing machines at
www.mitsubishigearcenter.com or contact sales at 248-669-6136.
publisher's page
Coordinating Efforts
Like many Americans, Ive been trained with the
idea that those who see a problem should be the
ones responsible for helping to solve it. If you see
that something is broken, and you know how to fix it, dont wait
for your dad, your boss or the government to tell you what to
do. Just fix it.
Publisher & Editor-in-Chief
Unfortunately, the bigger or more pervasive the problem, the
Michael Goldstein
more difficult it is for an individual or small group to fix it. No
amount of gung-ho attitude and determination can solve it.
One such problem is the public perception of what takes place cational program geared specifically towards manufacturing
in a factory. Students, parents and advisors often think that man- careers. In fact, this individual has pledged that anyone who
ufacturing operations are dark, dirty and dangerousand that completes the program at this community college is guaranteed
working in a factory is a good way to come home with fewer job placement at his company.
than 10 fingers. They think manufacturing requires more brawn A number of others indicated a strong interest in meeting with
than brains. In truth, manufacturing today offers a clean, bright Congressman Schneider and exploring ways they could help.
workplace that requires a solid education in math and science. Interestingly, nobody asked what political party
Manufacturing is an interesting and challenging vocation that Congressman Schneider belongs to. They only saw a leader
offers enormous opportunities. Just ask any of those gray-haired who was interested in their problems, and theyre willing to
old men who are currently working in manufacturing. work to help him better understand their needs and concerns.
But ask them soon, because if you wait much longer, theyll Nobody saw this as a Democratic problem or a Republican
all be gone. problem. They all saw it as an American problem.
Too many workers are getting near the end of their careers. And its not just in the 10th District of Illinois that people are
But even though manufacturing has been one of our economys doing something. I also recently spoke with a gear manufac-
bright spots, between 600,000 and 800,000 manufacturing jobs turer in Ohio, who told me that he belongs to an Ohio-based
remain unfilled in the United States. If we dont solve manu- manufacturing association whose goals are to tackle many
facturings image problemand get bright young people inter- of the same problems identified by CAM and Congressman
ested in itAmerica may lose a lot of very important expertise. Schneider. Clearly, all across America, various individuals and
Its well past time that we reinforce the idea that a strong groups are working toward common goals.
manufacturing base is essential to a productive economy and But it occurs to me that if were all interested in solving the
strategically vital to our nations welfare. same problems, we should be working together, rather than
Many of you are aware that I serve on the board of directors independently. We should know what other groups and indi-
of Citizens for American Manufacturing (CAM). The nonprofit viduals are doing, so we arent duplicating efforts. Ive got to
group was founded by Joe Arvin, president of Arrow Gear. Joe believe that with the few phone calls I made, Ive only scratched
has written extensively on the importance of manufacturing to the surface. Many of you are probably involved with local asso-
the welfare of our nation. Were a group that banded together ciations, manufacturing groups and educational institutions.
because we saw some problems, and we wanted to be part of Youve probably got programs in place that others would benefit
the solution. from learning about.
Recently, CAM board members met with newly elected And perhaps this is what CAMs role should be: coordinating
Representative Brad Schneider from the 10th Congressional efforts.
District in Illinois. Congressman Schneider also happens to be So Im asking you, our readers. Are these topics of interest
an industrial engineer. As it turns out, he and his staff under- to you? Do you think theyre important? More to the point, are
stand these problems and are interested in solving them, too. you involved in solving these problems, or are you aware of oth-
In order to learn more about specific manufacturers needs, ers near you who are doing so? If so, tell me at publisher@geart-
he asked me to recommend manufacturing companies in his echnology.com about your group. Give me your web address.
district that would be good candidates for him to visit. Give me a leaders name so we can contact them, so I can help
So I called a number of gear manufacturers in the area, to CAM build a network of like-minded groups and individu-
talk about the things that we, as Americans, should be doing to als. Lets make this a coordinated national effort rather than a
solve the problems we see. collection of local efforts, and lets also present a loud voice to
Those I talked were more than just receptive to the idea of Congressman Schneider and other like-minded leaders.
problem-sharing. In many cases, they were also taking action,
working with local associations, educational institutions and
government agencies.
For example, one manufacturer I talked to works very closely
with a local community college, in order to develop an edu-
May 2013|GEAR TECHNOLOGY 9

letters featur
e
MY GEA
Ri s Bigger t
Industry han YOU
M
Battles i
t Out fo
r Worlds
R
a tt
Feedback: My Gear Is Biggerethan
h w Your Gear Jaster, Largest
I read your article My Gear is Bigger than Your Gear Sen inio r Editor
the Gear T
March/April issue. I worked in engineering at Philadelphia Gear MAR/APR
I n 2 0 0 9we built the drive sys-
2013
at
,
re
from 1963 until 1984. In the mid-1960s s
T
c
t
i entists a
Hea
tems for the JPL/NASA 210 ft. radio
Institutelescope.
te of MaI tremember t the
a n d erials Rethe delivered
2013
azimuth drive gear was approx. 80 ft. in in E n g e e r in g[24
diameter s
meters].earch in 20
d e v e lo , S in g a ti on in Arm 08 for a mining op
The two elevation gears were sectors of 110 p e d atow120 orkin p
degrees with o r e , enia. (A g era- worlds LA
s iz e d g e ar thave g m o le c u la
more than
6 5
ear that w
e ig h R G E ST
a radius of approximately 37.5 ft. The gears
c o h a a smooth
t could b track r- lbs] b oast
,0 00 k ilo g rams [143,3 e d a nyone talk
n
on the inner diameter of the gear rims. dt r o ll e , rodrive
The e f ully mm e d 3 0 0 ,3 e d to G
w is e tatinreducers
g bothhave fa
62 teeth,
0.75 DP, 8 0
a floating mount system so that the drives a n d coufollow
nter-the c lo
and ck- c e w id th 6 3 .6
w s made clocgears
kwgears. m diamete , 12.4 m O
tting D and a 10.5
Opening a
are not affected by the largeathermal pgrowth
ossible bof the
y nudging big ise. This Au to
Brown hSin
mortiv boereGe ). A t thcat time, T he worlds
HUGE
with the p th a d ce
c la rel y Plasti D a v la rgest
The gears were precision form cut in segments ro be of a scof about 10 ft.geare im ed the size id spot for so
microscop anning, tu Not to ta
ars Ar e Big ger record. m e manu
of circumference and assembled at the A e . construction
ccording to site. Thereling n n e My Ge k e a
Book of W th e eng ine ersthan Yonur ythGe ingars away from tions. It ca
n b e
were three systems built that I believe are o rld still
Recorunning. G u in
The first essn a n d scientists : th e c ome
working ge rds, it is th but lookin GearLabin Singap ore subject pa
is at Goldstone in Mojave, California. in a r The e sm a TH E gOSa t U
a rt ic u la rly i
theother
worldtwo .
are nearllest a mSti icro king a Joy moful
lecNoulaise
r gear th , from c om
In an attem ll Ma TECHNICAL
Madrid, Spain and in Australia. I have pbeen atctwo of the sites, sc o p e is nt nearly ro u g h
HEAT p e ti n g fi r
ge ar in th t to lo ate th as seeing as im
ION
INNOVATION UPDATEtopic.
IND UCT
This was b
but not the one in Australia. That one G e inuAustralia e L A R G E a G IG p re ss iv e ro
in n e ss B owas the sub-ST ANTIC pie NO SWEAT! u
TRE AT AUDIT?
R e c ords , o k of Wo getting th
HEA
ce DUA
T
SM E me e
ject of a movie for the general publicth 10isyears ago or so. rl e job done of L-CL
meUTCta lH GEARBOX ti n g , s ay
sho . The a u th o r fe ll in d o r a sugar in a coppPRO FT OPT IMALLY m a rk e ti ng m an s
You can see the elevationrtgear
SHA
inrethe
s nopictures c r e d ib ly
at: http://wiki- mill. Its tr er CES
min SED
e a ge r,
mention a b o ue what th ASK THE EXPERT: ReKxno
p le , s o m e of, for exam- u t e n gineering e y sa rd. Some
comp
MULTI-TAS
of R e x no
mapia.org/472151/Goldstone-DSS-14-Mars-Station. Size does m and manu PINION
WOR KHOL
y
DING
play the ca
LARGE SKEW BEVEL
rd /Fa lks
HININ G:
girth gears
MAC
or the sing mHaas

in in g atter. facturing: pabilities o
Leonard
le-helical S So why can
www.geartechnology.com
THE JOURNAL OF GEARor ass
MAN UFAC TURI NG
ume that th f
girth gear AG mill t an intere
from DaConsulting
vid Brown Engineer g st th e ey ha
(England) eek find a ed enginee b est equipm
ny inform ring rese arch. e nt w i
ation toda Theres a
I enjoyed your article My Gear is Bigger than Your Gear today y on the lot
tion out th
ere so its n
and felt compelled to e-mail you. We are a machine shop in straight. ice
Rockford, Illinois and back in December my father and I were For Related Articles Search
in Germany to see the runoff of the last of three large machining
centers we ordered for our company in the town of Chemnitz. big gears
On our way back West to Frankfurt we had an open invitation to at www.geartechnology.com
stop and visit the Waldrich Coburg plant in Coburg, Germany,

where they build very large portal milling machines and verti-
cal turning lathes. On our tour in the last assembly bay was the
machine you mentioned for van der Wegen. We were able to
stand on its rotary table and witness the sizeabsolutely gigan-
ticand a photo really doesnt do it justice. The machine is a
gantry portal machine where the columns move across a station-
ary table to do milling work and then over the turning table that
is pictured to turn and cut gears on the same table. We were told
that Waldrich designed a special head to perform the gear cut-
ting work. If I recall correctly the turning table is in the neigh-
borhood of 910 meters diameter and the distance between col-
umns was 13 meters; this is the widest machine that Waldrich
Coburg has ever built. What is unique and what you pointed out
in the article is that, because the columns can move and back off
the turning table, this machine can cut up to a 17 meter diam-
eter gear.
Eric Anderberg
Dial Machine, Inc.
2902 Eastrock Drive
Rockford, IL 61109
Hofmann E
n
of 13.2 mete gineering recently sh
rs and weig ip
hing 73.5 to ped a gear boasting
nnes. an outs ide diamete
r
GE
Stronger Longer Lasting Gears
AR Reliable Precise Efficient Innovative
Title
T ge ar an d
why hasnt
Guinness a
bout it?
E Can of W
orms
gear is kin
d of a sore
ufacturing
organiza-
a rather co
ntentious
if you get
engineers
r ms d is c u
ss ing th e
ught up at
a recent
s Wil li a m
R h o d y,
m il l pro d
u c ts at
panies wil
l down-
their comp
eti
ave the big tors
gest or
ithout doin
g the
of misinfo
rma -
to set the re
cord
Inductoheat caters to your induction heating needs:
Process development
Just like gears, induction heating is all about
Single part process monitoring
precision. Inductoheats precision controlled, induction Metallurgical analysis
gear hardening systems provide ideal metallurgical Single-shot, scanning, tooth by tooth
patterns, minimum shape distortion, increased wear Single-coil dual-frequency technology
resistance and exceptional contact fatigue Strength. Wide range of gear & bearing diameters
Inductoheat, Inc. Madison Heights, MI (248) 585-9393

Visit us at Heat Treat 2013 & Gear Expo - Booth #1701 www.inductoheat.com

product news
Liebherr
LFG Grinding Machine Offers Precision and Productivity
This machine concept facilitates high- importance, the LFG relies greatly on the avoid tooth flank twist or intentionally
ly productive profile grinding for permanently active swivel axis for pro- produce it in compliance with the nar-
large workpieces. The range for exter- file grinding. Traditionally, the swivel rowest of tolerances.
nal and internal gears comprises mod- axis was a set-up axis that was pivoted
els for manufacturing workpieces up to and clamped for grinding purposes. The Topological Modifications
2,000 millimeters for industrial gear grinding head for producing internal Certainly the opportunities that the
units, wind power, and marine propul- gears is mounted over the outer grinding 5-axes create with respect to twist are
sion applications. Specific and controlled head. No contact is made with the outer limited by mathematics. Additional
handling of twist in profile grinding grinding head. Only the grinding disk clearance allows for precision topologi-
solves production-related problems, and must be removed. The dressing process cal grinding. The division of the topog-
simultaneously opens new gear man- for the internal grinding disks is consec- raphy into multiple strip-shaped areas
ufacturing doors. Various other solu- utive, with the aid of the shift axis. and corresponding processing with mul-
tions are available on the market for tiple strokes provide a multitude of spe-
dealing with twist problems. Liebherr Twist Problems under Control cific options, for example, for prototype
now introduces the five-axis LFG series Crowning could only be performed via development or academic applications.
profile grinding machines, with a novel the X-axis in conventional grinding The operator no longer has to concen-
machine design approach for twist-free machines. Twist, however, occurs when trate on fH and C corrections, but rath-
profile grinding (or, if needed, the man- this type of crowning is employed in er can target individual points for pro-
ufacture of specific twist designs) for profile-grinding. The result is an altered cessing.
single- and double-flank grinding. profile angle over the entire face width.
The problem of twist due to this crown- Removal-Optimized Grinding
Five Axes for Ultimate Precision ing method has played a rather minor through 5-Axis Infeeding
The machining concept works with role in gear manufacturing development The figure shows how, during radial
five axes. LFG does not require a dress- for quite some time. infeeding, the removed material near
ing axis, which rules out one potential Minimizing twist is one thing, the tooth head is greatest at three infeeds
source of inaccuracy. Another difference incorporating specific twist designs is during the final strokes. The workpiece
to comparable machines is the inversion yet another. LFG series machines can is subjected to unnecessarily high loads
of the shift and swivel axes. The mechan- grind anything required, explains Dr. as a result of variable grinding steps.
ical limitation that results from the pro- Hansjrg Geiser, manager de-velopment Micro-structure damage occurs fre-
cess of first swivel, then shift is over- and design gear cutting machines at quently.
come as a result. This special arrange- Liebherr-Verzahntechnik. Five-axis infeeding produces a (as far
ment allows for the dimensioning of The axes of the LFG facilitate addi- as possible) constant allowance distribu-
shift travel to be much larger than usual. tional movements and generate the tion over the course of the s t r o k e s .
The machines directly-driven table, opportunity to create the desired degree The pr incip a l
featuring a highly dynamic wear-free of crowning and prevent
torque motor, also delivers high preci- twists, even if double-flank
sion throughout the machines lifetime. grinding is involved, by
It is a key component in allowing the overlapping the axis move-
machine to single- or double-flank grind ments. By using the V, C
precision- and custom-topographic an d A- a xe s
tooth flanks. in addition
to theand
Simultaneous Dressing Shortens Y-axes, the
Cycle Times profile angle
Because the machine also uses the shift can be mod-
and swivel axes to dress the grinding ified and the
disks, the dressing axis can be elimi- twist prob-
nated. The basic LFG models grind- lem can be
ing disk is dressed by a single dresser solved for
in combination with the shift and swiv- both single-
el axes. The Syncdress design provides and double-
two dressing rolls that dress simultane- flank grind-
ously left and right and greatly reduce ing. In this way the
dressing time. As a result of its increased operator can completely

There is additional potential for inac- duction machine, and specifically this
curacy when a machine radially retracts 5-axis LFG.
and extends its stylus. The sensitivity is For more information:
considerably lower and, accordingly, the Liebherr Gear Technology
results more accurate when retracting Phone: (734) 429-7225
[email protected]
laterally (shifting). There is a lot to be www.liebherr.com
said for the precise measuring methods
that can be achieved right on the pro-
material for this wear-optimized grind-

ing is no longer left to wear-out on the
tip; as a result the risk of grinder-burn is
minimized, and the workpiece is protect-
ed. Number of strokes and production
time can be reduced as a result, depend-
ing on application.
The different involute gear profiles
(pinion/planet/cylindrical) show the dis-
tinction between the three tested gears,
which lies primarily in the curvature in
the involute gear profiles. Thus in the
case of a pinion with maximum curvature
the maximum benefit can be derived by
using the 5-axis infeed method.
The number of infeed steps is reduced
from 15 to 9 as a result of the 5-axis
infeed. The curvature of the spur gear
is small (due to the number of teeth,
among other things) and, therefore, the
savings in infeed steps is smaller (9 to 8).
Production Controls Profit from

Large Shift Travel
The measuring sensor swivels laterally
along the grinding disk. It uses the large
shift travel (300 millimeters) and, like
a dedicated measuring machine, mea-
sures the gear. This leads to an addition-
al acceleration of the process. Table rota-
tion and radial infeed are not required
for measuring, which contributes to
additional precision of the measurement
results.
With calibration in mind, conven-
tional methods of measurements usually
focus on a very sensitive fH profile angle.

product news
KISSsoft in the 3-D system, ensuring maximum

clarity. This provides a powerful analysis
tool for the planet system.
Releases 03/2013 Software
New dimensioning suggestions are now
KISSsoft is a modular calculation system The contact analysis has been greatly calculated for modifications, especially
for the verification, optimization and extended for planetary gear units. It is for planetary gear units. This ensures that
sizing of machine elements. The scope now possible to take into account the tooth trace modifications can be specified
of the application ranges from a single exact deflections of the shafts on the accurately, on the basis of the planet car-
machine element up to the automatic sun wheel, planet gear and internal gear. rier torsion and sun wheel deformation.
sizing of complete gearboxes. KISSsoft The planet carrier position is also deter- The contact analysis for cylindrical gears
Release 03/2013 once again contains a mined during a shaft calculation, or can has also been extended and improved.
wide range of new functions, including alternatively be specified as a displace- Experience gained following a comparison
the following highlights: ment. The results are finally displayed between various different commercial con-
tact analysis programs, carried out in fall
2012, has also left its mark on the calcula-
tion. For example, additional correction
Why
factors (including one for Hertzian flat-
tening) have been implemented, providing
the user with even more detailed setting
options. Of course, as you would expect,
HAINBUCH? appropriate standard values are also set
where suitable.
Thanks to improvements in calcu-
lation algorithms, the cylindrical gear
contact analysis is now faster and more
robust, and so enables the contact pat-
tern for cylindrical gears to be analyzed
more accurately.
Another highlight is the extended set-
ting and evaluation options for optimiz-
ing modifications for cylindrical and
planet gears. A new feature is that the
face load factor KH can now also be cal-
culated. This therefore reveals the direct
influence of the tooth trace modification
on the safeties of the classic tooth root
and flank load capacities.Some new fea-
tures have also been added to the plas-
Because Modular is Standard

Changing over from O.D. clamping to I.D. clamping without
disassembling the base clamping device is done in a matter
of 2 minutes with the HAINBUCH modular system.
With MANDO Adapt, just place the mandrel in the mounted
clamping device. Its a great time-savings solution, not to
mention that MANDO Adapt is extremely rigid and precise.
And best of all, its standard.
1.800.281.5734
Germantown, WI USA
www.hainbuchamerica.com

tics calculations. The draft of the new life situations. For example, you can cre- up. The new KISSsys Gear Unit Assistant
VDI guideline 2736 is especially worthy ate rules which check specified param- guides users through the process for
of mention. After many years work, with eters before and after the calculation and generating models of planetary gears
contributions from KISSsoft, this guide- output messages if required. 3-D models step by step. After the relevant kinemat-
line has now been released in draft form can now also be generated via a COM ics have been defined, the bevel gear and
and so is also available in KISSsoft. interface. worm wheel stages can now be rough
Freely configurable manufactur- Finally, the current release includes a sized directly in KISSsys.
ing drawings have now also been made completely restructured user interface For more information:
available for all cylindrical gears. The for KISSsys: the most commonly used KISSsoft USA LLC
toothing data and a range of different elements are now available as icons. To Phone: (815) 363-8823
[email protected]
graphics such as flank modifications, generate a model, a user can simply drag www.kisssoft.ch
etc. can now be displayed as graphics, and drop icons to add elements directly
output to screen or paper, and sent to the to the diagram window and link them
gear manufacturer.
Fine sizing functions have been added
to the worm gear and spiral toothed gear
wheel calculations. You can now vary the
macro geometry within specific rang-
es and select the best possible solution.
These modules, along with the cylindri-
cal and bevel gears, now cover the siz-
ing options for any tooth type. This lat-
est functionality can be viewed in the
shaft editor: Shafts and bearings are now
displayed with shadowing (optional).
Bearings are displayed according to their
attainable service life. The new versions
of the DIN 743 shaft calculation analy-
ses and the FKM Guideline (6th edition)
are also implemented in the 03/2013
KISSsoft release.
As before, the CAD interfaces are
designed to reflect the very latest version
of each particular CAD system. In addi-
tion to the calculations for machine ele-
ments, there are now additional software
features which make KISSsoft even more
powerful and effective in handling real

product news
EMAG
Offers Hard Turning and Grinding Advantages
The advantages of the process combi- can be drastically reduced. There are
nation hard turning + grinding lie in also benefits to be had in the reduction
process stream consolidation, improved of time and effort spent on setting up the
component quality and greater flexibil- machine.
ity. But process combinations can also An important requirement for com-
be used to great effect for the shorten- bination machines is the unhindered
ing of cycle times. Where all the hard fall of the turning and grinding chips.
fine-machining operations can be car- The VLC 250 DS with its vertical work
ried out on a single machine, through- spindle and its tools positioned below
put, transport times and storage periods the workpiece offers the best possible
chip flow condi-

tions. All machine modules
are mechanically sturdy and
particularly vibration resistant.
This is augmented by the machine base
in Mineralit polymer concrete, with its
great vibration damping properties, and
by the design of the work spindle, which
forms an integral part of a sturdy quill
that carries out its Z-axis movement in
a high-precision, hydrostatic guideway
also a design particularity that has a
highly effective vibration damping effect.
The tooling systems are firm-
ly anchored in the machine base and
provide a stable basis for demanding
turning and grinding operations an
important precondition for time-saving
hard pre-turning work and for achieving
the best surface finish with a hard finish-
turning or grinding operation. Number
and design of the stationary tooling sys-
tems can be chosen to suit the individu-
al machining requirement. Continuous
monitoring of the machine tempera-
ture ensures a high degree of thermal
stability. The operating temperature is
quickly reached and maintained within
tight limits of the ambient temperature
by a powerful cooling unit. The pick-up
technique employed on the VLC 250 DS
Turning and Grinding Center ensures
that the machine loads itself. Gantry
loaders or other cost-intensive, space-
devouring loading devices that involve
time-consuming resetting work can
be eliminated.
The VLC 250 DS can handle complex
manufacturing processes. Whether there
is a call for turning work at high chip
removal rates or for the somewhat gen-
tler grinding operation the machine
covers a wide range of applications. The

advantage is tear on the grinding wheel is therefore machine, generate absolutely scroll-
minimal and it needs to be dressed free surfaces.
obvious: com-
only infrequently, and only by a frac- Rear end faces are difficult to reach
plete-machin- tion. This is of considerable advantage with a grinding wheel a problem
ing in a sin- where cycle times are a concern. that is easily solved with hard turning.
gle setup, and The grinding wheel specification can
thus the elimi- be fixed as finishing quality, as only The cross-operational machine design
nation of rec- a very small allowance needs to be provides exceptionally easy access.
lamping errors. removed. This produces process-capa- For more information:
Measuring ble surface finishes in the Rz < 1.2 m EMAG
operations too range. Phone: (248) 477-7440
Unlike hard turning processes, the [email protected]
can be includ- www.emag.com
ed. This would grinding operation will, on the same
ensure opti-
mal integration
of a quality control
function into the
overall process. The
measuring probe
is located between
machining area and pick-
up station, where it is safe
from the ingress of chips and coolant. As
the workpiece remains clamped during
the gauging process, intermediate mea-
surements can also be taken.
A typical example of successful com-
bination machining is the manufacture
of gearwheels. The end face is hard fin-
ish-turned, whilst bore and cone are pre-
turned and then finish-ground to ensure
that the high quality requirements are
met. For this purpose the machine is
equipped with two grinding spindles,
whereby one spindle machines the bores
and the other carries out the external
grinding work. As the amount to be
ground is only a few hundredths of a
millimeter, the grinding wheels need
only be designed for finishing opera-
tions.
The advantages offered by the VLC
250 DS:
Vertical hard turning and finish-
grinding on a single machine and in
one setup
All sectors of the workpiece that can
be turned with process integrity are
hard finish-turned, and only those are
ground (after hard pre-turning) where
quality requirements and process
integrity demand it.
Improved workpiece quality and
higher productivity rates, as the work-
piece is complete-machined in a single
setup, whereby the hard pre-turning
process leaves an allowance of just a
few microns for the subsequent grind-
ing process.
The grinding process needs to remove
only very little material. The wear and

product news
Sandvik Coromant
Offers Cooling Technology Solutions
Accurate targeting of coolant during Sandvik Coromant offers cooling insert geometries and customized tool
machining provides maximum effective- technology solutions through advanced holders feature fixed nozzles that guar-
ness in chip evacuation. However, preci- nozzle technology and dedicated insert antee a precise coolant jet flow accurate-
sion and pressure are two equally impor- geometries for steel, stainless steel ly hitting the center of the cutting zone
tant aspects of coolant. A high preci- and HRSA material for all machin- target.
sion coolant requires lower pressure. The ing applications. The company recent-
higher the pressure, the more demand- ly announced additions to the growing Advanced Nozzle Technology
ing applications can be machined with range of options to apply coolant in the The coolant flows from the pump to the
excellent results. machining process. The range of new tool through nozzles directed exactly at
the cutting zone. This produces a wedge
of coolant that efficiently removes the
heat from the cutting zone and forms
the chip. Improved chip control and lon-
FORGED ger tool life are just two of the benefits

that contribute to secure and predict-
able machining, preventing unplanned
NET and machine stoppages. Increased produc-

tivity can even be achieved in tricky
NEAR-NET applications, and in difficult to machine

materials, regardless of the pressure you
use.
GEARS Low pressure 710 bar (100150 psi)
When using low pressure, the new
Sandvik Coromant CoroTurn HP hold-
ers, with high precision nozzles, outper-
form regular tool holders that can have
a tendency to flood coolant. This makes
Save Time and Money for improved chip control and better
process security in steel and other com-
Dedicated State-of-The-Art mon materials. Substantially higher cut-
Net and Near-Net Gear ting data can also be applied, as well.
Manufacturing Facility
.008 - .060 Stock

Allowance on Gear Flanks
ISO 9001:2008
TS 16949:2009
Presrite Corporation
Phone: (216) 441-5990
www.presrite.com
2 0 1 1 , P r e s r i t e C o r p o r a t i o n

PRS-029 GearAd-GearTech2.indd 1 12/22/11 9:50 AM

7080 bar (1,0001,200 psi) ing to utilize this highly productive cool-
For demanding materials, such as duplex ant solution, even in small lathes.
stainless steel and HRSA material, high- For more information:
er coolant pressures are needed. The Sandvik Coromant US
unique CoroTurn HP nozzle technol- Phone: (800) SANDVIK
[email protected]
ogy in combination with the new-SMC, www.sandvik.coromant.com
-MMC, -PMC insert geometries pro-
vides greater productivity.
150200 bar (2,2002,900 psi)

Few machines provide solutions
for these pressures, however Sandvik
C oromant of fers standard hold-
ers and inserts that allow for up to
275 bar (3,900 psi) of coolant pres-
sure. Coromant Capto clamping units
for high-pressure coolant with 200 bar
(2,900 psi) coolant pressure capability
provide unrivalled performance ensur-
ing that machine utilization is optimized
through reduced set-up and production
time.
Tool holders
The Sandvik Coromant advanced
cooling technology has been a solution
primarily for customers using quick
change with Coromant Capto, SL- and
QS holding system. Now, the same pre-
mium technology can be applied with
general shank tools, making it possible
for everyone working with wet machin-

product news
Gleason Corporation
Installs 10 Meter Capacity Gear Hobber in China
Gleason Corporation recently announced large industrial applications, as well as
the successful installation of a P with several of the worlds leading wind
8000/10000 Gear Hobber at Changzhou turbine manufacturers, producing plan-
Tianshan Heavy Industry Machinery Co. etary gears, sun gears and eccentric gears
Ltd., in Changzhou, China. The machine for wind turbine gearboxes. When asked
has the capacity to produce spur and Why Gleason Jiang Wenge, chairman of
twiCe as big, helical gears up to 10 meters in outside
diameter, and has been fully demonstrat-
Changzou Tianshan said, The efficiency
and accuracy of similar equipment on
just as fast. ed to consistently produce large gears at the market is low, but customer expecta-
DIN 7 quality or better, reducing cut- tions are increasingly high, and the trend
ting times from as much as a week on is to higher and higher accuracies and
older machines to as little as 10 hours. reduced lead times. Gleason-Pfauter has
1-2 weeK Founded in 2002, Changzhou Tianshan is

a producer of approximately 35,000 gears
the experience in gear technology, service
and support, so a high-quality produc-
DeliVeries
per year ranging in size from 100 mm to tion machine is assured. Among the man-
10,000 mm in diameter. Through invest- ufacturers of high-accuracy large gear
ment in the most advanced gear produc- equipment, Gleason-Pfauter is the indus-
with materials in stock. tion machines, Changzhou Tianshan has try leader. There really is no competitor.
expanded rapidly and is today a factory For more information:
of nearly 87,000 m2, with 300 employees. Gleason Corporation
The acquisition of the Gleason-Pfauter Phone: (585) 473-1000
[email protected]
Carbon,
P 8000/10000 hobber has opened the www.gleason.com
doors for new projects in mining equip-
alloy & ment, port mechanical equipment and
stainless
steel rings
4144 oD.
mcinnesrolledrings.com

feature
Heavy-Duty Demands
For Related Articles Search
Modern Coating Technology Examined
coatings
at www.geartechnology.com
Matthew Jaster, Senior Editor
The hob is a perfect example of how a little manufacturing ingenuity

can make a reliable, highly productive cutting tool. Its an engineering spec-
imen that creates higher cutting speeds, better wear resistance and increases rigidity. The
cutting tool alone, however, cant take all the credit for its resourcefulness. Advanced coat-
ing technology from companies like Sulzer, Oerlikon Balzers, Ionbond, Seco Tools and
Cemecon helps improve cutting tools by reducing overall costs, increasing tool life and
maintaining the highest levels of productivity. The following is a quick recap of new tech-
nologies and the latest information in the coating market.
Coating Technology with Sulzer

Sulzer offers a variety of coating equip- ity; prevention of cold
ment, material and services for the welding; and forma-
most complex surface applications. The tion of built up edges,
companys custom solutions based on says Annette Norin
PVD and diamond coating technolo- at Sulzer Metaplas
gies reduce production costs, increase GmbH.
tool cutting rates, reduce use of lubri- The key strengths of
cants, prolong tool life and improve wear the coating are its dra-
resistance. Significant for gear cutting matic reduction of the
is the companys new M.Power coating sticking material on
technology. M.Power is a micro-alloyed the cutting edge due to
TiSiXN-based coating that offers smooth reduction of the sur-
surfaces; high hardness; high oxidation face roughness. It also
resistance; high wear resistance; low boasts extremely high heat resistance. also to come up with specific problems
coefficient of friction; high tool qual- According to Norin, Sulzer provides and we develop solutions together,
custom solutions through the combina- Norin adds. We develop coatings on
tion of pre and post treatment of the tool our own R&D equipment and test new
surface coating material, layer architec- coating/layer designs together with our
ture and system/equipment technology customers.
with which the coating will be applied. Norin believes the hybrids mentioned
We focus on advanced plasma-assisted/ earlier will play a significant role in coat-
arc evaporator technology for innova- ing technology in the future. This tech-
tive coatings, Norin says. APA is based nology will include hybrids based on HI3
on the cathodic vacuum arc and offers technology, a combination of AEGD (arc-
diverse development possibilities for enhanced glow discharge), a plasma etch-
new layer architectures in terms of mor- ing process for layer adhesion; HIPAC
phology, stoichiometry, doping, multiple (high-ionization plasma assisted coat-
layers and nano layers. ing), a highly ionized sputter process; and
The benefits of APA include excellent APA Arc (advanced plasma-assisted arc),
coating adhesion and smooth coatings a highly ionized arc process.
through the reduction of macro-parti- For more information:
cles. APA is also the basis for new hybrid Sulzer Ltd.
technology. Phone: +(41) 52 262 11 22
www.sulzer.com
Customers are willing to test new
coatings to determine the benefits and

Hyperlox by CemeCon
Hyperlox is a new generation magnetron Hyperlox is best uti-
sputtering TiAlN coating produced by lized for hobbing oper-
Cemecon technology. It has been devel- ations with medium
oped with extremely low internal stress- and low cutting speeds,
es, maintaining high values of hard- in both dry and wet
ness and oxidation resistance. Hyperlox conditions; it is becom-
works for HSS hobs operating in wet ing widely used in
(oil) conditions but can be used also in Europe by major auto-
dry conditions on material with hard- motive groups such as
ness over 50 to 70 HRC. VW and ZF. It is used
Hyperlox offers a more stable perfor- also in milling applications
mance vs. standard CrAlN coatings in on milling cutters of hard metal
medium speed and wet cutting condi- (HM) and high-speed steel
tions. Furthermore the de-coating opera- (HSS).
tions of this layer do not cause the pro- CemeCon has been supplying in-
ductions of chromium (CrVI) in the house coating technology for 25 years.
stripping baths. For its low tensional Drawing on experience from Europes
stress, together with specific prepara- largest coating production operation,
tion of cutting edges, Hyperlox allows CemeCon has now tailored its system The benefits of CemeCon coating
extremely high chip thickness in hobbing technology to meet the needs of its cus- technology include:
(tests have been run up to 0.48 mm) with tomers with its CC800/9 series of coat- Economically sustainable, future-
a very stable and limited flank wear. With ing systems. Both existing and new coat- proof coating technology due to easy
these properties it is possible to offer sta- ing materials can be implemented on all upgrade (capacity, processes and new
ble and reliable conditions of production. models. developments). Option for modern
high-tech coatings; adaptations and

feature Heavy-Duty Demands
upgrades can be carried out quickly and ultra-smooth composite coatings on any
at low cost. desired substrate geometry.
A single coating system for diverse Transfer of know-how to the customer.
coating processes; all models in the Expansion of customers product port-
CC800/9 series are based on the same folio with versatile options for coating
platform and are available at various design (outstanding friction characteris-
configuration levels to fulfill different tics, surface quality, color, etc.).
requirements. Quality benefits by designing the pro-
Fast, low-impact coating or sput- duction chain to suit the customers
tering with extremely high metal ion- range of products.
ization; booster technology and high- For more information:
power impulse magnetron sputtering CemeCon AG
(HiPIMS), high ionization sputtering Phone: +(49) 2405 4470 100
www.cemecon.de
(HIS) for depositing numerous types of
Oerlikon Balzers
Expands Coating Operations
Many in the gear market are familiar To date, the company has 90 coating
with Oerlikon Balzers coating technol- centers worldwide.
ogy. Balinit coatings, for example, are In line with its global growth strat-
just a few thousandths of a millimeter egy, Oerlikon is also expanding its global
thick, but harder than steel; these low- service offerings. Increasingly, the com-
friction coatings are extremely wear- pany will be able to provide complete
resistant and chemically inert. The opti- solutions for the recondi-
mum coating is determined on the basis tioning of high-performance
of both conditions of use and economic round tools to its custom-
considerations. The material and prop- ers, particularly in emerg-
erties of Balinit coatings can be select- ing regions. To this purpose
ed to match customer-specific require- Oerlikon Balzers is adopting
ments. The typical coating thicknesses a standardized concept by the
that can be reproduced in mass-pro- brand rox for the setup and
duction lie between 0.5 m and 4 m. operation of regrinding cen-
Sharp edges, textured or mirror surface ters from the Austrian Tool
finishes and close production tolerances Management provider, TCM
remain unaltered. Therefore no finishing International, in addition to
work is required and the coating can be taking over the rox training
carried out as the final production step. facility in Stainz (Austria).
In order to meet the ever-increas- Coated high-performance
ing demands of its customers, Oerlikon tools such as drills and mill-
Balzers continues its global expan- ing cutters are crucial for
sion. The company recently opened its high productivity in present-
eighth coating center in India to estab- day metal processing. If cor-
lish a stronger presence in Chandigarth rectly reground and recoated,
(Punjab). they reach the same perfor-
Despite current economic uncer- mance as if in new condition.
tainties, we further invest proactively in Adds Manfred Kainz, CEO
our global footprint, explains Dr. Hans of TCM International, We
Brandle, CEO at Oerlikon Balzers. We are pleased that the concept
believe in the growing demand of mobil- developed by us has con-
ity in India and therefore increased our vinced Oerlikon Balzers. I am
presence in one of the automotive parts sure that the company will
and tractor industry hubs of the coun- see to its global and profes-
try. sional implementation.

Additionally, Oerlikon Balzers Ingenia The system can also be equipped with in its first coating centers and by third-
coating system recently won the German the new S3p technology, a system devel- party customers. The network is being
International Forum (iF) Design Award oped by Oerlikon Balzers that produc- constantly expanded.
2013 in the industry/skilled trade cate- es uncommonly smooth, thick coatings For more information:
gory. The award-winning Ingenia system that are both extremely hard and wear- Oerlikon Balzers
made its world premiere in September resistant. The award-winning system has Phone: +(423) 388 7500
www.oerlikon.com
2011 at the EMO fair in Hannover, already been successfully implemented
Germany. With Ingenia, Balzers engi-
neers and physicists succeeded in
extending the companys technological
lead by developing a coating system that
has the highest level of power densities
and takes up a minimal amount of space.
Helmut Rudigier, head of research and
development at Oerlikon Balzers, adds,
We were able to cut the cycle times in
half and thus significantly increase pro-
ductivity. And we accomplished this
while doubling the precision of the coat-
ing thickness.
The quality and precision of our

Broaches, Shaper Cutters and Gears
have won customers world-wide -
from the smallest gear shop to
NASA and the Mars Rover.
Broach & Shaper Cutter

manufacturing & repair
Gear & Spline
prototype to production
Master Gears & Gages
Small & fine pitch
Precision. Performance. Perfection.
The First time and every time.
ITY TOO
AL
QU
LS
The B roach Masters, Inc.

E
&
SER DEDICATED TO EXCELLENCE

VIC
1605 Industrial Drive

Auburn, CA 95603
Phone: (530) 885-1939
Fax: (530) 885-8157
Web: www.broachmasters.com
Email: [email protected]

feature Heavy-Duty Demands
I asked , Seco Tools

Duratomic Technology
Why does Ajax need The Duratomic technology from Seco
produces a durable coating by arrang-
a Finished Machining ing aluminum and oxygen atoms in a
unique way to provide increased tough-
Plant anyway? ness and abrasion resistance. The impor-
tance of atomic arrangement can be
understood by one extreme illustration.
Both graphite and diamond are made
from carbon atoms; but the properties of
those two materials are dramatically dif-
ferent because of the way the atoms are
arranged. In a somewhat similar way, the
Duratomic coating is more valuable than
traditional coatings because of its atomic
structure.
Controlling the structure of the alumi-
num oxide coating leads to several ben- ticularly important in stainless steel
efits for the user. First, it brings a hard- machining. The hardness and toughness
er and tougher atomic structure into of the Duratomic coating dramatically
the cut. Just as wood can be easily split reduce insert wear. The result of these
withbut not againstthe grain, alumi- properties is dramatic. Inserts coated
num oxide is more brittle in some atom- using the Duratomic process show less
ic directions than others. Seco builds the wear, less deformation and much greater
coating in a controlled way to ensure tool life.
the best structure is engaged in the cut. For more information:
This year I learned why. Secondly, controlling the structure
produces a smoother surface, resulting
Seco Tools
Phone: (248) 528-5200
. in less friction and heat during the cut.
www.secotools.com
Total. Quality Control
. from This translates directly to less build-up,
Cutting the Starting Stock
. . . a better surface finish, less tool wear,
to Cutting the Final Chips greater tool life and speed capability.
The flat facets on the Duratomic coat-
Faster Turnaround ing prevent built up edge and improve
for Our Customers surface finish. These benefits are par-
.
One-Stop Shopping
wnload
r n M o re: Do .ing
To Lea EE Rolled R
our FR. Paper at o m
Ajax de W. hite . e p a p e r . c
t
n
Desig oG u i axwhi TWP
w w w . a j ter Code: G
t s and en
ng
Rolled Ri
ROLLED RING & MACHINE

F O R G IN G A CIR CLE O F TR UST
Toll Free: 800.727.6333

Phone: 803.684.3133
. .
www.ajaxring.com

IHI Acquires Ionbond
Last fall, IHI Corporation of Japan medium lubrication; and is suitable for drilling, milling, and gear cutting with
entered into an agreement to acquire machining a wide range of materials. HSS and cemented carbide tools, a wide
100 percent of the shares of Ionbond, a Maximizer is an AlTiN-based coating range of lubrication conditions, a broad
manufacturer of wear protection coat- suitable for medium cutting speeds. The range of work piece materials including
ings headquartered in Switzerland. average crystallite size and stress have stainless steels and nickel alloys.
IHI provides thin-film technology to been optimized, resulting in increased For more information:
industrial customers through its physi- cutting performance. Crack propagation Ionbond US
cal vapor deposition (PVD) equipment is reduced by compositional fluctuations, Phone: (630) 231-9200
www.ionbond.com
and services, and together with its sub- and excellent ductility guarantees that
sidiary, Hauzer Techno Coating B.V. in coated tools are less susceptible to chip-
the Netherlands, acquired in 2008, is ping. It offers medium cutting speeds,
involved in diamond like carbon (DLC)
technology.
Joe Haggerty, CEO of Ionbond, saw
the opportunity to combine Ionbonds
process engineering and coating network
with the coating machinery at Hauzer.
This will lead to many innovations and
advantages for our customers in the
coming years. In addition, Ionbonds
strength in CVD products complements
the current PVD and PACVD offerings
within Hauzer and the IHI Corporation.
Hardcut is a multilayer coating for
high speed and high efficiency machin-
ing in minimum or zero lubrication con-
ditions. It is a TiSiN-based coating with
a support layer. Optimal performance is
possible by means of a patented process
that forms a true nano-composite mate-
rial whereby nano-crystallites of Si3N4
are embedded in a TiN matrix. The coat-
Polymat series of
ing properties protect the cutting edge CNC keyseating
from heat transfer, oxidation and abra- machine
sion. It offers ultra-high cutting speeds,
gear cutting with carbide hobs, finishing From simple
and semi-finishing milling, low lubrica- keyways
tion and dry machining, very hard and to multiple,
abrasive work piece materials and tita-
nium and exotic alloys.
special
Crosscuts AlCrN structure exhibits profiles,
reduced flank and cutting edge wear in a Leistritz
wide range of cutting conditions. As the Polymat
most versatile high-performance coat-
ing, it closes the gap between Maximizer
and Polyjet
and Hardcut. It offers medium to high machines have the
cutting speeds; milling and gear cutting features to improve
with HSS and carbide tools; reduced quality, shorten cycle
flank wear and cutting edge wear for a
wide range of cutting conditions; pre-
times and minimize
dictable abrasive wear by continuous set-ups.
wear instead of chipping; a high qual-
ity machined surface achieved through-
out the lifetime of the coating; low to 201 934-8262 www.leistritzcorp.com
Leistritz Corp. 165 Chestnut Street, Allendale, NJ 07401

feature
feature
Reinventing Cutting Tool

Production at Gleason
Investment in advanced
n ew m a n u f a c t u r i n g
technologies is help-
ing to reinvent pro-
duction processes
for bevel gear cutters
and coarse-pitch hobs
at Gleason deliver-
ing significant benefits
downstream to cus-
tomers seeking shorter
deliveries, longer tool
life and better results.
Manufacturers of bevel and
cylindrical gear cutting tools
have made enormous strides
in recent years to improve the
performance, quality, and tool
life of their products. New
substrates, advanced coat-
ings and new designs have
Gleason Cutting Tools facility in Loves Park, IL, where production processes for spiral bevel gear cutting
converged with faster, more systems, as well as coarse-pitch hobs, have been reinvented (all photos courtesy Gleason Corp.).
robust direct-drive CNC
machines to revolutionize bevel and cylindrical gear produc- youll find older machines sitting idle, with all the work they
tion. But there is another revolution underway as well, taking once did now being done much faster and more accurately
place on the shop floors of some of the leaders in this indus- by far fewer, advanced new machines. Thats good news for
try. This revolution has less to do with invention, and more to our customers seeking shorter deliveries on superior product.
do with investment, says Bob Phillips, senior vice president of Two of the best recent examples are our bevel gear cutters and
Gleason Corporations tooling products group. coarse-pitch hobs.
Highly productive new products are a big part of our solu-
tions approach, but of equal importance are the new processes Changes in Spiral Bevel Gear Cutter Production
were putting into place on every Gleason factory floor, says Spiral bevel and hypoid gear cutting has changed significantly
Phillips. Take a tour of our facility here in Loves Park, IL, and over the years. Many high-volume producers have made the
transition from mechanical machines performing traditional,
single-index, five-cut face milling or, more recently, the com-
pleting process, to much more productive CNC machines per-
forming carbide dry cutting completing as face milling or face
hobbing.
However, for a significant number of bevel gear jobbers
around the world, these older machines and processes still get
the job done. These jobbers rely on a system of different cut-
ter types still very much in production today: e.g., integral
blade (solid-body) type, and segmental or inserted blade type.
Gleason has long been a source for a variety of product in each
of these families of cutter systems, as well as the machines that
run them.
For example, the company manufactures well-known brands
such as its Ridg-Ac and Wedge-Ac inserted blade cutter sys-
tems for gear roughing and pinion roughing, respectively; its
A single Gleason IBG (inserted blade grinder) out-performs many older Helixform and Hardac cutter systems, also with inserted blades,
manual grinders, raising quality and productivity on inserted blade
production to unprecedented new levels.

For jobbers still using five-cut or completing processes to produce
spiral bevel gearsets, Gleasons inserted-blade and solid cutters are
now available with much shorter delivery times and greatly improved
accuracy and repeatability.
Gleasons coarse pitch hob cell machines tools complete from barstock,
even on hobs as large as 450mm diameter, 530mm in length and up to 40 product to well below the industry average, the older machines
module, to achieve 6-week deliveries.
simply werent relevant any longer, Chadwick recalls. While
for gear and pinion completing and finishing; and a variety of the soft blanking operations for these blades had been mod-
solid cutters for roughing, completing and finishing. ernized with new CNC machining centers in Plymouth, the
Until very recently, most of these cutter systems were pro- technology didnt exist at the time to make similar improve-
duced by Gleason at its Plymouth, England facility on dozens ments in the hard finishing operations. No one could have
of circa 1950s manual machines. According to Gleasons Paul guessed that today we would be producing the same inserted
Chadwick, production manager at the Loves Park facility, the blades and solid cutters many times faster, with substantially
production process relied heavily on the skills of highly experi- better quality, and with an operator with just weeks of training
enced machine operators and their ability to coax the best pos- versus the many years required previously.
sible productivity and quality out of these machines. Even an An intensive, multi-year effort involving a team of Gleason
operator with 30 years of experience would be hard- pressed to engineers on two continents has today resulted in the develop-
produce from blank a set of blades for a Hardac cutter in less ment of two revolutionary, special-design 6-axis CNC grinders
than six hours on these machines, and blades for a particular- a Gleason IBG (inserted blade grinder) and a Gleason SBG
ly large diameter cutter might take 18 to 20 hours, Chadwick (solid blade grinder) both employing proprietary technolo-
explains. The process was extremely laborious. gies and processes to cut production times to a fraction of what
The drawbacks inherent in this process were immediately was possible in Plymouth. Blanks now are produced complete
obvious to Gleasons Phillips and his team when bevel gear cut- in one fully automated setup, taking just minutes per blade.
ter production was moved to the Loves Park facility. In a manu- While faster throughputs translate into shorter delivery
facturing environment where waste is abhorred and lean manu- times for customers, Chadwick says, of equal importance to
facturing and Kanban systems have cut delivery time on every the customer are the accuracy and repeatability levels now
being achieved by these new machines. Were already hear-
ing very positive reports from customers in the U.S., Japan and
Europe who are the first to receive product produced by these
machines, he says. You can imagine how difficult it was to
maintain consistent, repeatable accuracies on the blades com-
ing off the old machines, given their age, all the manual steps
required, and the reliance on operator experience to get it right.
For the end user, the quality of the blade, particularly the criti-
cal edge-rounding radius dimension and the blending between
the edge rounding, the pressure angles and the front face where
cutting occurs, are critical to achieving lower cutting forces
and optimum chip shearing action and longer tool life as
a result. Chadwick points out that a better quality blade also
makes the initial process of truing the blades to the cutter
body within a certain assembly tolerance faster, because the tol-
New grinding machines and processes help produce finishing hobs with erances of each blade are essentially identical.
AGMA Class AA accuracies, precision ground with any desired profile or
special involute modification.

feature Reinventing Cutting Tool Production at Gleason
Coarse-Pitch Hobs: Bigger, Faster, Better

On the opposite end of the gear cutting tools spectrum are the
new manufacturing technologies being employed by Gleason
for the production of coarse-pitch hobs some as large as half
a meter in length and diameter, and up to 40 module. While the
end product and production methods are completely different,
says Phillips, the strategic objectives are very similar. Part of it
is attributable to growth in the wind power market, part to our
fast-expanding presence in markets like China and India, but
suffice to say, global demand for our large roughing and finish-
ing hobs has never been greater. Again, investment in new tech-
nology was the solution to meet our customers needs for faster
delivery on superior product.
Gleasons declared 6-week delivery from barstock on its
coarse-pitch hobs today stands in stark contrast to an industry
average of around 12 weeks. Older machines, long queues and
Every operation is totally integrated, even the final step: complete
a lot of non-productive time have given way to a new coarse inspection of all critical features on a Gleason GMM analytical gear
pitch hob manufacturing cell at Gleason that produces hobs inspection system.
complete from barstock, even including on-site final inspection classification and with any desired profile or special involute
of all critical hob features. Now, all the soft manufacturing modification.
operations such as gashing, threading and turning that previ- Yes, were busy inventing the next generation of advanced
ously required multiple machines are done in one stop on the new products, but in the meantime we never stop investing in
cells single large turning center. Heat treat is performed in close existing product, concludes Phillips. Ultimately, were helping
proximity to the cell, and then new grinding machines per- our customers get better results faster, even from cutting tool
form the finish grinding operations many times faster and more designs that have been around awhile.
accurately than what was possible before. Most importantly,
the cell has greatly reduced the costly non-productive time that
characterizes most large hob production, where many machines
and setups are required to perform all the necessary operations.
The cell is certainly much more productive than the
machines it replaced, and it also ties nicely to our lean manu-
facturing practices, which eliminates much of the typical time
wasted while product waits to be worked on, Phillips says.
The hob cell has also enabled Gleason to expand its product
range to include hobs as large as 450mm in diameter, 530mm
in length, and up to 40 module. These product offerings include
Gleasons popular E-Z Cut hob, which features a unique flute
design that adds extra cutting edges and delivers rough cutting
feed rates up to 70 percent faster than conventional hobs.
In addition, the hob cell affords Gleason the ability to pro-
duce more accurate finishing hobs, ground to AGMA Class AA Global demand from wind energy, mining, construction and other
industries has stretched the worlds large cylindrical gear making
capacity, creating unprecedented demand for products like Gleasons EZ
Cut hob (front), and the companys other roughing and finishing hobs.
For more information:

Gleason Cutting Tools
1351 Windsor Rd.
Loves Park, IL 61111
(815) 877-8900
[email protected]
www.gleason.com
The SBG (solid blade grinder) machine performs one-stop blade grinding
on Gleason solid body bevel gear cutters.

preciSion
power
partnerShipS
Photo courtesy of Gleason Corporation
See the Gear manufacturinG Supply chain in action!

Are you a gear manufacturer looking for the latest technology that will help you streamline your
operations and give you the accuracy, speed, and precision you need? Gear Expo 2013 brings
together gear buyers, manufacturers, and the best machinery in the industry.
Gear expo
2013 is the worlds only conference
at Gear expo 2013, youll:
and expo exclusively for the gear
) Meet face-to-face with suppliers from ) Talk to highly trained experts who can industry. Dont miss out and have to
across the country and abroadall in one answer questions from all your staff
highly accessible locationall at one time. who attend. wait another two years for this kind
of unique opportunity.
) See the machines in action and inspect ) Save time and money and build
the equipment up close and in person. trusting partnerships.
Visit www.gearexpo.com for information

on registering, travel, the exhibit hall, and more.
September 1719, 2013
Indiana Convention Center
Indianapolis, IN
www.Gearexpo.com
feature

When a customer needed gears delivered in three weeks,
heres how Brevini Wind got it done.
Randy Stott, Managing Editor
Recently a South American manu-

facturer needed four large, double-
internal replacement ring gears for
its sugar mill, and the OEM who provided
the originals was quoting eight months lead
time. Unfortunately, they needed their parts
fastermuch faster. Looking for alternative
manufacturers, they called on Brevini Wind,
in Yorktown, IN.
We were challenged to produce four large,
The large planetary component contained multiple internal
double-internal ring gears in three weeks, says gears of different geometry. In this view, the 12-module,
Dale Harder, director of facility operations at 76-tooth, 282mm face width gear geometry is shown. For semi-
Brevini Wind USA. Each of the large planetary finishing this gear, Brevini Wind was able to use a duplex
milling tool provided by Banyan Global Technologies for a
components contained two internal gears. On previous ring gear application
one end was a 12-module, 76-tooth, 282mm
face width internal gear. On the other end was
an 8-module, 116-tooth, 140mm face width
internal gear.
The biggest challenge in producing these
gears so quickly was figuring out the tooling,
Harder says. Getting new cutting tools would
have taken too long, so they looked at previ-
ous projects for parts with similar geometry
to see if they could re-use existing tools. As it
turned out, they had gashing cutters for previ-
ous internal gears with modules of about 12.1
and 7.3. But could these tools be used on this
part? To find out, Brevini turned to its cut-
ting tool supplier, Banyan Global Technologies
LLC.
Even though Banyan wasnt going to be able
to sell any additional cutting tools for this
project, they were happy to help, says Banyans
Darryl Witte, VP of sales. We have a fantas-
tic relationship with those guys, and theyre a
great customer.
Banyan prepared CAD drawings of both
internal gear elements, and then analyzed the
existing cutting tools and stock conditions that Machining Leader Tim Root removes one
of the approximately 3,000 lb. planetary
would result. After their analysis, Witte had components from the Youji 1200 CNC vertical
good news and bad news. Theyd be able to cut turning center, which Brevini Wind acquired
the 12-module gear with existing tools, but not and installed in the third quarter of 2012.
the 8-module.

For the larger internal gear element, we were fortu-
nate enough to have a duplex profile milling tool for an
application whose geometry was close enough to semi-
finish the internal gear, Harder says. Banyan Global
provided Brevini Wind with a CAD model of the cutter
profile versus the finished tooth profile, illustrating the
maximum depth of cut that could be made while main-
taining sufficient stock for finishing the gear teeth via a
subsequent internal gear grinding process.
But they still had some work to do. Even though
Banyan demonstrated that they could produce the
geometry they needed with the existing cutting tools,
Brevini Wind still needed a little bit of ingenuity to make
it work, Harder says. Because there wasnt sufficient
room for the cutter radius to break out without hitting
an adjacent shoulder in the part, our gear machining
leader, Chris Hayes, devised a process to first radially in-
feed utilizing our Gleason-Pfauter P2400 hobber at the
furthest possible point on the facewidth before begin-
ning to feed axially up the facewidth.
So Brevini Wind could make the 12-module inter-
nal gear with existing cutters. But what about the other
side? Unfortunately, Banyans analysis revealed they had
no cutting tools available with close enough geometry.
So we elected to grind the gear teeth from solid using A rendering of the duplex profile milling cutter used to generate the semi-
our Gleason-Pfauter P1600G gear grinder, Harder says. finished gear geometry of the 12-module gear. Profile milling using the duplex
cutter resulted in a total cutting time of under 55 minutes for the 76-tooth,
282mm face width gear. (image courtesy of Banyan Global Technologies)
WINNING LOSING
PTG. AbsoluTe Precision MAkes All The Difference

The difference between winning and losing can often Precision Technologies Group (PTG) is a world leader Holroyd Precision Ltd
be invisible to the naked eye. Thats why you need the in milling and grinding technologies, special purpose
absolute precision of PTG Holroyd Precision. machine tools and ultra precision components for HVAC, t +44 (0)1706 526590
aerospace, motor racing, medical, marine, steel, oil and gas. f +44 (0)1706 353350
Incorporating Holroyd, Binns & Berry, Crawford Swift,
e [email protected]
PTG Heavy Industries and Precision Components, For absolute precision, choose PTG Holroyd Precision.
Part of the CQME

Group of Companies www.holroyd.com

feature Delivering Big Gears Fast
This permitted us to generate the required gear geometry rela-

tively quickly.
Harder explains that even though grinding from solid is a
much more time-consuming processin this case six hours
versus the one hour that would have been required for gash-
ingit could be done using inexpensive, off-the-shelf grinding
wheels that didnt require any additional wait time.
After rough machining, the parts were inspected, stress
relieved and inspected again in Brevinis climate-controlled
inspection lab. Having heat treating and metallurgical facilities
in-house greatly enhances Brevini Winds ability to turn parts Machining Leader Tim Root prepares one of the large planetary ring
around quickly, Harder says, and it also allows them tight con- gears for the final turning process on a Youji 1200 ATC CNC vertical
turning center. The machine is equipped with live tooling, allowing
trol over every process. Brevini to machine threaded holes in the end face.
Due to considerable material removal from the required
machining processes, Brevini Wind elected to stress relieve The result was very precise threads, excellent size repeatabil-
all of the large planetary components prior to finish machin- ity and no broken taps, Harder says.
ing critical dimensional characteristics and gear geometries, In the end, Brevini was able to provide these parts on sched-
Harder says. ule for a customer with a very tight deadline. Because of our
Brevini Wind performed analytical inspections on the inter- equipment, expertise, innovative thinking and some very dedi-
nal gear tooth geometries before and after the stress-reliev- cated employees, we accomplished the mission, Harder says.
ing process to determine the level of dimensional movements
Inspection of components was completed in Brevini Winds climate-

controlled inspection lab.
Without an available cutting tool to semi-finish the 8-module, 116-tooth For more information:
145mm face width internal gear, Brevini Wind chose to grind the teeth Banyan Global Technologies LLC
from solid in order to facilitate delivering the large planetary component 20839 Hall Road #156
to their customer in the shortest possible time. The part is shown inside Clinton Township, MI 48038
Brevini Winds Gleason-Pfauter P1600G gear grinder, which is equipped Phone: (888) 247-7933
to grind both internal and external gears. www.banyangt.com
that occurred, Harder says. The information was utilized to Brevini Wind USA
2400 N. Priority Way
confirm green machining dimensional targets that will pro- Yorktown, IN 47396
vide minimal stock removals for the post-heat treating finish Phone: (765) 759-2125
machining processes. Fax: (765) 759-4728
www.breviniwind.com
Those finish machining processes included not only final
gear machining, but also finish turning on the companys newly
acquired Youji 1200 ATC CNC vertical turning center. With
the live tooling capabilities of the Youji, it was also possible to
process the numerous M36 threaded holes that were required
around the part end face. The holes were drilled and the M36
threads were generated using circular interpolating thread mill-
ing technology instead of conventional taps.

A brief history of Brevini Wind USA
Brevini Wind USA was built from the ground up with Despite that additional business, the company still has
wind turbine gearboxes in mind. The company broke plenty of capacity and can offer exceptional turnaround
ground in 2009 and began hiring staff in 2010. Brand new time on planetary gearbox components, Harder says.
machine tools began arriving late in 2010. And the company is in it for the long haul. Theyre con-
All told, the company spent over $35 million on the fident the wind turbine business will return and that
new factory. During 2011, the processing equipment was demand for their capacity will be strong for many years to
installed, staffing was hired, and the factory was prepared come. The economy is in some sort of degree of uncer-
for operations. tainty, Harder says. Nobody seems to want to move very
We made a lot of Brevini standard industrial parts to quickly. I think when things do rebound, particularly for
begin with in order to give the machining personnel expe- things that require large gears, were going to be well posi-
rience and to do run-off acceptance of the machines, says tioned, because everywhere you look out there [on our fac-
Dale Harder, director of facility operations. In late 2011, tory floor], you see the latest technologies available for the
Brevini Wind began producing precision planetary com- manufacturing of large, precision coarse-pitch gears.
ponents for one of its wind turbine customers gearboxes.
Unfortunately, the business of making main drive gearbox-
es for the wind market began to slow, leaving Brevini Wind
with unutilized capacity, Harder says.
But having extra capacity at a brand new, state-of-the-
art facility, custom-built for manufacturing large planetary
components wasnt all bad, Harder says. We would hope
that a lot of customers would want their parts made in a
facility with this kind of capabilities.
In fact, it allowed the company to attract new customers,
particularly in the heavy equipment industry. Throughout
2012 we manufactured a lot of ring gears for Caterpillar,
Harder says. What makes us unique is our process efficien-
cy. We cut a gear for Caterpillar in 39 minutes utilizing the A partial view of the 105,000 square foot Brevini Wind manufacturing
profile milling gashing process that would take a competi- facility. The company broke ground on the facility in 2009 and began
installing equipment by late 2010/early 2011. The facility also houses
tor, utilizing a typical gear shaping process, 68 hours. a 6.4 MW capacity back-to-back test bench for full load testing of
large planetary gearboxes.
All
All The
the Gear Cutting Tools You Will Ever Need are
Are Right Here
DTR is one of the worlds largest producers.
DTR. Your best choice for high quality gear cutting tools.
DTR is a world class supplier of the finest high performance long-life gear
manufacturing tools, for small and large gear cutting applications.
Established in 1976, we are one of the worlds largest producers of cutting
tools, shipping to over 20 countries.
DTR offers a full line of gear cutting tools including:
Hobs Chamfering and Deburring Tools
Carbide Hobs Broaches
Shaper Cutters Master Gears
Milling Cutters
We can produce virtually any tool you need for auto, aerospace, wind,
mining, construction and other industrial gears.
Every tool is precision-made utilizing high speed steel, premium powder
metal or carbide and the latest in coatings, to achieve superior cutting and
long life. DTR uses top of the line equipment including Reischauer CNC
grinders and Klingelnberg CNC sharpeners and inspection equipment.
Learn more about our outstanding quality tools at www.dragon.co.kr.
Call us at 847-375-8892 for your local sales representative or
Email [email protected] for a quotation.
DTR has sales territories available. Call for more information.

U.S. Office Location (Chicago) Headquarters
Email inquiries to: [email protected] 36B-11L, Namdong Industrial Complex, Namdong-Gu, Incheon, Korea
(formerly Dragon Precision Tools) 1865A Hicks Road, Rolling Meadows, IL 60008
PHONE: +82.32.814.1540
WWW.DRAGON.CO.KR PHONE: 847-375-8892 Fax: 224-220-1311 FAX: +82.32.814.5381

feature
JOB
lean manufacturing
SHOP
LEAN
Eds Note: This is the third article in an eight-part reality
series on implementing Continuous Improvement at Hoerbiger
Corporation. Throughout 2013, Dr. Shahrukh Irani will report on
his progress applying the job shop lean strategies he developed
during his time at The Ohio State University. These lean methods
focus on high-mix, low-volume, small-to-medium enterprises and
can easily be applied to most gear manufacturing operations.
Dr. Shahrukh Irani, Director IE Research, at Hoerbiger Corporation of America
The Tiger Team

The initial approach to engage the work-
force in implementing their own con-
tinuous improvement (CI) projects con-
sisted of a weekly one-hour training ses-
sion delivered to supervisors and team
leaders. This approach was ineffective
because considerable time was needed
to conduct weekly audits of each depart-
ment/cell to assess if the attendees had
applied what they had just been taught.
A different approach was needed. This
led to the creation of the Tiger Team.
Why Tiger? Because we wanted to take
big bites out of the waste that existed in
the shop and in the front office.
The team was designed to include (i)
managers who are well-versed in the
concepts, methods and CI tools, (ii)
shop employees who have demonstrat-
ed an enthusiasm and/or prior exper-
tise in implementing CI and (iii) office
staff who expressed interest in initi-
ating CI projects in departments that
are above the shop floor, such as
Customer Service, Purchasing, Design,
Engineering and Sales/Marketing.
Schedule of Activity
The initial plan called for the Tiger Team
to meet at least once a week for a period
of three months. Each meeting usually
consisted of two parts:
First, the SME (Subject Matter Expert)
in the team would make a presenta-
tion to the rest of the team on a basic
Tiger Team members each received a notepad to
record every instance of waste in the CA Cell.

problem-solving method/tool that is
frequently used by CI teams.
Next, the team would go to a par-
ticular area in the shop where they
would engage and collaborate with
the employees in that area to apply
the method/tool they had just learned
to improve the workspace and/or the
work processes performed in that area.
This weekly routine continued in
that particular area for the entire peri-
od of three months, or until sufficient
improvements had been made to justify
ceasing work in that area. Every surface in the room was crammed, stuffed or stacked with junk.
Focus of the Tiger Teams First

Project
Our group was a mix of talented indi-
viduals drawn from different depart-
ments who wanted the team to impact
any project at many levels. The team
was confident that it could (i) re-engi-
neer the daily work processes and (ii)
Innovation Days 2013:
re-design the work system to elimi-
nate waste in any manufacturing cell
Bigger and better than ever.
or department that was assigned to us.
Where should we do our first project
such that waste elimination would have
a clear-cut impact on the business? That
dilemma was quickly solved for us. As
part of a massive supply chain reorgani-
zation, corporate decided that HCA-TX
would build a certain family of prod-
ucts in the existing CA Cell. Currently,
this cell built assemblies using machined
parts that were being sourced from our
sister plant in Florida. Now that HCA-
TX would be responsible for the entire
CA Value Stream, the Tiger Team had
found just the right project. Our goal
was to observe and understand how the
CA Cell worked, document and map May 7-10 Chicago, IL
how it really operated and determine DMG / Mori Seiki USA headquarters
what it would take to fit the existing MAY 7-10 This year, theres only one event where you can see it all. Innovation
pieces together into a more efficient and
2013
Days 2013 is almost hereand weve got everything you need to

improve your manufacturing processes:
effective production system.
More than 40 machines under powerincluding five U.S. premieres
More seminars and partner exhibits
Ground Rules for the Tiger Team One-on-one application consultation
Everyone has an equal say No pull- Industry-focused manufacturing hubs: heavy equipment,
ing rank or position. automotive, aerospace, gear production and more
There is no single answer for any

problem.
Learn by doing It is okay to fail as
long as you try and try again to get a
better result. Learn more about this complimentary
Every idea is good Just prove that it event and register at iDays2013.com. www.dmgmoriseikiusa.com
is really good.
Ask Why? five times if you think
that the work system cannot be
improved.
dmori1470-2_april_ads_idays_GT.indd 1
May 2013|GEAR TECHNOLOGY3/8/13 2:10 PM 37
feature JOB SHOP LEAN
Maintain a positive attitude Avoid mainly to reinforce their pride and iden- to finish around the cell (Flow Diagram
blaming anyone or anything.
tity working in the cell. aka Spaghetti Diagram). After every ses-
Keep an open mind to change.
Practice mutual respect Treat oth- Set (The Third S in 5S): There is a sion inside the cell, the team would re-
ers the same way that you would have reason why the layout of any production convene upstairs. The good ideas started
them treat you. system is essential for Lean, regardless pouring in! The large table in the mid-
of whether it is a single workstation, a dle had become a crutch. It had good
Subsequent meetings covered Value single machine, a cell, a machine shop or lighting and that was the only reason
Stream Mapping (VSM), Process an entire factory. Flow happens (or fails) it was being used. Next, we found that
Mapping, Flow Diagrams, Operations primarily because of a good (or bad) lay- about half of the steps were being per-
Process Charts built from Bills Of out. In the case of our CA Cell, the initial formed against one wall, and the rest
Materials (BOMs), Problem-solving layout of the cell had tables and shelves of the process along the other wall. A
Tools (Five Whys, Ishikawa Diagram, lined along all the walls. A large table couple of steps were even being done
etc.). with lighting and racks on it sat in the on the small tables in between! All of
middle of the room. Several small tables these problems were solved simply by
What We Did and benches were scattered all over the implementing an assembly line/cell that
Sort (The First S in 5S): The CA Cell room. Assembly was not dedicated to required placement of two tables side-
hosts one full-time operator, and the a single table; instead, multiple in-pro- by-side and moving the toolbox, fixtures
room that houses it measures just 30 x cess assemblies, rework, and projects and gauges onto them, or adjacent to
15. Just about every surface in the room in different phases of completion were them at POU (point-of-use) locations. In
was crammed.It really was no wonder strewn throughout the room. The Tiger turn, this freed up space inside the cell.
that the team could claim resounding Team spent several consecutive weekly Now, material that was earlier staged in
success on that day when it undertook meetings just standing around the cell carts kept outside the cell could be posi-
the removal of any and all junk from the and watching how work was done (or tioned in a 2-cart Kanban queue just
room housing the CA Cell. Teaming up delayed) in the cell. During one meet- inside the entrance to the cell. We also
with the full-time operator and the floating, we mapped the movements of the knew that other departments, particular-
er from the machine shop, we achieved full-time assembly operator from start ly our supervisors, needed an area inside
this goal by filling up countless trash
cans and quarantining items for other
departments to review, especially if they
were going to be disposed of. This phase
of 5S was sorely needed given the mess
that cell was in, almost as if it had been
used as a dumping ground by other
departments. The removal of unused or
unneeded tooling helped to consolidate
the remaining tooling into the single
mobile toolbox that was purchased for
the cell.
Shine (The Second S in 5S): We want-
ed the cell to project a visual appeal that
would not only make us proud but also
impress customers and visitors touring
our facility. Among the many enhance-
ments that our maintenance depart-
ment helped to make were several coats
of epoxy for the floor, fresh new paint
for the walls, the ceiling tiles were fixed
and an array of bright ceiling lights
were mounted right above the re-locat-
ed assembly tables. Later, we would like
to install a synchronized digital clock
inside the cell and, outside the entrance,
mount a framed photograph of the main
product that the cell assembles. Beside
that products photograph, we hope to
post the autographed photographs of
the two employees who work in the cell,
Before and After layouts of the CA Cell.

the cell to work on special projects. To that our engineering group had a feed-
address this need, we added a rework/ back loop to us if revisions were made or
project table, as well as a staging rack for new fasteners created. We set acceptable
jobs and parts needing further attention. minimum/maximum levels for each fas-
Thereby, anyone doing support work tener and labeled the fastener bins with a
inside the CA Cell no longer needs to picture of the part, dimensions, Grainger
worry about interfering with the core reference number, and most important-
assembly work being done in it. ly, our ERP reference number. This way
Safety and Ergonomics in the there is no room left for error, ensuring
Workplace: Watching the operator lift that we procure and use the correct fas-
each heavy final assembly and hold it teners.
up during shrink-wrapping, often turn-
ing it around while doing that, raised
a red flag. The new layout includes a
jib crane and an automatic shrink-
wrapping machine to wrap each final CHALLENGE:
assembly before it is placed on a cart Reducing cycle times and costs
for cast iron turning operations
and rolled into the Shipping department.
Anti-fatigue mats have been bought to
reduce standing fatigue for the opera-
tor. The ceiling drop for the air hose has
been repositioned to reduce the travel
time and effort that the operator had to
exert yanking on the hose whenever he
required to blow air to clean an assem-
bled unit.
Inventory Rationalization: Several
pockets of inventory were stored in
the cell, all used in the final products.
We found that these items were poor-
ly maintained and controlled. BOMs,
drawings, or both, would be wrong.
Fortunately, our expert operator was
self-correcting these issues. To ensure
accuracy and quality, we pulled all of our SOLUTION:
gaskets, O-rings, and tie rod stock out of TK GRADES DURATOMIC INSERTS
Unique Duratomic technology
the cell into the Receiving department. optimizes toughness and
Now, only the correct items are delivered hardness
Substantial increases to wear
to the cell at the time of assembly. This resistance and insert life
also allows our operator to know if a More aggressive cutting data
for higher metal removal rates
BOM or drawing is incorrect, which per- Coating and substrate tailored
to cast iron applications
mits us to fix it immediately at that time,
making it accurate for the next time that
BOM configuration is pulled. After a few
months, not only were our inventories
accurate, but we could also ensure better
quality of our final product.
ATTACK CAST IRON
The products assembled in the CA
Cell also require fasteners. Our part
AT THE ATOMIC LEVEL
SECOTOOLS.COM/US
number Rolodex contained about 50 dif-

ferent nuts, bolts, washers and plugs.
What we found was that we were actu-
ally stocking 150 different part numbers.
Obviously something was wrong! To
eliminate this issue, we teamed up with
our MRO supplier (Grainger). We start-
SCAN TO REQUEST A FREE
ed from scratch and built our invento- SAMPLE TK GRADES INSERT!
ry from our current drawings, ensuring

Where Do We Go From Here?

Integrated Product and Process Design
(IPPD): Each assembly uses threaded tie
rods for shipping and installation pur-
poses. We found that we were calling out
for and procuring smooth rods, thread-
ing them ourselves then cutting them
down to size. This was all being done
during assembly, thereby wasting the
operators time as follows: The operator
Careers geared to succeed. would start assembly, see that he needed
tie rods, stop work, thread the rod and
Global opportunities available. cut it to specification, then complete the
Moogs motion control technology and products are found around the world
assembly. Today, we procure threaded tie
from helicopters to fighter planes and deep sea drills to syringe pumps. We
rod, which has eliminated the threading
foster an environment where our 11,000 engineers and technologists feel
and sawing operations. The threaded rod
empowered and inspired to achieve remarkable things. The work we do matters,
is less expensive than the smooth vari-
as does every single person who works with us.
ant. Next, we plan to locate the saw used
to cut the tie rod to size adjacent to the
Were looking for talented engineers with at least seven years of experience CA Cell; thereby, the operator will use
in gear manufacturing to join our business in Baguio City, Philippines, Torrance, his idle time to cut and fill a buffer of
California and Wolverhampton, United Kingdom. If you are interested in tie rods which would allow him to work
joining our team in the Philippines, but are not a resident there, you will receive uninterrupted during assembly periods.
housing benefits and travel allowance. WIP Reduction and Continuous
To apply, please send your resume to [email protected] or visit moog.jobs
Flow using Transfer Batches: Transfer
batches are not as good as one-piece
YOU CAN DO THIS flow. But at least they are smaller than
the shipment batch (aka process batch, if
you are familiar with Eliyahu Goldratts
GLEASON
Theory of Constraints (TOC). We real-
ized that for the CA product, most of
our order quantities are small (less than
10 units), although on occasion we
Model 642 receive large orders of 50 or more. So, all

these years, just to hold those occasion-
G-Plete Hypoid Generator al large orders we had packed all those
tables into the single room that housed
13" (330mm), 3.4 DP (7.5 Module), Excellent, Pinions, Ring Gears,
Helical Motion, Formate,
Extented Tilt, 1982
www.gearmachineryexchange.com
GLEASON
INDEX PLATES
Lift&Drop Cams, Genevas
for MODELS
605-610
Generators
www.gearmachineryexchange.com Several pockets of inventory were stored in the
cell, all used in the final product/s.

the CA Cell. That is not going to hap- Monday, one cup on Tuesday, another on
pen anymore! Now, instead of running Thursday and the last one next Monday.
a large order as a single batch, we are Guess when assembly of that particu-
using our ERP systems capability to split lar unit began? Only when that last cup
an order. Okay, so we still do not know arrived next Monday! Consequently, we
the optimal number of transfer batches are discussing with our sister plant in
that a shipment batch should be broken Florida how their machining cells could
into. At least we plan to allow transfer coordinate the completion times of the
batches up to a maximum size, and no components in the kit of components
more. This will make all the in-house that comprises a particular CA assem-
activities related to the Value Stream for bly, and ship that complete kit to our
the CA Cell product family more man- plant early enough so we can assemble
ageable ex. we could start building an and ship the assembly on time. This sup-
order using on-hand parts even as addi-
tional parts are on order. Or even give
the Shipping department a heads-up so
they can ready a table to package a par-
ticular CA order, even as the CA Cell is
sending more completed assemblies on
the next push cart from across the aisle
that separates them.
SECTION A-A
Kitbans Help to Simplify Supply
Chain Management: Everyone is famil-
iar with a kanban (card) being associated
with a batch quantity for a single part
number. A kitban is simply extending
the same idea to ensure completeness of CUSTOM COMMERCIAL FORGING
all the components that will be required Complete forging operation assures total control of all
to assemble a single, or batch, of prod- parts, components and products for ultimate fast
ucts. In the short term, we will contin- delivery. Martin can handle all phases of your custom
ue to receive machined parts (the cups forging work, including die design, forging, coining,
and flanges that go into the final prod- and heat-treating.
uct assembly) from Florida. Each case PLASTICS
is built from a specific list of parts, i.e. Injection Molding & Machined
Molding capabilities range from 50 - 1,000 tons.
X pieces of Cup X and 1 piece of Flange Quantities 1 to 10,000 or more
Y. However, analysis of our ERP records Engineers available to help expedite
showed that we may get one cup on customers needs.
Superior component complexity.
Maintain close dimensional tolerance
Broad material selection
SINTERED METAL
A
Fine surface finish.

Superior component complexity.
Accelerated time to market.
Broad material selection.
Excellent part to part repeatability.
Maintain close dimensional
tolerances.
Press capacity to 880 tons.
Offers great part value.
Engineers available to help expedite
customers needs.
For more information or to quote your next project
A
The ONE You Rely On!

817-258-3000 [email protected]
www.martinsprocket.com www.martinsprocket.com/plastics.htm

ply chain nightmare sound familiar to

those of you who make gear assemblies?
Besides, this will streamline our material
handling and labor costs for the same
activity.
Ratcheting Up by Several Notches
the Training Given to Tiger Team
Members: Management has been
requested to consider allowing team
members to receive more training.
Currently, the training that is being
offered to the team is loosely drawn
from the training program developed
to teach the Quick-Start Approach to
JobshopLean. In addition, a simple train-
ing program on CI has been developed
that will be offered only to the really
interested and motivated employees,
especially targeting those who first did The current state of the CA Cell. Upper management has begun to take notice
a tour of duty on the Tiger Team! Please of the Tiger Teams activities.
email [email protected]
to receive a copy of this curriculum. It popular product configurations. This
utilizes Productivity Presss (now CRC supermarket will be replenished with
Press) Lean for Operators (Shopfloor parts that will be machined in a FLEAN
Series) and popular videos available from (Flexible and Lean) machining cell that
Society of Manufacturing Engineers, will be designed and scheduled using
Greater B oston Manufacturing Drum-Buffer-Rope or Finite Capacity
Partnership and Lean Enterprise Scheduling logic.
Institute. Cell Performance Display Board:
Compensation for Team Members: This is going to be a standard display
Rewards and incentives are under dis- with a focus on Quality, Cost, Delivery,
cussion. Of course, the usual ideas are Improvement Ideas, and possibly an area
being thrown around (shirts, lunches, where the cell members can post some
honor parking spots, etc.). But, it is personal details.
heartening that management has taken
a very serious view of those who do, The Word is Spreading among
and do not, actively participate in one the Employees
of more Tiger Team projects. There has The next Tiger Team project is being
been talk of linking promotions, over- done in the MPC Cell. Kenny Pham and
time and bonuses to active and valuable Dhananjay Patil (a graduate intern from
Andrew Reynolds has been the inventory
participation in our CI program! the University of Texas at Arlington) and warehouse supervisor at HCA-TX for two
(Toyota) Lean will meet Job Shop have already started working with the years. Previously, he had been a production
Lean: It is but natural that these two fla- cells team. Having a Tiger Team mem- supervisor in the machining cells. While in
college, he worked for two years in Hoerbiger
vors of Lean, primarily developed for ber who has already worked on the CA Service, Greenville, SC. He is an accounting
low-mix high-volume manufacturing Cell project has fired up the employ- graduate from Furman University.
and high-mix low-volume manufactur- ees in the MPC Cell. They have already Dr. Shahrukh Irani
ing, respectively, come together at HCA- completed the Sort and Shine phases of is the director of
TX. The CA Cell will need to become the standard 5S effort! industrial engineering
more flexible as it begins to make a Upper management has got a whiff of (IE) Research at
Hoerbiger Corporation
wider range of products in the same the activities of the Tiger Team. We may of America (www.
product family. Heijunka (mixed model be asked to make a presentation at the hoerbiger.com). In
production) will have to be implement- Global Production Conference sched- his current job, he
has two concurrent
ed. The CA Cell will pull kits of parts uled to be held later this year. We hope responsibilities: (1) To
from a supermarket which will have to to include a short video documenting undertake continuous
be sized and configured to carry inven- the work that we did in the CA Cell. improvement projects in partnership with
tories of different parts that get used in employees as well as provide them on-the-job
training relevant to those projects and (2) To
facilitate the implementation of JobshopLean
in HCAs U.S. plants.


ATLAS delivers the best in...smart solutions.
Ipsens ATLAS integral quench furnaces are highly engineered, sophisticated machines that are easy
to operate and maintain, all while being extremely cost effective. ATLAS delivers top-quality
uniformity through cutting-edge technology and design:
Intelligent controls, Carb-o-Prof, provide you with your very own

electronic metallurgist
SuperQuench with adjustable oil speed and powerful agitators
Muffle system for uniform temperature control
Safety all ATLAS furnaces are water free for maximum safety
30% less gas consumption
Recon burners single-ended recuperated tubes (SERT)
The unique HybridCarb from Ipsen is an ultra-efficient gassing system designed to replace endothermic
generators and other gassing systems. Its core strength is precision gas control. Instead of burning off
excess gas, the process gas is reconditioned and reused, increasing efficiency up to 90 percent.
Other benefits of HybridCarb include:

Quick and easy hook-up
Increased carburizing efficiency
Reduces CO2 emissions by 90%
Significantly less expensive to operate than
endogenerators
Consumes significantly less gas
Environmentally friendly and cost efficient
Lowers heat output, creating a more comfortable
work environment
Powers up and down at anytime, quickly and easily
For more information, please visit

www.IpsenUSA.com/ATLAS
www.IpsenUSA.com/ATLAS
weve UNLOCKed
MORe PeRFORMANCe
FROM BeveL GeAR
CUTTeRS ANd
COARSe
PITCH HOBS
TOOLING SOLUTIONS FOR ALL CYLINDRICAL AND BEVEL GEAR PROCESSES,
Hobs Shaper Chamfering, Shaving Threaded Wheel Dressing and Diamond Honing
Cutters Deburring Cutters and CBN Dressing Master Gears Tools
Tools Grinding Wheels
For worldwide sales locations and additional information, visit:

Whether youre cutting spiral bevel gears by the thousands,
or just a few large cylindrical gears each day, Gleason has a
cutting tool solution to make your processes more productive.
Our investment in advanced production technology and lean
manufacturing has cut delivery times to the shortest in the
industry for our insertable-blade and solid bevel gear cutters,
and coarse pitch hobs. Even better, these products now deliver
superior accuracies and productivity.
Unlock your full potential, with a visit to:

www.gleason.com/cuttingtools.
Only Gleason offers the full range

of bevel and cylindrical gear
cutting tool solutions, as well as
a broad array of quick-change
workholding systems, to meet all
your requirements.
ANY SIZE AND TYPE
Bevel Gear Cutting Quick-Change Contract

Systems and Workholding Services
Grinding Wheels
www.gleason.com [email protected]
feature
If You (Re)build It, They Will Buy It

Retrofit, re-control, re-build, re-manufacture: Its all good.
Jack McGuinn, Senior Editor
Its been said that the best ideas are often some-
one elses. But with rebuilt/retrofitted/re-controlled/or re-
manufacturedpick one machine tools buyer beware
and hold onto your wallet. Sourcing re-work vendors and their
services can require just as much homeworkif not necessarily
dollarsas with just-off-the-showroom-floor machines.
According to Jerry Adamski, global customer service direc-
tor for Gleason Corporation (Rochester, New York), Many fac-
tors can influence this decision, including machine condition,
cost to upgrade, project timing, operator knowledge, machine
quality history, existing tooling, rebuild vs. new productivity
improvements, etc.
And Ken Flowers, owner and vice president of sales of
A fully re-built Lorenz LS-180 gear shaping machine that had a
Machine Tool Builders (Machesney Park, IL), elaborates on the custom tailstock/face gear table assembly added to it during the
points Adamski raises. re-build. This machine has five axes of CNC control and one spindle
It starts with the machine type and machine issues. For all controlled by a Siemens 840D CNC (Courtesy MTB).
example, a machine which is currently CNC that has an anti-
quated/unsupportable control, but is producing good qual- is due largely to the prices of new machines in the smaller size
ity parts, is a likely candidate for a full re-control for about ranges.
one-quarter to one-third (the price) of a new machine price. Depending upon the machine type, re-building and re-
Re-controlled machines can last another 10-15 years if the right controlling can produce benefits in the accuracy achieved; the
candidate is chosen for the upgrade. Gear cutting machines speed; the flexibility; features and functions; lower set-up times;
lend themselves well to re-building and re-controlling because, and lower cycle times.
in general, these types of machines are more valuable than David Goodfellow, Star-SU LLC (Hoffman Estates, Illinois)
machines like mills and lathes. However, size matters; generally president, puts things in an economic law of diminishing
machines in the size range of 300 mm diameter and larger pro- returns context.
vide a larger savings than machines with smaller diameters; this A re-build averages between 50-60 percent, and a full CNC
upgrade re-manufacturing is 70 percent of a new machine price
and is generally more applicable to larger machine tools, since
there are more parts of the machine that can be reused. CNC
re-manufacturing of old mechanical machines is often less
expensive than trying to rebuild a machine to the OEMs origi-
nal specifications for a mechanical machine.
Also doing some math for us is Jim Vosmik, Drake
Manufacturing (Warren, OH) president. Where the machine
itself is no longer able to be brought into tolerance by adjust-
ing gibbs, leveling and aligning the base, and other heavy pre-
ventative maintenance, a tougher decision needs to be made.
If re-manufacturing will cost more than 75 percent of a new
machine of similar function and the re-manufactured machine
is not guaranteed to produce at 100 percent of the speed and
quality of the new machine, you are likely better off with the
new machine on a total lifetime cost analysis that looks at ini-
tial, as well as productivity, operating and maintenance costs.
Of course, when a new machine of the same function is not
A mechanical shaper that was fully re-built, modified and available, the math becomes more forgiving. The upfront cost is
converted to CNC control. It has five axes under CNC control, only one consideration. Over the life of a machine the operating,
using a Siemens 840D CNC. It was modified to use a 2000 Nm
water -cooled torque motor to generate the up/down stroking consumables, and manpower costs generally dwarf the initial,
motions. The upgrade also provided CNC-controlled elevation upfront costs of the iron. The main driver of those lifetime costs
adjustment and high-speed return of the cutter, helping to reduce
cycle time from seven to two hours on most parts (Courtesy MTB).

is stiffness in the cut/grindstiffness drives productivityeither
through cycle time directly or through diminished tool life.
Another consideration is whether or not the carcass can be
automated. Does the physical layout of the machine allow for
automation to be utilized in a safe and efficient manner without
doubling the footprint of the machine on the shop floor?
Indeed, carcass hunting today can be a daunting task.
Depending what you are shopping for, its not like there exists a
Happy Hunting Bone Yard where one can be readily purchased.
Many of the carcasses result from plant closures and auc-
tions, says Flowers. Small machines are easily found on the
market, but larger machines are becoming rare.
Yes, (carcasses are) definitely harder to find, Vosmik
affirms. The large gear equipment has been used to exhaustion
to keep up with demand, until a couple of years ago. There are
just not too many large thread grinders still out there that have
not been CNC-retrofitted.
Adamski says that Carcasses are found at existing and new
customer (locations), on the used machine market and at auc-
tions, but concedes that Popular models can be difficult or
costly to find.
Of course its ultimately all about aside from trying to save
some moneyre-doing a machine to update its technical capa-
bilities and thus make its owner more competitive in the mar-
ket. But is that a double-edged sword scenario? Is it possible
that machine tool technology is advancing at a pace that ren-
ders re-dos almost superfluous? The reality is that the risk of GEAR CUTTING SOLUTIONS
sudden obsolescence is minimal. Or is it? Fact is it depends.
Adamski reasonably points out that Again, it depends on a
number of factors, the most significant of which is the level of
re-build, i.e., basic re-build vs. retrofit vs. re-contol, etc. A re- Toolholding Workholding Sub-contract Machining
control with new controls, motors, drives, etc., can bring the
machine up to current technology levels.
Those stipulations addressed, Flowers maintains that
Actually, there is little risk at all especially when you couple
the re-build with a full re-control or conversion to CNC. He
explains that in the case of re-making a machine for its cur-
rent user, If his process (has not dramatically changed), we
Over 50 years experience in the design and manufacture
of expanding mandrels and collet chucks
More precise and versatile than solid

mandrels or similar workholding
Quick and secure clamping
Interchangeable sleeves, in a range of sizes,
to cover a family of components
Suitable for almost all machining &
inspection procedures
A mechanical (change gear-driven) Modul ZFWZ800 gear hobbing

machine that was fully rebuilt and re-controlled to have four axes Collaborating with the worlds finest
and one spindle under CNC control. The CNC was Fanuc model www.chevintools.com Toll Free: 1 877 4 CHEVIN (847) 690 1278
0i-MD (Courtesy MTB).

feature If You (Re)build It, They Will Buy It
can assume that the original proven machine castings will work candidate for the re-control or re-build process. For example,
perfectly for (his) re-build project. The re-control or CNC con- the castings (which we always reuse) may not be suitable for the
version can use all the latest state-of-the-art controls and, as modifications required to implement the conversion to CNC.
such, can provide many of the newest technological features Another problem may be the structure of the machine is too
and the proper software. odd and flimsy, or the machine is simply not going to be rigid
And yet, pulling no punches, Goodfellow allows that in re- enough to provide sufficient process improvements to justify
purposing, There is significant risk, but balances that in add- the re-build.
ing that the cost savings may be justified especially with Staying with that point, Drakes Vosmik agrees that Physical
multiple machines and engineering utilized across more than age is not too important. Go back to productivityit does not
one machine. It is always about the money cost. matter how old or new the iron is, so long as it is stiff enough to
The mention of software gets right at one of the crucial ele- use todays cutting tools and abrasives.
ments of a successful, worthwhile re-do. The machines original OK: agenot so important. But the market is now flooded
capabilities must be considered, and more. For instance who with machinery boasting a much smaller footprint to accom-
writes the software? That can be tricky and time-consuming. modate todays factories, job shops and their lean manufactur-
The good news, however, is that todays sophisticated programs ing cells. Is a lean machine always the answer? Not so much,
can actually increase the likelihood that a re-do is economically actually, if you know your cutting machines.
justified. Ironically, the older gear cutting machines have smaller
As Adamski points out, A re-control will allow the machine footprints, Flowers reminds, following with a point that may
to use the most current software and features, which essentially surprise. Its the newer machines that are larger and consume
imparts new-machine capabilities, and Goodfellow adds that more floor space.
Applying a full CNC re-manufacture allows the latest CNC
technology to be applied to an old carcass, and often proves
cost-effective. But as to sourcing such software, he maintains
that Relatively few rebuilders have good software capabilities,
while machine tool re-manufacturers usually do.
Good, flexible process software can overcome quite a few
engineering challenges and help make a marginally productive,
manual machine a winner as a CNC machine, says Vosmik.
But again, the original process must have been stable on the
machinethe software and CNC retrofit can overcome the
inefficiencies of movement, but generally do not add cutting/
grinding stiffness.
Flowers says that Sometimes (software) is outsourced; but
two main issues occur therenamely, lack of support going
forward, and difficulty finding an expert in the subject matter.
After all, many programmers are not machine tool people. It is
best to choose a vendor that has a proven track record, because Before
it can take years to develop a robust, proven software pack-
age that embodies all the features and functions that a modern
machine would possess.
Gleason Straight
Gleason Bevel
straight bevel REVACYCLE Machine
REVACYCLE machine
Weve addressed some of the critical considerations, but decid-

ing to go the re-do route also requires finding a supplier who
knows where the bodies (parts) are buried or not (no longer
available). There is indeed a machine age-related tipping point.
As Gleasons Adamski puts it, Generally speaking, the older the
machine, the harder it is to rebuild. This is particularly true when
original components need replacement but become more difficult
to obtain, and substitutes require a high degree of engineering.
The single most difficult challenge is to determine how far
to update to what would be considered comparable to a new
machine, Goodfellow explains. There are limitations that exist;
you can (for example) replace ball screws, but the machine may
call for linear guides that create significant challenges.
On the other hand, MTBs Flowers maintains that the ques-
tions premise is off-base, in that it is not the age of the machine, After
as it is the beauty of its original design capabilities.
A machine might never be too old, he counters. But the
machine design could be such that it does not make a good These before-and-after photos from Gleason demonstrate the dramatic
results of a machine update (courtesy Gleason Corp.).

For Vosmik (addressing machinery in a broader context),
gear cutters aside, (Size) is another driver of the econom-
KEYWAYS
ics. In the past, stiffness was often achieved by mass and over-
engineering the statics. Today, the dynamics can be achieved by & SPLINES
other means and one can have a small, compact machine that
performs better than the old, massive machine.
UP TO 20
But Adamski makes the point that It can be (a problem), but IN LENGTH!
in many cases the rebuilt product is returned to the same space
it came from.
Three other points not yet addressed are biggies: price, war-
ranty, and delivery.
Regarding what youll pay, know this it varies. As one
might expect, cost depends on what you are buying and what
you will use it for; logistics are key as well.
It depends on the customers requirements, Adamski says,
also pointing out that (Another) major consideration is the
transportation expense to send the machine to Gleason and to
have returned to them when the rebuild has been completed.
Flowers stresses that (Cost) depends on the (carcass) price.
Rare, hard-to-find machines can fetch a steep price, even if
bought as a carcass. But he also says that some creative horse
or is it carcass? trading can help. Taking the customers
BROACHING SERVICES:
machine in trade can offset the additional expense of the carcass THROUGH, BLIND HOLE, KEYWAYS, SPLINES
purchase, provided the customer has a machine to trade in. SHAPING, SLOTTING AND KEY SEATING
As for warranty, one year is the typical industry standard. WWW.KEYWAY-SPLINE-BROACHING.COM

As for delivery timetheres nothing typical about it. And Call 262-820-1200 and broach the subject of why we are
up to a year is not atypical. THE KEYWAY & SPLINE CUTTING SPECIALISTS
It depends on many things, including the complexity of the Machines Tooling Subcontracting
product, condition you start with, customer requirements, and
availability of parts and resources that may be hard to find.
says Adamski.
Up to a year is accurate, Flowers allows, while managing to
somehow creatively invoke Henry Ford in his response. The
main difference lies in the roots of the mass production concept
laid down by Henry Ford. Once it is designed, you just build
many duplicates of it you can benefit from economies of
scale; familiarity; JIT (just-in-time) manufacturing and stock;
optimized production facilities, etc. Re-building is just a very
time-consuming process.
The bottom line here, according to Goodfellow, is that CNC
work will require the most time, due to the stripping out of the
old mechanical and re-designing and building into the carcass
the new technology.
All of the above reflects the presence of a mature market here
in the U.S. for machine re-builds and their variations. Weve
been doing it here for a very long time and doing it well. But
how about, say, Asian countries?China, for example.
Well defer to Vosmik on this one, given that he happened
to be in China on business when we caught up with him for
this article.
Almost (no market exists) in Chinathey want new, he
states flatly. They want productive; and, as important, the
Chinese government makes it difficult to import used equip-
ment even retrofitted and remanufactured.
While they want new sounds like a fashion statement,
those demands actually helped us (Drake) to discover how
much more productive our new machine designs could be vs.
the CNC retrofits and remanufactured machines. The dynam-

feature If You (Re)build It, They Will Buy It
Metrology Products Help Repurpose Rebuilds, etc.

Supplier provides machine tool users
assistance for retrofit and upgrade. When a retrofit application is presented, the machine needs
to be evaluatedboth mechanically and electricallyto under-
Frank Powell, product manager, Marposs Corp. stand the capability of the existing machine. For example:
Marposs supplies precision metrology equipment for improv- Is there a place to mount the new device?
ing productivity and reducing cost in manufacturing. And while Is the machine control capable of working with the new
the companys productssuch as gauges, sensors and probing device?
systemsare used on new machines, the same products are also What will be impact on the machine operation?
Most importantly, how much will this affect the machine
widely used for the retrofit and upgrade of existing machines.
operators job?
Marposs supports individual machine tool users with hard-
ware, software and service where a retrofit or upgrade may be When looking at the machine to decide what would be used
accomplished on-site and in coordination with the customers in a gauge retrofit, we start with the machine itself. Some of the
in-house maintenance staff. Marposs also serves as a supplier things that we evaluate include:
to many machine tool OEMs and integrators, but, as with the Determining available space within the tooling to install the
above, companies that specialize in rebuilding and remanufac- gauge
turing machines as well. Accessibility to the feature of the part to be gauged
In some cases, it is possible to incorporate these products Available clearance to load and unload the part in the
machine
in existing machine tools without machine modification, as
Marposs products are designed specifically for the machine tool That last item is very important, especially when the machine
environment. is manually loaded. If a new device is added to an existing
machine, and it impedes the operators normal routine, the
ic performance gains we were able to achieve with our new associated with direct-drive systems and torque motors; gear
designsdesigns initially made for the China marketdrove grinders with on-board inspection capabilities; shapers with
new productivity advancements around the globe. electronic guides, etc. All these candidates will at some point
As for re-doing thread and form grinding machines, Vosmik become targets for re-building and re-controlling.
believes that The productivity of our new machines vs. the Goodfellow couches his answer in a historical perspective.
retrofits has basically led our customers and, consequently, It will always be with us, as it has for the last 60 years.
us out of the re-manufacturing business. The productivity For more information:
of a new thread grinder is in its stiffness and the ability to uti- James Vosmik, President
lize modern abrasives. The productivity and finish gains from a Drake Manufacturing Services Co.
4371 N. Leavitt Road
new thread grinder far outweigh the savings from a remanufac- Warren, OH 44485 U.S.
ture and CNC retrofit, in most situations. (But) we still perform Phone: (330) 847-7291
in-plant CNC replacements where a machines electrical system [email protected]
www.drakemfg.com
is outdated and unreliable but the machine is still productive.
Will the re-build industry remain economicaland in Jerry Adamski, Global Customer Service Director
demanda decade from now? And what will it look like? Gleason Corporation
(It is) moving toward CNC replacements and linear rail/ 1000 University Avenue
Rochester, New York 14607 U.S.
truck replacements almost a heavy-maintenance type of Phone: (585) 461-8052
approach, says Vosmik. [email protected]
As for Adamski, As the price point for new machines con- www.gleason.com/globalservices
tinues to drop it may be more challenging for the re-build mar-
Kenneth J. Flowers, Owner, VP Sales
ket to sustain growth. Re-controls and machines with unique Machine Tool Builders, Inc.
capabilities where there are not newer alternatives will have the 7723 Burden Road
greatest success. Machesney Park, IL 61115 U.S.
Phone: (815) 636-7592
As for MTB (where re-working is its predominant business [email protected]
model), Flowers acknowledges an awareness of a landscape that www.machinetoolbuilders.com
is rapidly changing while projecting an eagerness and ability
to adapt to it. In not too many years hence, re-builders will be David Goodfellow, President
Star SU LLC
incorporating the newest wine (technology) into what will by 5200 Prairie Stone Parkway, Suite 100
then be older bottles OK, carcasses. Hoffman Estates, IL 60192 U.S.
Re-building will not go away, he states. But the machines Phone: (847)649-1450
Fax: (847) 649-0112
that are being rebuilt will have a different mix. The technology [email protected]
has advanced so much that the re-builders will have to step up www.star-su.com
their game to stay current and be able to tackle the problems

face; this way there are no requirements to change the machine
as it is currently running. If we are adding a new device to
a machine that never had one, then we must make sure the
machine control has the support systems in place for the new
device. This may require modifying software in the machine,
and/or adding solenoids, flow controls, piping, etc. to operate
the device. In some older machines with OEM proprietary con-
trols, the OEM would need to be consulted on possible modifi-
cations before proceeding with the upgrade.
Unfortunately, many OEMs of older machines are no lon-
ger in business, so a new control may be required. In that case,
Marposs will work with an integrator of the customers choice.
Once the machine environment, function and customer
needs and expectations are established, Marposs application
The grinder shown was originally upgraded by Marposs in the 1970s, engineers will design the proper system that will work with the
using an in-process gauge for automating the original, manually machine and process. Through numerous applications annually,
operated machine. It is an example of an existing machine that could many manufacturers find that new life can be put back into an
be a candidate for modernizing again, using the latest state-of-the-art
technology to add renewed life and performance. existing machine by installing modern gauges, sensors and/or
probing systems as part of a retrofit, rebuild or remanufacture
system will never work. The best possible scenario for installa- program.
tion of a new gauge on a machine is that it is transparent to the For more information:
machine operator. Once it is determined that there is a place Marposs Corp. North America
for the gauge, the next step is to evaluate the machines control 3300 Cross Creek Parkway
Auburn Hills, Michigan 48326
capability. Phone: (248) 370-0404
If the machine has an existing device that we are upgrading, Fax: (248) 370-0991
we need to see if it is possible to connect to the existing inter- [email protected]

gear train
Gear Research Institute: A Big Part of

Small World of U.S. Gear Research
The essence of designing gears few other companies. GRI maintains its
is often by necessity risk-averse, registration there to this day.)
given that many of them are GRI also shares DNA with sever-
used in applications where loss al other Penn State centers of research.
of life is a distinct possibility. Suren Rao, senior scientist and longtime
The Gear Research Institute (GRI) at managing director at GRI, explains.
The Pennsylvania State University con- ARL was started in 1945 and is an
ducts risk reduction testing with the inter-disciplinary research institute of
same goal in mindwhether it be gears Penn State, sponsored by the Navy. The
in fighter jets, Ferris wheels, tanks, or Drivetrain Technology Center (DTC)
countless other gear-reliant vehicles and was started in 1992 as a division of ARL
machinery. with support from the Navy ManTech
The institute, founded in 1982, exists program. GRI, started in 1982, became
to provide and supplement gear and a long-term sponsor of the DTC in 1996
related technological needs by conduct- because of the synergy between the
ing research and development, con- activities of DTC and GRI.
sulting, analysis and testing. GRI has GRI also boasts close ties with
long prided itself on being a leading the American Gear Manufacturing
proponent of cooperative pre-competi- Association (AGMA) and the American
tive research, but is also quite active in Society of Mechanical Engineers
working with individual companies in (ASME). How close? Six of the 10 mem-
their R&D projects. (Ed.s Note: An inter- bers comprising GRIs board of trustees
esting historical fact regarding the GRI is are nominated by ASME and AGMA.
that it was in fact founded in Illinois, in a As for trying to single out a particu-
Chicago suburb, by a group of gear engi- lar area of expertise relative to GRI, you
neers from International Harvester and a might say consider them something akin
to generalists in the gear world.
Or as Rao puts it: The common
theme is to improve the performance
of geared systems. Performance can be
many things like durability/life/power
density/noise, etc.
For non-profit entities such as GRI,
its all about developingand main-
tainingclose corporate relationships.
Without them, the institute could not
exist. And that existence is based in part
on the required $600 annual member-
ship fee. Some of those dollars are used
to support post- and undergraduate pro-
grams for Penn State students with engi-
neering careers in mind.
Undergraduates will work on any
research activity that needs support. A
graduate program will focus on a more
formal defined topic that would consti-
tute their thesis, says Rao.
Great idea! Right?
Some of the machinery used in GRIs research and testing efforts (photos courtesy GRI).

Unfortunatelyif not surprisingly federal flow-thru through the corporate
the level of participation thus far has sponsor.
been rather dismal. One might think another type of
To date, we have had only one com- fundingfrom the Dept. of Defense, for
pany, John Deere, sponsor and recruit an examplemight be drying up, given the
undergraduate through GRIs program, sequester.
Rao says. We have had a few other Surprisingly, however, At the moment
enquires, but no other bites so far. (early 2013), we have not seen the fund-
Not to point fingers, but this is the ing stream affected, says Rao. It is tight;
reality despite the continual hand-wring- but it has always been tight.
ing and lamentations we read and hear Which leads us back again to GRIs
about on the part of corporations/manu- cooperative pre-competitive research Suren Rao, GRI managing
director.
facturers bemoaning the dearth of tal- business model. Things look pretty good
ented young people pursuing engineer- in the aerospace sector for the institute,
ing and manufacturing careers. Why this but in other areasless so.
disconnect? Could it be that published Rao explains that At its heyday
reports and opinion pieces claiming that, (1980s), GRI had three or four research
despite American Businesss dire need groups conducting research in the cat-
for these new workers, they expect gov- egory of cooperative, pre-competitive
ernment to foot the entire bill? Just ask- research. Only two survived the relo-
ing. cation of GRIs activities to central
Returning to the subject of coopera- Pennsylvania. I would consider this
tive pre-competitive research, we asked reduction as a result of geographical
Rao for his own, non-Harvard Business obstacles. In the early 2000s the Vehicle
School definition. Research Bloc (GM, Ford, New Venture
The term cooperative is derived
from the fact that the cost of the research
effort is shared among several compa- To be honest locating sufficient funding
nies. Since the research results are shared
between several competitors, without to keep GRI alive, in spite of the minimal
any restraint, the effort is generally clas- competition, is a herculean task.
sified as pre-competitive. Suren Rao
But eventually, real-world reali-
ty reigns and cooperation reverts to
competitive.
The individual sponsors generally Gear, etc.) went into a steep financial
stop the research effort once they real- decline and decided not to continue to
ize that any further sharing would erode support GRI.
their competitive position, Rao says. That response prompted asking
And speaking of individual sponsor Rao to compare what GRI does with
research, the funding behind it is often- the work done at the Gear and Power
times anything but individual. Transmission Research Laboratory
Sometimes the single-client effort is (GearLab). Coincidentallyand it is in
funded by the sponsors internal R&D fact only coincidenceboth institutions
funds, Rao explains. In many instances began around the same time.
GRI supports a larger corporate pro- Until about five years ago, GearLab
gram that is funded by the Federal at OSU focused its efforts on gear noise,
Government (e.g., DoD, DoC, DoE), in and GRI focused (its) efforts on gear
which case GRIs funding is termed a materials and fatigue evaluation, he
points out. Apparently OSUs GearLab

gear train
(For their $600 gift) the corporate sponsor

(of Penn State graduates and undergraduates) can give them a better life than they have
in their native land.
gets the satisfaction that they are helping Good answer. But then theres this:
educating the next generation of gear during lunch recently with a young man-
engineers. agement person working for a major
company in the power transmission
Suren Rao component industry, he said that while
he was in school (a well-known private
university in Chicago), professors went
has expanded into fatigue testing in the out of their way to dissuade their stu-
recent past. dents from pursuing a career in engi-
In our March-April Gear Technology neering/manufacturing.
we asked GearLab director Ahmet Raos reaction:
Kahraman why there are so few institu- I am very saddened by this. No won-
tions like his the U.S. And so we asked der everything we utilize in our daily
Rao the same question. In some ways lives comes from China or Taiwan. I am
his answer creates more questions than also of the opinion that manufacturing
answers. is a very significant component of the
To be honest, locating sufficient wealth creation activity of any nation.
funding to keep GRI alive, in spite of We are all poorer as a result.
the minimal competition, is a hercule- For more information:
an task. Maybe I am a lousy salesman; Suren Rao
but marketing research for a technology Gear Research Institute
Applied Research Laboratory
that most consider ancient, is difficult The Pennsylvania State University
enough with just two or three players P.O. Box 30
(i.e., GRI, OSU Gear Lab, NASA-Gear State College, PA 16804-0030
Phone: (814) 863-9749
Research Center). If there were more, Fax: (814)863-6185
some of us would have to close. [email protected]
Raos candid response compels us to
ask of him the same
question we pose to vir-
tually anyone with an
enduring stake in the
gear industr y and
more importantlythe
countrys future: Given For Related Articles Search
the dwindling number
of aspiring engineers research
and skilled workers, do at www.geartechnology.com
you fear for the future of

high-tech manufactur-
ing in the U.S.?
That is a real con-
c e r n , R a o a l l o w s .
Howe ver, I am an
optimist. As a nation
of immigrants, we will
attract the best the
world has to offer if we
Single-tooth fixture equipment used for bending fatigue testing

ask the expert
Operating
Email your questionalong with your name,
job title and company name (if you wish to
remain anonymous, no problem) to: jmcguinn@
geartechnology.com; or submit your question by
Pressure
visiting geartechnology.com.
Angle
question
What is the difference between pressure angle and operating pressure angle?
Answer provided by John Mayhan, Xtek, Inc.

The pressure angle of a standard gear is defined as the angle
formed by a line tangent to the pitch circle, and the line nor-
mal to the tooth profile at the pitch circle. The profile angle is
defined as the angle formed by the line tangent to the tooth sur-
face, and the line normal to the pitch surface at a specified pitch
point. The profile angle is determined by the tool used to form
the involute curvature of the gear teeth. For a standard gear
profile, these angles are equal (Fig. 1).
The operating pressure angle is defined as the angle formed
by the line tangent to both base circle diameters of the mating
gears, and the line normal to their intersecting pitch circles. It
is common to design mating gears with base circles that dif-
fer from the standard dimensions, and that operate at center
distances different from the standard center distance. In these
cases the pressure angle generated by the tool will differ from
the pressure angle at which the gears will operate (Fig. 2).
John Mayhan, vice president, engineering for Xtek Inc.;
11451 Reading Road; Cincinnati, Ohio 45241;
Phone: (513) 733-7993.
Figure 2A pressure angle generated by the tool will differ from the
pressure angle at which the gears will operate.
Figure 1Standard gear profile with equal angles (Figures courtesy

Xtek, Inc.).

Answer provided by Dr. Hermann J. Stadtfeld, Gleason Corp.
If a cylindrical gear with a certain positive addendum modifi-
cation is mated with a cylindrical gear having the same amount
of negative addendum modification (V0 gearing), then the cen-
ter distance will be the same as that of a gear set with no modi-
fications (module times half the sum of pinion and gear teeth).
A quantum leap for
The pitch lines in both cases (no modification or a V0 profile
shift) will be the same, and the pitch diameter is, in both cases,
the overall inspection
calculated as module times the number of teeth. The relation-
ship between the two pitch diameters (or the pitch radii) is
of hob cutters!
equal to the relationship of the tooth count of the two mem-
bers (ratio). For involute gearing, the pitch circle is defined The hobCheck combines leading ZOLLER measu-
from the location, where the two interacting surfaces show no ring technology with the proven user-friendly and
sliding, but pure rolling. This is where the line of engagement worldwide unrivalled software pilot 3.0.
intersects the center connecting line, as shown in the involute
development in Figure 1. R1a (Fig. 1) is the pitch radius, and the
pressure angle is defined between the orthogonal to the line of
engagement and the pitch radius R1a in the pitch point.
Worldwide unrivalled
software pilot 3.0
hobCheck
You want
to know more?
Figure 1Line of engagement and pressure angle (Figures courtesy www.zoller-usa.com

Gleason Corp.).

RZ_Variante_1_ad_hobCheck_89x247_5_US.indd 1 19.12.2012 10:32:50
ask the expert
If one of the two cylindrical gears has an

addendum modification (Fig. 2) and the
mate does not, then the center distance
changes. It is calculated as module times
half the sum of pinion and gear teeth, plus
module times(whereis the addendum
modification factor or profile shift factor).
It is interesting that in such a scenario the
original pitch circles of the two gears lose
their function. The interaction of the invo-
lutes of two differently profile-shifted gears
(not V0 gearing) will lead to a new line of
engagement (Fig. 3; red line of engagement Figure 2Principle of addendum modification (or profile shift X).
for a+a) and a new working pitch point
between them where the sliding velocity is zero and the rela-
tionship between the radii from the center of the two gears to
that point is again equal to the relationship of the tooth count of
the two members (ratio).
The new profile dividing line is called
the operating pitch line. The pressure
angle, which was based on the nominal
pitch lines during the manufacturing of the
individual gears, can now be determined at
the operating pitch line location. In Figure
2, the pressure angle can be found in the
pitch point, and the operating (or work-
ing) pressure angle is defined in the work-
ing pitch point. Figure 3 clearly shows the
difference between the two lines of engage-
ment (which is equal to the difference
between the pressure angle and the oper-
ating pressure angle). The operating pres-
sure angle is more relevant to the gear sets
operating performance and is also required
to calculate the bearing forces. The pres-
sure angles of the tools are independent
Figure 3Pitch point and working pitch point after center distance change.
from operating conditions, but reflect the
nominal pressure angles.
Dr. Stadtfeld is Gleason Corp. vice president, bevel gear
technology, R&D
pressure angle
Dr. Hermann The Expert Stadtfeld, drawing involute and pitch line.

ISO/IEC 17025 CERTIFIED
GEAR LAB
FULL SERVICE CONTRACT INSPECTION
REVERSE ENGINEERING
SORTING
THIRD-PARTY VALIDATION
LEADING EDGE INSPECTION EQUIPMENT
HIGHLY TRAINED STAFF
FOR MORE INFORMATION, CONTACT TOM ACKER AT 1-734-793-2394
36251 SCHOOLCRAFT RD
LIVONIA, MI 48150
WWW.DELTAINSPECT.COM
technical
Gear Design Optimization for Low-

Contact Temperature of a High-Speed,
Non-Lubricated Spur Gear Pair
Carlos H. Wink and Nandkishor S. Mantri
A gear design optimization approach applied to reduce tooth contact temperature and noise excitation of a high-speed spur
gear pair running without lubricant. Optimum gear design search was done using the Run Many Cases software program.
Thirty-one of over 480,000 possible gear designs were considered, based on low contact temperature and low transmission
error. The best gear design was selected considering its manufacturability.
Introduction Contact pressure of gear teeth in mesh also changes along the line
Eliminating lubricant in geared systems is both cost-saving and of action (Ref. 3). Heat is generated by sliding friction of tooth
environmentally sound, but d o e s pose some technical chal- surfaces. The temperature distribution is proportional to the
lenges. Metal-to-metal contact of tooth surfaces sliding and roll- distribution of contact pressure and sliding velocity. The instan-
ing against each other under contact pressure causes high tooth taneous (or flash) temperature of tooth contact along the line of
temperature that may result in material microstructure changes. action is calculated by Bloks contact temperature theory (Ref. 4).
Tooth surfaces can severely wear away and even deform plasti- The contact temperature is the sum of maximum flash tem-
cally. Tooth-sliding velocity and contact pressure can be reduced perature along the line-of-action and the tooth temperature,
by changing the gear design. However, such design changes may which is the temperature of the tooth surface before it enters
adversely affect gear dynamics and noisecritical parameters the contact zone (Ref. 4).
of high-speed gears. This paper presents a gear design opti- The maximum contact temperature is obtained by Equation 1:
(1)
mization approach that was applied to reduce both tooth con- B max = M + fl max
tact temperature and noise excitation of a high-speed spur gear
pair running without lubricant. After defining upper and lower where:
M is tooth temperature, C
boundaries of the main design parameters, and the problem con-
fl max is maximum flash temperature along the line-of-action
straints, an exhaustive search within the feasible design region
which is calculated by Bloks equation:
was done using the RMC (Run Many Cases) software program (2)
from The Ohio State University (OSU) GearLab (Ref. 1). Each X(i) wn vr1(i) - vr2(i)
one of the designs was critically analyzed in terms of manufac- fl(i)=3162 K m(i)
(b ) BM1(vr1(i)) BM2(vr2(i))
0.5 0.5 0.5
turability. The selected optimum gear design was compared to H(i)
an existing gearset using LDP (Load Distribution Program) soft- where:

warealso from OSU (Ref. 2)which was also used to opti- K is 0.80a numerical factor for the Hertzian distribution
mize microgeometry modification of profile and lead. Tooth con- of frictional heat over the instantaneous contact band
tact temperature was calculated by LDP for both the existing and width;
optimum design, and with a dry, steel-on-steel coefficient-of-fric- m(i) is mean coefficient-of-friction;
tion. A favorable correlation between predicted tooth contact X(i) is load-sharing factor;
temperature of the existing gearset and test results was realized. wn is normal-unit-load, N/mm;
A 48 percent reduction of tooth contact temperature and a 79 X (i) is semi-width of the Hertzian contact band,mm;
percent reduction of transmission error were achieved with the BM1 is thermal contact coefficients of the pinion, and given by
optimized gear design. The low contact temperature of the opti- BM = 10-3 (M M CM)0.5
BM2 is thermal contact coefficients of the gear, and given by
mized design can significantly contribute to preventing tooth
BM = 10-3 (M M CM)0.5
surface damage under no-lubricant operating conditions.
M is heat conductivity, W/(m.K)
M is material density in kg/m3
Tooth Contact Temperature CM is specific heat-per-unit-of-mass in J/(kg.K).
Conjugate action of gear teeth in mesh consists primarily of slid- vr1(i) is rolling tangential velocities in m/s of the pinion;
ing and rolling motions. At the pitch line, sliding velocity is zero; vr2(i) is rolling tangential velocities in m/s of the gear;
however, sliding velocity increases when the conjugated tooth i is a subscript of line-of-action points.
contact line travels away from the pitch line in both directions.
Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Fifth Floor, Alexandria, VA 22314-1587. Statements
presented in this paper are those of the author(s) and may not represent the position or opinion of the American Gear Manufacturers Association.

Gear Dynamics and Noise The gears were made of SAE 4100 (Cr-Mo) series steel and
Transmission error (TE) is widely accepted in the gear communi- induction-hardened to 5661 HRC surface hardness. Tooth
ty as one of the major excitation sources of noise and vibration of flanks were ground to achieve AGMA grade A4 (Ref. 8). The
geared systems (Refs. 3 and 5). gear samples were submitted to a dynamometer cycle of rota-
TE can be described as irregularities of the motion transmitted tional speeds up to 16,000rpm (pitch line velocity up to 36.3
by gear pairs caused by deviations from the ideal tooth contact; m/s), and light loads (up to 0.86 N-m/mm of face width). The
these irregularities stem from tooth topological modifications, outlet air temperature recorded during the test was 150C.
manufacturing deviations, shaft deflections, tooth deflections Figure 1 shows the baseline gearset after over 100 hours of test-
and mesh stiffness variation along the line-of-action. Relative ing.
accelerations between the gears caused by TE result in vibration of The drive-side of the teeth of both gears was severely worn, and
gear masses and dynamic tooth forces (Ref. 6). material plastically flowed out toward the two faces (Fig. 2). The
Transmission error may be expressed as a linear displacement amount of wear measured on tooth profile of the driver gear (Figs.
along the line-of-actions by Equation 3. 1 and 2) was 0.130mm, and the driven gear was 0.115mm.
(3)
Both gears were metallurgically analyzed. Microhardness-
( )
TE = Rb 2 zz2 1
1 measured results on the gear teeth indicated that the gears were
where: exposed to a temperature range of 450C and 510C, which was
TE is transmission error,mm, estimated using the material tempering curve.
Rb is gear base radius In parallel with the metallurgical analysis, the tooth contact
1, 2 are the angular rotation of pinion (input) and output gear, temperature was calculated using the LDP program (Table 1).
respectively, The results of tooth contact temperature are shown (Fig. 3) for
z1, z2 are the number of teeth of pinion (input) and output gear, the baseline gear set, which is close to the lower limit estimated
respectively.
from the metallurgical analysis. In addition to the tooth contact
The dynamic response of the geared system to TE excitation temperature prediction at nominal design condition, a robustness
is influenced by the mass and stiffness of gears, shaft and other
major internal components, and by damping characteristics
(Ref. 6).
Gear Design Optimization Approach

The challenge is a multi-objective optimization to minimize tooth
contact temperature and transmission error, subject to maxi-
mum contact and tooth root stresses below allowable stresses
values; and also subject to constraints related to packaging size,
such as mounting center distance and maximum face width; and
manufacturability such as undercut condition, minimum top-
land, and root clearance. There are many design variables to
be determined as part of the problem solution; these variables
refer to the gear geometrical parameterse.g., module, pressure
Figure 1Baseline gear set after test.
angle, addendum modifications and outside diameter.
One convenient and robust approach for solving this opti-
mization challenge is to combine the gear design knowledge
and computational power of modern computers to completely
sweep or search the feasible design region to find the optimum
design.
Using the RMC program developed by the GearLab (Ref. 1), thou-
sands of potential gear design candidates are quickly generated
and analyzed based on the gear designers input. The gearset that
best meets the objective functions and constraints can be identi-
fied using range reduction methods that select design candidates
within defined ranges and parameter prioritization (Ref. 7).
Application Example
An existing spur gear set of an automotive timing gear application
that runs at high speed was tested without lubrication; results of
this exploratory test were used to create a baseline for comparison
with the optimized design.
Figure 2Base gear teeth after test.

technical
analysis was also performed over deviations and tolerances speci- distance and gear face width were kept the same as the current
fied on the gear drawings (Fig. 4). design; gear ratio is 1.0.
The robustness analysis results indicate that the tooth contact A total of 483,372 good gear design candidates were generated
temperature prediction for the baseline gearset falls in a range of under those conditions (Fig. 5).
411C543C with an average of 475C and standard devia- RMC uses a modified equation to calculate tooth contact tem-
tion of 23.78C. As such, excellent correlation was established perature that is different from Equations 1 and 2; thus RMC
for the baseline gear set. results were used as directional values only.
The boundary conditions were then established for the opti- The Range Reduction Method in RMC was used to eliminate
mum design search in RMC, along with upper and lower limits for candidates with bending and contact stresses that exceed the
the design parameters (Table 2). The last column in Table 2 is the allowable stresses for the applicationdespite the acceptable con-
number of points between the lower and upper limits. Center tact temperature and transmission error. The 31 candidates that
met the given restrictions are displayed (Fig. 6). The differences
among them in terms of tooth contact temperature and transmis-
sion errors are minor. (The point identified with a star was the one
Table 1Temperature parameters used for the calculation
Parameter Value selected as the best design because of its manufacturability.)
Coefficient of friction 0.5
Inlet bulk temperature 150C
Thermal conductivity 48 W/(m K)
Density 7860 kg/m3
Specific heat 544 J/(kg K)
Figure 5RMC transmission error vs. tooth contact temperature results.

Figure 3Predicted tooth contact temperature of baseline gear set.
Figure 4Robustness analysis of baseline gear set. Figure 6RMC best results (* identifies the selected design).

Table 2Variable limits for optimization For Related Articles Search
Design parameter Value Levels
Number of teeth 10 - 60 51
design optimization
Pressure angle, degrees 12.5 - 25 20 at www.geartechnology.com
Tool dedendum coefficient 1 - 1.2 10
Hob shift level - 10
Backlash coefficient 0.048 -
Minimum topland coefficient 0.20 - Summary
Minimum root clearance 0.15 - Favorable agreement between the predicted tooth contact
Minimum SAP roll angle, degrees 4 -
temperature using LDP and the temperature estimated from
Table 3Results before and after optimization microhardness and material tempering curve was obtained to
Parameter Current gear set Optimized gear set an existing gear set that was tested at high speed and without
Number of teeth 41 57 lubrication. The gear design was then optimized using both the
Module,mm 1.06 0.75 RMC and LDP programs. The best gear design for low contact
Pressure angle, degrees 14 18 temperature and low transmission error was selected from more
Contact ratio 52.24 2.15 than 480,000 designs. A 48 percent reduction of tooth contact
Slide to roll ratio 1.32 0.63
Contact stress, MPa 7.97 752
temperature and a 79 percent reduction of transmission error
Tooth root stress, MPa 1.31 198 were achieved with the optimized gear design, which is also more
PPTE, m 0.59 0.12 robust to manufacturing deviations than the current design. The
Contact temperature, C 447 232 main reason for the reduction in contact temperature of the opti-
mized design was the slip-to-roll ratio reduction, which was pro-
The best design geometry was then transferred into LDP portional to the reduction in temperature. The low contact tem-
to confirm the calculation results, optimize micro-geometry perature of the optimized design can significantly contribute to
modifications, and do robustness analysis. Microgeometry prevent tooth surface damage under no-lubricant operating con-
modifications were defined using the LDP 3D Microgeometry ditions, which will be confirmed through dynamometer endur-
Analysis module as 26mm profile crown, and 04mm lead ance testing.
crown. Table 3 shows a comparison of the current design and the
optimized design for low contact temperature and transmission Acknowledgments
error (PPTE). The authors thank Eaton Corporations Vehicle Group for sup-
The robustness analysis also showed that the optimized design port to develop this paper.
is less sensitive to manufacturing deviations than the cur-
rent one. Predicted tooth contact temperature ranges from References
233C262Cwith a standard deviation of 6.16C; compared 1. Run Many Cases RMC3K. Computer Program, GearLab, The Ohio State
University, 2010.
to the 411C543Cwith a standard deviation of 23.78C for the 2. Windows LDP 4.0.0. Computer Program, GearLab, The Ohio State
current design. University, 2011.
Gear samples were made for validation testing (Fig. 7). Two 3. Townsend, D. P. Dudleys Gear Handbook, McGraw-Hill, Second Edition,
heat treatment processes were considered: 1) induction hard- 1992.
4. AGMA 925A03. Effect of Lubrication on Gear Surface Distress.
ening (current process) and 2) nitridingwhich may provide 5. Smith, J. D. Gear Noise and Vibration, Marcel Dekker, Second Edition, 2003.
additional wear resistance because of high surface hardness and 6. ANSI/AGMA 2001D04. Fundamental Rating Factors and Calculation
a white, nitrided layer; in this case the gears were finished before Methods for Involute Spur and Helical Gear Teeth.
nitriding. 7. Ghezzi, L. Multiple-Mesh Gear Optimization Procedures Using Run Many
Cases, MS Thesis, The Ohio State University, Columbus, OH, 2004.
The gear samples of the optimized design were tested with 8. ANSI/AGMA 2015A01. Accuracy Classification System: Tangential
the same dynamometer cycle used for the current gear endur- Measurements for Cylindrical Gears.
ance testing, and results will be compared to the current gear set
test results.
Carlos Wink works for Eaton at their Vehicle Groups
headquarters in Galesburg, Michigan as global
CoE, gear engineering manager. He has 28 years of
experience in gear manufacturing and the design of
geared systems for trucks, automotive, hydraulic, and
aerospace applications. Wink has a PhD and master
degree in mechanical engineeringwith a focus
on gear designfrom the University of Campinas
(UNICAMP) in Brazil. Wink also holds a bachelor of science degree in
mechanical engineering from the University of Santa Cecilia, also in Brazil.
Nandkisor (Yash) Mantri works for Eaton in
Pune-India as a lead gear engineer. He has 14 years of
experience in the gear field, six of them specializing in
gear design and gear manufacturing, and eight years in
gear cutting tool design. Prior to joining Eaton, Mantri
worked for Dagger Forsts Ltd., and Jainex Aamcol Ltd.
He has a master degree in design from BITS, India.
Figure 7Gear samples of optimized design.

technical
Light-Weight Assembled Gears:

A Green Design Solution for Passenger
and Commercial Vehicles
Thales Sardinha Garcia Souza, Dr.-Ing. Mauro Moraes de Souza
and Juliano Savoy
Introduction limited weight optimization potential, due to the manufacturing

Discussions on climate change have been posing automotive process trade-off. Therefore, this challenge must be met through
industry challenges, as carmakers have to meet tight emission innovation.
standards from different countries. The European Commission
established through Regulations 443/2009 and 510/2011 the Existing Technology
goal of limiting average CO2 emissions from new passenger Gears are an elementary component of vehicle transmissions.
cars to 130 grams-per-km by 2012a reduction of around 25% The manufacturing and machining of gears is therefore a central
from 2006 levels (Ref. 1). This trend also exists in other coun- task in the transmission production. There is, on one hand, the
triesBrazil, for onewhich through Regulations 418/2011 possibility of giving the tooth contour its final geometry already
and 315/2002 set new emissions limits for CO (carbon monox- in the soft state, in which case the gear only need be hardened.
ide), HC (hydrocarbon) and NOx (nitric/nitrogen oxides) (Ref. The advantage of this method is the short process chain and
2). According to Steinberg (Ref. 3), the cost of reducing each resultant lower costs. On the other hand, inaccuracies caused by
gram of CO2/km has already risen from $17.03 (13) to $65.50 distortion due to hardening are usually unacceptable, in which
(50)before the 2020 target of 159 g of CO2/km has even been case hard machining must follow the hardening process. Figure
reached. 1 shows a planetary gear in various machining steps (Ref. 4).
It is widely recognized that the reduction of CO2 requires con- The current manufacturing process trade-off is presents itself
sistent light-weight design of the entire vehicle. Likewise, the in the forging operation, where, the higher the forging effort,
trend towards electric cars requires light-weight design to com- the lower the wall thickness. Presses must operate with a mini-
pensate for the additional weight of battery systems. The need mum distance between punch and die in order to keep the
for weight reduction is also present regarding vehicle transmis- press force under workable levels. Moreover, tool failure may be
sions. Besides the design of the gearbox housing, rotating mass- expected if this gap is not big enough to accommodate machine
es such as gear wheels and shafts have a significant impact on elasticity while operating with no working piece. Figure 2 shows
fuel consumption. The current technology shows little poten- the minimum thickness achievable for a gear body, and the shaft
tial of gear weight reduction due to the trade-off between mass elasticity during the forging process.
optimization and the manufacturing process. Gears are usually As a result, the wall thickness of the final product will be
forged followed or not by teeth cutting operation. Due to the constrained by this gap, which leads to a limited light-weight
elasticity of the equipment, current presses must operate with design. Figure 3 presents (Gear 1) the minimum wall thickness
a minimum distance between punch and die in order to avoid required for structural approval for a typical gear for a manual
tool failure when operating with no working piece. Also, the transmission; (Gear 2) exhibits the minimum wall thickness
press force is determined by this gap in cases where some flash possible in the forging. One can see that a reduction of 30% on
is formed during forging; and a minimum flash is required for a the gear body width would lead to a 14% mass reduction on the
forgeable part using the available press. This issue constrains the finished gear.
minimum wall thickness of a final product; e.g.the body of
an automotive gear. Therefore, some
gear designs must have a more robust
wall thickness than is usually needed
due to this conceptual restriction. This
applies even if a thinner wall thick-
ness were approved by accepted crite-
ria such as stiffness, permissible stress
and NVH (noise/vibration/harshness).
For these reasons, a gear that achieves
the abovementioned goals is greatly
coveted and will in fact be presented A B C
Figure 1Machining steps of a planetary gear: 1) forging; 2) turned blank; 3) soft- hobbed gear; 4)
here. Existing technology affords only hardened and finished gear (Ref. 4).

Some versions are designed with an asym-
metric gear body in order to optimize the stiff-
ness in a certain direction; also available are ver-
sions with holes which will reduce the weight.
Nevertheless, these versions are weight-con-
strained by their own process requiring initial
forging. That being the reality, further optimi-
zation must be achieved through an innovative
solution.
Light-Weight Assembled Gear

The method/process used in attaining the
necessary optimization is grounded in the idea Figure 2Minimum gap and shaft deformation for a typical horizontal press.
of redistributed mass combined with an assem-
bly process that maintains the system under
radial pre-load. Figure 4 describes each part
of the light-weight assembled gear: plate A is
mounted on the gear ring B and on the inner
part C by radial deformation in the elastic field.
The system is axially locked when the plate
reaches the existing steps for B and C. It is
tangentially locked due to D, and by the radial
pre-load that results from the plate deformation
during the assembly process.
The new concept requires a customized man-
ufacturing process (Fig. 5). It starts with forg-
ing and machining of the inner and outer part,
followed by heat treatment, assembly and teeth
grinding in order to eliminate potential concen-
tricity errors deriving from the assembly pro-
cess. The advantages of this process are: Figure 3Body width difference for a conventional forged gear of
Different materials can be used for the inner manual transmissions (Ref. 5).
and outer part. In other words, a more sub-
stantial and more expensive steel is restricted
to the outer partwhich must present the
highest mechanical strengthwhile the other
parts can be manufactured with lesser steels
or alternative materials.
The heat treatment can be applied locally. For
instance, the carburizing would be applied
only to the outer region, while the inner
region can be conventionally quenched and
tempered. According to the geometry of the
inner hub, shape of the splines, and transmit-
ted torque, the heat treatment can in fact be
eliminated. Both characteristics lead to cost
advantages for the final product.
Design advantages are achieved by moving
the gear body material farther from the neutral
line, leading to a section that presents a high-
er moment-of-inertia on the axial direction.
Comparing this proposed design with a stan-
dard gear, it can be seen (Fig. 6) that an increase
of 43.4% of axial stiffness is attainedwith 0%
Figure 4Light weight assembled gear concept.
weight alteration.
The stiffness advantage results in a lower axial
displacement variation of the gear teeth during
a transient torque, leading to enhanced NVH
behavior. By designing the articulation point

technical
farther away from the neutral line, a lower angular

variation of the gear body is realized (Fig. 7).
In addition to the lower angular variation, the teeth
contact area is positively affected. A homogeneous
contact path between the input pinion gear and the
output light-weight gear during alternating loads
now exists. In other words, the gear wheel perfor-
mance is enhanced while the profile correction
effort is reducedif not eliminated entirely (Fig. 8).
The performance limit for gear wheel designs
is basically determined by tooth failure resistance.
Vibration fatigue, pitting, scuffing, wear, spalling
Figure 5Customized manufacturing process. and bending stress at the root diam-
eter are the main causes for tooth
damage (Ref. 8).
Shown damage types (Fig. 9) limit
the load capacity of the gear wheels;
according to Naunheimer (Ref. 4),
the major factors that lead to these
failures are:
Operating conditions (type of load;
tooth forces and additional forces;
Figure 6CAD data comparison between the light-weight assembled gear and circumferential speed; tempera-
the current state of the art. ture)
Selection of materials
Gear geometry
Manufacturing accuracy
Surface treatment/surface roughness
Selection of lubricant (chemical and physical char-
acteristics)
Assuming that the proposed light-weight gear

works in the same environment and under the same
load conditions as Gear 1 (Fig. 3), the gear geometry
factor is the only point that requires careful study. A
virtual and experimental investigation of the above-
mentioned issues follows.
Development and Validation

The following is intended to present a complete
explanation of the development process for the light-
Figure 7Expected displacement behavior. weight assembled gear. This explanation does not
involve the use of sophisticated calculations, such as
the German standard DIN 3990 gear wheel calcula-
tion; rather, an attempt is made to present the fun-
damentals of structural calculation by merging the
finite element method (FEM) with experimental
engineering procedures.
The light-weight assembled gear was substituted
Figure 81) one-sided contact path; 2) longitudinal profile correction for removing
local load increases; 3) homogeneous pressure distribution possible to be for a customer application. By analyzing the maxi-
eliminated on the light-weight assembled gear (adapted from Ref. 4). mum engine torque times, the highest transmis-
sion ratio available for
the adopted powertrain,
and the maximum trac-
tive effort limited by the
tires of the vehicle used,
a maximum torque of
900Nm was calculated
Figure 9Modes of a gear failure: 1) vibration fatigue; 2) macropitting; 3) scuffing; 4) wear; 5) spalling; 6) crack at the for the transmission out-
root diameter due to bending stress (Refs. 4 and 8).

put shaft. An assumption of load distribution on
the teeth contact area is not required, because the
contact algorithm of the general computer pro-
gram is used to calculate the contact area and
stresses by application of torque to the pinion gear,
while the light-weight gear is considered at rest.
Figure 10 shows the FEM model discretization,
the boundary conditions, and the types of ele-
ments used for stress analysis. Element sizes were
assured by a convergence study.
The structural analysis resulted in the stress dis-
tribution shown (Fig. 11); the variation of contact
and bending stresses along the path of contact has
also been studied (Fig. 12).
Next, natural frequencies and vibration modes
were also investigated. Considering a four-stroke
engine with four cylinders for mid-size cars that
achieves a maximum revolution of 7,000rpm, a
frequency of 72 Hz may excite the gear system.
Proving ground data acquisition shows that the
excitation level from suspension systems is lower
than that reached by the engine. Thus the first
vibration mode of the proposed solution must be
above the critical excitation level imposed by the
engine in order to assure a safe working condition
(Fig. 13).
Figure 10Finite element model discretization, boundary conditions
The last step in the virtual development is and element types.
the life prediction of the component. The fail-
ure modes for a gear have been presented (Fig.
9). According to Stephens (Ref. 9), failure due to
fatigue is the most common cause of mechanical
failure. Although the number of mechanical fail-
ures compared to successes is minimal, zero defect
tolerance is required due to the potential for fatali-
ties, injuries and other major concerns. Proper
fatigue design can reduce these undesirable losses;
following are some Dos and Donts (Ref. 9):
Do recognize that the closer the simulated anal-
ysis and testing are to the real product and its
usage, the greater the confidence in the engi-
neering results.
Do recognize that proper fatigue design meth-
ods exist and must be incorporated into the Figure 111) Overall von Mises stress; 2) contact pressure at the tooth
overall design when cyclic loading is involved. contact path; 3) bending stress on the root diameter.
Dont rely on safety factors in attempting to
overcome poor design procedures.
Do consider that good fatigue designwith or
without computer-aided designincorporates
synthesis, analysis and testing.
Do consider that fatigue design durability test-
ing should be used as a design verification tool,
not as a design development tool.
Dont overlook the additive or synergistic effects
of load, environment, geometry, residual stress,
time and material microstructure.
The maximum torque to be transmitted by the
light weight gear was calculated at 900Nm for
a maximum acceleration case. As cyclic load-
ing can be expected for the component, a proper
Figure 12Magnitude of the contact and bending stresses along the contact path.

technical
fatigue design must be evaluated. Dynamic loads for

a given vehicle can be achieved through collected
data acquisition on the proving ground. However,
the random behavior of those loads may lead to a
very complex test bench in some cases, rendering it
unfeasible due to the huge amount of data to be stud-
ied. Durability testing laboratories often adopt severe
load cycles with a regular pattern in order to deter-
mine the life of a component. Figure 14 presents
the adopted critical cycles for the light weight gear;
they representthrough case Aconstant, maxi-
mum acceleration followed by torque interruption,
andthrough case Ba maximum acceleration
followed by a brake engine torque of 80% of the
maximum acceleration torque. The stress values
on the gear body shown on the vertical axis were
reached through the same static structural analysis
presented (Fig. 11), and they will be used as input
data for the life determination.
The analysis of the cycles presented (Fig. 14) are
necessary in order to verify the effect of the higher
tractive-mean-stress in Adespite knowing that
the alternating stress is much higher in B. The
effect of a tractive-mean-stress is always damag-
Figure 13Natural frequencies and vibration modes for the light-weight assembled gear. ing to the life of the componentonce it collabo-
rates with crack propagationwhile a compressive-
mean-stress allows load transfer and so would not
jeopardize fatigue life.
Having defined proper load cycles, a good
understanding of material properties, size effects,
microstructural aspects and surface finishing
are essential for the success of the fatigue design.
Mechanical properties of solids modeled in a vir-
tual environment are often considered homoge-
neous, isotropic and linearly elastic. But at the
microscopic level, none of these assumptions may
exist, and metal fatigue is significantly influenced
by microstructure; this includes chemistry, heat
treatment, grain size, anisotropy, inclusions, poros-
ity, flow lines and other discontinuities or imper-
fections (Ref. 9). The S-N curve presented (Fig. 15)
Figure 14Case A) maximum acceleration followed by torque interruption;
Case B) maximum acceleration followed by brake engine torque. is available in fatigue software, and it was achieved
through experimental tests on the actual mate-
rial. Here microstructural effects are inherently
accounted for and therefore do not have to be con-
sidered again for life prediction. Size effects, fre-
quency and surface finishing were incorporated
with the S-N behavior in order to represent the
real fatigue limit of the component.
Figure 16 presents the ratio between the expect-
ed number of cycles for failure of the component
and the documented number of cycles during
which the component actually failed.
Considering that the state-of-stress on the teeth
area of the light-weight assembled gear is either
equal or lower than that of the reference gear,
the fatigue analysis shows that both cases not
only reach the minimum life of 106 cycles, but
Figure 15Curve SxN (Ref. 10).

also exceed it, reaching 3.09.106 for case A and
1.28.106 for case B.
The high durability of the light weight assem-
bled gear in the virtual development phase allowed
for moving on to some validation procedures. The
extensive time and effort invested during the vir-
tual development process paid dividends in the
experimental phase. As the results of the finite ele-
ment analysis (FEA) didnt demonstrate worst-
case stress behavior in the teeth contact area
when compared with a standard gear, the goal of
the stress investigation presented here is to vali-
date the von Mises stress level on the gear body.
An alpha prototype of the light-weight assembled
gear was machined and assembled on a torque
Figure 16Fatigue damage of the light-weight gear for an expected life of 106 cycles.
test bench through several devices; parts
were assembled (Fig. 17). The torque was
applied manually through the crank wheel
and then amplified by the reducer in order
to reach 900Nm. The torque was record-
ed by the load cell placed after the reduc-
er. Devices are responsible to transfer the
torque from the load cell into the gear by a
single tooth. Because the main stress direc-
tions are unknown, a strain gauge rosette
was connected to the data acquisition equip-
ment in order to determinate deformations
at 0, 45, and 90. Thus, via analytical cal-
culation, it was possible to calculate the von
Mises equivalent stress on the gear body.
Also, the use of terminals was essential in
Figure 17Stress validation test bench.
guaranteeing the gauge integrity, thus pro-
tecting it from possible impacts that may jeopar-
dize the test result.
The expected linear behavior was verified for
deformations in directions 1, 2 and 3 (Fig. 18).
According to (Ref. 11), the relation between
deformations and main stresses for a rectangular
rosette is given by Equation 1.
(1)
2 [( ) ( )
1,2= E 1+3 2 ( )2+( )2
1v 1+v
1 2 2 3 ]
where:
E = Young modulus
= Poison coefficient
Finally, the von Mises equivalent stress is calcu-
lated by Equation 2 (Ref. 12):
(2)
Figure 18Stress test output data.
vM= 1 (12)2+(23)2+(13)2
2
Equations 1 and 2 lead to the stress evolution
shown (Fig. 19).
A difference of 5.7% was found when compar-
ing the experimental von Mises stress with the FEA
result. As the stress level on the gear body is much
lower than that of the ring gear, a solution that con-
siders a less-substantial material for the gear body
may indeed lead to cost savings. Given the current

technical
state of stress, spoke designs are also pos-

sible.
Figure 20 describes the methodology used
for NVH investigation. The gear was sus-
pended by an elastomer in order to isolate
possible external interference on the vibra-
tion results. An accelerometer was placed on
the gear body and connected to a data acqui-
sition system through flexible cable. The
software provides a wealth of mathematical
and graphical functions for quick analyzing
and evaluating the measured data.
Several excitations were performed, com-
bined with different accelerometer positions,
in order to reach good test accuracy; all exci-
tations lead to similar responses (Fig. 21).
Figure 19Stresses evolution on the gear body.
The difference between the theoretical
and measured data for the first vibration
mode may be considered high for a vali-
dation that presents stiffness and mass as
the only parameters. However, both cases
demonstrate natural frequency levels 17
times higher when compared to the excita-
tion source frequency of 72 Hz. According
to Olley (Ref. 13), a system that presents a
working condition twice as low as the first
natural frequency is considered safe.
Conclusions
In validating the results of the FEA, the
alpha prototype showed good accuracy
with the mathematical model. Comparing
both models, the difference found on the
stress test and natural frequency validation
precludes the need for a beta prototype at
this stage of the development.
The concept of the solution presented here
Figure 20Natural frequencies and vibration modes validation. allows different material combinations for
the inner and outer parts. Therefore, forg-
ing heat treatment can be applied locally
in order to guarantee the local properties
required by the component application.
The flexibility introduced by this new man-
ufacturing process leads to a rational appli-
cation of the raw materials, as well as the
available energy matrix, and thus leads to a
green design and manufacturing chain.
The light-weight assembled gear proved
to be a high-performance solution.
Combining high efficiency with the proper
manufacturing process appears to be criti-
cal in attaining mandated CO2 emission
reduction. Nevertheless, durability and
NVH tests should be done as a next step in
order to assure a reliable design.
Acknowledgments. The authors thank the
Centro Universitrio da FEI for its support
Figure 21Natural frequencies. during the experimental phase.

References
1. Regulation No. 510/2011 of the European Parliament
and of the Council, May 11, 2011.
2. Conselho Nacional Do Meio AmbienteConama;
CALL FOR PAPERS!
Are you sitting on an idea for a technical paper
Ministerio do Meio Ambiente. Resolucao No. 315,
de 29 De Outubro de 2002. but wondering where to present it? Do you have
3. Steinberg, I; R. Nasdal and A. Kurtzke. GETRAG one already written, sitting on your desk, gathering
6HDT451: Mild-Hybrid Including Wet-Running machine dust?
Dual-Clutch, 35th VDI Congress, Vehicle How about Gear Technology? We are always look-
Transmissions 2011, Mannheim, Germany. ing for gearing- and power transmission compo-
4. Naunheimer, H. et al. Automotive Transmissions: nent-relevant technical papers for publication in
Fundamentals, Selection, Design and Application, 2nd
the magazine and in its digital version. Having your
Edition, Springer, 2011.
5. Souza, M., J. Savoy and T. Souza. Topological Study work appear in Gear Technology guarantees you an
for Weight Reduction of Components in Automotive audience of the most experienced and discriminat-
Transmissions, First Virtual Powertrain Conference, ing industry players. You say your work has not been
So Paulo, Brazil, 2011. peer-reviewed? Not a problem, as we are luckyand
6. Gopinath, K. and M.M. Mauyuram. Machine Design thankfulto have on-hand some of the most experi-
II, Indian Institute of Technology. enced and brilliant minds in the industryour tech-
7. Stephens, Ralf, A. Fatemi and Robert Stephens.
Metal Fatigue in Engineering, 2nd Ed., New York,
nical editors. So if your work passes muster and
Wiley Interscience, 2001. is published, youll know you were reviewed by the
8. Magna Powertrain. FemFat 4.8 Engineering Center, bestand most demanding.
Styer GmbH. Chances are youll be creating the paper under the
9. Vishay. Strain Gauges Rosettes: Selection, auspices of the company for whom you work or own,
Application and Data Reduction. Vishay Catalogue, or for one of the various industry-relevant asso-
2008. ciations. That means they as well will bask in the
10. Beer, F.P. and E.R. Johnston Jr. Resistncia dos
Materiais, Third Ed., Makron Books, 1995.
reflected glory that accrues with publication in Gear
11. Milliken, W. F and D.L. Milliken. Chassis TechnologyThe Journal of Gear Manufacturing.
Design, Principles and Analysis, M. Olley, SAE For publication guidelines and more information,
International, 2002. please contact Jack McGuinn at jmcguinn@geartech-
nology.com.
Dr.-Ing. Mauro Moraes Juliano Savoy graduated Thales S. G. Souza

de Souza graduated in in mechanical industrial received his undergraduate
metallurgical engineering engineering at the and masters degrees in
at the Instituto Militar de Universidade So Francisco mechanical engineering at
Engenharia, IME, Brazil, in 2000, and completed his Centro Universitrio da FEI.
and received there his masters coursework in He joined Neumayer Tekfor
masters degree in materials technological innovation at Brasil Ltda. in 2010 as an R&D
science. He also holds a the Universidade de So Paulo product engineer, focusing
Ph.D. in engineering from the Institut fr Bildsame in 2006. He was also awarded masters degrees in on transmission components. He has written for
Formgebung, Aachen, Germany; an MBA with strategic innovation at WOIS Innovation School and international technical publications about the
honors from the College of Business at The in automotive engineering at Centro Universitrio virtual development process of transmission
Ohio University; an executive MBA in business da FEI. He joined Neumayer Tekfor Group in 1994 components supported by the finite element
administration at Fundao Getulio Vargas, Brazil; as a trainee, and elevated to technician in 1995. method and by experimental testing. He was
an MBA in automotive engineering from the Centro In 2000 Savoy was promoted to product engineer, responsible for designing, developing and testing
Universitrio da FEI, Brazil; and a specialization in working especially on the development of special three successful Formula SAE transmissions
strategic innovation at the WOIS Innovation School, fastening systems. From 2000 to 2002 he developed using CAD, CAE and optimization tools combined
Germany. Souza is currently the chief engineer at projects of technological transfer from Neumayer with data acquisition systems. Souza is also a
Neumayer Tekfor Brasil Ltda., responsible for R&D Tekfor headquarters in Germany to Neumayer Tekfor design judge of chassis and transmissions and an
and engineering in Brazil and, at a group level, Brasil Ltda. In 2008 Savoy was promoted to R&D active member of the SAE committee supporting
for R&D fasteners. During his career he has led engineering manager, where he focused on CAE the Formula SAE series in Brazil and the United
projects of technology transfer between Germany projects and new product development. Since 2008, States.
and Brazil, especially in the engineering and R&D he has been a member of the technical committee
fields for the automotive industry. He has more than of the SAE Brazil Congress and SAE Powertrain
60 national and international technical publications Brazil.
in the automotive, metallurgical and mechanical
areas, and also two books, published in Germany.
He has served as a lecturer, teacher and advisor for
several Masters theses at Brazilian and German
Universities. Souza is a member of the technical
committee of the SAE Brazil Congress and chair
of the SAE Brazil Powertrain-Transmissions
Committee and Symposium.

technical
Hybrid Gear Preliminary Results

Application of Composites to Dynamic
Mechanical Components
Robert F. Handschuh, Gary D. Roberts, Ryan R. Sinnamon,
David B. Stringer, Brian D. Dykas and Lee W. Kohlman
Composite spur gears were designed, fabricated and tested at NASA Glenn Research Center. The composite web was
bonded only to the inner and outer hexagonal features that were machined from an initially all-metallic aerospace quality
spur gear. The hybrid gear was tested against an all-steel gear and against a mating hybrid gear. Initial results indicate
that this type of hybrid design may have a dramatic effect on drive system weight without sacrificing strength.
Introduction tify the issues that need to be addressed ments in a gear. For example, gear mesh-
The components used in rotorcraft appli- to allow this technology to be suitable for ing vibration and noise should benefit
cations are designed such that the mini- rotorcraft drive systems. from this configuration by altering the
mum weight is attained without sacrific- acoustic path between the gear mesh gen-
ing reliability or safety. Since the drive Composite MaterialMetallic erating the noise and the housing that re-
system is an appreciable percentage of Gear Hybrid radiates the vibration and noise.
the overall rotorcraft vehicle weight (~10 Components that are lightweight and In theory it may be possible to produce
percent), many approaches have been high-strength are very important for a hybrid gear at reduced cost, as a por-
applied to improve the power to weight aerospace drive systems. The compos- tion of the machining required to reduce
ratio of these components. ite portion of the hybrid gear was fabri- component weight would be eliminated.
Past and current government-fund- cated using a tri-axial braid prepreg (Ed.s But the manufacturing process would
ed efforts for drive system technology Note: A fibrous material pre-impregnated have to be altered when making a hybrid
(Refs. 12) have used power to weight with a particular synthetic resin, used in gear to attain aerospace precision of the
ratio as the most critical performance making reinforced plastics) material made components.
metric. Through clever design modifica- with T700SC 12K carbon fiber tows and Unfortunately, for all the positive
tions, configuration arrangements and a 350F epoxy matrix material. A 0 60 implications of using this technology for
advanced materials, great progress has braid architecture was used so that in- dynamic drive system components, there
been made. plane stiffness properties would be near- are also some negative aspects. Some of
Material properties of composites ly equal in all directions. Representative these include:
make them very desirable. Having a very composite material properties are com- Attachment to the metallic features to
low density and high strength are two pared to that of the typical gear material produce a hybrid gear (gear teeth-to-web,
important properties that directly impact AISI 9310 (Table 1). Materials with these web-to-shaft, and bearings-to-shaft)
power to weight ratio. Therefore applica- characteristics have the potential to pro- Heat conduction issuescomposite
tion of these materials to rotorcraft trans- duce a design with a very high power-to- material through thickness conductivity
mission static and dynamic components weight ratio. Operation during extreme thermal
can have a drastic effect on overall drive There are other reasons for using a events such as loss-of-lubrication. In cur-
system weight (Refs. 34). hybrid of composite and metallic ele- rent drive system component design, the
The use of composites has been most-
ly limited in drive systems to housings Table 1Materials as used in the test gears
Composite Material AISI 9310 Gear Steel
and shafts (Ref. 5). A number of critical
Tensile - 6.4106
issues were identified and addressed in Modulus of elasticity (psi) 29106
Compression - 6.1106
these applications. These issues include Poissons ratio 0.3 0.29
metalcomposite attachment, corro- Density (kg/m3) 1800 7861
sion, strength, etc. The objective of this 9.4
Thermal conductivity (W/(mC)) 55
(T700 fiber axial)
research reported herein is to expand the
Useful maximum temperature (C) as gear material 150 175
use of composite materials to gears and Coefficient of thermal expansion (micro-m/m) 2 (in-plane) 13.0
to identify critical issues that may result Failure Strain (%)
Elongation (%)
in this application. Several tests were per- Tension - 1.89
15
formed on the composite gears to iden- Compression - 0.94
First presented at the 68th Annual Forum and Technology Display Forum 67 sponsored by the American Helicopter Society (AHS) Fort Worth, Texas, May 13, 2012.

gears and shafts are one piece and the
bearing inner raceway is typically part of
the gear shaft component. Use of a hybrid
gear would require attachment in some
manner from the composite material web
shaft to the gear teeth.
Hybrid Gear Design and

Manufacturing
The basic gear design used for this study
is summarized (Table 2). These gears
have been used in the past for loss-of-
lubrication testing and other experi-
mental work within NASA (Refs. 68).
Gears used were representative of aero-
space precision prior to modification to a Figure 1Hybrid gear assembly steps.
hybrid configuration.
Turning the gears into a hybrid config- region that was machined away from the 9). The inner metallic hub was located via
uration started with a portion of the web metal gear. This tight fit provided a load its inner bore.
being machined away; the metallic teeth path from the outer rim to the metallic The first step in the lay-up process was
and attachment regions were kept. A hex- inner hub. to place the inner metallic hub by locat-
agonal region was removed; this arrange- An epoxy prepreg, in conjunction with ing it around the feature in the mold cen-
ment was chosen due to the number of a quasi-isotropic braided fabric, was cho- ter. During the assembly process the larg-
teeth (42) on the gear to be modified. sen as the composite material. The fabric er ply stack was created by 12 layers of
By using a six-sided feature, no sharp provides nearly in-plane isotropic prop- the prepreg; each layer was rotated 60 in
edge was located near a tooth fillet/root erties that react similarly to that of the one direction to encourage the best iso-
region where the highest bending stress metallic features. tropic behavior. With the first ply stack
is reached. Prior to molding, any portion of the positioned and debulked, a film adhe-
Two unique ply stacks were used for metallic features that was to come in sive was added and the outer metallic
this configuration. The first ply stack was contact with the composite was sand- ring was placed on top. The second ply
larger than the metallic portion that was blasted and surface-primed to promote stack was created in the void between the
machined away and had a circular, out- good adhesion and increase bond-line two metal features. The same clocking
side geometry. This created an overlap strength. procedure was performed on these plies.
onto the surface of the outer rim. This A special fixture was then designed Another layer of film adhesive was added
overlap created a bonding surface that and fabricated to locate the gear rim and and the final ply stack was added in the
was critical for proper composite-to-met- the gear hub prior to composite material same fashion as the first. The composite
al adhesion. The second ply stack config- layup. The gear teeth outer rim was locat- material lay-up process is shown (Fig. 1).
uration was cut to match the hexagonal ed using measurement-over-pins (Ref.
Table 2Basic gear data for components tested

Number of teeth 42
Diametral pitch 12
Circular pitch 0.2618
Whole depth 0.196
Addendum (in.) 0.083
Chordal tooth thickness (in.) 0.1279
Pressure angle (deg) 25
Pitch diameter (in.) 3.5
Outside diameter (in.) 3.667
Root fillet (in.) 0.04 to 0.06
Measurement over pins (in.) 3.6956
Pin diameter (in.) 0.144
Backlash ref. (in.) 0.006
Tip relief (in.) 0.0005 to 0.0007
Weight all-steel gear (lbf) 0.8375
Weight hybrid gear (lbf) 0.7147 Figure 2Hybrid gear.

technical
This figure shows the assembly procedure

used prior to curing the finished part.
The gear mold assembly was placed
into a press and subjected to a 100 psi
load. The press was then heated at a ramp
rate of 4F-per-minute to a temperature
of 250F. A one-hour dwell was held at
250F to allow time for the metal and
composite to reach a consistent tempera-
ture. The temperature was then increased
to 350F using the same ramp rate. The Figure 3Hybrid gear manufacturing details.
temperature was held at 350F to fully
cure the composite prepreg. After the
cure cycle was complete the part was
removed from the mold and any excess
resin flashing was removed.
The finished hybrid gear is shown
(Figs. 23). There was no optimization
of the arrangement at this point, but the
gear produced was still on the order of 20
percent lighter than the all-metal one.
Free/Free Vibration Modes

A series of experiments using a modal Figure 4.Impact locations shown for hybrid gears (similar for all-steel gear).
impact hammer was conducted on a
standard AISI 9310 steel spur gear and ometer axis parallel to the rotational axis position on the gear, at a radius just
a hybrid spur gear specimen. The objec- of the gear. This placement was chosen inboard of the teeth. For the composite
tive was to experimentally determine the for convenience because it was accessible gear, this location was at the edge of the
modal properties of the hybrid spur gear on both test specimens. Finite element composite portion of the gear. For radial
and compare them to those of its conven- analysis (FEA) demonstrated that most impacts, a tooth near the ten oclock posi-
tional steel counterpart. displacement would be in the axial direction was impacted at the tip. A nylon
Additionally, a model of the convention for the modes of interest. bolt on either side of the tip was used to
tional spur gear was generated using Figure 4 shows the experimental con- more effectively set the standoff distance
finite element software and subsequent- figurations in which the impact experi- between the tip and the gear, enabling
ly compared with experimental data ments were performed. The test gear was more consistent impacts between tests.
obtained from the test specimen. A fur- suspended on rubber bands hanging on a A total of 10 impacts were performed in
ther effort is underway to include hybrid rubber cord, with this soft support at the each of these four configurations.
material parameters into the model and twelve oclock position. The accelerom-
correlate with modal data acquired from eter was mounted on the metal hub in the Impact Study
these experiments. six oclock position. Both the steel gear The time-domain data signal was import-
A series of modal experiments was and the composite gear were subjected ed into an automated signal analysis and
conducted on a baseline steel gear and to a series of impacts in the radial direc- filtering software package. The data was
the hybrid gear to identify natural fre- tion and a series of impacts in the axial then filtered to isolate the signal asso-
quencies and calculate modal damping. direction. Axial impacts were concen- ciated with the natural frequency cor-
An electric impact hammer was used to trated at approximately the seven oclock responding to the first non-rigid body
impact the gears in mul-
tiple orientations, with an Table 3Specimen modal property estimates
Impact position Axial Radial
accelerometer at the tip of
Gear specimen 9310-T42 Hybrid 42 9310-T42 Hybrid 42
hammer providing a trig- Mean 0.0145 0.1296 0.0261 0.0543
ger for the acquisition of Log decrement ()
Standard deviation 0.0004 0.0263 0.0028 0.0122
acceleration data from the Mean 0.0023 0.0206 0.0042 0.0086
Damping ratio ()
gear. In all cases, the single Standard deviation 0.0001 0.0042 0.0004 0.0019
accelerometer was placed Mean 0.4843 2.9887 0.8725 1.2520
General damping constant (c) (lbf-sec/in.)
on the metal hub of the Standard deviation 0.0143 0.6053 0.0928 0.2821
9310-T42 7219 43 n=19 data samples
test gear with the acceler- Natural frequency (n) (Hz)
Hybrid 42 6236 62 n=14 data samples

Table 4All-steel gear frequencies for modes 712
Mode number Frequency, Hz
7 7187
8 7270
mode. The log decrement was calculated ted vibration as compared to all- 9 12304
for each filtered data set. From this cal- steel gears. Note that the damp- 10 12853
culation modal parameters of the hybrid ing properties vary somewhat, 11 12924
specimen and its steel counterpart were depending upon the impact posi- 12 15237
estimated and compared. Figure 5 depicts tion. The experimentally deter-
an example of both a raw and filtered mined mean and standard deviation of the purposes of a modal analysis howev-
data set. the natural frequency corresponding to er, the solid model is a close approxima-
Additionally, the unfiltered results of the first non-rigid mode are also pro- tion to the test specimens.
each impact were viewed in the frequen- vided. The finite element mesh is a solid mesh
cy domain to compare results within con- consisting of 19,152 linear tetrahedron
figuration groups (Fig. 6). These figures FEA Modal Study: Steel Gear elements and having a total of 31,002
each show the frequency data from four A modal analysis was conducted for the nodes. The characteristic element size
of the 10 impacts for each configuration. 42-tooth steel gear to verify natural fre- is approximately 0.10 in. The gear spec-
Using the basic log decrement rela- quencies identified in the experiment and imens are made from AISI 9310 steel,
tionships, modal properties of the gears to provide information on the associated which is represented in the analysis as
were estimated (Table 3). As expected, mode shapes. The solid model of the gear a linear isotropic material with Youngs
the hybrid gear exhibits higher damp- captures the tooth geometry to a reason- modulus of 29106 psi (2.01011 Pa),
ing properties than its steel counterpart. able extent but does not include subtle, Poissons ratio of 0.29, and mass density
This has the potential to reduce transmit- geometric features such as tip relief. For of 0.284 lbm/in3 (7,861 kg/m3). The anal-
Figure 5Sample, raw data raw: (a) time domain signal; (b) filtered data. Figure 6Frequency domain resultsaxial location impacts: (a) all-steel
gear; (b) hybrid gear.

technical
ysis is conducted on the unconstrained modes of interest, guiding accelerometer mass density of 0.055 lbm/in3 (1,522 kg/
gear (free-free). placement. m 3). The analysis is conducted on the
The first six modes identified in the unconstrained gear (free-free); the com-
analysis are rigid body translations and FEA Modal Study: Hybrid Gear ponents are treated as welded together
rigid body rotations; one mode is associ- A modal analysis was also conducted for (node-to-node constraint at the interfac-
ated with each translational- or rotation- the 42-tooth hybrid gear to verify natu- es). It is notable that the calculated bulk
al-degree-of- freedom. Therefore, starting ral frequencies identified in the experi- modulus properties for the composite are
at mode 7 to 12, the frequencies associ- ment and to determine the associated not linear, as the tensile elastic modulus
ated with these modes are shown (Table mode shapes. As in the case of the steel of 6.4106 psi compares to a compres-
4); the mode shape for mode 7 is shown gear, the tooth geometry is a reasonable sive elastic modulus of 6.1106 psi when
(Fig. 7). The mode shapes found illus- representation but does not include all using bulk propertiesa difference of 5
trated that the modal displacements are subtle features of the teeth. The deviation percent. Based on the relatively minor
primarily in the axial direction for the of the model geometry from the physical difference and the square-root- depen-
specimens is expected to have a negligible dence-of-frequency on stiffness, the bulk
effect on the modal results. tensile modulus was used in this simpli-
The finite element mesh fied case. Based on these small differenc-
is a solid mesh consisting of es it was decided to use the bulk proper-
25,672 linear tetrahedron ele- ties to simplify the analysis.
ments and having a total of Modes 712, identified in the analysis,
39,166 nodes. The character- are shown (Table 5). The first six modes
istic element size is approx- are related to the rigid body transla-
imately 0.10 in. The com- tions and rigid body rotations. The mode
posite portion of the gear is shape for mode 7 is shown (Fig. 8).
constructed of prepreg tri-
axial-braided carbon fiber Comparison of FEA to Experiment:
with alternating orienta- Natural Frequencies
tion between adjacent layers, A comparison between the FE output
and resin. Due to the aniso- and the experimental results was con-
tropic nature of the materi- ducted in the first step of validating the
al, consideration was given FEA model. Figure 9 depicts a compari-
to modeling each individu- son between the measured frequencies
al ply with orthotropic prop- of the steel spur gear specimen and the
erties. However, due to the predicted frequencies of the FE model;
large number of plies, it was an exact frequency match falls directly
determined that the compos- on the diagonal. The result shows good
Figure 7All-metallic gear mode shape.
ite portion of the gear could agreement between model predictions
be modeled using isotropic and the experimental results.
properties. For the hybrid gear, however, modes
The hub and ring por- identified in the experiment generally
tions of the gear were mod- shifted to lower frequencies, whereas the
eled using properties of AISI model predicted a shift to higher frequen-
9310 steel, which is repre- cies. In the model, this is an expected
sented in the analysis as a lin- result since the composite has a higher
ear isotropic material with ratio of elastic-modulus-to-density than
Youngs modulus of 29106 steel, and the area moment of inertia
psi (2.010 11 Pa), Poissons is considerably larger for the cross sec-
ratio of 0.29 and mass
density of 0.284 lbm/in 3
Table 5Hybrid gear finite element vibration
(7,861 kg/m3). The com- modes and frequencies
posite portion of the Mode number Frequency, Hz
gear is modeled as a lin- 7 7,780
ear isotropic material 8 7,913
with Youngs modulus of 9 13,745
10 14,592
6.4106 psi (4.41010 Pa),
11 15,725
Poissons ratio of 0.30 and 12 16,483
Figure 8Hybrid gear mode shape.

tion of the hybrid gear. However, the FE
model assumes adjacent surfaces in the
components are bonded together.
Based on actual construction methods
the interfaces may have a lower effective
stiffness such that the experiment would
produce modes at frequencies lower than
predicted. Changes to the interfaces can
be made in the model to bring the natu-
ral frequencies within the ranges of the
experiment, but this may not provide
additional physical insight to the prop-
erties of the interface. However, such an
approach may be employed to improve
the model for subsequent stress analysis.
Unlike the steel gear, a comparison
between the hybrid gear finite element
results and the experimental results did
not produce similar mode frequencies as
the all steel gear. From the experiments, Figure 9Comparison of experimental and finite element natural
the hybrid gear exhibits two significant frequencies.
peaks: approximately 6,270 and 9,743
Hz. The modes found from FEA did not
compare well to the experiments. It is
expected that further model development
will reduce some of these inconsistencies
with the experimental data.
Dynamic Testing
Two types of dynamic tests were con-
ducted to determine if gears could be
considered as possible composite candi-
dates in future rotorcraft drive systems.
The first set of tests measured vibration
and noise at four speeds and four levels of
torque. The second test was an operation-
al endurance test.
The dynamic tests for noise and vibra-
tion were conducted with four different
gear arrangements, at four different rota-
tional speeds, and four different levels of
load. The gears were installed in the test
rig in the following configurations: (1) Figure 10Test facility shown with cover removed.
all-steel both sides; (2) hybrid gear left
side; all-steel gear right side; (3) all-steel 658 in.*lb torque. The vibration level in From the vibration data shown (Fig.
gear left side, hybrid gear right side; and gs is shown (Fig. 11). The noise level 11) the hybrid gear generally reduced the
(4) hybrid gear, both sides. When the was measured via a hand-held sound overall vibration level with mixed- or all-
facility is operating, the left- side gear is level meter at a distance of one in. from hybrid configurations. For the noise data
the driving gear and the right-side is the the test gearbox cover. The sound level (Fig. 12) the mixed-hybrid gear arrange-
driven gear. All vibration measurements was recorded on an A-weighted scale. ment and all hybrid arrangement pro-
were made on the driven side support The results of the sound level data are duced less noise for the two higher speed
bearing housing (Fig. 10). shown (Fig. 12). The four test rig config- conditions.
For the four configurations mentioned urations are shown at four speed and load Although some vibration and noise
above tests were run at 2,500, 5,000, 7,500 conditions. reduction were seen with the hybrid
and 10,000rpm and at 133, 238, 448 and gears, the results were not as dramatic

technical
as expected. There are several reasons bination of airborne and structure-borne Conclusions
why noise and vibration had only modest from the meshing gear teeth being reradi- Based on the results attained in this study
reduction. First, the manufacturing pro- ated from the test facility cover. the following conclusions can be made:
cess used to fabricate the hybrid gear did Hybrid gear arrangement shows prom-
not result in aerospace-quality accuracy. Long-Term Testing ise, as the gears were operated for an
The composite curing actually reduced An endurance test was conducted on extended period of time at a relatively
the backlash of the components due to the hybrid gears in NASAs spur gear test high speed and torque.
stretching of the metal outside rim. The facility. The hybrid gear arrangement was Power-to-weight improvement could
backlash also was not consistent around run for over 300106 cycles (gear revo- be possible, as steel webs could be
the gear. Both of these manufacturing lutions) at 10,000rpm, 250 psi torque replaced by lightweight, composite mate-
errors could be corrected by post-com- load (553 in.*lb torque) with an oil inlet rial. For the gears tested, a ~20 percent
posite-attachment, final grinding of the temperature of ~120F. The hybrid gears decrease in weight was realized without
gear teeth. The noise data is related to operated without any problem during optimization of the components.
how well the teeth mesh during opera- this extended test period. The gears did Reduced noise and vibration would
tion. In effect, the noise measured at a not show any signs of fatigue during be expected, when manufacturing pro-
small distance from the cover is a com- post-test inspection. cessing produces aerospace quality gears;
the hybrid gears tested show only mod-
est improvements in vibration and noise.
More significant improvements are pos-
sible with improved manufacturing pro-
cesses and possible material tailoring
through the composite structure.
References
1. Henry, Z. Bell Helicopter Advanced Rotorcraft
Transmission (ART) Program, NASA
CR195479, June 1995.
2. Anderson, N., R. Cedox, E. Salama and D.
Wagner. Advanced Gearbox Technology: Final
Report, NASA Contractor Report CR179625,
June 1987.
3. Lenski, J. Advanced Rotorcraft Transmission
Program (ART), NASA CR195461, Army
Research Laboratory Report ARL-CR-224,
April 1995.
4. Lin, S. and S. Poster. Development of a
Braided-Composite Drive Shaft with Captured
End Fittings, 60th Annual Forum of the
American Helicopter Society International, June
2004.
Figure 11Vibration data taken for four speeds and four load levels. 5. Cecil, T., R. Ehinger and C. Kilmain.
Application and Configuration Issues of Resin-
Transfer-Molded-Composite Transmission
Housings: A Program Review, 63rd Annual
Forum of the American Helicopter Society
International, May 2007.
6. Cope, G. Model 427 Drive System, 55th
Annual Forum of the American Helicopter
Society, May 1999.
7. Spears, S. Design and Certification of the
Model 429 Supercritical Tail Rotor Drive Shaft,
64th Annual Forum of the American Helicopter
Society, May 2008.
8. Handschuh, R. and G. Roberts. Patent
Application: Hybrid Gear, 2011.
9. Handschuh, R., J. Polly and W. Morales. Gear
Mesh Loss-of-Lubrication Experiments and
Analytical Simulation, NASA/TM2011
217106, November 2011.
10. Handschuh, R. and T. Krantz. Engagement
of Metal Debris into a Gear Mesh, ASA/
TM2010216759, July 2010.
11. Dudley, D. Handbook of Practical Gear Design,
McGraw-Hill, Inc. 1984.
Figure 12Sound level measurements made for the four different test arrangements, made at four
different speed and load conditions.

Dr. Robert Handschuh Lieutenant Colonel
has over 30 years of
experience with NASA and
Blake Stringer, PhD.,
is an active-duty army Unlocking
Department of Defense
rotorcraft drive system
analysis and experimental
officer with 19 years of
military experience as an
army aviator and research
the Vault
methods. He has served engineer. He has a bachelor
as the Drive Systems of science degree in
team leader for the Tribology & Mechanical aerospace engineering from the U.S. Military, We recently sent a team
Components Branch at NASA Glenn Research a master of science in aerospace engineering of Gear Technology
Center in Cleveland, Ohio for over 15 years, and from Georgia Tech University, and a doctorate
currently leads the research there in high-speed in mechanical and aerospace engineering from editors into the tunnels
gearing, including windage, loss-of-lubrication the University of Virginia. Colonel Blake has and vaults under Randall
technology, and hybrid gearing. Handschuh is performed fundamental research on aerospace
credited with successfully developing many mechanical components, focusing on gear
Publications to find
experimental research test facilities at Glenn, fatigue, health monitoring and the rotor-dynamic every back issue of Gear
and has conducted testing in the following modeling of transmission systems. He has also
areas: high-temperature, ceramic seal erosion; served as instructor and assistant professor
Technology magazine
blade-shroud seal rub; planetary geartrains; on the engineering faculty at West Point. As a and make them available
spiral bevel gears and face gears; high-speed, military aviator, he has over 1,000 flight hours
helical geartrains; single-tooth-bending fatigue; of rotary-wing and fixed-wing experience, and
online.
and high-speed gear windage. is rated in the UH-1 and CH-7D helicopters and
Dr. Gary D. Roberts C-12 airplane. Colonel Blake also holds a FAA This user-friendly
has a master of science
commercial airmans certificate.
archive, enhanced by our
degree (physics) from the Brian Dykas is presently optimized search engine,
University of Waterloo, a research engineer with
Ontario, Canada and a PhD the U.S. Army Research allows subscribers to
(polymer science) from the
University of Akron, Akron,
Laboratory (ARL) at
Aberdeen Proving Ground,
locate specific articles on
Ohio. He has been at NASA Maryland. Dykas has a PhD topics like gear design,
for 30 years, where his
primary area of research has been polymeric
in mechanical engineering
from Case Western Reserve
spiral bevel gears,
and composite materials, with emphasis on University in Cleveland, Ohio inspection, cutting tools
light-weight aero engine structures. More
recently, Roberts has focused on composite
and over 10 years of research experience in
tribology of propulsion mechanical components.
and more.
and hybrid structures for rotorcraft drive
systems. In addition, Roberts has served as a
Dr. Lee W. Kohlman Theyre simply a
has a bachelor of science
Technical Lead for several projects in the NASA
Fundamental Aeronautics Program and the
degree (physics) and a keyword away.
PhD (engineering) from
Aviation Safety Program.
the University of Akron,
Ryan Sinnamon is a Akron, Ohio. He has been
graduate student studying at NASA for two years,
mechanical engineering following two years under
at Wright State University NASAs GSRP program. His primary area of
(WSU) in Dayton, Ohio, research is composite materials, including
where he also received his testing and failure mechanics. Kohlmans more
bachelor of science degree recent research is focused on composite and
in mechanical engineering. hybrid structure for rotorcraft drive systems.
www.
He is a member of the
National Engineering Honor Society/Tau Beta Pi.
In addition, he is working on material concepts
for thin and adaptive fan blades, ballistic geartechnology
Sinnamons previous professional experience penetration of cryogenic water ice, and .com.
includes working on advanced composite electrospun, thermoplastic nanofiber deposition
mechanical components at NASA Glenn. for composite toughening.
Since 2012, he has started a masters thesis
researching hybrid fuel cell/gas turbine power
systems under Dr. Rory Roberts, WSU.
Subscribers receive
Gear Technology and
get free access to
almost thirty years of
gear manufacturing
knowledge and insight.
www.geartechnology.com/
issues.

industry news
Stanley Miles Sitta Wenzel America

1930-2013 Partners with Liebherr Gear
Technology
Stanley Stan the Man Sitta
passed away peacefully April Wenzel America proudly announces their new partnership with
7, 2013 at the age of 82 in Liebherr Gear Technology, Inc. Liebherr will exclusively repre-
Bradenton, Florida. He was sent the Wenzel GearTec product line in the United States and
born May 22, 1930 in Chicago, Canada. Liebherr Gear Technology, Inc. is based in Saline, MI
Illinois to Czech immigrants and manufactures, sells, and supports a wide range of gear hob-
Stanley Sitta and Camille bing, shaping and grinding machines. The Saline, MI facility is
Blaha Sitta. He resided for also home of Liebherr Automation Systems, Co., a global sup-
40 years in Wheaton, Illinois plier and integrator of automation for advanced manufacturing
before moving to Bradenton, systems.
Florida 2 years ago. The Wenzel GearTec product line includes a range of granite,
Sitta graduated from air-bearing horizontal gear testing machines named WGT and
Morton High school and Morton Jr. College in Cicero, Illinois. can also offer 4-axis gear measuring technology on any Wenzel
He received a bachelors degree from Loyola University in biol- CMM frame to give customers gear and traditional CMM mea-
ogy and chemistry and graduated from Harvards 52nd AMP surement on the same platform.
Business School. Andy Woodward, president of Wenzel America, summed
Sitta began his business career at U.S. Rubber. He moved to up the new relationship: We are very excited at the prospect
Marion, Virginia in 1958, joining Brunswicks defense divi- of working with Liebherr. Their knowledge of the gear manu-
sion and eventually becoming the plant manager. After a trans- facturing customer base in North America is second to none
fer to Muskegon, Michigan, he brought his family back to the and we are certain that they will be able to introduce our gear
Chicago area. Sitta became president of the Foote-Jones Gear testing product line to many more prospective customers in
Division of Dresser Industries in Downers Grove and Chicago, our market. Also, joining our forces will produce an unrivalled
Illinois. customer support team going forward. This agreement repre-
He was involved with Illinois Benedictine University and was sents the first of many between the two companies around the
a patron of St. Michaels Catholic Church. He served as presi- world.
dent of the Downers Grove Chamber of Commerce and nation- Peter Wiedemann, president of Liebherr Gear Technology,
al Chairman of the American Gear Manufacturers Association. Inc., added: We have a history of providing our customers
Sitta is survived by his loving wife of 61 years, Zdenka (Vrla) with turnkey solutions in gear production and inspection. The
Sitta, four children: Ellen (John) Hoefer of Kansas City, KS, Wenzel GearTec product line enables us to continue to offer
Janet (Mike) Schraer of Bradenton, FL, Stanley J. (Donna) our customers the best products and services available.
of VA Beach, VA, and James M. (Liz) of St. Charles, Illinois., Wenzel Group has been manufacturing metrology equip-
ten grandchildren and four great grandchildren, nieces Jenny ment for over 45 years and celebrates their 10th
Smith, Karyn (Chuck) Fischer, and Nina (Larry) Biddinger. anniversary of supply-
Sitta has one sibling, Camille (Yarmil) Pekarek of Sun City, ing gear testing sys-
Arizona. tems to some of the
Sitta was greatly influenced by his father, who taught him worlds most
an appreciation of nature, particularly for birds, plants and
fish. He was an avid collector of coins, stamps, postcards,
model trains and antique toys. He enjoyed hunting and trav-
eled extensively. Some of his favorite times were spent enjoy-
ing the woods of Marion, Virginia and the lakes of Montello,
Wisconsin.
The memorial service was held at Williams-Kampp
Funeral Home, 430 E. Roosevelt Rd., Wheaton, Illinois on
Saturday April 13. Donations can be made in his name to
St. Michaels Catholic Church in Wheaton, Illinois or
can be sent to the National Parkinson Foundation.

prestigious gear manufacturers, including some very large
machines to Liebherr. Wenzel remains a family owned compa-
Custom Gear & Machine, Inc.
T h e G e a r S p e c i a l i S T S
ny and prides itself on its long-term relationships with its cus- 5466 east rockton rd. roscoe, il 61073
Tel 815.389.6065 Fax 815.389.4548
tomers. cgearinc.com
Since 1949, the Liebherr Group has been a family-owned
business. Today, the entire organization consists of over 39,000
employees in more than 130 companies across all continents.
Gleason Cutting
Tools
Recognized as John Deere Partner-
Level Supplier
Gleason Corporation recently announced that its Gleason
Cutting Tools Corporation facility in Rockford, Illinois has
earned Partner-level status in the John Deere Achieving
Excellence Program. This status is Deere & Companys high-
est supplier rating. Suppliers who participate in Deere &
New Capabilities
Companys Achieving Excellence program are evaluated annu- Hofler Model 800 CNC Single Tooth
ally in several key performance categories including quality, Gear Grinder 31 x 60 long with
cost management, delivery, technical support and wavelength, internal grinding capabilities
which is a measure of responsiveness. John Deere created the
Klingelnberg P-100 Gear Inspection
Machine 40 Dia. Maximum
program in 1991 to provide a supplier evaluation and feed- www.suhner.com

back process that promotes continuous improvement. Robert
P. Phillips, senior vice president, Tooling Products Group and
Gleason Cutting Tools Corporation said Gleason Cutting Tools
Corporation is proud to be a supplier to John Deere, and are
honored to have our performance recognized at such a high
level. Partner-level status was awarded to Gleason Cutting
Tools Corporation for all cutting tool products and services
provided by Gleason to the John Deere operations in Waterloo Flexible Shafts &
and Des Moines, Iowa. Spiral Bevel Gears
Two different ways to transmit rotary motion.
SUHNER Manufacturing Inc. Rome, GA 30161

Phone: 706-235-8046 [email protected]

industry news
Liebherr Gear of operations for Horsburgh & Scott, in Cleveland, a maker

of large gears and gear drive systems. At Horsburgh, He was
Technology in several positions of increasing responsibility ultimately

accountable for the entire operating structure of the orga-
nization of 135 individuals, including procurement, qual-
Appoints Service Manager for
North America ity, product engineering, manufacturing engineering and all
facets of the manufacturing organization. Before Horsburgh,
Liebherr Gear Technology, Lonsberry had his own business, was manager of engineering
Inc., Saline, Michigan, has and manager of operations at Parker Hannifin (Youngstown),
app oi nt e d R o b e r t ( B o b ) and held other engineering and engineering management posi-
Jelic service manager over- tions in Michigan and Ohio. He has a B.S. in Manufacturing
s e e i n g Nor t h A m e r i c a n Engineering, holds two patents, and is well versed in the Lean
operations for machine tool and Six Sigma tool kits.
and automation systems,
announced Peter Wiedemann,
president, Liebherr Gear
Technology, Inc. and Liebherr
Solar Atmospheres
Donates Vacuum Furnace to ASM
Automation Systems, Co. Jelic
is a 1996 graduate of Michigan In commemoration of ASM Internationals 100th anniversary,
Technological University and since then has been designing, Solar Atmospheres Inc. is donating a vacuum furnace to ASM
building and installing automated manufacturing systems. for use in its Teaching Lab at their headquarters in Materials
For the last seven years, he has been employed by Liebherr Park, Ohio. William R. Jones, CEO of Solar Atmospheres, Inc.
Automation Systems Co., a subsidiary of Liebherr Gear states, This gift, valued at $250,000, is being provided to edu-
Technology in Saline, MI. During his time at Liebherr, Bob has cate future technical personnel on the latest design and capa-
designed gantry and automation systems, managed their instal-
lation, and supervised complete projects from concept to imple-
mentation, said Wiedemann. His customer interaction and
site management has provided Liebherr with a level of custom-
er satisfaction that has resulted in success and growth.Bob now
brings his practical knowledge and desire for excellence to the
service and installation team to continue to insure the quality,
timing, and customer satisfaction that our customers deserve
and expect from all Liebherr installations, Wiedemann added.
Drake
Manufacturing bilities of the modern vacuum furnace. This new furnace is
Welcomes Kenneth Lonsberry
expected to ship in June 2013 and be operational in July.
Drake Manufacturing Services The furnace is being built by Solar Manufacturing, a Solar
Co., a Warren, Ohio, pre- Atmospheres company. Currently under construction is a
cision machine tool builder, Model HFL-2018-IQ horizontal, internal quenching furnace
has recently hired Kenneth with a hot zone that measures 12"wide12"high18"deep and
Lonsberry as vice president is capable of operation to 2,400F. The hearth will accept a load
operations. Lonsberry will be of 250 pounds. The hot zone insulation package will consist
responsible for managing and of a heavy graphite foil hot face backed by 4 layers of inch
driving improvements in engi- graphite felt, all supported in a stainless steel ring. The elements
neering; materials manage- will be curved solid machined graphite.
ment (purchasing and inven- The vacuum system will incorporate an Alcatel mechani-
tory control); manufacturing cal pump, a Varian 6 VHS-6 diffusion pump and an Alcatel
and assembly; and the new holding pump to allow the furnace to operate in the 10-6 Torr
start-up, warranty, and service range. Gas quenching will be via an internal 5 HP blower/
group. He comes to Drake with 14 years of operations expe- heat exchanger combination that recirculates the cooling gas
rience and 16 years in engineering management, design and through fixed gas nozzles located throughout the hot zone.
product support. He is very adept at working on the manu- Instrumentation will include a Honeywell DCP100 program-
facturing floor and has broad knowledge of manufacturing mer/controller, a Eurotherm 6100 temperature/vacuum record-
processes. His experience includes the role of vice president

er, a Honeywell UDC2500 overtemperature controller and an
Allen Bradley Micrologix 1500 programmable logic controller.
Featuring state-of-the-art vacuum furnace technology, this
furnace will allow students to perform a wide variety of tests
and experiments relating to vacuum heat treating, brazing and
sintering processes. It will also give them a hands-on under-
standing of the value and advantages of using vacuum over
other heat treating equipment.
Burkhardt+Weber
Start Sales Operations in United
States
Romi Machine Tools Ltd. is pleased to announce the open-
ing of the North American office of Burkhardt+Weber
Fertigungssysteme GmbH. The combination of Romi and
Burkhardt+Weber will strengthen both companies to efficiently
serve customers in the North American market. The mutual
office will be opened in February 2013. The Premium Quality
Machining Centers and Special Machines, made in germany,
deliver premium performance and are serving all industries
that need accurately machined parts weighting up to 44 tons.
These industries include power generation, gearbox manu-
facturing, diesel engine technology, mining, machine tools,
alternative energy, paper processing, wood/plastics, industrial
pumps and more. Burkhardt+Weber manufactures three basic
lines of large CNC Machine Tools: The BW MCX - Series
for reliable production, speed, accuracy and precision from a
strong roller bearing design. The BW MCR - Series for the
extreme demanding applications, combining high capacity
roughing with longevity and precision from a superior slideway
design.The BW - Series for ultra-precision machining with
repetitive micron accuracy.
SDP/SI
Donate Components to Team
SpacePRIDE
Stock Drive Products/Sterling Instrument (SDP/SI) recently
announced the donation of components to Team SpacePRIDE
for the NASA Lunar Rover Challenge 2013, enabling the team
to better compete by improving robotic and automation tech-
nology for space applications. Their space rover will traverse up
to 80,000 sq. meters, avoid obstacles, navigate, and locate dif-
ferent samples autonomously. The rovers drive trains consist
of two wheel pods, each having two sets of XL pulleys and belts
which are powered by a 100W DC gearmotor. The motors each
drive a 90-degree miter gear arrangement, which allows them
to sit inside each wheel pod. The belt drive expansion allows
more reduction capability and shock absorption. Members
of Team SpacePRIDE will compete in June at Worcester
Polytechnic Institute. Details of the competition can be found at
www.spacepride.com.

calendar
May 2223AGMA Marketing and Forecasting June 1014NAMRC 41. Monona Terrace Community
Conference 2013. Crowne Plaza, Chicago OHare Hotel and Convention Center, Madison, Wisconsin. The North
and Conference Center, Rosemont, Illinois. Whats going on in American Manufacturing Research Conference is sponsored by
the gear market? What is happening in the end user market that the North American Manufacturing Institution of the Society of
will affect next year? How can you better prepare your company Manufacturing Engineers (NAMRI/SME). It is co-located with
for the ups and downs of the current economic climate? The the 8th Annual ASME International Manufacturing Science and
Marketing and Forecasting Conference will present a com- Engineering Conference. The conference schedule will include
prehensive report on the U.S. Economic Conditions, Industry keynote presentations, technical presentations, expert panels,
Conditions for Gears, Gear Market Bookings and Gear Market student poster presentations, an early career forum, university
Shipments. This will be broken down into a series of end user lab tours and more. The purpose is to disseminate the most
markets including total gears, industrial machinery gears, con- recent manufacturing research and development through both
struction machinery gears, farm machinery gears, power trans- technical presentations and panel sessions. For more informa-
mission equipment, mining, ship and offshore, railroad and aer- tion, visit www.sme.org.
ospace gears. IHS Global Insight has developed news reports that
will forecast these various markets. This AGMA member-only June 2427PowderMet2013. Sheraton, Chicago.
event includes a reception and dinner for networking opportuni- More than 200 worldwide industry experts will present the latest
ties. For more information, visit www.agma.org. in powder metallurgy and particulate materials. 100 booths will
showcase leading suppliers of powder metallurgy and particulate
June 36HxGN Live. Las Vegas. Formerly known as materials processing equipment, powders and products. The
Hexagon 2013, HxGN Live is the international conference from event will feature special guest speakers, award luncheons and a
Hexagon Metrology that offers an opportunity to preview tech- main social event where you can relax, network and talk powder
nologies, attend presentations and participate in targeted tracks/ metal business. The MPIF/APMI sponsor this conference and
breakout sessions. This years theme, Great Stories Start Here, exhibition aimed at powder metallurgy and particulate materials
empowers attendees to do great things that have a global impact. engineers, technical staff, and sales and management personnel.
The metrology track will offer opportunities to hear experts dis- Held in late spring, and located each year in a different first-tier
cuss industry trends and challenges on 3-D scanning, automa- city in North America, the conference presents the latest indus-
tion/robotics, emerging metrology techniques, metrology in the try technical advances through technical papers and presenta-
supply chain, temperature compensation and more. Other tracks tions, posters, special interest programs, and general sessions.
include geosystems; process, power and marine; and security, For more information, visit www.mpif.org.
government and infrastructure. For registration information,
visit www.hexagonmetrology.com. July 711ICME 2013. Salt Lake Marriott Downtown
at City Creek, Salt Lake City, Utah. Integrated Computational
June 36Gleason Cutting Tools Gear Materials Engineering (ICME) has received international atten-
School. Loves Park, IL Fundamentals: This comprehensive tion due to its potential to shorten product and process develop-
3-1/2 day program is a blend of shop time and classroom study. ment time, while lowering cost and improving outcome. Building
A coordinated series of lectures is presented by engineering, pro- on the success of the 2011 conference, the 2nd World Congress
duction, inspection and sales staff members averaging 27 years on ICME will bring together researchers, educators and engi-
experience. Its an ideal course for those individuals seeking to neers to examine topics relevant to the global advancement of
understand the fundamentals of involute gear geometry, nomen- ICME as an engineering discipline. This conference will provide a
clature, manufacturing and inspection. Training groups are forum for presentations and discussions on the ICME approach,
kept small so that individual concerns may be fully addressed. challenges of integrating models, data management issues,
Students are welcome to bring sample gear prints and inspection engineering education and set the stage for further growth in
charts for discussion and interpretation. Shop tours and demon- the worldwide application of ICME. The event is sponsored by
strations are conducted to visually enhance the understanding of Ford Motor Company, University of Michigan, Carnegie Mellon
classroom discussions. For more information: Phone: (815) 639- University, NIST and Fraunhofer Institute for Mechanics of
4201 or [email protected]. Materials. For more information, visit www.tms.org.
June 3June 7ASME Turbo Expo 2013. San

Antonio Convention Center, San Antonio, Texas. Connect and
reconnect with turbomachinery colleagues from around the
world at the ASMEs premier turbine technical conference and
exposition. The scope of the conference has now expanded to
include fans and blowers, steam and wind turbines, solar energy,
and supercritical CO2 power cycles. Highlights include a five-day
technical conference, organized to meet the needs of growing
participation; a three-day exposition of gas turbine products
and services supported by leading companies in the industry;
and a keynote session featuring prominent industry leaders. The
registration package includes proceedings, access to all activities
and abundant networking opportunities, including receptions
and lunch as well as in-depth training workshops providing fun-
damental study on selected subjects. For more information, visit
www.asmeconferences.org.

Unlock the
Archive
The complete set of back issues of Gear Technology
is available online--but ONLY if you're a subscriber.
Make sure you have access by filling out the form!
YES I want to receive/continue to receive Gear Technology FREE!

No thank you.
1
Name:_________________________________________JobTitle/Position: ___________________________
(print)
Signature _____________________________________________________ Date: ______________________

(required)
2 E-mail __________________________________________________________ SAVE a TREE!

(So we can notify you when the online edition is available)
I ONLY want the digital edition
(e-mail required)
Please update your contact information or
3 attach your business card here. (No Staples)
Company Name: ______________________________________________________
Address: ______________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
City: __________________________________________________________________
State/Province: _____________________ ZIP/Postal Code: __________________
Country: ______________________________________________________________
Telephone: __________________________Fax:______________________________
E-mail: _______________________________________________________________
Website: ______________________________________________________________
What is your primary JOB FUNCTION

4 (check ONLY one) DIGITAL SUBSCRIPTIONS
Corporate Executive (B) Purchasing (L)
Manufacturing Production Management (C) Marketing, Sales or Communications (M) YES, I want to be notified each issue when Gear
Manufacturing Production Department (D) Quality Control Management (P) Technology is available online
Manufacturing Engineering Management (E) Quality Control Department (Q)
Manufacturing Engineering Department (F) Other (Please describe) (N) YES, I would like to receive Gear Technologys
Product Design, R&D Management (H) ______________________________
monthly e-mail newsletter
Product Design, R&D Department (I) YES, I would like to receive Gear Technologys
monthly e-mail Product Alerts
YES, I would like to receive 3rd-party e-mails from
How are YOU involved with gears
5 (check all that apply)?
Gear Technologys advertisers and partners
My company MAKES gears (20)

YES, I would like to receive subscription renewal
notices by e-mail
My company BUYS gears (22)
I DESIGN gears (23) No, I do not wish to be contacted by e-mail.
I am a SUPPLIER to the GEAR INDUSTRY
(please specify product or service) (24)
FAX TO 1-847-437-6618 or
VISIT US ONLINE AT
www.geartechnology.com/subscribe.htm
ad index
AGMA page 31 Liebherr page 5
www.agma.org www.liebherr.com
Ajax Rolled Ring page 26 Machine Tool Builders Inc. page 4
www.ajaxring.com www.machinetoolbuilders.com
All Metals & Forge Group, LLC page 24 Martin Sprocket & Gear Inc. page 41
www.steelforge.com www.martinsprocket.com
Careers geared
Careers gearedto succeed.
to succeed. B&R Machine & Gear Corp. Inside Back Cover McInnes Rolled Rings page 20
Global opportunities available.
Global opportunities available. www.brgear.com www.mcinnesrolledrings.com
Moogs motion control technology and products are found around the world
Moogs motion control
from helicopters to fightertechnology andsea
planes and deep products are found
drills to syringe around
pumps. We the world The Broach Masters & Universal Gear page 25 Midwest Gear & Tool Inc. page 49
Were
foster
from anlooking
environment
helicopters
for our
where
to fighter
talented
11,000and
planes
engineers
engineers
deep seaand technologistswithfeel pumps. We
drills to syringe www.broachmasters.com [email protected]
at least seven years
an environment where our of11,000
experience
engineers and in technologists feel
empowered and inspired to achieve remarkable things. The work we do matters,
foster
gear
empowered manufacturing
and inspired to achieve toremarkable
join our business
things. The work we do matters, Broaching Technologies LLC page 49 Mitsubishi Heavy Industries page 8
in
Were looking for talented engineers with at least seven years of experience
Baguio City, Philippines,
in BaguioTorrance,
www.keyway-spline-broaching.com www.mitsubishigearcenter.com
Careers
in gear manufacturinggeared
to join to
our business succeed. City, Philippines, Torrance,
California
California
Were
Global
joining
looking forand Wolverhampton,
and Wolverhampton,
talented
our opportunities
United Kingdom.
engineers
available.
team in the Philippines,
with atIf least United
you areseven
interested
yearsinof experience
but are not a resident there, you will receive
Chevin Tools page 47 Mitsubishi Materials page 83
in gear manufacturing to join our business in Baguio City, Philippines, Torrance,
Kingdom.
housing benefitsIf
Moogs motion
andyou
control are
travel allowance.
technology interested
and products are in
found joining
around theinterested
world
www.chevintools.com www.mmus.com
California and Wolverhampton, United Kingdom. If you are in
our
joiningteam
from
To
our teamin
helicopters
apply, to the
please send fighter Philippines,
planes
your resume
in the
toand
Philippines, but are notbut
deep sea drills to
[email protected] are
orsyringe
a resident not
pumps. We
visit moog.jobs
there, you will receive Circle Gear page 87 Moog Inc. pages 40, 86
foster an environment where our 11,000 engineers and technologists feel
ahousing
resident
YOU benefits
CAN DO
empowered THIS
and there,
and travelyou will
allowance. receive housing
inspired to achieve remarkable things. The work we do matters, www.circlegear.com
benefits
as does everyand travel
single person allowance.
who works with us. moog.jobs
To apply, please send your resume to [email protected] or visit moog.jobs
Custom Gear & Machine page 81
Were looking for talented engineers with at least seven years of experience
www.cgearinc.com Overton Chicago Gear page 86
To apply, please send your resume to
in gear
YOU CANmanufacturing
DO THISto join our business in Baguio City, Philippines, Torrance, www.oc-gear.com
[email protected] or visit moog.jobs
California and Wolverhampton, United Kingdom. If you are interested in
joining our team in the Philippines, but are not a resident there, you will receive Delta Inspection page 59
housing benefits and travel allowance.
www.deltainspect.com PowderMet 2013 page 55
To apply, please send your resume to [email protected] or visit moog.jobs www.mpif.org/Meetings/2013/13_gateway.htm
DMG/Mori Seiki page 37
YOU CAN DO THIS
www.dmgmoriseikiusa.com Presrite Corp. page 18
www.presrite.com
DTR Corp. page 35
www.dragon.co.kr Process Equipment page 23
www.gearinspection.com
Forest City Gear page 7
www.forestcitygear.com Proto Manufacturing page 16
www.protoxrd.com
s Gear Consulting Group page 87
i n g need 0 www.gearconsultinggroup.com PTG Holroyd page 33
www.holroyd.com
eAr -10 0
ur g f r o m 1
The Gear Machinery Exchange page 40, 87
o Quality Transmission Components page 83
y www.gearmachineryexchange.com
All l u m e s www.qtcgears.com
in vo
The Gear WorksSeattle, Inc. page 87
www.thegearworks.com Sandvik Coromant page 21
www.sandvik.coromant.com/productnews
Gleason Corp. pages 44-45
Gear boxes www.gleason.com Schnyder S.A. page 47
www.hanikcorp.com
Herringbone Hainbuch page 14
Large internal www.hainbuchamerica.com Seco Tools page 39
www.secotools.com/us
Worm gearing Hans-Jrgen Geiger Maschinen-Vertrieb page 51
www.geiger-germany.com Star SU LLC pages IFC1, 87
Spur & helical www.star-su.com
Gleason bevel gearing up to 4 meters Index Technologies page 87
www.gallenco.com Stock Drive Products/Sterling Instrument page 4
Klingelnberg bevel gearing up to 4 meters www.sdp-si.com/plastic
Inductoheat page 11
www.inductoheat.com Suhner Manufacturing page 81
Chicago Addison Lombard www.suhner.com
(630) 543-9570 Ingersoll Cutting Tools pages 13, 15, 17, 19
125 years of precision gears www.ingersoll-imc.com Yager Gear Enterprise Co. Ltd. page 87
www.oc-gear.com www.yagergear.com
for the most demanding
[email protected] gear applications. Ipsen International page 43
www.ipsenusa.com Zoller page 57
www.zoller-usa.com
Kapp Technologies page 3
www.kapp-usa.com
NEXT ISSUE Klingelnberg Outside Back Cover
www.klingelnberg.com
Focus on Leistritz Corp. page 27
QUALITY &
INSPECTION
Be a part of the
discussion by contacting
our editors:
Randy Stott, Managing Editor
[email protected]

[email protected]
Matt Jaster, Senior Editor

[email protected]

classified
ear School for

Gear Manufacturing Technology
onsulting
roup Conducted by
Geoff Ashcroft, Gear Consulting Group
3 DAY CLASS to cover the practical aspects of gear technology and
geometry aiming toward a logical approach to trouble shooting and
optimizing the manufacturing processes
Gear geometry and its Trouble shooting the process Hob shifting procedures and
relationship to gear from inspection data. optimization.
generation. Cutter wear and failure Use of standards.
Gear inspection procedures analysis. Open forum on attendees
and analysis. Cutter materials and coatings. experienced problems.
Understanding the processes of Optimization of feeds
Hobbing, Shaping and Shaving. and speeds.
QR-Code Generator
ID KAYWA READER FEED2MOBILE DATAMATRIX GENERATOR NEW: DOKODARE PHOTO LENDORFF KAYWA
http:/
2013 Class Schedule

June 5, 6 & 7, 2013 / Statesville, NC October 2013 / Anaheim, CA
RP Machine GMI (Gear Manufacturing Inc.)
June 19, 20 & 21, 2013 / Addison, IL More information Contact Bobbie ph: 904-392-0907
Overton Chicago Gear www.gearconsultinggroup.com [email protected]
Save this code to add it to your blog
or your documents.
You can also use the code's permalink,

or copy-paste the following HTML code:
<img src="http://qrcode.kaywa.com/img.php?s=12&d=http%3A%2F%2Fww
QR-CODE GENERATOR
Content type:
URL Text Phone Number SMS
Content:
URL:
http://www.gearconsultinggroup.com
Size: XL
Spiral Bevel Gears

Generate!
Version: 1.00 BETA | Non-Commercial Use Only KAYWA // TECHNOPARKSTRASSE 1 // 8005 ZUERICH // SW ITZERLAN
A D V E R T IS E ME N T:
1 of 2 10
for Electric and Pneumatic Tools,

Machine Tools, Agricultural
Machinery and Automobiles
ISO 9001:2008
Yager Gear Enterprise Co., Ltd.

ADD: No. 57, Shigu Ln., Guozhong Rd., Dali Dist.,
Taichung City 412, Taiwan
Tel: +886-4-24076223 EXT. 30
Fax: +886-4-24076218 216.642.5900 216.642.8837
E-mail: [email protected] 5755 CANAL ROAD VALLEY VIEW, OH 44125
http://www.yagergear.com
CONIFLEX QUALITY CUSTOM GEARING!

CUTTER Documented
BODIES Quality Control Program

Inspection Lab
including Complete
W/BLADES Gear Tooth Diagnostics
for Tooth Cutting, Grinding & Shaving Services Available
Gleason Model All Sizes & Configurations

104 & 114 Reverse Engineering
IR CL Circle Gear and Machine
C
C Quality Custom Gearing Since 1951

E
See at Design Analysis G C

1501 South 55th Ct. Cicero, IL 60804
Complete Machine Shop Including CNC Machining
EA
G
R C
Ph: 708-652-1000 Fax: 708-652-1100
www.gearmachineryexchange.com
Please email your inquiries to [email protected] www.circlegear.com

back to basics
Hardness Testing
Rockwell Testing
Specifying the hardness of fin- designation HRC
Force Force
ished gears is just one way that along with the hard-
gear engineers can ensure they ness number. The
are made of the right materi- H stands for hard-
al and properly heat treated. ness, the R for
However, a wide variety of hard- Rockwell, and the
ness testing methods exists. C corresponds to Depth of impression
determines hardness
Here is a brief introduction to those the appropriate hard-
most commonly used in gear manufac- ness scale. Thus,
Diamond-shaped
turing. HRC 55 might be the Spherical indenter
cone indenter
Rockwell. The Rockwell hardness Rockwell C hardness
test was invented in 1919 by Stanley P. of 4140 steel.
Rockwell, who developed his method as Brinell. Swedish engineer Johan an easier alternative to Brinell testing.
a nondestructive way to quickly, repeat- August Brinell invented the Brinell hard- It uses a standardized indenter, and the
ably and reliably test the hardness of the ness test in 1900. It is often used on results are largely force independent
bearing races made by his company. large parts, particularly castings or forg- (although there are special consider-
Like all of the other major testing ings whose grain structure is too coarse ations for microindentation tests done at
methods, the Rockwell test determines for testing via the Rockwell or Vickers forces of less than 200 g).
hardness based on the results of an methods. Like the Brinell test, the Vickers test
indentation test, wherein a hard mate- With Brinell testing, a spherical calculates hardness based on the surface
rial is pressed into the test piece under a indenter is pressed into the test piece area of the indentation. However, the
specified load. and held for a specified time under a Vickers indenter is a pyramid-shaped
Rockwell testing is done in two phas- controlled force. The hardness of the diamond rather than a ball. The dia-
es. First, a minor load is applied. This piece is calculated based on the surface mond tip is pressed into the test surface
reduces the effects of surface asperities area of the indentation, which must be under controlled force for a specified
and establishes a zero reference point. measured optically, either by microscope period of time. The Vickers hardness is
Then, a major load is applied for a set or by an optical device integrated with a function of the test force divided by the
time period, and released, leaving an the tester. surface area of the indent.
indentation in the test piece. The testing Brinell testing is very much dependent The Vickers test has two distinct force
device determines hardness based on the upon the specific force applied as well as ranges: macro (1 kg100 kg) and micro
depth of the penetration. the material used for the indenter. Today, (10 g to 1,000 g). ASTM E384 covers the
There are many variables involved in Brinell testing is typically done using 3,000 micro force ranges, while ASTM E92
Rockwell testing. The indenter can be kgf and a 10mm tungsten carbide ball. covers the macro force ranges. ISO 6507
either a diamond cone or a steel ball, ASTM E10 and ISO 6506 are the rel- covers both ranges.
and steel balls of varying diameters evant standards for Brinell testing of Knoop. The Knoop hardness test is
can be used, depending on the mate- metals. According to ASTM E10, Brinell used for particularly thin or brittle mate-
rial to be tested. Also, different materials hardness should be specified using the rials, where only a small indentation
require different minor and major forces designation HBW, where H stands for can be made. The Knoop test is similar
to be applied, resulting in 30 different hardness, B stands for Brinell, and W to the Vickers test, except that it uses
Rockwell scales (named A, B, C, etc.). stands for tungsten carbide, the mate- an elongated pyramid indenter and is
The scale most widely used for gearing is rial used for the indenter. In addition, reserved for microindentation testing.
the Rockwell C scale, which covers most the size of the ball and the force applied Because the indentation is very small,
steels. In addition, there is a Rockwell should be included with the specifica- and optical identification of the surface
superficial test, which uses light loads tion. Thus, an HBW 10/3000 hardness area is required, the Knoop test requires
and which is meant for thin or easily of 187 would indicate a Brinell hardness a highly polished, flat surface. This often
damaged surfaces. of 187 was achieved using a 10mm tung- means the test piece must be destroyed
ASTM E18 and ISO 6508 cover sten carbide ball, applied at 3,000 kgf. in the process.
Rockwell hardness testing for metals. Often materials suppliers and manufac- Knoop testing is described by ASTM
According to ASTM E18, Rockwell C turers leave out this important informa- E384. Because it is force-dependent, it is
hardness should be specified using the tion, even though Brinell hardness num- crucial that the Knoop hardness speci-
bers obtained using different forces or fication include the testing force. Thus,
indenter materials are not comparable. HKN50 500 is the proper designation for
hardness Vickers. The Vickers hardness test a Knoop hardness of 500, achieved at 50
was developed in England in 1921 as grams testing load.

BIG
GEARS
IN-HOUSE STEEL MATERIAL WAREHOUSE
STRAIGHT BEVEL GEARS: 80"PD
SPIRAL BEVEL GEARS: 66"PD
FULL HEAT TREATING SERVICES

SPURS, HELICALS, SPLINE SHAFTS
GEARBOX REPAIR/REBUILDS
EDM WIRE BURNING
REVERSE ENGINEERING BREAKDOWN SERVICES
TOLL FREE: 8002380651

[email protected] www.brgear.com
MACHINE AND GEAR CORPORATION
TEAMPLAYER.
GEAR MANUFACTURING SOLUTIONS
FOR MAXIMUM PERFORMANCE
BY KLINGELNBERG
OERLIKON HFLER KLINGELNBERG

BEVEL GEAR TECHNOLOGY CYLINDRICAL GEAR TECHNOLOGY MEASURING TECHNOLOGY
A winning team has a system. It is perfectly tuned and balanced.

It acts with the utmost precision. The strengths of each individual
work together like perfect gears.
Klingelnbergs divisions are true team players:

Ground breaking solutions for an optimal production process
of Bevel and Cylindrical Gears give manufacturers worldwide
a leading edge in gear manufacturing.
NEXT FAIR:
Win the match: KLINGELNBERG America, Inc. Metalloobrabotka
www.klingelnberg.com p. +1 734 470 6278 Hall 8.2. Booth B 05
Expocentre Fairgrounds
www.hofler.com e. [email protected] May 27-31, 2013
Moscow, Russia
SUBJECT TO CHANGES.
BEVEL GEAR TECHNOLOGY CYLINDRICAL GEAR TECHNOLOGY MEASURING TECHNOLOGY

Rev I Stage Ards

Uploaded by

Copyright:

Available Formats

Rev I Stage Ards

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rev I Stage Ards

Uploaded by

Copyright:

Available Formats

What are some of the gear cutting tools and services mentioned?

What are some of the gear cutting tools and services mentioned?

What are two gear hardness testing methods described?

What are two gear hardness testing methods described?

MAY

Repurposing Machine Tools

OPTIMIZING HIGH-SPEED, NON-

THE JOURNAL OF GEAR MANUFACTURING

Shaving cutter and master gear grinding

28 Reinventing Cutting Tool Production

52 Gear Research Institute: A Big Part of 72 Hybrid Gear Preliminary Results

2 GEAR TECHNOLOGY|May 2013

Customers Say it Best.

Quality without compromise!

Bobbers, bucktails, and shumway seem the same, but an

MTB offers meticulous and quality craftsmanship in 2013

Repurposing Machine Tools

OPTIMIZING HIGH-SPEED, NON-

Call MTB: 815.636.7502 or visit www.machinetoolbuilders.com

THE JOURNAL OF GEAR MANUFACTURING

4 GEAR TECHNOLOGY|May 2013

Liebherr Gear Technology, Inc.

2014-003 Umbau Profilschleifen_216x279_GB.indd 1 22.03.13 14:2

Randall Publications LLC

6 GEAR TECHNOLOGY|May 2013

Dont let gear challenges go undetected.

11715 Main Street, Roscoe, IL 61073

The Game-Changing Mitsubishi GE Series

May 2013|GEAR TECHNOLOGY 9

or the sing mHaas

stop and visit the Waldrich Coburg plant in Coburg, Germany,

Inductoheat caters to your induction heating needs:

Inductoheat, Inc. Madison Heights, MI (248) 585-9393

May 2013|GEAR TECHNOLOGY 11

12 GEAR TECHNOLOGY|May 2013

material for this wear-optimized grind-

Production Controls Profit from

May 2013|GEAR TECHNOLOGY 13

KISSsoft in the 3-D system, ensuring maximum

Because Modular is Standard

14 GEAR TECHNOLOGY|May 2013

May 2013|GEAR TECHNOLOGY 15

chip flow condi-

16 GEAR TECHNOLOGY|May 2013

May 2013|GEAR TECHNOLOGY 17

FORGED ger tool life are just two of the benefits

NET and machine stoppages. Increased produc-

NEAR-NET applications, and in difficult to machine

.008 - .060 Stock

18 GEAR TECHNOLOGY|May 2013

PRS-029 GearAd-GearTech2.indd 1 12/22/11 9:50 AM

150200 bar (2,2002,900 psi)

May 2013|GEAR TECHNOLOGY 19

1-2 weeK Founded in 2002, Changzhou Tianshan is

alloy & ment, port mechanical equipment and

20 GEAR TECHNOLOGY|May 2013

The hob is a perfect example of how a little manufacturing ingenuity

Coating Technology with Sulzer

22 GEAR TECHNOLOGY|May 2013