Gear Technology India 2014 1

GEAR
TECHNOLOGY
INDIA
VOLUME 3 ISSUE 1 - QUARTERLY
KARENG04277
FEBRUARY 2014
BANGALORE
Free Distribution
Taking BigGears
Measure
IPTEX 2014:
Exhibitor Previews
GEAR INDUSTRY PROFILE
TECHNICAL
Antonio
Maccaferri
Ask the Expert

CROWNING SPUR TEETH
SPECIFYING GEARS TO
STANDARD
WORKING WITH HIGH-TEMP
GEAR MATERIALS
Design and Optimization

of Planetary Gears
www.geartechnologyindia.com
INsight
Will the Indian Economy

Shake Its Inertia?
THE JOURNAL OF GEAR MANUFACTURING
Gear up for higher reliability

with upgraded SKF Explorer bearings
A robust solution for harsh and demanding gearbox
environments, upgraded SKF Explorer bearings enable a
gear unit to transmit more torque, sustain higher external
loads, or even be downsized to improve cost efficiency.
In addition, these bearings provide substantially longer
life than other bearings. In fact, they have up to twice the
rating life of original SKF Explorer bearings, especially
under contaminated and poor lubrication operating
conditions.
With expertise in bearings, sealing, and lubrication
solutions, SKF engineers can add value to the complete
gear unit by enhancing reliability and performance, while
improving the cost-effectiveness of the complete solution.
Enhance gear unit reliability and improve performance
Upgraded SKF Explorer self-aligning bearings have enhanced
wear and contamination resistance, and are better able to
run under tough conditions up to 100% longer bearing
rating life.
The Power of Knowledge Engineering
For more information, please visit skf.com or contact your

local SKF representative.
GEAR
TECHNOLOGY
INDIA
contents
VOLUME 3, ISSUE 1
16
20
features
12 IPTEX 2014
A sampling of exhibitor offerings to be

found at IPTEX.
16 Interview with Antonio Maccaferri
CEO dreams big SAMP and bigger

Maccaferri Industrial Group.
20 Super-Sized Quality Control
Big gears offer unique inspection challenge.
technical
26 Ask the Expert
Crowning Spur Teeth

Hot Gears
Specifying a Quality Gear
36 Design and Optimization of

Planetary Gears
Robust-design gearboxes for high load

capacity and power density.
44 Introduction to Bearings
The ABCs of bearings\
48 The Workhorse of Industry:

The Induction Motor
VOLUME 3, ISSUE 1 GEAR TECHNOLOGY INDIA
contents
GEAR
GLEASON MACHINES TECHNOLOGY
INDIA
AND TOOLING
departments
VOLUME 3, ISSUE 1
www.wmtg.co.uk
Leading supplier of other used:
GEAR MACHINERY
STANDARD MACHINE TOOLS
Call and ask for details
or visit our website
WESTMINSTER MACHINE TOOLS LTD
06 Publishers Page
IPTEX 2014: Go For the Weather, Stay for the Gear

Show
08 Product News
New equipment, software, etc.
50 Industry News
The who, what and where
54 Events/Calendar
Upcoming shows, conferences, etc.
55 Advertiser Index
Advertiser contact information
56 INsight
Can Indias Economy Get it in Gear?
Tel: +44 (0)1572 767922 Fax: +44 (0)1572 768321 Email: sales@wmtg.co.uk
www.wmtg.co.uk
TOP TOOLS TECHNOLOGY
Precision Gear Cutting Tools
Top Tools is a long experience & established company Producing-Stockiest

Complete Range of Precision Gear Cutting Tools since 1990.
We specialize manufacture of standard &
as per customer requirement
In Different Profiles
For Various applications
Gear Hob : Finish /Rough
Spline/Serration
Semi-Topping
Pre-Grind / Pre- Shaving
Sprocket / Timing Pulley
Fine Pitch-Mikron, WormHob
Rack / Milling Cutter
Gear Shaper: Disc / Shank / Hub Ty

Sprocket / Timing
Spline / Serration
Bevel Generating Tool
WMW Blade & Accessories
Gear Shaving / Broaches
Spline Gauge / Dp-Mod Gauge
Accuracy: AA, A, B, C
GEAR
TECHNOLOGY
INDIA
VOLUME 3 ISSUE 1 - QUARTERLY
KARENG04277
FEBRUARY 2014
BANGALORE
Free Distribution
Taking Big Gears

Measure
IPTEX 2014:
Exhibitor Previews
GEAR INDUSTRY PROFILE
TECHNICAL
TOP TOOLS TECHNOLOGY
Address: 24/2nd Floor,

Indu Ganesh CHS,
Trimurty Soc.Rd.
Sion- Chunabhatti -EastMumbai - 400 022. India.
Telephone: 91-22-234 15831

Mobile: 91-9323115831
91-9820182981
E-mail: toptools.shah@gmail.com
toptools99@gmail.com
GEAR TECHNOLOGY INDIA VOLUME 3, ISSUE 1
Antonio
Maccaferri
Ask the Expert

CROWNING SPUR TEETH
SPECIFYING GEARS TO
STANDARD
WORKING WITH HIGH-TEMP
GEAR MATERIALS
Design and Optimization

of Planetary Gears
INsight
Will the Indian Economy

Shake Its Inertia?
Photo courtesy of Klingelnberg

[www.GearTechnologyIndia.com]
Gear Grinding in
Swiss Precision
Since Reishauer Switzerland invented Continuous Generating Gear Grinding, we have constantly been pushing the performance of our machines to new heights: Higher productivity higher accuracy. Thats why the leading automotive
companies rely on Reishauer.
Reishauer AG
Zrich / Switzerland
+41 44 832 22 11
info@reishauer.com
www.reishauer.com
M/S. Proteck Machinery Pvt. Ltd.

Chennai/India
+91 44 249 531 77
mtdsales@proteck.co.in
www.reishauer.com
GEAR
TECHNOLOGY
INDIA
GEAR
TECHNOLOG
Y
INDIA
VOLUME 3 ISSU
E 1 - QUA
RTERLY
GEAR TECHNOLOGY India is published quarterly by Virgo Publications, Bangalore (India) under
license from Randall Publications LLC, Elk Grove Village, IL (USA). Randall Publications is also the
publisher of GEAR TECHNOLOGY and POWER TRANSMISSION ENGINEERING magazines in USA.
Virgo Publications has been established by one of the promoters of Virgo Communications and
Exhibitions Pvt. Ltd., the organizers for IPTEXthe International Power Transmission Expo (a gear
engineering event) for the purpose of establishing Indian editions of foreign technical journals.
KARENG0427
Taking Big
G
Measure ears
FEBRUARY 2014
BANGALORE
Free Distribut
ion
PUBLISHERS
IPTEX 20
Exhibitor 1P4:
reviews
Missing Something?
All of the back issues
Anton of
Maccafeio
i
rt
Gear Technology Indiarrare
available online.
GEAR INDU
STRY PROF
ILE
CROWNING
SPUR TEETH
SPECIFYING
STANDARD GEARS TO
WORKING W
GEAR MATERITH HIGH-TEMP
IALS
Design and Op
of Planetary timization
Gears
Matthew Jaster, Senior Editor,

mjaster@geartechnology.com
INsight
ADVERTISING SALES (INTERNATIONAL)
Michael Goldstein, Publisher & Editor-in-Chief

Dave Friedman, Associate Publisher/Sales Manager
www.geartech
nologyindia.com
L OF GEAR MA
Michael Goldstein, Publisher & Editor-in-Chief,

publisher@geartechnology.com
Jack McGuinn, Senior Editor,

jmcguinn@geartechnology.com
Will the Indian

Shake Its Iner Economy
tia?
THE JOURNA
EDITORIAL STAFF
William R. Stott, Associate Publisher/Managing Editor,

wrs@geartechnology.com
TECHNICAL
Ask the Expe
Michael Goldstein, Publisher (USA) & Editor-in-Chief

Anitha Raghunath, Publisher (India)
DESIGN
NUFACTURIN
David Ropinski, Art Director,

dropinski@geartechnology.com
ADVERTISING SALES (INDIA)
INDIA
HEAT TREAT AUDIT
Q1
2013
DONE RIGHT
PROFILE:
INDIA
Anitha Raghunath, Publisher (India)

G. Raghu
Q2
2013
MOTOR
TECHNOLOGY
FOCUS
WHO MAKES THE

BIGGEST GEARS?
Mitsubishi Heavy
Industries India
DC MOTOR PROTECTION
When a Good Gear Drive System

Goes Bad
PROFILE:
TECHNICAL
Blaser Swisslube India
TECHNICAL
Enhanced Induction Hardening

of Gears and Components
Morphology of Micropitting
Progress in Gear Milling
INsight
The Involute Curve
Ask the Expert: Couplings

Case Depth and Side-Face
Carburizing Effects
Real Savings with
Synthetic Lubricants
Optimal Gear Shaft
Manufacturing
INsight
Finding and keeping

skilled employees
October-December 2012
INDIA
I N D I A S G E A R A N D P O W E R T R A N S M I S S I O N R E S O U R C E
BUYERS GUIDE
GEAR MANUFACTURING POWER
MACHINES, TOOLING TRANSMISSION
AND SERVICES COMPONENTS
FEATURE
Metrology Basics
April-June 2012
INDIA
BIG2012?
I N D I A S G E A R A N D P O W E R T R A N S M I S S I O N R E S O U R C E
FEATURE
POWER TRANSMISSION
COMPONENTS
Technical
Analyzing Wear in HCR Gears

Internal Clearance in Ball Bearings
Point-Surface-Origin Macropitting
Micropitting of Big Gearboxes
INsight
No Small Measure
INsight
Help Wanted
w w w. g e a r t e c h n o l o g y i n d i a . c o m
w w w. g e a r t e c h n o l o g y i n d i a . c o m
Download them for free at
4
Randall Publications LLC

1840 Jarvis Ave., Elk Grove Village, IL 60007, USA
Phone: +1-847-437-6604
Fax: +1-847-437-6618
publisher@geartechnology.com
INDIA SALES AND REGISTERED OFFICE
Virgo Publications
Virgo House, 250, Amarjyoti Layout,
Domlur Extension,
Bangalore 560071.
India
Telephone: +91-80-25357028/29, 41493996/97.
Fax: +91-80-25357028
gti@virgopublications.com
PRINTER
Sri Sudhindra Offset Process,

No. 27-28, 8th Cross, Malleshwararam
Bangalore 560003
Karnataka, India
For Cutting Tools
Technical
Wear-Resistant Bearings
Ask The Expert: Profile Shift
GLOBAL SALES AND HEADQUARTERS
GEAR TECHNOLOGY India is published in the interest of the members of the gear
and power transmission industry in India, to improve communication and further update
members of that industry on all the latest developments in the sector. The publishers
have made every effort to ensure that the processes described in GEAR TECHNOLOGY
India conform to sound engineering practice. Neither the authors nor publishers can
be held responsible for injuries or damage sustained while implementing the technology
published, which is informatory and not specific.
GEAR TECHNOLOGY is a registered trademark of Randall Publications LLC, and
application for registering GEAR TECHNOLOGY India as is a trademark of Randall
Publications LLC is pending. The contents of this publication are Copyright Randall
Publications LLC, 2013. All rights are reserved. For permission to reprint any portion of
this magazine, contact the publisher at the USA Headquarters office, listed above.
Advertising and subscription information is available at
machines tools processes
complete solution for the gear and profile grinding from one source
gear centre KAPP KX 300 P

Flexible system and loading options for your special gear requirements.
Roughing and finishing in one set-up or machining of several gears
in one set-up for fast and precise results.
gear prole grinding machine NILES ZP 12

Direct drives in the rotary table as well as in the grinding and dressing
spindle make the processing highly dynamic.
The machine can be operated from the factory floor and, as is typical
for NILES, is set up without the need for an elaborate foundation.
rotor grinding machine KAPP RX 120

The new and patented roughing process helps to reduce the grinding
time by up to 45 %!
Integrated in an automated machining cell, finished rotors can be
deburred concurrent to the machining time.
visit us
at the IPTEX:
Hall 6
Booth D6
further information on our website: www.kapp-niles.com
publisher's page
IPTEX 2014:
Go For the Weather,

Stay for the Gear Show
The weather in Chicago lately has been quite
miserable. Like many cities throughout the United States,
weve had one of the coldest and snowiest winters on record.
Today its fairly warm outside. And by warm, I mean todays
high temperature is about 10C (14F), with a wind-chill factor of about 18C (1F).
I would much rather be in Mumbai, where I see todays temperature is a balmy 29C (84F). But its not just the weather
that makes me wish I were there. Its the gathering of gear and
power transmission technology professionals coming to IPTEX
2014.
IPTEX 2014 takes place February 27-March 1 in Mumbai.
Now in its third installment, the show has quickly become a
central meeting place to learn about the latest technology in
gear manufacturing, as well as a terrific event for buyers of
mechanical power transmission components. You can read
about a number of the exhibiting companies in this issue of
Gear Technology India. But to get the full experience, you really
have to go to the show. This year, to make it even more worthwhile, the event is co-located with GRINDEX, which has a
focus on grinding and abrasives technology.
Hopefully the warm weather and IPTEX will combine to generate substantial new business for Indian companies in the gear
and power transmission industries. Perhaps things will start to
heat up in our industry.
A substantial area of opportunity for Indian manufacturers
continues to be exports, particularly now, given that key markets in Europe and North America have stabilized over the past
year. If your companys products have potential demand overseas and you are looking for the right customers to buy them,
then perhaps IPTEX would benefit you. In addition to attracting visitors from all around India, IPTEX also attracts key buyers from around the globe who are looking to do business with
Indian companies.
Publisher & Editor-in-Chief

Michael Goldstein
But if youre really interested in doing business with North

America and Europe, take a look into our sister publications,
Gear Technology (USA) and Power Transmission Engineering.
Each of these magazines reaches a global audience, heavily
concentrated in North America. Depending on your products,
advertising in one or both of these could help attract the attention of new potential customers from markets where demand is
growing and where your pricing could have significant advantages.
If you manufacture products (such as machine tools or cutting tools) for use in gear manufacturing industries, please
visit www.geartechnology.com/adinfo.htm to learn more about
advertising in Gear Technology. If you manufacture mechanical
power transmission products (such as gears, bearings, motors,
speed reducers, etc.), please visit www.powertransmission.com/
adinfo.htm for additional information about advertising in
Power Transmission Engineering.
In any case, I wish all of you the best of luck for the coming
year. Hopefully IPTEX will help provide the spark that ignites
the flames of expanded business in the gear industry.
LMT THE PERFORMANCE TEAM
LMT TOOLS
GLOBAL MANUFACTURING FACILITY IN INDIA

The LMT Tools Division of the LMT Group has
inaugurated its first state of the Art Global
Manufacturing Facility in India at Chakan, Pune.
Spread over a 3 acre land, LMT Indias
manufacturing facility is in line with the global
standards in terms of aesthetic looks, techniques and technologies being used.
The primary reason behind this expansion is
Indias dynamic and fast growing market,
proximity to customers production sites and
the ability to supply the Asian market faster.
This plant will cater to both domestic and
international market needs.
With around 30 of the best quality and latest

machinery in place and 60 well trained employees, LMT India is inclined towards developing
and producing the best quality and efficient
tooling systems for the precision tool industry.
This facility will cater to the requirements
from the various industries including automotive
industry, die and mold industry, mechanical
engineering industry, medical technology industry,
aeronautics and aerospace industry.
LMT India Pvt Ltd
Global Manufacturing Facility
Plot No. A-40/1, Phase I,
MIDC Chakan, Village Nighoje,
Tal. Khed, Dist. Pune 410 501.
Phone +91 2135 394900

sales@lmt-tools.co.in
www.lmt-tools.com
product news
EMAG
FOCUSES ON DIMENSIONAL ACCURACY IN HARDENING

Shorter model life-cycles and increasing demands on quality, accompanied
by many technological innovations,
are driving developments in high-tech
industries such as automotive or aerospace manufacture ever harder. The
effect this has on the production environment is best shown by the example
of hardening. Many of their key components go through this process at
one stage. It is a process that has to be
not only highly accurate, but guarantee unvaryingly good component quality. It is for this reason that the specialists at Eldec have committed themselves
wholeheartedly to the required standard
of reproducibility. Their Mind modular
hardening machines stand for exceptional precision and economic processes.
Reproducibility is an inalienable
word in automotive production. After
all, the car as a product is reliant on the
unvarying component quality of the
drive shaft. In this context, the focus is
on the indispensable hardening process.
It is well to remember that during this
process the components micro structure
undergoes a change that considerably
improves its stability. It is the reason why
this key process has to guarantee constant reproducibility.
Where Quality Matters
The Eldec experts are very well aware
of the fact that the interaction between
key components such as inductors,
generators and coolant systems and a
multitude of other components such as
indexing tables, spindle drive and control system is of the utmost impor-
tance. O ver the

last three decades,
t h e c o mp a ny
w i t h h e a d q u a rters in Dornstetten,
near Freudenstadt,
G e r m any h a s
further developed
t he i r h ard e n i ng
technology. And in
2013, Eldec became
a part of the EMAG
Group. Precision
and the integrity
of the production
process are important to the Eldec
experts, as Dr. Christian Krause, head
of application technology, explains, We
are frequently contacted by companies
that require their components to be of
exceptional quality. We can guarantee
this with our system technology.
At the centre of it is the Mind (Modular
Induction) hardening machine, offered in
the variants Mind, Mind-M and Mind-S
and their different sizes. Generally speaking, using modular technology, the
machines are configured to suit individual workpiece dimensions, hardness
profiles and production requirements.
The modular system ensures that only
well-proven components are used. This
increases machine stability and guarantees that the technology can be offered
at an advantageous price-performance
ratio. Engineering of the machine is, of
course, greatly influenced by the workpieces to be hardened, explains Krause.
Requirements are discussed in detail
with the customer. This is followed by the gradual assembly of the
Eldec Mind system, selecting the
required key components: basic
machine, energy
source, inductor,
coolant system and
where required
the automation
components.
High Efficiency, Precision Dosing

For every machine component, the
machine builder relies on quality details
and the accumulated know-how. The
result is a machine that considerably
improves the economic viability of the
process.
Example: Basic machine. The base is
constructed of massive, high-precision
welded components and includes the
main column for the z-axis. The vibration-resistant construction ensures great
machining accuracy. Depending on the
clamping system used, Eldec machines
can accommodate workpieces of up to
1,200 mm diameter.
Example: generator. Available are
micro-processor controlled single- or
dual-frequency generators with a capacity of five to 3,000 kW. They are highly
efficient and allow for the required energy to be adjusted with great precision.
Their performance also adjusts itself
automatically, and with equally great
precision, to that of the inductor used.
Example: inductor/tools. These are
manufactured according to customer
specification, using 3D-CAD software.
They are of micrometric accuracy and
made with the help of state-of-the-art
machinery and experienced staff.
Even the simplest performance data
of the Mind technology from Eldec is
bound to impress. For instance, a driving pinion is processed in as little as 14
seconds. The component is inserted into
the indexing table of the machine either
automatically (for instance by robot) or
manually. Depending on the workpiece,

the hardening process takes between 100
milliseconds and a few complete seconds.
After quenching, the hardened steel is
gradually tempered. The machining cycle
is completed with the subsequent cooling
process. Of decisive importance to us is
not just the enormous speed of the process, but also the precision of the hardening operation, explains Krause. For
instance, on Eldec machines the variation
in effective hardening depth is no more
than 0.1 mm an extremely low value
when it comes to hardening.
Benefitting from the General Trends
With this background, it is hardly surprising that Eldec is benefitting from
the general trends in the automotive and
aviation industries. The geometries of
many components are becoming more
complex and, at the same time, the
pieces tend to get smaller. The hardening process has to keep pace with this
development and guarantee the required
quality despite more demanding basic
conditions. With their Mind series of
machines the Eldec machine builders
have even lent more flexibility to the

workflow by providing a suitable degree
of automation. Their machines are now
available in versions ranging from manually loaded stand-alone solution to fully
integrated in-line hardening cells for the
soft and hard machining of components.
It is in the emerging markets in Asia
in particular, where the highly flexible
use of these machines scores heavily.
Here, large automobile manufacturers
put their faith in Eldec machines when
they are building their new production
facilities. In China, for instance, the

production quality of components has
to be on par, in every respect, with that
in Europe or the United States. And we
offer the hardening machine technology they need. It is a technology that
impresses with its economic processes,
concludes Krause.
For more information:

EMAG Holding GmbH
Phone: +(49) 0 7162 17-267
www.emag.com
MIKRON
DMG | DISKUS
TBT | HELLER
ELB | NAGEL
SCHAUDT
KEHREN
KARSTENS
MIKROSA
INDEX | ZEISS
BOEHRINGER
GILDEMEISTER
SCHTTE
AGIE | SCHULER
HANS-JRGEN GEIGER
Maschinen-Vertrieb GmbH
Metzingen / Stuttgart
Gear cutting
machines:
High quality used machine tools

from Germany since 1968.
Please visit our showrooms:
7000 sqm display area with more than
600 machines in best condition.
HANS-JRGEN GEIGER
Maschinen-Vertrieb GmbH
James-Watt-Strae 12
D-72555 Metzingen (Germany)
Phone +49 (0) 7123 / 18040
Fax +49 (0) 7123 / 18384
E-Mail: geiger@geiger-germany.com
LORENZ | HURTH
PFAUTER | KAPP
KOEPFER | NILES
LIEBHERR
REISHAUER
LINDNER
KLINGELNBERG
GLEASON
WMW
b-werk.de
www.geiger-germany.com
product news
Burri
RETROFITS REISHAUER GRINDING MACHINES FOR GEAR

MARKET
Burri Werkzeugmaschinen GmbH
Co. KG was founded in 2003 and has
emerged as a world leader in the new
grinding wheel dressing machines and
in retrofitting the Reishauer gear grinding machines. According to Burri, the
gear grinding machine after reconstruction is technically at par with a
new machine and has an unbeatable
price-performance ratio. Burri GmbH
offers a 12-month warranty and a CE
Declaration of conformity like a new
machine.
A typical retrofitted machine evolves
through the following process: The old
machines are completely dismantled,
mechanically reworked and repainted.
All scraped guides are replaced by standard linear guides and retrofitted with
ball screw spindles and Heidenhain
measuring systems.
The grinding support holds a direct
drive from the grinding servo motor to
the grinding spindle, thus eliminating
the mechanical troubleshooting components. The machine is fitted with a new
profiling slide and dressing unit with
water-cooled, speed-adjustable, built-in
dressing spindles. The four measuring
systems on the newly built dressing unit
help the operator to store the set values
and reduce the setup time.
The workpiece spindle is designed as
a water-cooled direct drive, thus eliminating the wear and tear of the gear
box. The movement of the work slide is
changed from hydraulic to servo movement. A new tailstock
with quill preload in the control is also

included.
The machine receives a completely
new control system with compact flash
card on which hundreds of gear programs can be saved including USB interface, remote maintenance for troubleshooting and software update, dialogue
guided user interface. All drives are
equipped with water-cooled digital controllers with network recovery and servo
motors.
The new state-of-the-art control from
B&R Automation has reduced the cabinet to a quarter of the original size. The
hydraulics are only used for workpiece
clamping and A-axis clamping. The
machine hood, hydraulics and the electrical cabinet are fixed to the machine
and can be transported without dismantling. The Acopos multi-drive system achieves very good energy efficiency and reduces the power consumption
nearly to one third. The machines now
have the advantage of auto fine balancing and a single centering system for
the entire module range coupled with
an automatic adjustment of the centering probe. The tooth flanks can be
corrected on profile and lead through
a user friendly software. The machine
has been designed to reduce cycle and
setup time. With the new control, the
machine is very flexible and well suited for small, medium and large series.
Burri India Pvt Ltd is a subsidiary unit
of Burri Werkzeugmaschinen GmbH &
Co KG and supports sales and service
in India.

Burri India Pvt Ltd.
Kedar.katre@burri.de
www.burri.de
10
Igus
EXTENDS SELF-ALIGNING
BEARINGS LINE
Plastic bearing
expert Igus will be
presenting their
line of detectable self-aligning bearings for
the food industry.
The detectable bearings are an extension
of the Igubal self-aligning bearings line from
Igus, which includes
a range of lubrication
and maintenancefree rod-end bearings,
clevis joints, flanged units, press fit and
pedestal bearings. Both the housing and
spherical ball are detectable by standard
metal-detection systems to pick up even
the smallest particles of the bearings
were failure to occur. The bearings are
easy to install, adjust to all angular misalignments, and can replace traditional metal bearings, which can weigh up
to 80 percent more than Igubal. Igubal
detectable bearings are dry-running,
unaffected by dirt and dust, operate well
in liquids and a variety of chemicals, and
are corrosion resistant. They are suited
to run in temperatures from -40 - 176F,
and are able to absorb very high forces
due to their vibration-damping properties. They also possess high levels of
compressive strength and elasticity.

Igus (India) Pvt. Ltd.
Phone: +(91) 80-45127800
www.igus.in
SKF
RELEASES CARB BEARINGS

FOR STEEL MILLS
SKF Carb toroidal roller bearings introduce robust non-locating bearing solutions engineered to withstand the tough
operating conditions encountered in a
wide range of rotating machinery applications in steel mills. These self-aligning
bearings designed for radial loads exhibit
very high load-carrying capacity, high
running accuracy, low friction, and resistance to wear, resulting in reduced noise
and vibration and promoting improved
reliability and longer service life. Typical
steel industry applications for these bearings include casters, large electric motors,
gearboxes, fans, and others where nonlocating bearings must be specified.
A Carb bearing (for radial loads only)
in the non-locating, or float, position in
combination with a spherical roller bearing (for combined axial and radial loads)
in the locating, or held, position ultimately can deliver a highly efficient bearing arrangement to eliminate the influence of shaft contraction or expansion
due to temperature fluctuations often
associated with steel mill applications.
Carb bearings integrate design features from several conventional bearing types to realize optimized capabilities
and performance.
They can accommodate misalignment (similar to
a spherical roller
bearing), adjust
for axial expansion of a shaft
(similar to a cylindrical roller bearing), and maximize
load capacity due
to long, self-guiding
rollers (similar to needle roller bearings).
All Carb bearings have further been
upgraded to the SKF Explorer performance class characterized by high-quality steel and an improved heat treatment
process to impart superior hardness and
toughness for operation in the most difficult conditions.

SKF
Phone: +(46) 31 337 10 00
www.skf.com
11
feature
IPTEX Exhibitors Preview

IPTEX 2014, the third International Power Transmission Expo, is dedicated to the gear and power transmission industries. India is rapidly turning into a global manufacturing hub, thanks to the countrys manufacturing and engineering capabilities, vast pool of skilled expertise and its size. These qualities offer it a
strategic advantage for the manufacturing segment. A large number of international companies in varied
segments have already set up a manufacturing base in India and others are following suit. Heres a rundown of some of the booths attendees should make sure to visit during their time at IPTEX 2014.
Gleason
Corporation
Booth # P3
Gleason will introduce its latest Analytical Gear

Inspection System, the 300GMS, along with advanced
tooling and global customer support services at
IPTEX 2014. On display in Booth P3 will be:
The Gleason 300GMS Analytical Gear
Inspection System: For the complete inspection of
automotive transmission gears and other smaller
gears, gear cutting tools and non-gear parts. This
latest addition to the GMS Series of inspection systems (with models available for gears up to 3,000
mm in diameter) was developed specifically to
meet the needs of the worlds leading automotive,
aerospace and other like-size gear producers for a
faster, more economical solution for complete gear
and even non-gear parts inspection. It is the first
GMS to feature the new Windows 7-based Gleason GAMA
3.0 applications software suite which, like its GAMA 2.0 predecessor, offers users a highly intuitive user interface and simple
input screens for programming of workpiece and cutting tool
data. Those features, combined with ease of setup, a .NET control system, and movement optimization, reduce the cycle times
required for the complete inspection of almost any gear or gear
tool. The 300GMS also features a Renishaw 3-D probe head
to provide maximum accuracy and flexibility for the complete
inspection of all kinds of gears and gear-cutting tools and, in
particular, finer pitch gears.
The 300GMS is equipped with new ergonomically mounted
operator workstations and an Advanced Operator Interface
both designed to greatly improve the operators effectiveness at
every stage of the inspection process. The Advanced Operator
Interface puts a number of powerful tools right at the operators fingertips, including a weather station to record temperature and humidity, and video telephony, note pad and voice
mail messaging capability, enabling the user to capture video,
describe a particular programming issue and transmit it over
the web to others in the customers organization or to Gleason
for support. In addition, the 300GMS, like all the systems in the
12
GMS family, offers users the

ability to meet a variety of inspection tasks beyond just gear
geometry on a single platform, including surface finish and
form measurement and even prismatic (CMM) measurement.
Visitors to Gleason Booth P3 will also have the opportunity
to learn more about our local production of advanced Genesis
Hobbing Machines, workholding and cutting tools along with
our state-of-the art cutting tool re-sharpening and re-coating
capabilities. They will also be introduced to a number of other
significant products, technologies and services, including: a
complete line of gear cutting solutions, advanced workholding solution, Gleason Global Services and the Gleason Connect
Remote Service technology, which enables Gleason service specialists from anywhere in the world to quickly and cost effectively identify, diagnose, repair and monitor products, minimizing costly downtime.

Gleason Works India
Phone: +(91) 80-2852-4376
www.gleason.com
Stresstech Group
Since 1983, Stresstech Group (from the foundation of American
Stress Technologies, Inc.) has served the metal industry all
over the world with solutions and high-tech instruments
for non-destructive testing of the quality of components.
Stresstech Oy- Finland (head office and manufacturing facility), American Stress Technologies, Inc. (AST) - USA, Stresstech
GmbH- Germany & Stresstech Bharat Pvt. Ltd- India form the
Stresstech Group. Stresstech Bharat Pvt. Ltd. (SBPL) is a fully
owned Indian subsidiary of Stresstech Oy Finland and is the
groups authorized service centre in India.
The main products that will be presented during IPTEX 2014
include:
Barkhausen noise analyzers, sensors and custom inspection
stands. Barkhausen noise is utilized to study magnetic properties and thus the presence or absence of material defects and
residual stress levels in various components like gears, bearings,
camshafts, crankshafts, universal joints, piston pins, etc.
X-ray diffraction analyzers and inspection stands. X-ray analyzers use X-ray diffraction to measure residual stresses and
retained austenite contents.
Residual stress testing instrument based on hole-drilling. The
Prism system is based on hole-drilling technique for measuring
residual stresses.
In short, this equipment is used for studying: grinding burns,
heat treat defects, hardness changes, residual stresses, retained
austenite contents, etc. or for controlling the quality of: grinding, heat treating, shot peening, machining of camshafts, crankshafts, ball bearings, gears, valves, rotors, turbine blades, cylinder blocks, cylinder heads, etc. As per customers requirement,
the company can supply manually operated, semi-automatic
and fully automatic non-destructive testing (NDT) equipment. They also serve to all types of metal industries by offering
residual stress and retained austenite measurements with X-ray
diffraction and Barkhausen noise analysis in addition to the
equipment for sale.
Stresstech Bharat Pvt. Ltd.

Phone: +(91) 22 2500 1047
www.stresstechgroup.com
KISSsoft
Booth # A8
India is a key market both in terms of supply and

demand, paired with a good overall design capacity and
a deep interest of the involved engineers in the fundamental theories. Hence, the need for and the interest in
top level gear design software is very strong in India,
possibly stronger than in any other emerging market,
says Hanspeter Dinner, managing director at KISSsoft.
KISSsoft has been answering this need for the last ten
years. It is used by the leaders in two wheelers, cars and
trucks, agricultural vehicles, industrial gearboxes and
aerospace industry, be it for private entities, universities
or government/defence establishments. Regular trainings and an experienced local support team ensure that
the customers can benefit most from their investment in
the software. Dinner notes a particular interest in their
system software KISSsys, as the Indian engineers tend to look at the
design process in a holistic manner, preferring to start their work
on a system level. Recently, the highly detailed loaded tooth conVOLUME 3, ISSUE 1 GEAR TECHNOLOGY INDIA
13
feature
IPTEX EXHIBITORS PREVIEW
tact analysis has created excitement as the Indian gear industry has been
moving away from low tech to high tech products with increased power
density. We also observe a shift from worm gears that have been
very popular in India for a long time to more efficient planetary
gears. Here, the dedicated planetary modules in KISSsoft, including fine sizing function for planetary sets and the loaded tooth
contact analysis for planetary systems, are of great interest. We
strongly believe in this market, it has been one great success
story and we are dedicated to tailor the KISSsoft software also to
the Indian gear engineers needs, he adds.

Kadkraft Systems Pvt. Ltd.
Phone: +(91) 20 30461527
www.kadkraft.com
Drake Manufacturing Services Co.

Booth # A21
Drake Manufacturing Services Co. designs, builds and services state-of-the-art,

precision CNC manufacturing systems for parts with form, index and helix such
as threads, worms, gear teeth and racks. Drake provides machine solutions in the
steering systems, power transmission, speed reducer, cutting tool, ball screw, linear
motion and aerospace industries. The company recently announced the expansion
of its local India support team. G. Rajasekhar Reddy will be on-hand at the Drake
booth during IPTEX. Reddy has more than 20 years in the machine tool industry
and has experience in thread gear and worm grinding requirements. Drakes established sales and service support continues with VMT Technologies in Bangalore.

G. Rajasekhar Reddy
Phone: +(91) 98 4527 8216
www.drakemfg.com
VMT Technologies
Phone: +(91) 98 4405 3743
vmtindia@vsnl.net
Shanthi Gears
Shanthi Gears is
the unique gateway to a wide
range of power
transmission products which includes
gears, gearboxes,
geared motors and
gear assemblies
both standard and custom-made. With headquarters at Coimbatore, South India, they
are in the business of designing, manufacturing and supplying
various kinds of gears and gearboxes to almost all industries and
applications for the past four decades. Market leaders in segments including abrasives, auto components, cycles, sugar, farm
inputs, fertilizers, plantations, bio-products and nutraceuticals,
the group has forged strong alliances with leading international companies like Groupe Chimique Tunisien, Foskor, Cargill,
Mitsui Sumitomo, Morgan Crucible and Sociedad Qumica y
Minera de Chile (SQM). The Group has a wide geographical
14
presence spanning 13 states in India and five continents. Shanthi

acts as consultants in the field of engineering design, advisors
and purveyors of technical know-how and applied technology,
solution providers and business process outsourcers in the field
of engineering design and drawing, software programming etc.

Shanthi Gears
Phone: +(91) 422 2360987
info@shanthigears.com
www.shanthigears.com
SFH 160/250 CNC

Horizontal Gear Hobbing machine
Horizontale CNC-Wlzfrsmaschine
6- axes CNC controlled horizontal gear hobbing machine with excellent dynamic property,
for precision gearing and having ability to machine helical gear up to 70 helix angle.
Horizontale, CNC-gesteuerte 6-Achsen-Verzahnungswlzfrsmaschine.
Die moderne mechanische Bauweise gewhrleistet ausgezeichnete dynamische
Eigenschaften der Maschine bei der Anwendung leistungsstarker Werkzeuge bis 70.
SFH 160 CNC
SFH 250 CNC
Max. Diameter of gear / Max. Raddiameter
160 mm
250 mm
Max. Module / Max. Modul
4 mm
6 mm
Max. Helix angle (*OPTION) / Max. Neigungswinkel (*OPTION)
45 (* 75)
Max. Clamping length / Max. Klemmlnge
800/1250/2000/3000 mm
www.gearspect.com
gear profile
GEAR SAMPLE:
INTERVIEW WITH
ANTONIO MACCAFERRI
Q
A
: What are the keys to success for

a family-run business now in its
third generation, operating on a
global scale?
: Surely the industry has dramatically changed,

especially as far
as internationalization and
diversification
on a global scale
are concerned.
For example,
when I started
in 1995 nobody
could imagine
that China would
grow in such a
spectacular way,
to the point that
today SAMP has
three manufacturing plants in
Shanghai, one for
each business unit of the company (Samputensili, Sampsistemi
and Sampingranaggi).
Another important effect of the
globalization was represented by the huge opportunities
offered by the North American
market. For this reason, in 2002
Samputensili started a strategic partnership with Star Cutter
Company through the creation
of the joint-venture Star SU LLC,
the sole go-to-market organization based in Hoffmann Estates,
IL, responsible for the sales and
distribution of cutting tools and
machine tools technology for the
North American market.
: SAMP is in fact only a part of the

family business, the Maccaferri
Industrial Group, which is an
international company boasting
a rich portfolio of activities ranging across the widest of sectors,
from environmental engineering
solutions to real estate and construction, from the food industry
to tobacco, going through biotechnologies and the field of
renewable sources of energy.
One of the main keys to success
can be found in the fact that our
Group has always relied on a
strong team of experienced managers and high-skilled professionals specialized in their own
field, whereas family members
take care of the strategy and coordination.
: How has the gear industry

evolved since you took over as
President in 1995?
Q
A
: What are your goals for SAMP

in both the near-term and longterm with regard to being a supplier to the worldwide gear manufacturing community?
: We have always followed a global, international approach both as

a company and as an industrial
group. Our main goal has always
been the satisfaction of our customers needs with high profes-
16
Q
A
sional skills, capacity and quick

actions driven by our will to constantly improve.
By doing this, we have always
worked hard in order to be close
to our customers as a reliable
manufacturing company, providing them with the support
and service they need in a fast
and comprehensive way. This
approach had led us through
the decades to the creation of a
broad network of manufacturing facilities, such as the one in
Brazil in 1974, the one in South
Korea in 1995, the creation of our
American joint-venture Star SU
in 2002 and of a Chinese jointventure between Samputensili
and STW in 2005. This has always
been our philosophy and we will
certainly continue to do so also
in the years to come.
: What do you see as your major

challenges in both the near and
long term, both as a company
and as a manager?
:O
ur major challenges will be
represented by the continuously
evolving technology, the ever
Q
A
growing competition amongst

machine tool manufacturers and
gear cutting tool manufacturers,
as well as the features and new
technologies that are specific
to each market in which we are
present and to each market that
we serve. These are and will continue to be our major challenges
both in the near and in the long
term.
: What regions of the world are

showing the most promise for
growth for SAMP in gear manufacturing and why?
: We are closely following the

evolution of China, South-East
Asia, Brazil and South America
in general. Of course, in terms
of volume, Europe and the
United States remain our most
important markets for highquality gears and gearboxes,
supplied by our business unit
Sampingranaggi, and we expect
these areas to recover very shortly.
Q
A
: What innovations, changes or

trends do you see in the coming
years that will impact the worldwide gear manufacturing community?
: The innovations we are experiencing around us are not real

revolutions. More than anything
else, we are seeing production
centralizations, large companies
merging together, especially in
the automotive sector, and we
believe that the average size of
corporations in the future will
continue to grow.
THE HISTORY OF SAMP

BY ANTONIO MACCAFERRI
The history of SAMP and its brands

has always been eventful, and it
represents a perfect example of
company verticalization. At the end
of the 19th century, in Casalecchio
di Reno near Bologna, Italy, my
grandfathers uncle began to use
wire mesh to assemble gabions
(boxes filled with rocks, concrete, or
sometimes sand and soil) to repair
dams destroyed by floods of the
river Reno. At the beginning of the
20th century, he purchased a patent for a new type of wire mesh box
gabion and started the industrial
production of gabions for civil engineering use.
As a consequence, in 1936 Gaetano
Maccaferri, my grandfather, started
out with a small workshop for the
production of wire machinery. The
production included wire drawing
machines, looms for weaving metallic meshes and general mechanical parts. He called his company
S.A.M.P., which translates from the
Italian as Company for Precision
Metalworking. Since it was difficult
to find good quality gears at that
time, he started manufacturing his
own.
During the Second World War, SAMP

supplied the Italian air-force with
precision gears, but the demanding quality requirements forced the
company to produce its own highprecision gear cutting tools. For the
same reason, the company was later
to start developing its own tool
grinding machinery, manufacturing
equipment that set the standard at
those times.
With a wide range of quality
gear cutting tools on board by
1949, SAMP decided to establish
Samputensili, an ad hoc structure
and trademark through which to
trade these products. In the years
that followed, this new company
was to grow into a worldwide supplier of gear cutting tools and, later,
also of grinding machines for cylindrical gears, shafts, worms, rotors
and screw threads.
The second spin-off of SAMP,
Sampingranaggi, came into being
in 1973, extending the companys gear production program to
include bevel gear sets and highprecision gearboxes. Before long,
Sampingranaggi was able to supcontinued on page 39
Q
A
: What are your goals for SAMP

over the next five years? Do you
have any plans on expanding
in the near future, outside your
existing operations?
: We will surely strive to remain

among the market leaders and
further increase our market penetration in those segments where
we still are not a reference brand.
At the moment we do not foresee
the opening of new manufacturing plants, but we are working
towards the creation of new sales
17
gear profile
Q
A
ANTONIO MACCAFERRI
and distribution offices in India

and in South-East Asia.
: How have your customers

demands changed in recent
years? What is SAMP doing to
accommodate those demands?
: Our customers are becoming

more and more price-sensitive.
In addition, we have experienced
an increase in the request for
technical support and production
optimization, as a consequence
of the internal restructuring that
many companies have carried out
over the past few years.
In order to meet these needs, we
have established new sales and
technical capacities and have
further expanded our network. In
our main markets we are locally present with manufacturing
plants to supply our customers
with fast, reliable and excellent
sales and after-sales service.
Q
A
: Tell us about your North

American distribution, sales and
service oriented representation.
: SAMP S.p.A. and SU America have

a strategic partnership with Star
Cutter Company through Star SU
LLC (Hoffman Estates, IL) to sell
our machine tools, gear cutting
tools and tool services under the
highly visible Star SU brand in
North and South America. Star SU
18
Q
A
is supported by 30 direct regional sales managers and eight service engineers.

Our partnership with Star started
in 2002 and was further extended in 2013 to include not only
the sales organization, but also
the manufacturing plants in the
United States, the service center
in Mexico and the Samputensili
plant in Brazil.
: What do you see as your major

challenges as a supplier to the
gear industry?
: We are challenged to supply a

broader range of support activities within customer facilities.
We are managing this by extending full product support and
manufacturing support activities
with Star SU on-site engineers.
Though challenging, this is a tremendous opportunity to supply
these services as an added value
proposition at a reasonable cost.
Q
A
:D
o you have any concerns
regarding recruiting and retaining skilled workers in your workforce?
: In manufacturing, we are faced

with the great challenge of making our business attractive to
young, skilled engineers and
technical people. This involves
a great commitment to promote
Q
A
and educate potential employees by our company and private

industry, but it must also work in
cooperative partnership through
universities and high schools.
Once we have recruited these
young workers we need to have
the right training available to
them and growth plans in place
to keep them.
: Are there any other subjects you

would like to talk about?
:S
AMP is known to the world market not only for its high-quality
and reliable gear manufacturing tools, but also for its wide
range of grinding machines. At
Samputensili we began producing machine tools some 50 years
ago to improve the manufacturing quality of our gear cutting
tool range.
In particular, our horizontal
grinding machines are amongst
the finest machine tools for gear,
rotor and screw manufacturing in the world. Our experience
stems from our own manufacturing needs in terms of prototyping and in-house job shopping.
Know-how matured in such a
way has flowed directly into the
end product, and this is what distinguishes our solutions from the
rest. Our machines are extremely
flexible and allow customers to
continued from page 37
ply both single components and

finished gearboxes.
In 1997 SAMPs wire drawing
machinery division took the name
of Sampsistemi and, thanks to the
acquisition of competing companies, it broadened its portfolio to
include extrusion equipment for the
manufacture of finished cables.
In 2000, with the acquisition of the
former Modul company based in
Chemnitz (Germany), Samputensili
added hobbing technology to its
manufacturing program, becoming
one of the few players in the world
to offer a complete gear manufacturing program, covering both
roughing and finishing operations.
use both ceramic grinding tools
and electroplated CBN grinding
wheels. Therefore they represent
the ideal solution both for prototyping/small batch production
and for high-volume gear manufacturing.
Star SU, LLC

5200 Prairie Stone Parkway, Suite 100
Hoffman Estates, IL 60192
Phone: 847-649-1450
Fax: 847-649-0112
sales@star-su.com
www.star-su.com
Maccaferri Industrial Group
www.maccaferri.it
SAMP
www.sampingranaggi.com
www.sampsistemi.com
www.samputensili.com
In 2002 Samputensili started a strategic partnership with Star Cutter

Company through the creation
of the joint-venture Star SU LLC,
the sole go-to-market organization based in Hoffmann Estates, IL,
responsible for the sales and distribution of cutting tools and machine
tools technology for the North
American market.
In 2006 Samputensili, Sampsistemi
and Sampingranaggi merged to
form SAMP S.p.A, a new holding
company which put together the
three macro-sectors of its business:
Samputensili, global provider

of complete solutions (machine
tools, tools and services) for the
production of gears;
Sampsistemi, manufacturer of
machines and systems for wire
and cable production;
Sampingranaggi, specialized producer of high-quality spur and
bevel gears as well as complete
gearboxes.
Each of the three business units has
its own technical department, sales
force and after-sales service, whereas corporate services like human
resources, procurement, IT, finance
and administration are shared
among the three divisions.
In 2009 SAMP moved to a brand
new plant in Bentivoglio (Bologna),
Italy, which integrates all European
manufacturing sites of the three
divisions in one modern, state-ofthe-art plant.
Star SU, LLC

5200 Prairie Stone Parkway, Suite 100
Hoffman Estates, IL 60192
Phone: (847) 649-1450
Fax: (847) 649-0112
sales@star-su.com
www.star-su.com
Maccaferri Industrial Group
www.maccaferri.it
SAMP
www.sampingranaggi.com
www.sampsistemi.com
www.samputensili.com
19
feature
SUPER-SIZED Quality Control

A Guide to Improving Big Gears
Matthew Jaster, Senior Editor
Its not easy being big.
Maybe thats not exactly how the phrase

goes, but its applicable, particularly when discussing the quality requirements of large gears. The size alone
promises unique engineering challenges.
Those involved in producing large gears
continually strive to meet higher quality requirements, adapt to new testing
methods and seek out ways to top their
own manufacturing capabilities. Seems
an awful lot needs to go right in order to
achieve the quality requirements necessary to survive in the big gear business.
In-shop inspections are mandatory,
says Fabrice Wavelet, product line manager, Ferry Capitain. No customer can
afford to put a gear into service that is
not 100 percent sure/sound. A mining

company, for example, can do nothing
without a functional driving system on
its mill, as 100 percent of the ore is going
through it. Failure is not acceptable.
The quality of large gears takes technical expertise, years of experience and
proper equipment, says William Quinn,
business development lead, mill products at Rexnord. Improvements in
materials, lubrication and gear quality
levels have made positive impacts in the
life of todays large gears. Modern gear
cutting and grinding machines need to
be met with equally advanced geometric
inspection equipment.
With higher accuracies of the gearing
we can extend the lifetime of the equip-
ment, says Holger Fritz, product manager mill gearing, Hofmann Engineering.
To be able to determine higher qualities, the measuring equipment has to be
a minimum of one accuracy level higher than the item that is being inspected. This is a challenge for the future
and were working hard to improve the
inspection methods and one day might
have a minimum big gear (above eight
meters) quality level of AGMA 12.
While its always good to improve the
quality of large gears, the current requirements are already impressive thanks to
ASTM A609 and ASTM E709 or E1444,
adds Wavelet. The same requirements
for a 3m gear and for a 10m gear makes
the 10m gear of a comparatively higher
Photo courtesy of Rexnord
20
quality, simply because casting such a

heavy part (more than 20 tons a segment,
finished weight) has nothing to do with
casting a 3-ton segment.
Tools of the Trade
Whats the best way to inspect these

large gears? According to our big gear
experts, its a combination of many different tools.
Hofmann Engineering is using laser
trackers for the dimensional inspection
on big mill gears and portable CMM
arms to determine the form on the involute and the lead line, Fritz says. For the
pitch we use a special D&P pitch tester.
But the ultimate test is still the mesh test
of a precision ground mill pinion that is
measured on a CMM together with the
mill gear. Mill pinions are always measured on a gear CMM machine.
He adds that before they even start
machining at Hofmann they use ultrasonic units and magnetic particle units
to determine the quality of the material
or of the welds.
Varying challenges exist depending on
the inspection required; in-process nondestructive inspections can be done with
relative ease in the manufacturing environment. Once the gear is in operation,
the same type of nondestructive testing
can take a significant amount of time
from a couple hours to multiple days.
Usually this involves shut down, removing guarding, and cleaning the area to be
inspected of lubricant, Quinn says.
Other operational inspections can be
completed continuously or with ease,
such as vibration monitoring, lubrication testing, and infrared temperature
monitoring, says Quinn. In-process
non-destructive testing is done primarily with magnetic particle inspection and
ultrasonic inspection. Complex geometry in large gears can present challenges
to ultrasonic inspection, but with skilled
technicians and control processes we can
overcome these.
For field inspections, infrared thermometers and cameras, and multi-axis
vibration monitoring equipment with
read out capability make continuous monitoring relatively straightforward. More in depth field inspections
of the gear may involve using a MAAG
TMA gear checker to check pitch, magnetic particle inspection with a hand
Photo courtesy of Hofmann Engineering
yoke, and standard ultrasonic inspection

equipment, Quinn adds.
The development of UT Phased Array
and of Eddy Current (classical or Phased
Array) is of the highest interest for us.
These techniques have been successfully
used on site, allowing an interesting time
saving compared to the classical methods, but they are not economical on large
surfaces and in-process inspections
for the moment, Wavelet says.
The question regarding the most useful inspection cant really be answered as
all the above mentioned inspections are
necessary to prove that we manufactured
a top quality gear, Fritz adds.
Why are so many different inspection
requirements necessary for big gears?
The size of the items in question,
Fritz says. Temperatures for example
have a big impact on the final sizes and
a temperature controlled environment is
necessary.
Also, large gears today imply large
module and consequently, large rim
thickness, particularly when talking
about foundry. I suppose it is the same
thing with forgings or plate; the main
challenge is to maintain the high quality level required into such parts. For a
gear module 36 in cast steel (something
that was exceptional 10 years ago and
usual today), the as-cast gear rim is easily wider than 220mm, considering both
the machining stock and the riser deformations. Avoiding internal indications
as small as 5 cm in this outer rim is the
highest challenge a foundry is confronted with today, says Wavelet.
Such defects have to be avoided or the

foundry undertakes the risk of having
the part rejected.
This is where the experience and
the knowledge come into the equation,
whether the gear is in steel or in ductile
iron. The number of foundries capable
of doing small gears (i.e. 3m) in cast steel
or ductile iron is high throughout the
world. The number of foundries capable
of producing the largest and most powerful gears today can be counted on the fingers of one hand, Wavelet says.
Although size matters, the inspection
techniques (ultrasonic or magnetic particle) are identical for small and large
gears as well as the quality requirements.
These techniques are reliable and
repeatable when used by qualified personnel. The type of products being made
for narrow markets use in-house inspection people. This is what we do in Ferry
Capitain. All our inspection personnel
are qualified ISO 9712/Cofrend level 2
(at least equivalent to ASNT level 2) for
UT, MPI, dye penetrant test and radiography, although these two last techniques
are not commonly used on gears. Use of
classical techniques, rather than the UT
Phased Array, for example, is still justified as this saves time in production,
while the equipment is economical. We
believe at Ferry Capitain that the new
techniques, including UT Phased array,
are of the most interest, but for expertise,
not production control, Wavelet says.
Magnetic particle inspection is still
the industry standard for checking sur-
21
feature
SUPER-SIZED QUALITY CONTROL
face discontinuities; it is widely used and

acceptance criteria are clearly defined by
manufacturers and industry standards,
adds Quinn. Ultrasonic inspection is
the accepted method for checking subsurface discontinuities. Continuous temperature monitoring, lubrication testing, and vibration monitoring are still
the most beneficial inspections that can
be performed in the field. Monitoring
these parameters over time and tracking deviations from baseline readings
quickly allow a user to identify potential
problems.
One wonders how much time these
techniques take from a quality control
perspective.
It really depends on the type of
inspection being performed. In-process
ultrasonic testing of our largest ring
gears can take up to 7 hours; magnetic
particle inspection of the teeth can run
up to 3 hours per segment, Quinn says.
Field inspections consisting of contact checks and root clearance measurements can take from 4 to 8 hours. More
involved inspections are usually scheduled during planned shut downs and can
last from a couple days to a week plus.
Big Gear Standards
One area that continues to play a vital

role in the inspection process is the
gear standards. Whether its AGMA,
ISO, DIN or any others, they need to be
updated and modified regularly to keep

up with demand.
Fritz at Hof mann Engineering
believes AGMA standards cover most
of the inspections. It would be good if
they would have chapters about mesh
test results, surface finishes and general guidelines for dimension tolerance.
As a gear designer/manufacturer you
know all about these things, but most
third-party inspectors want to have some
documentation/recommendation of an
AGMA standard referring exactly to
these points, Fritz says.
AGMA 6014, and especially the
next version, which should be issued
sometime next year, addresses all the
inspections and quality requirements
large gears need to respect. We, at Ferry
Capitain, have developed an intensive
R&D program on materials and defects
with the aim to be able to quantify the
influence of surface or internal defects
on the service life, Wavelet says. The
number and concentration of indications do not matter to us as one defect
is enough to ruin a complete gear and
compromise the driving function of it.
Then, the size of a unique defect, and its
location, are the parameter to be considered. A better understanding of the
nature of the defect and its influence
on the service behavior is what we are
working on today.
Quinn at Rexnord agrees that the

standards work but tweaks are in order.
AGMA 6014 addresses magnetic particle, ultrasonic, as well as geometric
inspections required during the processing of large gearing. The annex contains
essential operational inspections and
recommended frequency for large gears,
recommending lube analysis, vibration
monitoring, infrared alignment, visual
inspection, gear joint tightness, pictures,
contact pattern and root clearance. (But)
the AGMA standard does not directly
address nondestructive field inspection
of ring gears, Quinn says.
Pushing the Technology Forward
Whats next for inspecting big gears?

What can the industry look forward to
in the near future? Hofmann, Rexnord
and Ferry Capitain all have ideas. The
technology and the machines will grow,
according to Fritz.
I know of an eight-meter machine
so far but I know that there are plans to
build bigger machines. The challenge of
big gear measurements will be to measure
the much tighter tolerances of AGMA 12
or 13 on 15m gears, Fritz says.
The development of computer-assisted are not economically viable for inshop inspection and for Eddy Current.
It is thus probable Eddy Current will
take over MPI in the close future, as this
technique is easy, fast and reliable. As for
Photo courtesy of Rexnord
22
UT Phased Array, the only question that

inspection equipment manufacturers
have to solve is the question of probes:
they have to be reliable, economical and
adaptable to all kinds of materials, surface finish and size, Wavelet says.
Improvements in continuous monitoring system analysis will offer faster
indication of distress, helping plant personnel to make necessary adjustments
and avoid costly downtime. Condition
monitoring/analysis systems allow the
user to identify a problem in one area
before it has an adverse effect on equipment in another. Eddy current inspection is likely to gain ground as a quick
and thorough way to check for surface
discontinuities in ring gears, allowing the user to log a permanent record
(map) for future reference. Phased
array will gain wider acceptance as an
improved method for inspecting subsurface defects as acceptance criteria are
established and validated in the large
gearing industry, Quinn says.
The technology is changing when
it comes to inspecting large gears.
Manufacturers of these components will
be the first to tell you there are no shortcuts. Good news for those looking for
the highest quality components for a
massive application.
Ferry Capitain
Phone: +(33) 3 2594 0424
ferryby@ferrycapitain.fr
www.ferrycapitain.com
Hofmann Engineering
Phone: +(61) 8 9279 5522
Mail.hofmann@hofmannengineering.com
www.hofmannengineering.com
Rexnord Corporation
Phone: (414) 643-3000
www.rexnord.com
Photo courtesy of Ferry Capitain
Big or Small:
Inspection is
Key to Success
While Hofmann, Rexnord and Ferry
Capitain know big gears, companies like Carl Zeiss, Wenzel and
Klingelnberg know a little bit about
inspecting them.
Nowadays, large toothed gears are
subjected to the same requirements
as smaller toothed gears in stationPhoto courtesy of Klingelnberg
ary transmissions or vehicle gearboxes. Beyond the quality of the gearing,
inspections must be conducted on the surface of the tooth flanks and the dimensions and measurements of the workpiece must be analyzed as a whole, says
Gunther Mikoleizig, product manager for precision measuring center, Klingelnberg
GmbH.
The actual inspection process for gears is quite simple, says Todd Woijoviets,
technical sales engineer at Zeiss Metrology. The challenge comes when we look at
gear standards. Manufacturers use different standards and different versions of the
standard. This makes it difficult for everyone throughout the process because they
must be up-to-date on all these standards and the changes between versions.
Safety, of course, is always one of the key parameters for large gears. A precision
test of all parameters on large toothed gears provides a higher level of safety for the
components, says Mikoleizig. An ongoing analysis of the results of the gear measurement can also provide helpful supplemental information, such as how to define
or simulate the running conditions for the transmissions. This in turn produces
shorter production and development times.
At Wenzel GearTec, the company manufactures traditional, horizontal arm gear
testers called WGTs, which are capable of measuring gears up to 3,000mm in diameter (10 feet) and gantry-style vertical gear testers capable of measuring gears up to
4,000mm (13 feet) in diameter. The vertical gantry-style machines called LHFGear
also have the advantage of being able to measure large geometric, CMM parts, such
as large bearing profiles and gearboxes on the same system and are also advantageous when measuring large internal gears.
23
feature
SUPER-SIZED QUALITY CONTROL

Portable gear testers can measure some gear features such as the pitch of
adjacent teeth or lead and profile of individual teeth, but cannot accurately measure diameters (reference diameters or dimensions over pins), planes, run-outs and
other geometry, says Andy Woodward, president, Wenzel America Ltd. All Wenzel
gear measuring machines offer a full
software suite for any gear type and
also for gear cutting tools. Barkhausen
Noise Analysis (for measuring stresses
or damage due to grinding burn) and
surface finish devices can be added to
any Wenzel system.
As a manufacturer of precision measuring centers, including for large and
heavy workpieces of up to 4,000mm
outside diameter, Klingelnberg has
been proactive in the development of
equipment to test additional parameters within a clamping. This includes
opportunities for measuring surface
roughness or undertaking grinding
burn tests.
Measurement of the dimensions,
shape and position of the drive components can also be undertaken, to delivPhoto courtesy of Klingelnberg
er comprehensive measurements of all
parameters for a workpiece, Mikoleizig
says.
Contact measurements are one of
the best ways to inspect form and location of gear teeth. Plus with a Zeiss
CMM, not only can you inspect the
requirements of the gear but you can
also inspect the housing of the gear,
which is something that cannot be
done with dedicated gear inspection
equipment, Woijoviets says. The largest bridge type CMM Zeiss offers is
a 2,000mm4,200mm1,500mm.
T h e n w e m ov e i nt o a g a nt r y
CMM. Our gantr y typ e CMMs
have a measuring volume of up to
5,0007,0003,500.
When Wenzel was presented the
challenge of designing a CMM measuring solution for inspecting large ring
gears and bearings for Liebherr Werk
Bieberach GmbH, a German manufacPhoto courtesy of Wenzel
turer of large construction cranes, the
company designed and built a special
CMM machine that combined their standard components and dual-arm measuring
technology with the precision air bearing mechanics of the Wenzel WGT series of
Gear Checkers.
The inspection machine is capable of inspecting bearings and ring gears up
to 6,000mm (19.68 ft) diameter. The dual-arm machine design is similar to what
Wenzel has applied in the automotive industry to measure car bodies and body
components, Woodward says.
24
In this design, the CMM measuring arms are each mounted to a table that is
mounted on a large corresponding granite base. The measuring arms feature high
accuracy linear guideways for the X-axis. The Y- and Z-axes feature finely tuned
preloaded roller bearings providing minimum friction and operational wear. The
base units are positioned opposite each other with a rotary fixture table in between.
Both arms measure the large rings concurrently, and the metrology of each measuring arm is harmonized through the use
of a specially designed calibration tool.
The ring gears and bearings are
located and clamped on the 2,200mm
(7.21 ft) diameter hydrostatic rotary table that can handle loads up to
100,000 lbs. The complete circumferences of the rings are inspected
by a single inspection part program.
Application software is also provided
that can calculate the optimum fitting
tolerance for inner and outer bearing
components.
So whats the moral of the story?
Manufacturers of large and small gears
can get technology that will make gear
inspection easier and more user-friendly no matter the size requirements.
Carl Zeiss Industrial Metrology

Phone: (800) 327-9735
metrology@zeiss.com
www.zeiss.com/metrology
Klingelnberg GmbH
Phone: (734) 470-6278
usa.sales@klingelnberg.com
www.klingelnberg.com
Wenzel America
Phone: (248) 295-4300
inquiries@wenzelamerica.com
www.wenzelamerica.com
Photo courtesy of Carl Zeiss
Photo courtesy of Wenzel
25
ask the expert
Crowning Spur Teeth

QUESTION #1
When designing spur teeth, is there a formula/guideline/design
guide for determining the amount of crowning?
Response provided by Octave LaBath.

In September 2005, I produced a spreadsheet comparing four
references for crowning on parallel shaft gearing. I have since
added a fifth reference:
References on Crowning:
1. McVittie, Don. Our Experts Discuss Hobbing Ridges,

Crooked Gear Teeth and Crown Shaving, Gear Technology,
March/April 1992, pp. 41-43.
2. Stokes, Alec. High Performance Gear Design, Machinery
Publishing, 1970, p. 89.
3. Merrit, Henry Edward. Gear Engineering, John Wiley & Sons,
1972, p. 124.
4. Dudley, Darle, Ed. Gear Handbook, McGraw Hill, 1962, p.
5-24.
5. National Broach & Machine Division. Modern Methods of
Gear Manufacture, Lear Siegler, Inc., p. 77.
Example 1 (McVittie)
The amount of crown is critical, McVittie says, since too

much total crown in the pair of gears will concentrate the contact into a narrow area of the face and lead to premature pitting
failures. A reasonable rule of thumb is no more than .0003 to
.0005 inch of crown per inch of face.
based on the gears pitch, with crowning per flank commonly

around .005/P to .01/P.
Assuming a square pinion, the pitch diameter would be 2.000
inches.
Pitch
Crown

10 NDP (2.54 module), 20 teeth

Minimum=0.005/NDP=0.0005" (0.0127mm)
Maximum=0.01/NDP=0.0010" (0.0254mm)
Pitch
Crown

20 NDP (1.27 module), 40 teeth

Minimum=0.005/NDP=0.0003" (0.0064mm)
Maximum=0.01/NDP=0.0005" (0.0127mm)
Example 4 (Dudley)
In effect, crowning allows a rocking-chair-like action between

the teeth when the shafts deflect into increasingly nonparallel
positions, Dudley says. Heavy concentrations of load at the
ends of the teeth are avoided. Dudley suggests that the ends of
crowned gears are made .0005 to .0020" thinner at the ends as
compared to the middle.
Crown

Minimum=0.00025" (0.0635mm)
Maximum=0.0010" (0.0254mm)
Example 5 (National Broach)
Therefore the tooth thickness of a 2.0" face width gear would

be 0.0012" to 0.0020" less than in the center of the face width.
According to this handbook, Excessive crowning is as great an

evil as no crowning. When the amount of crown is too great,
effective face width is sacrificedIf the accumulated mounting
errors or shaft deflection appear to call for gear tooth crowning
in excess of 0.0005-in. per inch of face width on each tooth side,
more rigid mounts, or stronger gear teeth should be considered.
Example 2 (Stokes)
Face
Crown
Face
Crown

2.000" (50.8mm)
Minimum=Face 0.0003=0.0006" (0.015mm)
Maximum=Face 0.0005=0.001" (0.025mm)
For any power gearing application, Stokes says, it

is essential that perfect tooth contact is obtained.
To allow for any misalignment in the mountings of
the gears, or heat treatment distortion, it is usual to
crown the tooth form, i.e., produce elliptoid teeth,
thus eliminating any chance of end loading the gear
tooth.
According to Stokes, crowning is usually .0002 to
.0003 inches crowning per inch of face width, with
a maximum of .0005 inches per inch of face width.
Face
Crown

2.000" (50.8 mm)

Maximum=Face 0.0005=0.0010" (0.0254mm)
Crown
Magnitude
2.000" (50.8mm)
Minimum=Face 0.0002=0.0004" (0.010mm)
Maximum=Face 0.0005=0.0006" (0.015mm)
Example 3 (Merritt)
Symmetrical crowning is applied in order to avoid

hard bearing at tooth-ends, which might otherwise occur as a result of errors of tooth alignment,
says Merritt. According to Merrit, crowning can be
26
Do YOU have a gear-related technical question?

Get an answer by submitting it to our expert panel!
Submit you question to Jack McGuinn, Senior Editor,
via e-mail at jmcguinn@geartechnology.com
Gear Up Your Quality Control

Photo courtesy of Forest City Gear
Discussion
I prefer the methods that have the

amount of crown as a function of the face
width. This eliminates References 3 and 4.
The method given in Reference 2
seems to give too small an amount of
crown.
The Reference 1 method is similar to
the method given in Reference 5, but has
a tolerance range. There should be a tolerance on the amount of crown, so I like the
method given in Reference 1 best. This reference actually mentions Reference 5.
Robot systems for quality control of surface treatment such as grinding

and shot peening by Barkhausen Noise and X-ray stress measurements.
RoboScan system
automated inspection
all surfaces with one set-up
safe, fast and easy measuring,
also on large and complicated parts
instant feedback
quantitative results for production control
environmentally friendly
Octave LaBath enjoyed a 30-plus year
career at Cincinnati Gear. A Gear Technology

technical editor and longtime AGMA member
and contributor of his time and expertise
to the association, he now heads up a
consultancyGear Consulting Services of
Cincinnati, LLCand can be contacted at
octave@fuse.net.
For residual stress testing

by X-ray diffraction
Xstress Robot
reaches hard-to-reach areas
handles complicated and large parts easily
provides maximum flexibility and
easy positioning
is fast and precise
Power Transmission Engineering Expert/

Technical Editor Octave LaBath with his gear
apprentice Max, who also happens to be his
grandson.
Stresstech Bharat Pvt. Ltd. Office No. B-8, Bhaveshwar Arcade, LBS Marg
Near Shreyas Cinema, Ghatkopar (West), Mumbai 400 086. Maharashtra. India.
Tel: +91 22 2500 1092, Fax: +91 22 2500 1047, info@stresstechbharat.in,
www.stresstechbharat.in, www.stresstechgroup.com
27
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ask the expert
High-Temperature
Gear Materials
QUESTION #2
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 visiting geartechnology.com.
What gear material is suitable for high-temperature (350 550C),

high-vacuum (10 8 torr), clean-environment use?
Expert response provided by Dr. Philip Terry:

From time to time, general questions
arise concerning the maximum temperature at which gear materials can operateor specific questions about what
material is suitable for a specificusually elevatedtemperature. When faced
with these questions, gear metallurgists
and material technologists usually look
at the limits imposed by virtue of the
previous thermal processing of the gear
materials. Gears are rated (that is, the
ability of the gear teeth to carry Hertzian
contact stresses and bending loads) as a
function of the hardness of the material
and, in particular, the surface hardness
of the tooth.
The hardness of gear steels is typically achieved by through-hardening
(quenching and tempering), nitriding or
carburizing.
In the production of through-hardened
gears, the part is taken to a high temperature to austenitize the material, and then
quenched in oil, water or other cooling
medium to produce a hard, martensitic, metallurgical structure finally tempered to impart toughness and ductility.
The tempering temperature is typically in
the range 900 to 1,150F. Following this
final temper, any exposure to temperatures at or close to the selected tempering
temperature will reduce the hardness of
the material and, consequently, lower the
load-carrying capability of the material
when used for gearing.
Nitriding is also typically performed
in the region of 900F, and so material
30
intended to be nitrided is normally tempered at around 950F to avoid overtempering during the nitriding process.
Nitrided gears are, therefore, constrained
to running temperatures below 900F to
prevent softening in service.
The highest hardness material used in
industrial gears and therefore the gears
with the greatest load carrying capability are those which are surface hardened
by carburizing. However the final tempering temperature used on carburized
gears immediately prior to finishing is in
the region of 375F, and although carburized gears have the highest known load
capacity, this low tempering temperature
restricts the temperature at which they
can be used to around 300F.
Below is a summary table based on
ensuring that gear hardness does not
drop as a result of exposure to high temperature in service based on a maximum
temperature 50F below the final temperature used on the material during
thermal processing.
Temperature limits for gear materials
Process Temperature Limit
F
Through-hardened
850
Nitrided
850
Carburized
300
The values shown in the table are typical levels; if details of a specific heat
treatment cycle are known, and higher
final temperatures are used, the limits
can be raised to within 50F of the actual
temperature. Similarly, if a specific service temperature needs to be accom-
modated, lower limits can be imposed

on the tempering temperature to ensure
that parts will not soften due to overtempering in service.
The temperatures quoted here are for
the commercial alloys most frequently
used for gear manufacture; other more
specialized alloys exist which have been
specifically designed for higher temperature applications such as the Pyrowear
family of alloys for carburized parts.
Some of these alloys are tempered after
carburizing at 550F, thus extending
their range of application up to 500F.
The comments in this article refer to
the temperature limits of the steel base
material of gears, and do not discuss the
issue of temperature limitations for gear
lubricants, which need to be evaluated
separately.
Dr. Philip Terry was born and educated in the
U.K., receiving in 1972 his doctorate in materials

science/fracture mechanics. He has decades of
metallurgy-and-materials experience in various
design and managerial capacities at companies
such as British Steel Corp., Cameron Iron
Works, and, for 15 years until his retirement in
2011Lufkin Industries. Terry has also been an
invaluable AGMA member over the years, having
served on or chaired many of its materials- or
heat treat-related committees. He currently
serves as the standing U.S. representative on
ISO TC 60 WG 14 Metallurgy. Terry is now unretired, working as an independent consultant
specializing in material selection, heat treatment,
welding-and-fabrication, and failure analysis
(Philip.terry@orange.fr).
ask the expert
So Whats to Know About

Specifying a Gear?
Only Everything!
QUESTION #3
I am trying to specify a few .8 module metric gears and am being asked to include as many gear
specifications as possible on our drawings.
For example, one of the gears we need is a .8 module 40t gear, so my plan was to say this:
Spur Gear: Teeth=40, Module=.8, PD=32, Circ Tooth Thickness=1.17 (using this to determine
backlash, but there is probably a better way)
For all other tolerances and design information, reference AGMA 2000-A88, Q8 (we found some
stock gears that listed this number but dont really know what it means). I see so many different
AGMA and ISO standards for gears and Im just not sure which one I need. We havent purchased
any yet and dont want to until we know which one to use. Can you shed some light on this or
point me in the right direction? I dont know why but this seems like a real mystery to us!
Thank you!
Expert response provided by Rob Frazer, senior engineer at the Design Unit:
The position that you find yourself in is very common. Gear
technology is not a particularly difficult subject to understand, but it covers many fields of expertise and thus there
are many elements that need to be appreciated and understood before a full specification can be prepared that will
ensure that you get gears that are fit for purpose and meet
your needs.
To put it bluntly, if we dont specify gears properly we get
the gears we deserve rather than the ones we actually need.
This is a challenging task for people who do not regularly
specify gears. Because we have no knowledge of your specific application for fine-pitch gears, the following guidance
is generic for most gears and we will assume that specifying
the geometry itself is sufficient and that the life and loading is
evaluated separately.
Gear standards, whether they are published by AGMA or
ISO, are a very valuable source of reference material for gear
designers. However these are written for people who have the
relevant background gear knowledge and expertise to implement the procedures and, more importantly, interpret the
results from applying the standard procedures. The AGMA
information sheets and ISO Technical Reports are prepared
by the expert working groups to provide guidance on implementing and understanding them. It is also of course important to ensure you are referring to the latest version of the
standard. This is not helped by the fact that within AGMA
and ISO publications, none fully address the specification
requirements of gears.
32
But before you try and specify gears starting with a

blank sheet of paper, there are other options that should be
explored first that, although apparently more costly, may save
much of your time and potentially avoid costly mistakes:
Employ a consultant to specify the gears for you. The benefits from this are that you will get a full specification that will
provide you with the gears you need. The disadvantage is that
you wont learn anything yourself and if you need to modify
the design or experience quality problems, you will have to
re-employ your consultant.
Alternatively, you can seek a reputable gear supplier who
is willing to provide the design and manufacturing expertise
to supply gears that will meet your needs. You would need
to specify life and duty cycle (load and speed) requirements;
the drive element (e. g., electric motor specification); the load
characteristic; size envelope; gear shaft and gear housing tolerances; manufacturing methods; environmental conditions
(temperature and humidity); preferred materials; operating
backlash; noise requirements; and annual quantities. Again,
if you want to modify anything, you rely on the supplier for
these design changes.
The application in this example is not defined, but the
0.8mm module gears could potentially be supplied by a catalog gear supplier who specialize in small-pitch, standard
geometry gears; your question implies that you have already
considered this. A number of catalog gear companies offer
a range of gears that may be suitable for your requirements.
They can supply small quantities of gears but may also be
suitable for larger volume manufacture and also provide
guidance on suitable geometry tolerances, tooth

thickness tolerances to ensure the gears operate
with acceptable backlash. Using off-the-shelf or
modified catalog gears often provides the costeffective solution to prototype or small volume gear
applications.
There are many commercial software programs
available that can assist you to design, analyze and
specify gear geometry. These range considerably
in terms of complexity and cost, but the best allow
users to invoke ISO and AGMA accuracy standards, use standard proportion cutting tools, define
and evaluate tooth thickness (for backlash calculations) and evaluate the gear pair using stress analysis standards such as AGMA 2101 or ISO 6336.
Many programs provide graphics that enable the
users to properly visualize the gear pair they are
specifying. The most basic of these programs is a
simple automated gear calculator, while the most
sophisticated programs provide help and guidance when things are starting to go wrong (Fig. 1).
But users need to understand what the programs
are doing and thus it is recommended that proper
training is obtained prior to use. Few people are
provided with sufficient training in gear technology in college and university courses, but help
and guidance is provided by the AGMA in their
training program (www.agma.org). In the U.K. the
British Gear Association (BGA) has an extensive
seminar program that allows those new to the gear
industry to attend a series of short courses to introduce them to gear technology (www.bga.org.uk).
The strategy adopted by the Design Unit (at
Newcastle University, U.K.) for specifying gears is
Figure 1Example of a software package used to develop a gear specification with
that you provide unambiguous data relating to the
built in warnings when you approach normal geometry limits (courtesy
Dontyne Systems Ltd).
geometry of the finished gear. Our policy is not to
specify the details of the manufacturing procedure
no ISO standard directly related to tooth thickness allowand thus a full gear specification comprises seven
ance and backlash.
elements:
5. A
gear geometry accuracy specification is defined by ISO
1. The nominal basic macro gear geometry (module, tooth
or
AGMA tolerance classification standards. Two methods
number, helix angle, tip diameter, root diameter, face
are
commonly used here:
width, addendum modification coefficient). ISO 21771
a. The
measurement of individual errors (profile, helix or
provides formula for these parameters.
tooth
alignment, pitch errors, radial runout of the tooth
2. The specification of microgeometry corrections to the
space
and tooth thickness). AGMA 2015-1 (replaced
tooth flank (tip relief, helix crowning) on gears that are
AGMA
2000) specifies allowable limits for different toltransmitting significant amounts of power or have strinerance
classes
and is similar to ISO1328-1. Note that
gent noise and vibration requirements.
these
do
not
provide
guidance on which tolerance grade
3. Cutting tool geometry data (depth, pressure angle, cutting
to
pick.
For
most
applications,
precision-cut gears of
tool tip radius used to cut the tooth root region, grinding
grade
7
or
better
(lower
grade
number)
are achievable,
allowance or backlash allowance). AGMA 1003 and 1006
with
molded,
fine-pitch
gears
of
grade
9
to grade 10
provide information of the proportions of tooth for finecommonly
specified.
The
tolerances
that
are specified
pitch gears and plastic gears.
must
consider
power
transmission,
noise
and tolerance
4. Tooth thickness data specifying the tooth thickness tolerbuild-up
of
the
assembled
gear
assembly.
The
accuracy
ances to ensure operating backlash is achieved when the
of
the
gear
is
verified
by
measurement
with
CMMs
or
gear is manufactured and assembled. We normally define
dedicated
gear
measuring
machines
and
fine-pitch
gears
gear circular tooth thickness indirectly because measuring
of 0.4mm module can be easily measured (Fig. 2). The
a circular arc length is difficult. We use parameters such as
process provides feedback to show that the gears comply
dimension-over-pins or span size over several teeth. Refer
with the accuracy specification and also identify what
to ISO 21771 for tooth thickness calculations. AGMA 2002
has gone wrong with the manufacturing process.
provides guidance on tooth thickness tolerances. There is
33
ask the expert

b.
Figure 2Klingelnberg P65 with a 0.5mm diameter probe Inspecting

a 0.7mm module gear in accordance with ISO1328-1 (the
minimum standard probe is 0.3mm diameter).
Figure 3Frenco-dual flank roll tester for measuring composite Radial

deviations in accordance with ISO1328-2.
The second method is the measurement of radial comDr. Rob Frazer is a senior engineer at the Design Unit, the Gear
posite errors or dual-flank errors, and is commonly used
Technology Centre at Newcastle University in the U.K. Frazer is head of the
to control fine-pitch gear tolerances. The method involves
U.K.s National Gear Metrology Laboratory and is responsible for gear design
meshing a product gear with a precision-ground masand gear analysis within the Unit. He also serves as chair of BSI MCE-5, the
ter gear (a minimum of 3 accuracy grades better than
U.K. committee responsible for over 90 gear-related standards and is the
U.K. representative on the ISO Gear Accuracy Committee (ISO TC60 WG2).
the product gear) under light load with zero backlash,
Frazer is actively involved in delivering the British Gear Associations training
and recording the change in center distance as the gears
seminar program in the U.K.
rotate. AGMA 2015-2 and ISO 1328-2 both provide allowable tolerances for gears of 0.8mm module, and the quality grades mentioned
GEARDATA
GEARDATA
above equally apply to this measurement
Basic Geometry
Basic Geometry
method. This also provides a method of
Number of teeth
40
Number of teeth
40
Normal module
0.800
Normal module
0.800
measuring tooth thickness by specifying
Reference pressure angle
20.000
Reference pressure angle
20.000
upper and lower indicator limits based on
Ref.helix angle (left)
0.000
Ref.helix angle (left)
0.000
Addendum Mod. coefficient
0.0000
Addendum Mod. coefficient
0.0000
maximum and minimum center distance
Nominal tooth depth/Mn
2.400
Nominal tooth depth/Mn
2.400
values.
Reference Data
Reference Data
6. Material specification, including material
Facewidth 5.000
Facewidth 5.000
Tip Diameter
33.600
Tip Diameter
33.600
type and where appropriate the range of
Root Diameter
29.760
Root Diameter
29.760
acceptable hardness values and case depth
Topping
Topping
Base
helix
angle
0.000
Base
helix
angle
0.000
requirements.
Reference Diameter
32.000
Reference Diameter
32.000
7. The datum axis that is used to define the
Base Diameter
30.070
Base Diameter
30.070
gear geometry and provide a functional
Finished Tooth Thickness
Finished Tooth Thickness
Ball Diameter
1.440
Ball Diameter
1.440
location for the gears when in service.
Dimension over balls (nom)
34.022
Dimension over balls (nom)
34.022
A typical realization of a gear specification is illustrated in Figure 4 for ISO 1328-1
grade 9 gears, assuming quality is controlled
by helix, profile, pitch tolerances and tooth
thickness, defined by dimension over balls or
pins. An alternative specification using ISO
3128-2 for dual-flank testing measurement
strategy is illustrated in Figure 5.
In conclusion, the specification of gears
requires a detailed knowledge of gear geometry, manufacturing methods, inspection methods, material and the functional requirements
of the application. Every gear designer has his
or her own preferred method, but asking the
right questions, using the appropriate standards and support software ensures it is possible to specify gears reliably.
34
Dimension over balls (max)

34.022
Dimension over balls (min)
33.943
Flank Tolerances
Reference axis
datum bore
A
Accuracy Standard
ISO 1328-1/95
Grade 9
Adjacent pitch tol
20 m
Cumulative pitch tol
57 m
Profile tol
21 m
Helix tol
25 m
Tool tip radius
0.312
Meshing Information
Mating gear
Centre distance nominal
32.000
Start of active profile dia
30.851
Contact ratio
1.714
Normal backlash max
0.160
Normal backlash min
0.100
Material & Heat Treatment

Through Hardened (V)
Surface hardness
200 Hv
Angles are in and distances inmm unless
otherwise stated
Dimension over balls (max)

34.022
Dimension over balls (min)
33.943
Flank Tolerances
Reference axis
datum bore A
Accuracy Standard
ISO 1328-2/97
Grade 9
Single composite tol
11 m
Total composite tol
56 m
Tool tip radius
0.312
Meshing Information
Mating gear
Centre distance nominal
32.000
Start of active profile dia
30.851
Contact ratio
1.714
Normal backlash max
0.160
Normal backlash min
0.100
Material & Heat Treatment
Through Hardened (V)
Surface hardness
200 Hv
Angles are in and distances inmm unless
otherwise stated
Figure 5Example gear specification for

ISO 1328-2 accuracy gears.
Figure 4Example gear specification for

ISO 1328-1 accuracy gears.
technical
Design and Optimization of

Planetary Gears Considering
All Relevant Influences
Tobias Schulze
Gear Design Process
Light-weight construction and consideration of available

resources result in gearbox designs with high load capacity and
power density. At the same time, expectations for gear reliability
are high. Additionally, there is a diversity of planetary gears for
different applications. Gears with one or more stages and with
one or more gearbox inputs and outputs are not uncommon.
Furthermore, different kinds of teeth exist: e.g., spur and helical
gears, and also double-helical gears are doable. For the mounting of shafts and gearings, roller bearings and sliding bearing are
used (Fig. 1).
All of these conditions require exceptional and robust design
criteria, including maximum load and dynamic loads under different load situations. Experience with drivetrains with stiff foundations and constant, external loads is not directly applicable, due
to unique boundary conditions, dynamic excitation of the structure, and changing influences by external conditions (Ref. 12).
The product design process of a gear typically begins with the
load calculation, followed by gear and component layout, to the
point of structure analysis (Fig. 2).
Only at a test bench, or in industrial use as a component
in the whole drivetrain, can the quasi-static and dynamic
behavior of the gear in actual conditions be verified. This long
chain in the process does not allow for an efficient gear cal-
Figure 1
Application of planetary gears (Ref. 13).
Figure 2
96
36
culation especially considering the insecurities of the load

assumptions and with that the inevitable, inaccurate stress
of the single machine elements and resulting strains.
In these cases the highly precise and, in part, standardized
calculations of machine elements can only be applicable as far
as the accuracy of the load assumptions allow. Any interactions
of the single elements within the stressed gear (e.g., the influence of axle bending on the load dispersion of the gearing) are
thereby lost. Furthermore, the gear must especially with flexible shafts, housing or dynamic excitation be understood as a
sub-system of the drivetrain; only in this way can a realistic load
gradient be constructed (Ref. 13).
An evenly balanced calculation model for drivetrains that
connects all concerned sub-disciplines (external conditions,
drivetrain dynamics, structure dynamics, electrical phenomena
and machine regulation) in a comparative model depth does
not exist (Fig. 3). And yet, only such a balanced model allowing for all needed conditions can deliver the realistic and reliable statements on dynamic strains needed to make the safe
design of drive components possible (Ref. 15).
The resulting problems and damages cannot be fully explained
through mere analysis of the single modules. In fact, the essential influences of the surrounding system components must be
accounted for and included in the computation. Here arises the
Classic product design process.
GEAR TECHNOLOGY INDIA

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[www.geartechnology.com]
real difficulty of finding the necessary system parameters to

solve the respective question, which is why the product development process of the future is moving more and more to system
analysis, rather than the design of single machine elements. Vital
to gear development is continuous mostly software-supported analysis, result-conditioning and data maintenance to the
point of supervision of the lifecycle of a gear. On one side, all
calculations of the machine elements gear, axle, bearing, axlehub connection, screw connection, etc. are to be implemented
following the current standards. These must be supplemented
through detailed examination of load gradients and load distribution and to the point of optimization of single target parameters (mass, stiffness).
Gearbox Development and Calculation According to

Standards
Especially for design concepts of planetary and spur gearboxes, the newest software development of DriveConcepts
GmbH MDESIGNgearbox is established. This calculation
software gives complete product information in the early phase
of the product lifecycle (PLC). The calculation cannot replace
measurements and test drives, but iteration steps can be reduced
economically. The software allows for an intuitive and easy handling in the design process of the entire gearbox dimensioning
of the machine elements (shafts, bearings and toothings) all

according to the existing standards (Refs. 57).
For toothing:
DIN 3990:1987 T1T6
ISO 6336:2008 T1T3, T5 and Technical Corrigendum 1:2008
Future work for toothings:
Micropitting according to ISO/TR 151441
Scuffing according to ISO/TR 13989 1 and 2, AGMA 925
Gear mesh efficiency/loss factor HV and HVL
The shafts of the gearbox are calculated according to:
DIN 743:2008 T1T4 and Beiblatt 1, 2
Different calculations possible for the roller bearings:
Lifetime LH10 according to DIN ISO 281:2009
Modified lifetime according to DIN ISO 281:2009, Beiblatt 1, 3
Advanced modified lifetime according to DIN ISO 281:2009,
Beiblatt 1, 3
Lifetime according to ISO/TR 16281:2009
The software enables calculation of the system gearbox in one
step, including a complete documentation into a PDF/A document, according to ISO 190051:2005 (Fig. 4).
Gear Optimization (Macrogeometry)
The following shows the gear optimization in some case studies:

Load distribution. Next to the load distribution factor KH
one of the important tasks of gear development is to optimize
Figure 3
Design process of a gear as a system.
Figure 4
User interface of MDESIGN gearbox with 3-D-GearDesigner and result page (Ref. 10).
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technical
Figure 5
Computation model for load distribution KH.
Figure 6
Variation studies for load distribution KH
Figure 7
Variation studies for load distribution KH and KH.
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the load distribution of each planet gear. This is

done using a pure statistic model that determines
load distribution factor K. The load distribution
factor is defined as the ratio of the maximum
tooth normal force to the median tooth normal
force at the speed of zero. Dynamic factors are
represented by the factor Kv. The median contact stiffness from the load gradient calculation is
used for the analysis, as well as wheel body stiffness (sun, ring gear), bearing stiffness and bearing clearances (sun, planet, ring gear and planet
carrier). The following deviations can be accommodated (Fig. 5):
Single-pitch deviation sun and ring gear
Tooth width variations planet gear
Center distance deviation and planet carrier
pitch deviations
Displacement sun, planet carrier, ring gear
The computation of the load distribution allows statements
on suitable tolerances or tolerable location variations with exact
knowledge of the real load for every single planet. These investigations allow, for example, single parameters to be analyzed
with regard to their influence on the load-bearing capacity of
the gearing (Fig. 6).
Suitable construction parameters, as well as sensible tolerances of gearings and location
variations, can be defined.
Research on load distribution (K and KH) has shown
that only a simultaneous
optimization of load distribution on flank (KH) and planets (K ) results in an optimal gear (Fig. 7). An effective instrument for a balanced
load distribution is the use
of optimized, flexible planet gear bearings. The impact
is due to the targeted overlapping of bolt and bushing bending, with the goal of
minimizing the tilt angle of
the planet, which in turn is determined by the deformation of the bushing (Ref. 16).
Stiffness optimization. The optimization of construction parameters with the goal of optimal stiffness of all
relevant gear elements is probably one of the most complex development tasks in the design process. Typical is
the description of the following variation analysis of a
planet mount: the goal is a design with the least possible mass while retaining necessary stiffness requirements needed in view of the load gradient (Fig. 12).
Both one-sided and two-sided samples can be considered; they can be constructed with a round or optimized
outline (triangular, square) (Fig.8).
The geometric parameters to be varied in such a
study are shown (Fig. 9). Through the large amount of
parameters it is necessary to use software programs
Figure 8
Variants of planet carriers: single-plate (left); double-plate (right) (Ref. 3).
Figure 9
Geometric parameters of planet carriers: single-plate (left); double-plate (right).
Figure 10 Optimization mass and design space.
with integrated FE solvers for calculating stiffness parameters;

only i n this way can optimal configurations be found for the
entire parameter area.
Mass/design space optimization. Not only has the just-introduced stiffness optimization led the engineer to a number of
detail problems; the search for a mass, construction-size optimized gear is a highly complex question due to the number of
overlapping influences. Figure 10 shows the field of results of a
variation study for a constant, given total gear ratio and defined
load.
The investigation can be used for improving present gear
solutions, as well as for new designs. Using an existing design
as an example, the following shows how great the potential
can be (Fig. 11).
At similar dimensions for the ring gear outer diameter d3
of gear Stage 2, one arrives at a mass savings by adjusting the
ring gear diameter for Stage 1 and reducing the tooth width.
MDESIGNgearbox avoids the over-dimensioning of planet gears

by pre-setting safety factors for the gearbox machine elements.
The mass of the original is at mges 2,200 kg. All generated,
optimized solutions arrive at a mass reduction in comparison
to the actual gear. The mass, optimized preferred variation is
shown (Fig. 12, right).
In this example the mass savings amount to about 25 percent,
in respect to the original design. At the same time the optimization of the construction space amounts to 15 percent (Fig. 3). In
a second step the consideration of CAD geometry data of housings will be possible. Therefore the software imports a standard
geometry format, generates finite element models, calculates stiffness matrices for the housing, and delivers this information to the
design process of MDESIGgearbox (Fig. 14).
Optimization of microgeometry. The calculation of load distribution in a planetary gear system essentially depends on
the helix angle deviation between the contact flanks of the gear
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technical
Figure 11 Variation study mass optimization: initial state (left); mass

optimized gear (right).
Figure 12
Variation study design space: Initial state (left); spaceoptimized gear (right).
Figure 13 Savings potential: mass (left); design space (right).
Figure 14
100
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Determining of stiffness matrices in 3-D-HousingDesigner.

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pairs; it can be understood as the sum of different influences. It is assumed that the effects are overlying independently, thus the sum of contact line deviation can be
calculated with the single deviations (Ref. 11).
The calculation of single displacements and deformations of all gearbox bodies especially the planet carrier, the coupling of ring gear and gear wheel bodies and
the deformation of teeth is more complex in planetary gearboxes than in spur gearboxes. To determine
the load distribution, the flank deviation for the tooth
contact sun/planet and the tooth contact planet/ring
gear is calculated by the new software MDESIGNLVRplanet
(Refs. 8 and 9). The result of the calculation is the exces- Figure 15 Verification of planetary gear stages.
sive line load, which is expressed by the factor KH. In
general, the excessive line load is on the flank side
The deformation is calculated by FE method and is then
opposite the deviated flank side.
added to the flank deviation. All parts of the helix angle deviNext to the calculation of the ratio of maximum and middle ation have to be added as values normal to the flank. The
line load, the software gives detailed information about tooth database of the calculation is saved in XML format. With this,
a structured depositing of design, modification, deviation, load
flank pressure and tooth root stress distribution (Fig. 15).
and control data is possible. Furthermore, the program has a
The flank deviation (FLKM) consists of the following parts:
Elastic deformation of gear body (veRK)
project management capability for saving projects, standard
Elastic tilting difference of roller bearings /17/ (veWL)
examples and more calculation guidelines (Ref. 14).
Torsion deformation of planet carrier (vePT)
After input of all necessary parameters: all data are checked,
Tilting of planet due to of sliding bearing (verkippPL)
the design models are generated and the FE models for the
Effective helix angle modification (fHeff)
gears with coupling design and the planet carrier are created.
Elastic deformation of tooth flank
For an efficient calculation it is necessary and reasonable to use
Elastic deformation difference of planet carrier bearing
drive technology software. DriveConcepts GmbH develops
Deformation of housing
software solutions for drive technology, which is characterized
The helix angle deviation for tooth contact sun/planet is cal- by clear and intuitive handling of all data. In the background,
academic-established calculation kernels and consistent, strucculated by the following equation:
(1)
tured interfaces help solve the actual task efficiently.
FLKM = ve1 + ve2 + veWL + vePT verkippPL + fHeff
172
The helix angle deviation for tooth contact planet/ring gear

is calculated by the following equation:
FLKM = ve1 + ve2 + veWL + vePT verkippPL + fHeff
ve1 = deformation difference of sun

ve2 = deformation difference of planet
ve3 = deformation difference of ring gear
Figure 16 Application case.
(2)
Case Study
The example of a wind turbine with 2,000 kW output power

should show the consequences of different flank modifications
with constant load (Ref. 12). The main gearbox consists of one
planetary gear stage and two spur gear stages (helical gearing).
The detailed parameters of the first planetary gear stage are
listed (Fig. 16). The initial state of unmodified gearing under
module
m
number of teeth z1|2|3
center of distance a
pressure angle
helix angle
16 mm
face width
b1|2|3
20 | 36 | -91
add. modification sun
x1
463 mm
add. modification planet
x2
20
add. modification ring gear x3
8
310 mm
0.4
0.3156
-1,6429
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technical
Figure 17 Initial state (left side); first optimization (right side).
Figure 18 Final design (left side); bad solution with too much lead crowning (right side).
nominal load is shown (Fig. 17, left side). In this case the ratio
of maximum and mean value of line load is 1.67.
In the first step of optimization with a helix flank modification, the factor can be reduced to KH = 1.23 (Fig. 17).
The rest of t h e unbalanced distribution along the face
width which comes from planet carrier torsion deformation can be offset with an optimal lead crowning. The ratio
of maximum and middle-line load can be reduced to KH = 1.16
(Fig. 18, left).
At t h e right side of Figure 18 i t is shown that an oversized lead crowning can also lead to poor conditions. In this
case the lead load distribution changes to KH = 1.98. The example shows the n e c e ss it y of the right dimension of macrogeometry and also of used modifications. If these are correct,
the lead load distribution K H can be reduced from 1.67 to
1.16; but with unfavorable modifications, the opposite will be
the result.
This case study shows advantages of MDESIGN 2010 with
the libraries LVR, LVRplanet and gearbox to develop gearboxes in
a very efficiency way.
References
1. Brner, J. and M. Senf. Verzahnungsbeanspruchung im

Eingriffsfeld Effektiv Berechnet, Antriebstechnik 1, 1995.
2. Brner, J. Very Efficient Calculation of the Load Distribution on External
Gearsets Method and Application of the Program LVR, International
ASME Conference, San Diego, 1996.
3. Hartmann-Gerlach, Christian. Verformungsanalyse von Planetentrgern
unter Verwendung der Finiten Elemente Methode, Internal Draft, TU,
Dresden 2008.
4. Hohrein, A. and M. Senf. Untersuchungen zur Last und
Spannungsverteilung an Schrgverzahnten Stirnrdern, Ph.D. Thesis, TU,
Dresden 1978.
5. ISO 6336. 2006 Calculation of Load Capacity of Spur and Helical Gears.
6. Linke, H. Stirnradverzahnung Berechnung, Werkstoffe, Fertigung,
Mnchen, Wien: Hanser, 1996.
102
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7. Linke, H. Beitrag zur Ermittlung der Zahnflanken und

Zahnfutragfhigkeit unter Bercksichtigung der Abweichungen
geometrischer Gren, Deformation der Getriebeteile und der
Werkstoffkennwerte, Habilitationsschrift, TU, Dresden 1978.
8. MDESIGN LVR 2010. Software for Load Distribution of Multi-Stage Spur
and Helical Gears, DriveConcepts GmbH, 2010.
9. MDESIGN LVRplanet 2010. Software for Load Distribution of Planetary Gear
Stages, DriveConcepts GmbH, 2010.
10. MDESIGNgearbox 2010. Design and Calculation Software for Multi-Stage
Gearboxes, DriveConcepts GmbH, 2010
11. Schlecht, B., M. Senf and T. Schulze. Beanspruchungsanalyse bei
Stirnradgetrieben, Antriebsstrnge in Windenergieanlagen-Haus der
Technik, e.V., Essen, (Refs. 910), Mrz 2010.
12. Schulze, Tobias. Ganzheitliche dynamische Antriebsstrangsbetrachtung
von Windenergieanlagen, Sierke Verlag, 2008, Ph.D. Thesis, TU, Dresden.
13. Schulze, Tobias. Getriebeberechnung nach Aktuellen Wissenschaftlichen
Erkenntnissen, Vortrag Anlsslich des Dresdner Maschinenelemente,
DMK, Dresden, DriveConcepts GmbH, 2007.
14. Schulze, Tobias. Load Distribution in Planetary Gears under Consideration
of All Relevant Influences, JSME International Conference on Motion and
Power Transmissions, May 1315, 2009, Matsushima Isles Resort, Japan.
15. Schulze, Tobias. Load distribution in Planetary Gears, Danish Gear Society
Gearteknisk Interesse Gruppe, February 11, 2010, SDU, Odense, Denmark.
16. Schulze, Tobias. Calculation of Load Distribution in Planetary Gears for
An Effective Gear Design Process, AGMA Fall Technical Meeting 2010,
Milwaukee, Wisconsin.
17. Wiche, E. Radiale Federung von Wlzlagern bei Beliebiger Lagerluft,
Konstruktion, Berlin 1967.
Dr.-Ing. Tobias Schulze studied (1996-2001)
drivetrain and gear technology at the TU Dresden.

From 2001-2006 he was a scientific assistant at the
TU Dresden in the analysis of the dynamic behavior
of drivetrains with multi-body simulation, including
the influence of holes in ring gears with FEM, and
the influence of manufactured deviations on bevel
gear stress run on a servo-hydraulic test stand for
steering systems. Since 2006, Schulze has served as managing director of
DriveConcepts GmbH, Dresden.
The Unrivaled Authority

in Power Transmission Solutions
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well as superior service.
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the individual requirements of customers, has propelled ahead companies in such sectors as
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Widely regarded as world leaders in Helical Reduction Gear Boxes, KPCL has continued to enjoy
worldwide reputation for crafting exceptionally durable and reliable products through its state of art
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Transmission Division
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E-mail: transmissions@kpcl.net Web: www.kirloskarkpcl.com
technical
Introduction to Bearings
Structure and function. A surprisingly
large number of bearings can be found all
around us. Take automobiles, for example: there are 100 to 150 bearings in a
typical car. Without bearings, the wheels
would rattle, the transmission gear teeth
wouldnt be able to mesh, and the car
wouldnt run smoothly.
Bearings are not used only in cars, but
in all kinds of machineryfrom trains to
planes and automobiles and much, much
more.
Bearings enhance the functionality
of machinery and help to save energy.
Bearings do their work silently, in tough
environments, hidden in machinery
where we cant see them. Nevertheless,
bearings are crucial for the stable operation of machinery and for ensuring its top
performance.
The word bearing incorporates the
meaning of to bear, in the sense of to
support, and to carry a burden. This
refers to the fact that bearings support
and carry the burden of revolving axles.
The two pictures below show the most
basic bearingscommonly known as
rolling bearings.
44
Rolling bearings are made up of four

elements and have an extremely simple
structure:
The basic function of bearings is principally to reduce mechanical friction. By
reducing friction
1. Machinery will run more efficiently.
2. There will be less frictional wear,
extending the operating life of the
machinery.
3 . Abrasion burn is prevented, thus
avoiding mechanical breakdown.
Bearings also contribute to lower energy consumption by reducing friction and
allowing the efficient transmission of
power. This is just one way in which bearings are environmentally friendly.
Figure 1Rolling bearing (ball bearing).
History
The principle of bearings was known to

the ancients, and they were in fact used
in building the pyramids in Egypt. The
illustration is a replica of a relief depicting construction in ancient Mesopotamia,
where urban civilization flourished in
parallel with that of the Pharaohs Egypt.
Later, that famous genius of the Middle
AgesLeonardo da Vincicame up
with an idea for a mechanism that is
remarkably similar to modern uses of
bearings. The machine-based civilization that was born in the Industrial
Revolution of the 18th century led to the
development of modern bearings.
In 1916 NSK started up in Japan
the first specialist production of
bearings. However, it was not until
after the end of the World War II
that Japans bearings technology
made substantial progress. 1955
marked the beginning of growth
in demand for private automobiles, in addition to home appliances such as washing machines,
refrigerators and air conditioners. In this environment, one of
the key characteristics that the
Japanese demanded of these home
appliances was quietness. However,
bearings manufacturers outside Japan
didnt place much emphasis on this
requirement; so Japanese manufacturers proceeded to build up know-how
Figure 2Rolling bearing (roller bearing).
Figure 3Outer ring: the large ring of the outer

race.
through research and development efforts

based on the objective of developing the
worlds quietest bearings. Later, Japanese
bearings, renowned for their quietness,
were exported to the United States and
Europe. Before long they also offered a
high degree of durability.
Bearing specifications have been standardized in accordance with international
ISO standards. Japanese-made bearings
are used around the world for their high
performance and high quality. There are
said to be around 3 billion bearings made
annually in Japan, of which over 40 per-
cent are for automobile

use; nearly 30 percent are
exported.
B earings have been
Figure 7Without bearings, Egypts pyramids of the pharaohs
developed and improved
may never have gotten off the ground.
in a global environment,
Bearing Types
and results from research into further
reducing friction are accumulating all
Anything that can be called a machine
the time, continually anticipating the will invariably incorporate bearings.
needs of the times. The ongoing challenge Bearings must fulfill a great variety of
remains to:
needs, and they constantly evolve in
Reduce weight
response to this. Following are bearing
Increase compactness
types and their various applications:
Lengthen life
Reduce energy requirements
Reduce the impact on the environment
Figure 4Inner ring: the small ring of the inner

race.
Figure 5Rolling elements: Several balls or

rollers that are contained in the
space between the outer race and
inner race.
Figure 6Cage: Used to fix the position of the

rolling elements.
Figure 8Deep groove ball bearing: The most

widely used bearing in the world.
Figure 9Angular contact thrust ball bearing:

The rolling element meets the inner
and outer ring raceways at a contact
angle. This bearing can carry radial
and axial loads.
Figure 10Thrust ball bearing: Capable of

handling loads in the axial direction
(axial loads), and can support heavy
loads.
45
technical
Figure 11Cylindrical roller bearing. The

rolling elements are the cylindrical
roller type.
Figure 12Cylindrical roller bearing: Here,

too, the rolling elements are the
cylindrical roller type. However in
this instance the shape of the cage
differs from that in the previous
example.
Figure 13Tapered roller bearing: The rolling

elements are of the tapered roller
type; because the rollers are
tapered, this bearing is able to
carry combined axial and radial
loads.
The Amazing World of Bearings
Vibration of less than 100 nm. It is no

exaggeration to say that the accuracy of
machinery is determined by the accuracy
of the revolution of the bearings. A bearing supports each end of the axis of rotation. If there is a large run-out from the
center of that axis, you could not expect
the machine to operate with high performance. The deflection from the central axis of a computers external memory
device (hard disk drive) that uses ultrahigh-precision bearings is less than 100
nm (one nm is one billionth of a meter).
What determines this ultra-high precision is the accuracy of the rolling elements such as balls and rollers.
15 years in space. Bearings are also
essential to space development. Such
information as weather reports, satellite broadcast data and car navigation
positioning data come to us from satellites orbiting the earth. These satellites
have a piece of equipment known as a flywheel that maintains them in the correct
position and orientation. This flywheel
uses ultra-high-precision bearings; such
bearings have been patiently revolving in
space for the past 15 years.
From 253C to +500C. The bearings
that are used in the coldest temperatures
are those that are incorporated in the liquid fuel pumps of space rockets, and they
rotate in liquid hydrogen at 253C. At
the other extreme, bearings that operate
in a very high-temperature environment
include the high-performance bearings
used in CT scanners in the medical service field. Even in a vacuum tube where
X-rays are generated and temperatures

reach 300 to 500C, the bearings continue to revolve, helping us to maintain our
health.
Size varies from 2mm to 6 m. Bearings

come in all sizes: The worlds smallestminiature bearingshave an
inner diameter of 0.6mm, an outer diameter of 2.0mm, and a width of 0.8mm.
They are used in ultra-compact motors.
At the other extreme, there are bearings
with an outer diameter of 6 meters that
weigh over 15 tons. These are used in
giant boring machines that dig tunnels,
such as the Euro tunnel linking France
and Britain under the Straits of Dover.
400,000 revolutions in one minute.
Bearings that can revolve at ultra-high
speeds are used in dental drills. These
drills incorporate two ultra-high precision bearings with an inner diameter of
3.0mm, an outer diameter of 6.0mm a
width of 2.0mm, and incorporating ball
bearings with a diameter of 1.0mm. The
bearings revolve at the astounding speed
of 400,000 revolutions-per-minute. This
ultra-high-speed, together with extremely accurate revolution, almost eliminates
vibration in the dental drill, helping to
provide safe, comfortable dental treatment.
Ball revolves at a speed of 160 m/sec.
These bearings are used in the main shaft
of a V2500 jet engine in an international passenger airplane. The rolling elements in this bearing revolve at a speed of
160 meters-per-second. This is equivalent
to 580 km/h. Next time you fly you can
relax as these high-performance, highspeed bearings support the fast, powerful
and lengthy operation of jet engines.
46
The Future for Bearings
In closing, following are some themes on

the further evolution of bearings.
Figure 14Self-aligning roller bearing: Has

an automatic aligning function
to compensate for minute
misalignments between the inner
and outer rings during operation.
Figure 15Thrust needle bearing: Used in

parts such as compressors that
deliver the air in automobile air
conditioning units.
1. Greater energy savings. The smaller

a machine becomes, the smaller its
components. Further, the smaller a
machine becomes, the greater the
need for precision becomes, and this
could mean that even a small amount
of friction could lead to a breakdown. Moreover, no matter how small
machines become, total energy consumption will be large when viewed
on a global scale. In order to produce even greater energy savings, we

should continue to seek out even better ways of reducing friction using
bearings.
2. Cleaner credentials. Improving
bearing technology can have beneficial effects on the environment: a
reduction in vehicle exhaust gas emissions, for example. Additionally, the
vast majority of bearings are made
from steel that doesnt contain any
harmful chemical substances; this
steel can be recycled into new steel
materials. Bearings offer excellent
potential as products for recycling and
reuse.
3. Comfort. Machines must be agreeable
for both people and the environment.
In the past, machines have supported
improved production; in the future,
Figure 17Miniature bearings, have an

inner diameter of 0.6mm, an outer
diameter of 2.0mm, and a width of
0.8mm; they are typically used in
ultra-compact motors.
Figure 16Cage and roller: One of several

kinds of bearing used in vehicles
manual transmissions; it is required
to be highly durable.
there will be demands that machines

help society and individuals enjoy
more fulfilling lives through education, medical services, welfare and
entertainment. Also, the bearings that
are used in those machines may be
asked to fulfill functions and roles that
differ from the old ones.

NSK Precision America
3450 Bearing Drive
Franklin, IN, 46131
Phone: (800) 255-4773
Fax: (317) 738-5050
info@nskprecision.com
www.nskamericas.com
Figure 18Bearings such as shown here can

revolve at ultra-high speeds and are
used in, for example, dental drills.
47
technical
The Workhorse of Industry:

The Induction Motor
Dan Jones, President, Incremotion Associates
History
As with many new inventions, the first

practical single-phase induction motors
appear to have been invented in 1885
by Galileo Ferraris, an Italian. Two year
later, Nicola Tesla, a Serbian-born naturalized citizen of the United States.,
created the 2-phase induction motor;
Tesla was granted U.S. patents in 1887.
George Westinghouse employed Tesla
for one year to develop the induction motor for his company. The first
wound-field, 2-phase AC induction
motor product family was announced by
Westinghouse in 1892. In 1888, Mikhail
Dovilo Dobrovolsky created a 3-phase
induction with a squirrel cage motor. GE
began developing 3-phase AC induction
motors beginning in 1891 under Charles
Steinmetzs leadership. Induction motors
continued to evolve in form and use. The
3-phase induction motor is used in the
larger horsepower application above 1 hp
while the single-phase AC motors were
48
used in the smaller, below 1 hp applications.
Construction
The AC induction motor consists of two

major assembliesrotor and stator. AC
power in the form of 60Hz sinusoidal
signals are fed into the 3-phase stator
windings. This rotating magnetic field
induces a rotor field in the rotors shorted
(closed circuit) squirrel cage windings.
The established rotor field runs at a frequency and rotor shaft speed that is not
in synchronism with the rotating stator frequency. This condition, defined as
slip, results in the rotor shaft speed to be
tens of rpm below the induction motors
synchronous speed (frequency) developed by the stator. The slip value varies
between one percent and five percent on
most AC induction motors. The 3-phase
stator signals establish a series of rotating magnetic vector fields that allow the
induction motor to continue to rotate
freely without external support.
The single-phase AC induction motor
works in a similar manner except it possesses a second wind-
ingor auxiliary windingthat allows

one to use a capacitor to establish a near
90 electric degrees between the stator
winding and auxiliary winding. This
action supports continuous rotor and
shaft rotation. The housing, end caps and
bearings complete the AC motor construction that supports the motors rotation (Fig. 1).
Performance
The mechanical output is represented

by the motors torque vs. speed curves,
based first on 60Hz input voltage and
current inputs, and later on a range of
input frequencies. The motors shaft
speed is a function of the number of
magnetic poles within the motor. It runs
at a no-load speed of almost 3,600 rpm
for a 2-pole and 1,800 rpm for a 4-pole.
Remember the impact of slip. The AC
induction motors torque vs. speed curve
is highly non-linear. There are three
different regions on an AC induction
motors torque vs. speed curves. They
are the near-vertical-rated portion of the
curve (Fig. 2). Once the torque speed
curve begins to bend horizontally, one
reaches the maximum percent torque
pointthe breakdown pointthe AC
induction motors speed falls rapidly to
stall or zero speed.
For the design A, B, C and D NEMA
Mg-1 standard-rated torque-speed
curves, only the design D AC induction
motor curves can re-start and move up
the curve back to the rated torque region.
The price for the Design Ds higher starting torque performance is much lower
power efficiency. The other three
design curves require extra
help to return to the rated
torque region.
Current is non-linear;
the most current for all four
A
B
CURRENT
C or D
PERCENT OF SYNCHRONOUS SPEED

Figure 1
Figure 2
design torque-speed curves is drawn

at stall (Fig. 3); the Design B curve is
the most popular one today. The AC
induction motor was originally designed
for applications that have a near-constant load. One just plugs the AC induction motors power cord directly into
the 60Hz wall outlet for constant speed
applications. The motor can self-regulate
its speed within 20 percent of rated
load.
Enter the Variable-Speed Drive
The AC induction motor has a flaw

when operating in its normal-rated
torque region. At very light application
loads, it draws nearly the same current at
rated load. Power efficiencies could drop
to 35 percent from its rated efficiency of
PERCENT TORQUE
300
90 percent to 95 percent, depending on

an AC motors hp output.
The emergence of the 3-phase adjustable or variable speed drive (VSD) in
the late 1980s provided the AC motor
with a much wider speed operation.
The variable speed drive is a solid- state
power conversion unit that controls the
frequency, voltage and current into a
3-phase induction motor. Typical VSDs
can seamlessly vary volts and frequency
to eliminate the difficulty in high current
and low starting torque in AC induction
motors. Field weakening, pulse width
modulation (PWM), and current control
provides other drive strategies available
to be more controllable and to maintain
high power efficiency over a variable
load.
250
200
150
A or B
100
50
0
50
100
PERCENT SYNCHRONOUS SPEED

Figure 3
The AC induction motor is the most

popular motor for use in a wide range
of speed-based applications. Simple
in design and rugged in construction,
lower in cost and in maintenancethe
AC induction motor continues to dominate industrial and powered home applications.
Dan Jones received his
BSEE degree from Hofstra

University in 1965 and MS in
Mathematics at Adelphi in
1969. He has over 50 years
experience in the design of
all types of electric motors
and generators from 10 W
to 500 kW and has held engineering design,
management and marketing management
positions at a number of companies. He is
recognized as an international authority on
electric motors and motion control. He has
written 250+ technical articles/papers and
held seminars in 10 countries. He is a past
member of the board of directors of SMMA and
EMERF. He currently is a member of the board
of directors of the Motion Control Association
(MCA). He is a life member of IEEE and a
member of ASME. This article was adapted
from his seminar on motor types, which was
presented at Motion Control 2013 (October
1517 in Los Angeles) and at the Motor, Drives
and Automation Systems 2014 Show (January
2930 in Orlando).
49
industry news
Timken
OPENS INDUSTRIAL SERVICE CENTER

The Timken Company recently announced the opening of
its new industrial service center in Raipur, in the state of
Chhattisgarh, India. The 30,000-square-foot facility provides
gear drive and bearing repair and upgrade services to meet
growing customer demand in central India.
We are pleased to open a dedicated service center with
advanced inspection techniques and machine tools that can
promptly diagnose and repair our customers mission-critical
equipment, said Carl Rapp, Timken vice president of industrial

services. The Raipur facility offers a one-stop-shop solution to
our many customers in Indias growing cement, primary metals,
mining and power generation sectors.
The Timken Company has been steadily expanding its industrial services portfolio within the process industries segment,
adding to its existing bearing repair capabilities and leveraging
recent related service acquisitions, which include gearbox repair
and motor rewind, to further expand the geographic footprint
of the services business. The Raipur center is the companys
first industrial service center in India to offer gear repair, and
joins the Timken facility in Jamshedpur, India, as the second
offering bearing repair. Timken also operates production bearing facilities in Chennai and Jamshedpur, as well as a research
and technology center within its Bangalore headquarters.
50
SPC Automation
India
PROVIDES PLATFORM FOR INDUSTRIAL

AUTOMATION
Messe Frankfurt Trade Fairs India together with Mesago Messe
Frankfurt introduces Europes leading automation exhibition
SPS IPC Drives to the Indian market. The organisers feel it is
the perfect time to harness business opportunities across all
verticals of the automation industry in India and believe the
launch of SPS Automation India - Driving manufacturing processes of the future will be the ideal platform to aid this development.
The trade fair, like the mother event SPS IPC Drives
(Nuremberg), will represent a leading platform for innovations in the field of industrial automation and host a vast range
of displays of products, systems and services. SPS Automation
India will be held from 5 7 February 2015 at Mahatma
Mandir Convention and Exhibition Centre in Ahmedabad,
Gujarat.
In India, industrial automation is an inherent need as well as

a market requirement. Raj Manek, managing director, Messe
Frankfurt Trade Fairs India stated: The solution to Indias pursuit of being a world-class industrial competitor is automation,
and we are confident that SPS Automation India will present
the sector players the perfect platform to showcase technologies while allowing the Indian market to access automation
solutions designed to improve business profitability and optimize manufacturing operations. Moreover, we are also proud to
combine strengths with our brand partner Mesago. For registration information, visit www.spsautomation-india.in.
GE
HELPS POWER INDIAS FIRST DIESELELECTRIC SHIP

India continues to grow as a global center of technological excellence, accounting for 10 percent of
research and development and home to five of the
top 10 science and technology schools in Asia. The
Government of India, having a network of more than
50 laboratories deeply engaged in developing a range
of technologies from electronic and computer sciences, through life sciences and materials, to marine
research and development, will invest in a new scientific research platform vessel to be built by Bharati
Shipyard, based in Mumbai. The Class XII merchant
vessel will host scientists from various Indian government scientific laboratories. It will be used to carry
out multipurpose research along the coastal sea belt
of India.
Bharati has chosen GE Power Conversion, with its
extensive experience and understanding of the global
marine industry, to supply the power and propulsion
system for the ship. This will be the first diesel-electric ship built in India to incorporate medium-voltage
equipment, an area in which GE already has a strong
position globally. Delivery of the vessel is expected in
the year 2015.
Paul English, marine business leader for GE Power
Conversion says, GE has built up a good reputation
in India over many years, and this has clearly helped
us to win this interesting new contract. The people at
Bharati know they can trust us to deliver with a medium-voltage propulsion system that will be unique
in Indian waters. They also know that we are very
good at accommodating application-specific needs
into individual projects, according to each customers
unique situation.
We are also very happy to gain the Government
of India as the final end user of this type of mediumvoltage diesel-electric propulsion vessel for the first
time, and we will be working hard to make sure it is
not the last, English added. We have been working
on this project for two years, and I think it is fair to
say that all parties are very satisfied with the outcome.
Overall, we see good prospects for power and propulsion systems in India in the marine industry.
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51
industry news
Siemens
DELIVERS SOUND START TO 2014

Siemens delivered a sound quarter to start its fiscal year 2014.
Supported by several major orders, new orders rose 12 percent year-over-year, while revenue development was nearly
stable. We delivered a sound quarter to start our fiscal year. As
expected, market conditions were not in our favor. We continue
to focus on our productivity program for the year, and on the
actions we will take beyond 2014, said Siemens president and
CEO Joe Kaeser.
quarter. New orders at the Sector climbed four percent to 3.2

billion and revenue increased one percent to 3.1 billion.
At the Industry Sector, new orders rose ten percent to 4.6
billion, driven by a substantially higher volume from major
orders in the Sectors long-cycle businesses. At 4.3 billion,
revenue remained at the prior-year level. Profit was down
five percent to 482 million. Profit increased at the Industry
Automation Division while declining at the Drive Technologies
Division. The profit margin at the Sector was 11.2 percent,
compared to 11.5 percent in the prior-year period.
At the Infrastructure & Cities Sector, new orders soared 45
percent, driven by a major order totaling 1.6 billion for two
driverless subway lines in Saudi Arabia to be supplied by the
Sectors Transportation & Logistics and Power Grid Solutions
& Products businesses. Revenue increased four percent yearover-year to 4.4 billion. Profit at the Infrastructure & Cities
Sector climbed to 330 million from 141 million in the comparable period a year earlier, supported by profit increases in
all the Sectors businesses. Improved project execution at the
Transportation & Logistics business was a key factor. The profit
margin rose to 7.6 percent, compared to 3.4 percent in the prior-year period.
HSBC
OFFERS PROMISING DATA ON

MANUFACTURING REVIVAL
Excluding currency and portfolio effects, new orders at
Siemens increased in the first quarter of fiscal 2014 12 percent to 20.8 billion. At 17.3 billion, revenue was one percent
below the prior-year level. The book-to-bill ratio was 1.20. The
order backlog at the end of the first quarter again reached the
record level of 102 billion. Total Sectors profit was up 15 percent to 1.8 billion, while the Sectors profit margin rose to 10.2
percent, compared to 8.6 percent in the prior-year quarter. Net
income increased to 1.5 billion from 1.2 billion. Earnings per
share climbed to 1.70 from 1.42.
Sector overview
New orders at the Energy Sector increased three percent to 7.2
billion in a market environment that remained highly competitive. While declining at the Power Generation and Power
Transmission Divisions, new orders doubled at the Wind Power
Division. Revenue at the Sector declined four percent to 5.8
billion. Due in part to lower charges compared to the prioryear quarter, profit at the Sector improved to 506 million from
410 million, while the profit margin rose to 8.8 percent from
6.5 percent a year earlier.
The Healthcare Sector contributed 471 million to profit in
the first quarter, compared to 503 million in the first quarter
of the prior year. The decrease includes burdens on profit from
currency effects. The Sector also faced ongoing market challenges, including weak economic conditions in Europe, uncertainty in the healthcare market, an excise tax on medical devices in the U.S. and slowing growth in China. The profit margin
was 15.2 percent, compared to 15.5 percent in the prior-year
52
Operating conditions for Indias manufacturers improved further in January, according to the HSBC India Manufacturing
Purchasing Managers Index (PMI). The index, fuelled by
higher output and strong orders, rose to 51.4, from 50.7 in
December the highest reading since March 2013. However,
the pace of expansion was below the series average of 55.1. New
orders expanded at the fastest rate for ten months, helped by
an improvement in new export business. Output rose for the
third consecutive month, with respondents citing new contracts as the main reason for increased production levels. Leif
Eskesen, chief economist for India and ASEAN, HSBC, said:
Manufacturing activity moved into a higher gear led by faster
growth in new orders. However, inflation pressures also firmed,
suggesting that the Reserve Bank of India has to keep up its
inflation guards.
The survey suggests that consumer and intermediate goods
were behind the recent expansion, but that capital goods production softened. Backlogs of work continued to rise but at a
slightly slower rate, probably helped by stronger employment
growth. Purchasing activity picked up at the start of 2014, in
line with the rise in order flows. Average input costs increased,
with manufacturers reporting that higher prices for raw materials were passed on to customers. Manufacturing activity
moved into a higher gear led by faster growth in new orders.
The HSBC India Manufacturing PMI is a composite indicator
designed to provide an overall view of activity in the manufacturing sector. A reading above 50 signals improvement, while
below 50 signals deterioration.
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calendar
March 1922WIN Eurasia Automation 2014.
Istanbul, Turkey. The worlds leading trade show for highgrowth automation technology, electrotech, hydraulics/
pneumatics and material handling. More than 86 unions and
associations come together to provide new market opportunities in Asia, the Middle East, Africa and the Balkans. Main
topics include assembly, robotics, controls, sensors, measuring
systems, IT and software, laser technology, automation systems
and services, packaging, cranes, transportation, hydraulics and
pneumatics, gears, motors, transformers and much more. The
2013 show welcomed professionals from more than 77 countries particularly in the machinery, energy, automotive and
metal sectors. For more information, visit www.win-fair.com.
April 711Hannover Messe 2014. Hannover
May 57Renewable Energy World Conference

& Expo. New Delhi. Under the theme, Power: Key to Indias
Future Growth, the event brings together decision makers and

influencers as well as technical experts and professionals from
leading companies involved in the renewable, conventional,
hydropower, transmissions and distribution power generation,
within India and around the world. With a track record attracting more than 7,000 attendees from 40 countries around the
globe, the event is co-located with Power-Gen India & Central
Asia, DistribuTech India and incorporating HydroVision India.
The show will focus on the ways to prevent useless wastage of
energy and will discuss about the effective mediums which will
help in protecting Indias energy future. For more information,
visit www.renewableenergyindiaexpo.com.
Fairgrounds, Hannover, Germany. The worlds leading trade

show for industrial technology returns in 2014 with a full
lineup of trade shows under the banner Integrated IndustryNext Steps. The seven co-located shows include Industrial
Automation; MobiliTec; Digital Factory; Industrial Supply;
IndustrialGreen Tec and Research and Technology and Energy.
The Netherlands is the official partner country in 2014.
Discover new perspectives on energy, automation and industrial supply and engineering topics as well as a broad range
of events and displays affecting the global industrial market
today. Other Hannover highlights include the Robotics Award,
the 11th WoMenPower Conference, Metropolitan Solutions,
economic forums, job and career fair and more. For more information, visit www.hannovermesse.de.
May 9Manufacturing IT Summit. Mumbai. The 5th

edition of the Manufacturing IT Summit is highly focused and
designed for IT leaders in the manufacturing sector to present
global case studies, benchmark business strategies and ensure
that your manufacturing facility has a coherent, logical IT strategy. Face-to-face networking opportunities, keynote presentations and executive exchanges will help give a clear understanding of the issues and challenges faced in this industry today. This
is one of the largest gatherings in India of CIOs and more than
200+ delegates from the manufacturing sector. Topics include
cloud security, data virtualization and overcoming the legacy crisis. For more information, visit www.mitsummit.com.
April 911Pump, Valve & Compressor Expo

2014. Chennai. Pumps and valves are the integral part of any
in Automotive Plants. This event centers on the automotive

manufacturing processes with the automobile factory as its
focal point. Featuring more than 120 exhibitors, Automotive
Engineering will present solutions to an audience of 6,000+
users from the auto industry. Exhibition categories include
automation systems, assembly line systems, machining centers,
robotics, metrology, material handling, productivity enhancers and more. Exhibitors can increase sales leads, develop new
market shares, launch new product/services and expand competitor advantage. Senior executives will present their thoughts
and debate on the current manufacturing scenario and future
trends. For more information, visit www.aes-show.com.
process where a transportation of liquid is required. Over the

years, the usage of pumps, which was primarily for water, has
undergone a total change and now there are pumps available
for every material which needs to be moved. Along with pumps,
the technology for valves and associated control equipment
has also changed considerably. Exhibitors include companies
involved in shafts/seals, motors, gearboxes, couplings, bearings,
actuators, sensors and more. A separate Compressor Pavilion
will be available to attendees as well as a special focus on solar
powered pumps. For more information, visit www.cii.in.
April 1921Indian Machine Tool and

Automation Expo. New Delhi. This event provides a plat-
form for manufacturers or suppliers of machine tools and automation products to display their products before a professional
community dealing with machine tool, automation, cutting tool
and commercial consumers. It will be a forum for discussion
and demonstration of machine tool and automation. Exhibition
categories include lathes, boring machines, drilling machines,
forging, grinding, machining centers, machine tools, abrasives,
measuring equipment, tooling, industrial cleaning and more.
For more information, visit www.toolautomationexpo.com.
54
May 2931Automotive Engineering Show

2014. Pune. The 8th edition will focus on Lowering Costs
June 1114Pack Plus 2014. New Delhi. This event
will include a packaging zone, converting zone, processing zone

and supply chain zone and include important decision makers
and specifiers from top and middle management from various
industries including pharmaceutical and chemical, food and
beverage, dairy and meat, engineering, garments and textiles,
personal care products and logistics. Printers, converters,
packaging professionals and packaging end users as well as the
providers of materials, equipment and services will also visit in
large numbers. Relevant industrial subjects will include automation, barcodes, smart cards, biometrics, RFID, bulk packaging
and more. For additional information, visit www.packplus.in.
ad index
Bevel Gears (India) Pvt. Ltd.Inside Back Cover
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KlingelnbergOutside Back Cover
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G-Plete Hypoid Generator

13" (330mm), 3.4 DP (7.5 Module), Excellent, Pinions, Ring
Gears, Helical Motion, Formate,
Extented Tilt, 1982
FOR SALE
FOR SALE
UNIVERSAL HYPOID
GEAR TESTERS
GEAR GENERATOR
MODEL 114
GLEASON 6 GLEASON
STRAIGHT BEVEL "CONIFLEX"
AIRCRAFT QUALITY
190MM CAPACITY
SPLIT & SOLID HEADS
16" (400MM) DIAMETER TOOLING

BLADES, CUTTER LIFTING RIG
CONIFLEX
CUTTER
BODIES
FOR SALE
.0025MM ACCURACY
Reishauer Page 3
(M/S. Proteck Machinery Pvt. Ltd.)
Phone: +91-44-2495-3177
mtdsales@proteck.co.in
www.reishauer.com
Shanthi Gears LimitedPage 31
Phone: +91-422-2361-500
info@shanthigears.com
www.shanthigears.com
SKFInside Front Cover
Phone: +91 22-66337777
Fax: +91 22-22042738
www.skfindia.com
Stresstech Bharat Pvt. Ltd.Page 27
Phone: +91-22-2500-1092
Fax: +91-22-2500-1047
info@stresstechbharat.in
www.stresstechbharat.in
Top Tools TechnologyPage 2
Phone: +91-22-2341-5831
toptools.shah@gmail.com
Westminster Machine Tools Ltd.Page 2
Phone: +44 (0) 1572-767922
Fax: +44 (0) 1572-768321
sales@wmtg.co.uk
www.wmtg.co.uk
W/BLADES
for
Gleason Model
104 & 114
See at
GLEASON MODEL
503 HYPOID
GEAR LAPPERS
255MM CAPACITY
SWING PINION CONE LAPPING
HYDRAULIC BRAKE
AUTOMATIC BACKLASH CONTROL

SEVERAL AVAILABLE
55
INsight
Indias Economy:
Moving Mountains or Cursing the Darkness?
According to the law of Dharma, you have a
unique talent and a unique way of expressing it.
There is something that you can do better than anyone else in the
whole worldand for every unique talent and unique expression of that talent, there are also unique needs. When these needs
are matched with the creative expression of your talents, that is
the spark that creates affluence. Expressing your talents to fulfill needs creates unlimited wealth and abundance.Deepak
Chopra
Consider it a call-to-arms for the Indian government to
overcome their atrophy and begin addressing Indias vast, yet
underdeveloped, potential workforce. Also: now is the time to
sharpen the pencils, get the slide rules out, and develop a master plan to tackle a woefully lacking national infrastructure
to help attract international businessesbusinesses that look
longingly at India from afar, licking their collective lips while
wishing the country would get its act together. What makes this
all the more an in the moment issue is a China whose knees
are buckling. But if India continues its dithering, there is a real
possibility of a lost, historical moment on a grandif not economically tragicscale.
And yet theres good news as well.
Witness: Electrical equipment maker Havells is one of several
Indian companies to have shifted production or sourcing from
China. That cudgel in the form of cheap labor and cheap energy
that China has wielded for the last 2530 years has begun to rot
and splinter. Apparently the seeds of a Middle Class are taking
root there and the workers are demanding equal pay for an equal
days work, and so on. And easy-access electricity?there is less
of itthe worlds worst polluter notwithstanding.
So Chinese manufacturers passed the hot potato on to their
customers, such as in India, and raised prices by as much as 20
percent. This went on for quite a while. But, as quoted in a piece
from a recent businesstoday.com article, A time came when we
said this was enough, and we should look at manufacturing in
India, says Sunil Sikka, Havells president.
It gets better.
Consumer appliance company Godrej and consumer appliance company/auto parts maker Bosch have started expanding or
exploring manufacturing operations in India.
And get thisChinese companies are scrambling aboard the
bandwagon, looking for their piece of the pie. Business Today, a
prime source for this article, interviewed 16 companies that transitioned at least part of their business (production) to India.
Chinese costs are going up; this is a great time to move production from China to India, says Adi Godrej, chairman of the
Godrej Group, in the same Business Today article. His company
has shifted its air conditioner and washing machine production
to India. And while Godrej believes the trend will continue for
20 years, the time to get those roads, bridges, electrical and other
infrastructure needs built is now.
56
Unfortunately, as Indias efforts at

building a Middle Class fall short,
so too does its manufacturing base
and national economy. And
despite the countrys
brisk export activity, it will take more
than an election to
move mountains
and lay wire.
Fact is, there
simply are
not enough
people in
India with disposable income
to buy air conditioners or cars or
washing machines or refrigerators, and so on, to sustainmuch less help create
a sound domestic economy. By
the end of 2013, the share of
manufacturing in Indias gross
domestic product dropped to its
lowest in a decade.
But even if there were enough
consumers, theres thistake ACs
for example. Chances are
they would be off more
often than on, given the
state of the countrys electrical supply.
On this matter of infrastructure, an expert no less than economist
and Nobel laureate Joseph Stiglitz worries for
Indiaworries whether she has the wherewithaland the willto do what it must to assume
what should be its logical place in the worlds manufacturing pecking order.
As Stiglitz explains, If you dont have electricity or have high
cost of electricity, it will not help manufacturingeven if labour
is cheap. I do worry that there are certain things, like lack of
infrastructure, that are impediments for some kinds of manufacturing that would have otherwise come to India, he says.
So there you have it. Let Indias manufacturing renaissance
beginnow.
All that is needed is a level playing field for the games.
And if you (India) build it, they (manufacturers) will
comein droves.
TEAMPLAYER.
GEAR MANUFACTURING SOLUTIONS
FOR MAXIMUM PERFORMANCE
BY KLINGELNBERG
KLINGELNBERG
OERLIKON
HFLER
MEASURING TECHNOLOGY
BEVEL GEAR TECHNOLOGY
CYLINDRICAL GEAR TECHNOLOGY
A winning team has a system. It is perfectly tuned and balanced.
MEASURING CENTER P 40
It acts with the utmost precision. The strengths of each individual

work together like perfect gears.
Enhanced measuring technology:

Even more precise measuring results
due to groundbreaking improvements
Klingelnbergs divisions are true team players:
CUTTING MACHINE C 30
Ground breaking solutions for an optimal production process

of Bevel and Cylindrical Gears give manufacturers worldwide
a leading edge in gear manufacturing.
Win the match:
KLINGELNBERG India Pvt. Ltd.
p. +91 20 65 00 33 30
www.hofler.com
e. info@klingelnberg.in
Sales Agents:
www.nemade.in
www.francisklein.in
GRINDING MACHINE VIPER 500

Highly versatile:
Retooling from profile grinding to
generating grinding within short time
(VIPER 500 W)
IPTEX 2014
Booth P-1
February 27 March 1, 2014
Mumbai, India
BEVEL GEAR TECHNOLOGY
CYLINDRICAL GEAR TECHNOLOGY
SUBJECT TO CHANGES.
MEASURING TECHNOLOGY
New unique operating concept:

Simplifying the manufacturing process
due to an easy-to-use touchscreen display

Gear Technology India 2014 1

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GEAR

VOLUME 3 ISSUE 1 - QUARTERLY

Ask the Expert

Design and Optimization

Will the Indian Economy

THE JOURNAL OF GEAR MANUFACTURING

Gear up for higher reliability

The Power of Knowledge Engineering

For more information, please visit skf.com or contact your

A sampling of exhibitor offerings to be

16 Interview with Antonio Maccaferri

CEO dreams big SAMP and bigger

20 Super-Sized Quality Control

Big gears offer unique inspection challenge.

Crowning Spur Teeth

36 Design and Optimization of

Robust-design gearboxes for high load

48 The Workhorse of Industry:

VOLUME 3, ISSUE 1 GEAR TECHNOLOGY INDIA

WESTMINSTER MACHINE TOOLS LTD

IPTEX 2014: Go For the Weather, Stay for the Gear

New equipment, software, etc.

The who, what and where

Upcoming shows, conferences, etc.

Advertiser contact information

Can Indias Economy Get it in Gear?

TOP TOOLS TECHNOLOGY

Precision Gear Cutting Tools

Top Tools is a long experience & established company Producing-Stockiest

Gear Shaper: Disc / Shank / Hub Ty

VOLUME 3 ISSUE 1 - QUARTERLY

Taking Big Gears

TOP TOOLS TECHNOLOGY

Address: 24/2nd Floor,

Telephone: 91-22-234 15831

GEAR TECHNOLOGY INDIA VOLUME 3, ISSUE 1

Ask the Expert

Design and Optimization

Will the Indian Economy

THE JOURNAL OF GEAR MANUFACTURING

Photo courtesy of Klingelnberg

M/S. Proteck Machinery Pvt. Ltd.

Matthew Jaster, Senior Editor,

ADVERTISING SALES (INTERNATIONAL)

Michael Goldstein, Publisher & Editor-in-Chief

Michael Goldstein, Publisher & Editor-in-Chief,

Jack McGuinn, Senior Editor,

Will the Indian

William R. Stott, Associate Publisher/Managing Editor,

Ask the Expe

Michael Goldstein, Publisher (USA) & Editor-in-Chief

David Ropinski, Art Director,

ADVERTISING SALES (INDIA)

HEAT TREAT AUDIT

Anitha Raghunath, Publisher (India)

WHO MAKES THE

When a Good Gear Drive System

Blaser Swisslube India

Enhanced Induction Hardening

The Involute Curve

THE JOURNAL OF GEAR MANUFACTURING

Ask the Expert: Couplings

Finding and keeping

Max. Helix angle (OPTION) / Max. Neigungswinkel (OPTION)

: What are the keys to success for

: Surely the industry has dramatically changed,

: SAMP is in fact only a part of the

: How has the gear industry

: What are your goals for SAMP

: We have always followed a global, international approach both as