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Company profile: JLM Systems, Ltd.
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The NILES ZE Series has NEW features: High feed-rate grinding, Module 25 (1 NDP), High-speed measurement for full contact grinding.
KAPP Technologies 2870 Wilderness Place Boulder, CO 80301 Phone: (303) 447-1130 Fax: (303) 447-1131 kapp-coburg.de | niles.de | kapp-usa.com kapp-asia.com | kapptec.com firstname.lastname@example.org
Ltd. Nagel Precision provides the details. this company provides clean and efficient fluid handling devices to customers found around the world. Gary J. Alternatives to Gear Grinding 40 By Sanjai Keshavan Honing and cup wheel superfinishing can be a costeffective and higher-quality alternative to gear bore and face grinding.28 Refurbishing Wind Turbine Gears By Mark Michaud. 26 By Russ Willcutt Developer of OILMISER technologies. Sroka. and Ronald E. Isotropic superfinishing represents a value adding. Reducing Gear Rattle By Mikel Janitz 48 The professionals at Muncie Power Products help you to address—and eliminate—gear noise/rattle one step at a time. low cost option for refurbishing both case carburized and nitrided gears. Benson features Company Profile: JLM Systems. JUNE 2011 3 .
........7507) is published monthly by Media Solutions. Inc...... P.. 8 23 24 25 53 68 American Gear Manufacturers Association In this section the premier supporter of gear manufacturing in the United States and beyond shares news of the organization’s activities................Resources MACHINES MARKETPLACE 61 64 Departments Industry News Trends....... No part of this publication may be reproduced or transmitted in any form or by any means.. including photocopy....com.... ADVERTISER INDEX 67 Terry McDonald Many doctors believe that carpal tunnel syndrome is caused in the workplace by making repetitive motions without stopping periodically to stretch your muscles.... POSTMASTER: Send address changes to Gear Solutions magazine.... 22 JUNE 2011 5 .......... Site Safety JUNe 2011 | VoLUMe 9 / No.......O..... Publications mail agreement No. are purely their own..... Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72............... or who are not specifically employed by Media Solutions.............. Box 1210 Pelham AL 35124............... Letter ...............O........ 266D Yeager Parkway Pelham....... upcoming educational and training opportunities... and the actions of AGMA councils and committees. Copyright®© 2006 by Media Solutions....... All rights reserved... Tooth Tips Hot Jack Titus Seat This month the author presents a discussion of the equipment used in the endo and low pressure carburizing processes..00 per year.. and resources from across the manufacturing spectrum that will help propel your company toward success............... electronic or mechanical. Product Showcase News of products. 41395015 return undeliverable Canadian addresses to P........... or any information storage-and-retrieval system without permission in writing from the publisher.... ON L4B4R6. technical meetings and seminars... Inc. Comments and submissions are welcome... which is assumed to be cleared for release.. president Q&A Cotta Transmission Co...... The views expressed by those not on the staff on Gear Solutions magazine..... and can be submitted to editor@gearsolutions.... standards development.. Printed in the USA.......... and developments to keep you aware of what’s happening with your colleagues in the gear-manufacturing industry around the country and world.............. recording.............. the author continues his outline of the evolution and continued development of hobs. Box 503 RPO West Beaver Creek Richmond Hill... William Crosher In the second installment of a three-part column....... Periodicals Postage Paid at Pelham AL and at additional mailing offices. AL 35124.. 19 Association News . equipment..... All "Industry News" material has either been submitted by the subject company or pulled directly from their corporate web site..... 99 Gear Solutions (ISSN 1933 ............. Matt Mondek. 20-21 Masthead ... Inc... data.
editor PResident Gear Solutions magazine editor@gearsolutions. an awesome group of contributors have stepped in to fill our pages with great information this month. Periodic stretching is encouraged as a means of avoiding carpal tunnel syndrome in Terry McDonald’s “Site Safety” column. for this piece made me recall a conversation I once had with the dean of a school of engineering. is that “AGMA members are just an awesome group of people. beginning with “Refurbishing Wind Turbine Gears” by Mark Michaud of REM Surface Engineering and Gary J. for example. has penned “Alternatives to Gear Grinding. In closing I’d like to thank all of you who stopped by our booth last month at the American Wind Energy Association’s WINDPOWER 2011 Exhibition & Conference in Anaheim. Benson of the REM Research Group. despite his many responsibilities.com (800) 366-2185 Chad Morri son viCe PResident OPeRatiOns Teresa Cooper 6 gearsolutions. Cooper Russ Willcutt. During our conversation for this issue’s Q&A I asked him why. to which he was recently named chairman of the board. the company’s founder and president. O. I think most engineers would choose ‘efficiency. Cooper PuBlisheR As president of the Cotta Transmission Company. Speaking with Dick Gangnon. al 35124 (800) 366-2185 • (205) 380-1580 fax David C.Letter From tHe EDITOR David C. thereby strengthening an already longtime and mutually beneficial relationship. Bill Crosher continues his discussion of the history and evolution of hobs and hobbing in this month’s installment of “Tooth Tips. It was a great show. CROsheR mikel Janitz sanJai keshavan teRRy mCdOnald maRk miChaud GaRy J. Matt could relate how Cotta and its vendors have helped each other through tough times.” describing how honing and cup wheel superfinishing can be a great alternative to gear bore and face grinding.com . Matt Mondek is a pretty busy guy. We look forward to seeing you there! Chad Morrison assOCiate PuBlisheR Russ Willcutt editOR eDitoriAL Brad Whisenant natiOnal sales manaGeR sALes Teresa Cooper manaGeR CirCuLAtion Kassie Hughey COORdinatOR Jamie Willett assistant Jeremy Allen aRt diReCtOR Art Michele Hall GRaPhiC desiGneR Contributing writers ROnald e. my response was “precision. BOx 1987 • Pelham. My thanks go out to each of these individuals for their contribution to this issue. My favorite comment.” helping you to address—and hopefully eliminate—gear noise and rattle. California. In addition to educational opportunities and helping develop industry standards. which you’ll read at the conclusion of this issue.’” I feel that Dick would probably agree. for which I produced a magazine. Sanjai Keshavan. Asked to sum up the characteristics of an engineer in one word.” Speaking of which. and it’s always a pleasure to see our friends from the gear-manufacturing world who are also involved in the wind energy market. BensOn William P. Sroka and Ronald E. sROka JaCk titus Vertical Logo Published by Media solutions. and just enough to whet our appetites for the AGMA’s Gear Expo in Cincinnati next November. We were there to support Gear Solution’s sister publication. allowing you to make a better-informed decision. of the ECO Hone Division of Nagel Precision Honing. If you’re concerned about the integrity of your supply chain.” and Jack Titus describes the equipment used in the endo and low pressure carburizing processes in his “Hot Seat” column. in which case other AGMA members who’ve done the same might be willing to share their experience. Mikel Janitz of Muncie Power Products has written “Reducing Gear Rattle. P. he pointed to the value of having fellow members as a resource when presented with professional challenges.” Her reply? “While that’s certainly important. Wind Systems magazine. and JLM Systems is our company profile. Dennis Gimpert—president of Koepfer America— discusses his plans as chairman of the AGMA Foundation in the association’s special section. he still feels it’s important to be involved in the AGMA. which also includes news of upcoming educational opportunities. and especially to the gear manufacturing industry at large. inc. Or maybe you’re thinking of expanding into a new market or region.
Services..com . CCAM will provide the industry with transformational improvements in advanced manufacturing technologies for surface engineering and manufacturing systems. 8 gearsolutions. and Rolls-Royce. “This is our opportunity to shape the future of manufacturing technology by collaborating with diverse industry sectors with similar problems as well as to have access to resources for combined development work. Newport News Shipbuilding. Located in Prince George County. nuclear. In addition. Siemens. Virginia Tech.” Companies wishing to submit materials for inclusion in Industry News should contact Editor Russ Willcutt at email@example.com. Sandvik Coromant will be among some of the best industrial partners. and Developments Sandvik Coromant Joins Commonwealth Center for advanced Manufacturing Sandvik Coromant has united with the Commonwealth Center for Advanced Manufacturing (CCAM) as an originating industry member.INDUSTRY NeWS New Products. Inc. Trends. the facility is specially designed to be a collaborative research center in which the member companies and academic partners can work together on R&D initiatives.” according to John Israelsson. Chromalloy. and suppliers from a broad range of industry sectors including aerospace. “This is an exciting venture for us. president of Sandvik Coromant USA. Releases accompanied by color images will be given first consideration. and electronics. Virginia. CCAM’s academic members include University of Virginia. shipbuilding. OEMs. and Virginia State University. These founding members include Canon Virginia.
org]. University of Virginia. president. and customer success managers. It also works with corporations such as General Electric. include both audio and video components. Charles Steger. Following the Society of Manufacturing Engineer’s acquisition of Tooling U last fall. and Harley Davidson as well as small and mid-sized companies and technical and community colleges. has relocated its headquarters to Tyler Village. Andreas Saar. synchronous training. CCAM. vice president and chief technology officer. and the location is still accessible for our employees. For more information about Tooling U. David Lohr.sandvik. the leading developer of online manufacturing training. of the 6th District of Illinois serving Addison and Lombard. Caterpillar. We like the unique atmosphere. e-mail info@toolingu. SMe’s tooling U Relocates to Brick and Mortar Site Tooling U. Dr.. governor of Virginia. Tooling U’s division manager. “Manufacturing is leading the recovery. Siemens PLM Software. support staff. we needed to expand our brick and mortar offices.com]. Barry Johnson. vice president of the administration group. John Sparks. senior associate dean and associate dean for research. William Powers.” The 8.com]. president and CEO. “We like the story that we've repurposed this space for a high-tech application. Don Leo. Ohio’s. vice president of component manufacturing solutions. president of Sandvik Coromant USA. Virginia State University. executive vice president and CFO. director of engineering and technology programs. Newport News Shipbuilding. 2011. Tyler Village—a former industrial complex and now a thriving. Tooling U allows operators to take classes 24/7 in a host of manufacturing topics. which is one of Cleveland. “In order to support Tooling U’s e-learning offerings. Dr. ccam-va. Robert Shenton. Bob McDonnell.com or visit [toolingu. associate dean of research and graduate studies. “Our bread and butter is manufacturing. Congressman Peter Roskam. To learn more about CCAM go to [www. Aerojet. Teresa Sullivan.” Schron says. Virginia Tech. a search began for a new location that allowed for continued expansion. president. Rolls-Royce North America. Learn more about SME at [www.com . Classes are interactive. Virginia Tech. Aerojet.In the accompanying photo you’ll find (top row. which led to the launch of a new composites training curriculum. defense. He is a member of the Ways and Means Committee and known as an advocate of ESOP companies.. and oil and gas sectors. Congressman Visits overton Chicago Gear Overton Chicago Gear (OCG) recently had the pleasure of meeting their Illinois representative.com/us]. Ph. University of Virginia. visited the facility on April 27. Roskam was interested in hearing about the strength of the industrial manufacturing sector in his district. Chromalloy. Canon Virginia Inc. In the bottom row (left to right) is found Dr. OCG shared 10 gearsolutions.D. Visit Sandvik Coromant at [www. Ron Briggs. medical. Armand Lauzon. VP and COO.” Only six miles from its previous office. aerospace.” says Chad Schron.000 square-foot site has already enabled Tooling U to add additional writers.sme.coromant. left to right) Peter Diakun. president and executive director. president. and provide one-on-one. John Israelsson. mixed-use business complex—fit the needs of the growing company. and manufacturers are in greater need of training their employees. largest downtown redevelopment projects. and Dr. Tooling U provides training for operators in the automotive. Keith Miller.
The company also invests aggressively in internal leadership development for promising management candidates. managing member of Takihyo LLC. who has given great support both intellectually and materially. Philadelphia University is focused on innovation. automotive and wind energy. Meidar is an alumnus and trustee of the university. Everyone at OCG thoroughly enjoyed the visit and looks forward to future visits to their facility. Philadelphia University MaG Chairman Receives Leader of innovation Medal MAG IAS. Jr. is the world’s leading developer of automation technologies for producing composite structures for aerospace. “It’s an honor to be recognized with such a distinguished group of achievers as represented by this year’s award recipients. MAG. MAG recently funded the new Philadelphia University MAG Composites Institute and has donated a machining center to be used by students in manufacturing of engineering prototypes. We want them to have every competitive advantage possible as they launch their careers. LLC Chairman and CEO Dr.” In addition to its collaboration with Philadelphia University. but they also exemplify the university’s mission.com]. Meidar received a Leader of Innovation Medal from Philadelphia University at its Spirit of Innovation Gala April 30. Dorothy Roberts. Founded in 1884. “MAG enthusiastically supports the work of Philadelphia University in its development of the next generation of leaders in manufacturing.. and innovative spirit.their continued success in the manufacturing of gears and gearboxes. and Tomio Taki. “As a model for professional university education. Spinelli.oc-gear. Also honored were Jose Maria Alapont. Meidar’s company. Eng. sense of purpose. working through local community and technical schools around the world.” according to Philadelphia University President Stephen JUNE 2011 11 . engineering and other fields. Mo I. According to Philadelphia University. The company is also one of the largest global suppliers of machine tools and automated manufacturing systems for the durable goods industry.” “These friends and alumni are worldclass leaders and innovators. MAG supports student apprenticeships with salaries and 100-percent tuition. MAG has manufacturing and sales operations around the world. For more information go online to [www. They are not only accomplished in their fields. even with the challenges of foreign competition and challenging economic conditions. chairman of The Echo Design Group. president and CEO of Federal-Mogul Corp. The careers and successes of our honorees across a range of disciplines inspire us.” Meidar says. the Leader of Innovation Medal recognizes creative entrepreneurs who have made significant contributions across many fields that better society and shine a light on the impact of innovation.
Process inefficiencies can then be corrected by a closed-loop control for natural gas and oxygen injection through burners and lances. and jet-oxygen and burner-gas consumption.Siemens Wins order for New off-Gas Monitoring System Siemens Industry.com www. 408.edu].ws2coating. By continuously monitoring the EAF off-gas analysis and offgas flow. and by utilizing the measured values with a SIMETAL holistic process model.723. It is already a market leader for such technology in basic oxygen furnaces (BOF). The LOMAS system also offers increased operational safety attributes due to its ability to quickly detect dangerous gas compositions during the melting and refining process.com].0700 270 Hillsdale Avenue | San Jose. this system provides instant feedback from the process and gives guidance for users to make adjustments as needed.mag-ias. has received an order to provide an electric-arc-furnace (EAF) off-gas monitoring system at Steel Dynamics’ Roanoke Bar Division’s mini mill in Roanoke.com 12 gearsolutions.723. Greenhouse gas emission control is an added environmental benefit. electrode. Consequently the technology results in reductions of overall energy. Inc. CA 95136 Fax: 408. as well as augmented metallic yield and productivity.. “The decision to install the LOMAS system was based is a private university with 3.500 students enrolled in more than 60 undergraduate and graduate programs. Go online to [www. MAG is a leading machine tool and systems company serving the durable goods industry worldwide with complete manufacturing solutions for metal cutting and composites applications. philau. Learn more at [www.0710 E-mail: info@ws2coating. This order marks Siemens VAI’s expansion of its patented continuous off-gas sampling and analyzing system (LOMAS) into electric-arc-furnace process optimization through continuous offgas monitoring. Virginia.com .
reduce the cost of energy. Konecranes has assembled some of the most talented and experienced applications engineers in North America. Inc. vertical boring mills. turning centers. A new operator’s pendant and magnetic panel typically accompanies a complete retrofit.” says Paul Schuler. sustainability. grinders. Many CNC control systems will allow for reuse of some of the existing drives. which we expect to reduce costs. After inspection a CNC control retrofit performed by Konecranes may include replacing the existing antiquated control JUNE 2011 13 . Konecranes has the experience to work with modern PC-based control products. manufacturers are challenged to produce more precise parts in a timely manner and at an affordable rate. Konecranes control retrofits allow customers to sustain their competitive edge in the global marketplace.siemens. manager or melt and cast at SDI Roanoke. The company’s integrated hardware and software technologies enable comprehensive industry-specific solutions for industrial and infrastructure providers to increase their productivity. and improve “mean time between failure” rates. transportation. and building technology solutions. Many manufacturing companies are leveraging their competitive advantage via CNC controls. including but not limited to gantry mills. machining centers. all existing wiring is removed from the machine and replaced with new.usa. Go online to [www. The group is a recognized leader in the CNC control retrofit business. servomotors. Konecranes Machine tool Service offers Retrofits Konecranes Machine Tool Service has extensive experience integrating numerous makes and models of CNC and PLC controls to a variety of complex and conventional machines. Additionally.com/ industrysolutions]. and specialty machines. (SII) is the U. and profitability.” Siemens Industry. When properly engineered a new CNC control retrofit can increase productivity significantly. and improve safety in the melting process. state of the art CNC control system. “This experience and their desire to bring off-gas analysis to EAF shops gave us confidence that Siemens’ state of the art system would allow us to monitor and control in real time our process efficiencies. and drives retrofit from their existing machinery. horizontal boring mills.on Siemens’ extensive experience and success with off-gas monitoring in BOF shops. They are experienced and capable of performing control retrofits using a variety of CNC & PLC controls. In today’s competitive marketplace. system with a new. affiliate of Siemens’ global Industry Sector business—the world’s leading supplier of production. New digital servomotors and drive amplifiers are properly sized to match the machine’s capabilities.S. increase productivity.
Kentucky. The facility’s “production on demand” manufacturing concept uses the latest in machine tool technologies as part of its lean strategy. Mazak plans technology Center expansion The continued upswing in business in the Midwest has spurred plans for expansion at Mazak’s Midwest Headquarters and Technology Center located in Schaumburg. “In line with our new Southwest Headquarters and Technology Center in Houston and a new $9 million investment in our Kentucky plant.mazakusa. thereby reducing the cost that is typical with a complete retrofit. LMS TPA methods are the problem-solvers of choice for noise and vibration engineers in the world’s 14 gearsolutions. Built on more than 30 years of continuous research and development work. LMS expands test. service and sales support to its customers.com] or [www. If a machine is mechanically sound but suffers from control related failures due to age or other performance deficiencies. with a grand opening targeted for April 2012. including a new facility in Houston and production expansion at its manufacturing campus in Florence.Lab transfer path analysis portfolio Market leader LMS International offers the most complete portfolio of transfer path analysis (TPA) solutions available. without the expense of replacing the existing servo motors and drives.” Mazak plans to move quickly on the Midwest expansion project. its world-class facility in Florence. Mazak Corporation is a leader in the design and manufacture of productivity-improving machine tool solutions.com .com]. konecranesamericas.motors and wiring. The expansion represents Mazak’s continuous investment in American manufacturing and coincides with other recent investments. The company will keep customers up to date on the latest details of this and future investments via its social media outlets and Web site. recently initiated a $9 million manufacturing expansion. Committed to being a partner to customers with innovative technology. it may need a “control-only” retrofit. the goal of the Midwest expansion is to continuously serve our customers with solutions for improved manufacturing productivity to competitiveness of North American manufacturing. more room for seminars. “The vibrant manufacturing market and our long-term commitment to customers in the Midwest convinced us to accelerate our expansion plans of our Technology Center in Illinois. For more information go to [www. Konecranes will work with the customer to discuss value priced options such as upgrading controls. and a spacious area for customer turnkey projects and test cuts. For more information visit [www.mtsunlimited. Kentucky. president.com]. Mazak maintains eight Technology Centers across North America to provide local hands-on applications. Illinois.” says Brian Papke. as well as expanded machine tool technology demonstration facilities. The expanded facility will feature a new auditorium space. to meet customer demand.
Lab provides a highly efficient solution to identify unwanted noise and vibration. Using its wider frequency range for increased accuracy. These complex noise and vibration issues can be thoroughly examined using enhanced TPA techniques to help engineers detect root causes early in the design cycle. and quickly evaluate design improvements. vice president of the test division at LMS International.leading manufacturing industries. Plus.” In complicated structures with various sub-assemblies such as cars. aircraft. For example. trace it back to its origin. “As a systematic approach for any test-based engineering process. including practically every major automotive OEM. vibro-acoustic phenomena at a certain location may be caused by a remote vibration source. or ships. TPA is a valuable time-saving method that helps engineers set the right brand-critical JUNE 2011 15 . “We listen to our customers and help them implement the right techniques for the variety of noise and vibration problems they encounter. and even indirectly via the drive shafts and the wheel suspension. LMS Test.” says Bruno Massa. A top example in our TPA portfolio is our patented LMS Test. the energy from a car engine is transmitted into the passenger cavity by a number of different routes: from the engine mounts. “What the market appreciates is our hands-on and comprehensive approach to transfer path analysis. engineers can quickly identify the root causes of noise and vibration issues faster than ever before. the exhaust system connection points.Lab OPAX technique. the depth of our portfolio means that there is a TPA solution to tackle all kind of issues from every possible angle.
This is a very special trust and we do our best to preserve it. when they maintain such "top of mind awareness" for customers. to exacting customer specifications. Obtain more information at [www. time after time after time. and is rapidly spreading from its core application area in automotive to other manufacturing industries. associate publisher of FMA Communications.” says Jim Gorzek. Inc. such as white goods. thefabricator. as it isn't for our customers. to the careful product handling and packaging. consistency is not the hobgoblin of little minds. which focuses on the unique needs of companies engaged in tube and pipe producing and fabricating. 11715 Main Street. their reputation rides. engineers actually ‘pre-design’ the ideal components to avert undesirable noise and vibration. We'll be thinking about you.” The metal forming and fabricating industry’s leading online resource. The glossary currently lists over 570 industry terms with an estimated expansion to over 3.com adheres to the same editorial standards as all publications from FMA Communications.100 members working together to improve the metal forming and fabricating industry. Plus. news. and Web sites. as our products help their products perform better. Thefabricator. As a result. In our world. TPA remains a popular method for troubleshooting existing vibroacoustic issues. e-newsletters. check out www. We do this by maintaining a machine shop that's the envy of the gear world. FMA Communications. lmsintl. Go online to [www. IL 61073 815-623-2168 16 Forest City Gear Ad4806 Island “GearHeads” Gear Solutions—Bernard & Company 12/14/10 gearsolutions. and the FABTECH® show.com]. networking events. The goal is for the glossary to be the largest and most comprehensive available online in the industry. Inc. they bring an unmatched knowledge of materials and CNC machine tool functionalities to the difficult task of making the world's very best gears. industry Glossary on fMa Communications Web Site FMA Communications. but we know better at Forest City Gear.Lab solu- tion. vendor directories.. currently serves the metal forming and fabricating industry by publishing business-to-business magazines. Founded in 1970. Our gearheads live with the math and physics of gears on their minds. “Visitors can now find a quick definition and then look for more in-depth knowledge using thefabricator. FMA also has a technology affiliate. office equipment and even aviation and shipbuilding.noise and vibration performance targets on both the full system and component levels. from the first drawing to every step in the machining process to the final inspection in our state-of-the-industry QC department and finally. on ours. in part. all the while trying to improve the products we deliver. Some folks might think a diametral pitch is a roundabout way of selling something.com. com attracts more than 120. On the other hand. Emerson (the essayist. For a sample of how good a gear company can be. We Always Have Gears On Our Minds. FMA brings metal fabricators and fabricating equipment manufacturers together through technology councils. you see. “The glossary is a tremendous tool for newcomers to the metal forming and fabricating industry. FMA is a professional organization with more than 2. Doing something right "most" of the time simply isn't good enough at Forest City Gear.com/glossary].. Gearheads? You Betcha.” Massa says.com . thefabricator. every day. not the electric motor magnate). with all apologies to Mr. Glossary terms are also listed in the articles on the site so visitors can learn more about a particular term. “With an optimized product development cycle..” A pioneer of transfer path analysis. and products they need to operate and grow their businesses.com’s robust search capabilities. announces the addition of a comprehensive industry glossary to its Web site. (TPA). every time. educational programs. At Forest City. and content is divided into tech cells that allow visitors to zero in on their areas of interest. Roscoe. LMS commercialized the first TPA product in the early 1990s under the LMS CADA-X platform.000 unique visitors every month who are looking for articles..200 entries. the Tube & Pipe Association Intl.forestcitygear. Today this know-how is baked into the market-leading LMS Test. the publishing affiliate of the Fabricators & Manufacturers Association. They demand we make it right.
000 of direct savings to the customer. saving the customer almost $10. Quaker assisted one automotive manufacturer to recycle almost 15. 12” x 24” type 321 heat treating sheets. many manufacturers found it necessary to decommission machines. The sheet design keeps handling to a minimum. aluminum. but we are focused on making the best decision for our customers' bottom line. Rather than dispose of unused process oils and lubricants. improve product quality. or reformulating them for use in completely different processes. which sometimes includes recycle and reuse versus disposal. This may not always be the best decision for Quaker’s bottom line.” Quaker Chemical Corporation is a leading global provider of process chemicals. mining. automotive.000.000.com]. heat treating Sheets from precision Brand products Precision Brand Products introduces a safer. to other facilities.a Green alternative to fluid Disposal from Quaker Quaker Chemical offers its customers a greener alternative for the disposal of used process fluids. In addition to hard cost savings. “It’s our job to educate and counsel our customers on how to get the most value from their metalworking process fluids. The result can be significant cost savings. and construction materials. aerospace. tube and pipe. not only in terms of waste disposal. coatings. and lower costs. senior director of metalworking and services in North America. In another instance Quaker took hydraulic fluid from a decommissioned machine and transferred it for use at another of the customer’s facilities.000 gallons of straight oil from a machining operation and reuse within the facility. there are the obvious environmental benefits to the recycling of metalworking process fluids. we do this through the entire life cycle of the chemical. but also as related to buying new virgin materials. saving the customer around $20. and technical expertise to a wide range of industries including steel. Quaker’s products. Quaker helps its customers to recycle these fluids by capturing them and either transferring them to other lines. including disposal. chemical specialties. Learn more at [www. and chemical management services enhance customers’ processes. The 12” x 24” JUNE 2011 17 . For example. By recycling and reusing many of the process fluids utilized in a metalworking facility.quakerchem. When automotive production declined in the later part of 2008. resulting in almost $100. technical solutions. more economical alternative to the standard tool wrap rolls.” says Kyle Campbell. Yet another example is when Quaker worked with an automotive manufacturer to convert obsolete material to meet the specification of a straight oil used for broaching. services. Quaker helps its customers to lower their costs and lessen their environmental impact. “When a customer hires Quaker to manage the chemical specialty products in their facility.
sheet size has been tested and chosen to be the optimum size to accommodate the vast majority of parts. By making the measurement process easier for the operator. together.precisionbrand. flanges.com]. accuracy. or other geometric features can now be included in the measurement routine. bend correction to reduce scrap. flawless operation. simplicity. a range of noncontact infrared probes provide operatorassisted visual notification via a laser stripe indicating the measured area. Packaged in convenient 10. For more information call (800) 535-3727 or visit [www. especially those heat-treated in small bench type furnaces. Proprietary absolute encoders are located in the arm’s primary axes. The probes are interchangeable with traditional ball probes without the need for re-calibration. so the operator can turn on the system and Continued on pg. industrial and Automotive industries. 20. our superior manufacturing capabilities. highly trained workforce and ability to manufacture highly engineered and customized products set us a part from all the other aerospace gear manufacturers. Less handling means less risk of being cut. and fixture verification. The unique package allows for easy access to each individual sheet and protects from dirt and damage during storage. non-destructive testing and engineering solutions deliver aerospace quality at automotive prices. This eliminates antiquated homing procedures. and productivity for the entire tube shop. The new 12” x 24” sheets are convenient- ly packaged for easy handling and storage. New to the system. we have improved efficiency. no recalibration also provides an additional layer of error proofing in the field. Excess material can be conveniently stored “flat” in the box. requiring one cut or less to form into a usable heat-treating envelope for the part. The sheet design means less waste from excess handling and improved product performance. Inc. shop.—announces their new line of noncontact tube inspection systems. System enhancements focus on expanded flexibility. or 30 sheet packages. Zvonimir Kotnik. Delta Gear products are recognized around the world for precision-quality and on-time delivery. now we have the privilege of taking the tiFCo Gage & Gear legacy of products forward with us into the future. “The straightforward operation of the overall system guarantees simple. Besides saving time. enhanced Non-Contact tube inspection Systems from RoMeR ROMER—a brand of Hexagon Metrology. or lab. sums up the new tube inspection product line. so the arm always knows the position of its joints. 58 > the premier gear manufacturer for Aerospace. bosses. reverse engineering. our continuous capital investment in precision CnC machinery. defense. director of the business management group of Hexagon Metrology. without risk of deflection. and ease of use to increase shop productivity. Individual sheets are easy to access and fabricate.com . Brackets. The operator can view where data points are acquired on a tube or wire during the inspection process. As with ROMER’s legacy systems. 18 gearsolutions. trained personnel. the non-contact probing feature enables measurement of the most flexible tubes or wires from 4mm to 130mm in diameter.” ROMER’s tube inspection system is based on the patented ROMER Absolute Arm portable CMM. delivering true “plug and play” capability. The enhanced product line provides solutions for a wide array of tube and wire bending applications including tube inspection. there is a quantity for every size. iSo9001 and aS9100 registrations.
” This summer the foundation board of trustees will meet at the AGMA headquarters in Alexandria. The original mission of the foundation was to facilitate special financial funding of AGMA’s ISO standards work. It is important to note that these funds are used for foundation purposes. to conduct a strategic planning session. In its final form the strategic plan will provide a blueprint for annual and future actions. and where it should be going. and ” our current mission statement is: “To support the establishment of global gear standards. They will be contacting both you and your companies to ask for financial contributions.The mission was later broadened to include funding of educational and research projects in addition to the ISO and standards work. We hope to build a closer relationship with our supporters and learn your specific interests and needs. trustees from your AGMA Foundation board will be contacting selected individuals for a brief telephone interview. We look forward to receiving your input and suggestions. Dennis Gimpert chairman AGMA Foundation President. The current vision statement for our foundation is: “Excellence in gearing through the advancement of gear science. Virginia. as well as building a permanent endowment fund. The AGMA Foundation was originally organized in 1994 as a non-profit 501(c) (3) charity. the building of a commitment to those priorities. and the planning for allocation of resources. ” • Funding of research at the Gear Research Institute on “Gear Noise and Vibration Documentation. Our strategic planning process will lead us to specific priorities. Some of the recent projects that the ” AGMA Foundation has supported include: • Creation of a web-based version of AGMA’s “Detailed Gear Design” program. the foundation trustees and other volunteers will begin our annual fund-raising drive. The foundation’s legal structure allows companies and individuals to make fully tax-deductible contributions.agmafoundation. you as a member have the opportunity to submit ideas for worthy projects as well as to participate in the scholarship program. • Establishment of a scholarship program to financially assist graduate level engineering students whose programs focus on gear technology or gear research. We will ensure that our donors—who are mostly AGMA members—will be effectively represented and served. either with current or future projects.American Gear Manufacturers Association Looking Ahead: The AGMA Foundation’s Future During the 2011 AGMA/ABMA Annual Meeting. Koepfer America (703) 684-0211 www. Also. Beginning this summer.org . Funding of a research program at Ohio State UniverUniver sity on “Prediction of Micropitting. I began my three-year term as chairman of the AGMA Foundation. Prior to this important strategic planning session. Our goal will be to organize our vision and priorities in response to both our dynamic global environment and the changing desires of our donor base. As we move forward I would like to share some of my thoughts on what I feel our foundation is. standards and education. research to strengthen those standards and training and education to ensure their effective use.
and scoring hazard. or a way for your voice to be heard in the standards process. Course Outline 1) Basic introduction to gear rating theory and standardized AGMA/ISO analyses methods including theoretical models for strength. reliability. networking opportunities. Not a member? Send e-mail to membership@agma. wear. Calendar of Events ** Event open to AGMA members only.org. liability. and the possible consequences of failure are just some of the factors that are covered in this course. VA WebEx Chicago. CT gearsolutions. 2) Practical considerations and limitations associated with the application of standard AGMA/ISO durability rating analyses: • The theoretical surface contact stress model and its application to gear tooth contact conditions. time out of the office. durability. If you would like more information on any of the following events visit www. case crushing. safety. In providing Web alternative learning opportunities—digital courses and webinars—AGMA hopes to fulfill needs of members on a more-broad basis.org or send e-mail to events@agma. and subcase fatigue. transportation costs. and learning styles may hamper students from attending the classroom versions of courses.com . spalling. the AGMA has something to offer you. How do we optimize a gear? How do we get the most capacity out of a gear? These questions and more are answered in this course. Detailed Gear Design: Beyond Simple Service Factors begins with a discussion of the true aim of gear design and brings into focus many of the often-conflicting considerations of designing gears to meet specific customer’s expectations. Get the same great lectures and course materials from renowned gear educator Raymond Drago at the convenience and privacy of your own personal computer. IL Hartford. Cost. • Conversion of subsurface shear stress profile into required subsurface hardness profile. WebEx WebEx WebEx WebEx 1:00 – 2:30 pm EDT June 1 Mill Gearing Committee Meeting 7 Helical Gear Rating Committee Meeting 9Energy Efficiency 14 14 Enclosed Drives for Industrial Applications Committee Meeting 15 AGMA Webinar SeriesConditions for Cutting Tools Cutting Tools Committee Meeting 7-8 Wind Turbine Committee Meeting 14-15 Plastics Gearing Committee Meeting 21-22 Helical Enclosed Drives High Speed Units Committee Meeting Alexandria. Whether you’re looking for technical education. 3) Investigation of the differences in stress states among the various surface durability failure modes including pitting. AGMA recognizes that its members need high quality advanced gear education. Detailed Gear Design: Beyond Simple Service Factors is now available online in a course offering of 15 one-hour video segments.agma.Detailed Gear Design… Online! AGMA has taken one of its most popular courses out of the classroom. but the organization also recognizes that schedules. 4) Extended load capacity analysis techniques (beyond the AGMA/ISO standard methods) including: • Subsurface shear stress analysis for the determination of optimum effective case depth and relation to subcase fatigue and case crushing.org.
5) Consideration of friction in the calculation of surface compressive stresses: • The relation between pure Hertz-type compressive stress and pitting. • The relationship between spalling and the occurrence of a combined tension and compression state at the tooth surface due to mesh friction effects. 6) Practical considerations and limitations associated with the application of standard AGMA/ISO strength rating analyses. 7) The theoretical strength stress model and its application to gear tooth bending stress evaluation: • Correspondence between calculated stress numbers and actual measured tooth root stresses. 8) The effect of gear blank rim thickness on the tooth root stress state: • Rim bending participation. • The rim thickness factor, development and limitations. 9) Discussion of differences between fatigue, time dependent, and time independent failure modes as related to gear tooth design: • Durability and strength. • Wear. • Scoring. 10) Wear evaluation by the application of elastohydrodynamic analyses • Basis of the analysis development. • Probabilistic nature of wear evaluation. • Time dependent, non-fatigue nature of wear progression. • Self propagating mechanism.
11) Scoring Hazard evaluation by the application of Blok’s Critical Temperature theory: • Basis of the analysis development. • Probabilistic nature of the problem. • Time independent nature of failures. 12) Optimization of gear tooth detail design parameters including: • Considerations for minimum roll angles. • Effect of and design for specific sliding (slip ratio) and entraining velocity. • Stress balanced or life balanced gear pinion and gear relative design. • Influence of geometric characteristics such as tooth top land, tooth thickness, etc., on optimized tooth design. 13) Considerations of fillet geometry in the avoidance of fillet interference and excessive stress concentrations due to adverse fillet geometry. Computer generated animated graphics will be used for examining mesh action and tooth interaction. Each section discussion will be followed by a brief question and answer period. The registration fee will include all meeting materials, scheduled meal functions, and an opening evening networking reception. A certificate will be awarded to each attendee.—Jan Alfieri, AGMA Education Manager
Providence, RI WebEx WebEx Alexandria, VA
23 Committee Meeting 27-29
Gear Failure Analysis Seminar
Spline Committee Meeting
Helical Enclosed Drives Marine Units Committee Meeting
Sound & Vibration Committee Meeting
Helical Gear Rating Committee Meeting
Powder Metallurgy Committee Meeting
WebEx Big Sky, MT
Online Workforce Education
Gain basic gear training in three courses: Fundamentals of Gearing, Gear Inspection, and Hobbing. Go to www.agma.org/events-training/ detail/online-workforce-education.
AGMA Announces Fall Education Schedule
Gear Failure Analysis Seminar
September 19-21, 2011 Big Sky Resort, Big Sky, MT
AGMA is looking forward to an education-packed fall season. Registration is now open for the following events at [www.agma.org].
Gear Manufacturing & Inspection: Methods, Practices, Application & Interpretation for the Design Engineer
October 18-20, 2011 Cleveland, OH
Avoid gear failure and save thousands of dollars in repair costs by knowing what causes gear failure and how to prevent it from occuroccur ring. This course is a perennial sellout and is limited to 30 students, so register soon. Students will examine the various types of gear failure such as macropitting, micropitting, scuffing, tooth wear, and breakage. Possible causes of these failures will be presented, along with some suggested ways to avoid them.
Basic Training for Gear Manufacturing
October 3-7, 2011 Chicago, IL
In this seminar students gain a broad understanding of the methods used to manufacture and inspect gears, and more. The course takes the process one step further, teaching how the resultant inforinfor mation can be applied and interpreted in the design process. This seminar aims to narrow and possibly close the information gap by providing gear design engineers with a good foundation in both manufacturing and inspections processes and procedures.
Gearbox System Design: The Rest of the Story…EveryStory…Every thing but the Gears and Bearings!
December 6-8, 2011 Clearwater, FL
The AGMA Training School for Gear Manufacturing will enable students to become more knowledgeable and productive. The Basic Course teaches participants to set up machines for maximum efficiency, to inspect gears accurately, and to understand basic gearing. Although the course is designed primarily for newer employees with at least six months experience in setup or machine operation, it has proved beneficial to quality control managers, sales representatives, management, and executives.
This program addresses what gear engineer can do to optimize the gearbox system, from the housings to the lubrication and much more. The seminar starts with the basics: history of design, the environment in which the gearbox must “live” and the loading to which the system will be subjected in service. Loading includes starting/ stopping, continuous, reversing, cyclic and possible errant loads conditions.
Board of Directors
Norbert Benik: VP of Industrial Sales, Ontario Drive & Gear, Ltd. Jim Bregi: President, Doppler Gear Company Sulaiman Jamal: Managing Director of Bevel Gears (India) Private Limited Tom Marino: President & CEO, Gear Technology Gordon New: Managing Director, Ronson Gears Pty, Ltd. Bob Phillips: Senior Vice President, Gleason Cutting Tools Corp. Bob Sakuta: President, Delta Gear Kyle Seymour: President & CEO, Xtek, Inc. Mike Smith: Vice President of Sales and Marketing, Capstan Atlantic Mike Suter: Vice President of Marketing, Emerson Industrial Automation Dirk Wernecke: Global Manager, Pricing, The Timken Company
Chairman: Matt Mondek President, Cotta Transmission Company, LLC Treasurer: Louis Ertel President & CEO, Overton Chicago Gear Corp. Chairman, BMEC: John Strickland VP of Marketing and Strategic Planning, Fairfield Manufacturing Co., Inc. Chairman, TDEC: Dr. Phil Terry Chief Metallurgist, Lufkin Industries Chairman Emeritus: Dave Ballard Director of Marketing & Business Development, North & South America, Siemens Industry, Inc.
Joe T. Franklin, Jr., President Charles Fischer, Vice President Technical Division Jan Potter, Vice President Membership
Contact the AGMA
General requests: firstname.lastname@example.org Membership questions: email@example.com Gear Expo information: firstname.lastname@example.org Technical/Standards information: email@example.com AGMA Foundation: firstname.lastname@example.org
500 Montgomery Street, Suite 350 Alexandria, VA 22314-1581 (703) 684-0211
We’ve all seen people Wearing those braces on their wrists that extend from the knuckles to midway up the forearm, and most of us know someone who’s had to wear one—if we haven’t had to, ourselves. While some might be the result of a tennis injury or something along those lines, most often they’re being used to treat something known as carpal tunnel syndrome, or CTS. Although doctors have different theories, most agree that CTS is caused by repetitive motion such as typing on a keyboard for many hours each day or performing the same physical motion in the workplace. Steady pounding and constant vibration have also been cited as possible causes. What happens is that the median nerve passes through the carpal tunnel in your wrist,
Member of the ANSI Subcommittee on Gear Safety
Many doctors believe that carpal tunnel syndrome is caused in the workplace by making repetitive motions without stopping periodically to stretch your muscles.
“Carpal tunnel syndrome gets more painful as it progresses, and you can even experience weakness in your hands, which can really cause problems for people who work in manufacturing.”
and when the surrounding tissue begins to swell it presses against the nerve, and with no way to relieve the pressure within the carpal tunnel you begin to experience pain and numbness in your hands. And, yes, it seems to be another one of those complaints that you need to protect yourself against even before it starts hurting, which can be difficult to do without that painful reminder. Many doctors think the damage is cumulative, so it just seems to get worse once the aching begins, and wrist braces can’t do anything about the damage that’s already been done. They mostly serve to immobilize the wrist—and to remind you to take a break every now and then. you want to keep your hands in motion. I sometimes think that there seems to be more people getting migraine headaches these days, and ABOuT THE AuTHOr: I’ve often wondered if it doesn’t have something to Terry McDonald is partner and manager of Repair Parts, Inc., and a member and do with all the time we spend staring at a computer past–chairman of the ANSI B11.11 Subcommittee on Safety Requirements for screen, sometimes only a foot or two away. They Construction, Care, and Use of Gear Cutting Equipment. Contact him at (815) say that if you do that type of work you should take 968–4499, rpi@repair–parts–inc.com, or [www.repair–parts–inc.com]. a break once an hour or so and stare off into the
distance so that your eyes can adjust. That’s good advice for people who perform a repetitive motion with their wrist all day, too, like working on an assembly line or some type of manually operated machine like a drill press. It can be hard to find the time to do it when you’ve got a schedule to keep, but it’s important to stop what you’re doing periodically and stretch your wrist into positions that are different from those you’re doing in your work. By gently flexing your wrist backwards and forwards, then to the sides, and repeating that motion, you should feel your muscles begin to limber up, and hopefully they won’t start getting stiff as quickly once you’ve resumed your work. Like I’ve said, though, it’s a good idea to go ahead and get in the habit of doing this before you start experiencing pain. It’s called being proactive, and that’s always a good idea. In case you’ve been feeling pain in your wrist and wondered what it was, the symptoms involve tingling and numbness at the base of your fingers and in your wrist in the early stages. It gets more painful as it progresses, and you can even experience weakness in your hands and a loss of grip strength, which can really cause problems for people who work in manufacturing. While machines are more automated than ever, there is still plenty that has to be done by hand, so losing the ability to grip tools and controls firmly is something you definitely want to avoid. If you’re involved in this type of work and are experiencing these feelings in your hands and wrists, you need to pay your doctor a visit where they can diagnose CTS fairly easily. If you do have it treatments can involve everything from steroid injections, to occupational therapy, to the immobilizing wrist braces I’ve already mentioned, to a procedure called carpal tunnel release surgery. The good news about the surgery is that it has a 90-percent success rate, with people able to go back to their jobs after a short period of recuperation. The bad news is that it’s still surgery. Like I’ve said, doctors aren’t in agreement about what causes carpal tunnel syndrome. Some think it’s genetic, while others feel that it’s a result of repetitive motion. Whatever the cause, statistics show that one in 10 people will develop CTS at some point, and those who do will end up shelling out about $30,000 for treatments and surgery during their lifetimes. So stop and stretch periodically if
the gear blank must be rotationally advanced and retarded for a trimming cut on each flank. etc. Transmission. To obtain maximum benefit after the hob is fed to the proper depth. Hobs are form-relieved cutters. was properly mounted. The hob’s cutting edges maintain the correct pressure angle and lie along a helix with the established lead. They are sharpened by grinding the faces of the hob’s teeth to the bottom of the flute. Two designs of cutter are used are either a rotary type or a planer type tool. The hob accuracy can be affected during the sharpening process by errors in the rake angle. and the others by the Metal Cutting Tool Institute.TOOTHtipS williamCrosher Author. A Class AA will be capable of producing an AGMA A5 (Q12) gear. “Hobs are form-relieved cutters. Errors frequently arise after the hob has been sharpened. The most complex and costly tools used for metal cutting are those that are used for cutting teeth. and modifications to assist following operations such as shaving and grinding. and it reduces the tooling cost when manufacturing small quantities of high-precision special gear forms. The hob accuracy has a direct relationship with the quality of the gear being produced. and their tolerances maintained after sharpening. It is essential to inspect the hob after sharpening. one tooth space at a time is cut. C-Accurate Unground and. and pineapple. and later at Flender Graffenstaden. The latest hob technology is to use coated carbides or high-speed steels. Coatings for shaper cutters and hobs have been in widespread use since 1980. and if Class B an AGMA A7 (Q10) gear when the hob has an adequate number of gashes. engineer. particularly form cutters. The errors are usually in profile and lead. addendum and dedendum. TangenTial feed hobs are in Three basic designs: pancake.com . A-Precision Ground. ACCurACy grADes Hobs are available in five accuracy grades: Class AA-Ultra Precision Ground.” Cutting teeth There are two popular methods used to cut the teeth: generating. A consistent amount of metal must be removed from each succeeding row of teeth. All standard hobs are designed with a generating profile (basic rack) that defines the pressure angle. The better the surface before the coating is applied. The former are low in cost with a narrow face and a minimum of cutting edges. and by using a formed cutter. multiple-spiral cylindrical. The thin ultra-hard film increases the tool’s abrasion resistance and reduces tool-part adhesion. and indexing. The tolerances for Class AA were established by the Barber-Colman Company. and by keeping most of the heat away from the substrate material. leaving a gap the same shape as the cutter. The cutter is fed radially into the blank to produce the form. D-Commercial Unground. Hobbing is five times faster than fly cutting. but hobs are much more expensive. the author continues his outline of the evolution and continued development of hobs. and have longer cutting times. wear rapidly. An alternate to the use of a hob is a fly tool. B-Commercial Ground. ABOuT THE AuTHOr: William P Crosher is former director of the National Conference on Power . and former director of the National Conference on Power Transmission In the second installment of a three-part column. sharpened by grinding the faces of the hob’s teeth to the bottom of the flute. Coatings are successfully used to improve tooling economics by increasing the time between sharpenings. the better the overall results. and errors frequently arise after the hob has been sharpened—usually in the profile and lead. He is author of the book Design and Application of the Worm Gear. Using the formed rotary cutter. The mating gear is for all practical purposes impossible to cut by conventional methods. the fillet radius. He was resident engineer-North America for Thyssen Gear Works. An estimated increase in tool life of 200-300 percent is considered conservative. The simple tool is reasonably easy to make. flute lead. as the hob profile can be changed from its true position by exposing the cutting edge to a different plane. Globoidal worms can be produced on a standard hobber by reversing the location of the cutter or bladed cutter assembly with that of the gear blank. 24 gearsolutions. and they are frequently used in the cutting of a worm wheel with tangential feed. as well as former chairman of the AGMA’s Marketing Council and Enclosed Drive Committee. The first coating to find general use was the gold colored titanium nitride (TiN). This method has none of the irregular flank contours that are present when a hob is used.
atmospheric pressure allows us to breathe. JUNE 2011 25 . therefore the (secondary) electrical power connected to the heating elements must be limited to 80 volts AC.afc-holcroft. and when someone had the idea of adding heat the most practical solution was a heated box inside of the jar and the space between the jar and box for wiring.1013 millibar remain. Thus. Your local weather forecast in the U.com. The reasons.ald-holcroft.i’ve explained in previous columns a few basic tenants of endo and low pressure carburizing processes. are twofold: • he very first R&D vacuum systems consisted of a tabletop mounted bell T jar and vacuum pump located beneath. Vacuum. In the U. 60 Hz. almost all vacuum furnaces have water-cooled casings. 30 inches of mercury. solution—reduce the thickness.com] or [www. with atmosphere furnaces requiring 13½ inches of insulation. • s vacuum furnaces evolved and cooling was added to single chamber A furnaces in an effort to force cool the parts as fast as possible. Go online to [www. Since heat transfer in vacuum is significantly less than at one atmosphere it worked. in an effort to duplicate the integral quench batch atmosphere furnace. These furnaces fall under the broad category of “hot walled” furnaces. One may wonder why. Vacuum furnaces continued to evolve retaining a gap between the insulated hot zone and the water-cooled casing. devices that are warm or hot to the touch. in-situ gas such as LPG (liquefied petroleum gas and air). Atmosphere carburizing with endothermic gas. In metric terms pressure is referenced in bar. Since oxygen has been removed graphite (carbon) won’t burn as it would in air. In scientific terms 1 x 10-4 millibar. a vacuum furnace has only a few inches when they can operate a much higher temperature. it became necessary to reduce the heat stored in the insulation. This means atmospheric pressure at sea level can be stated as 14. ABOuT THE AuTHOr: Jack Titus can be reached at (248) 668-4040 or jtitus@afc-holcroft. in about the mid-seventies. Vacuum furnaces designed for traditional hardening and LPC due to the hot zone/inner chamber construction and because of higher operating temperature most often have resistance heated graphite elements.0001 of an atmosphere. has very little resistance to high voltage jumping across a small space resulting in an arc. Ninety-five percent of all heat treating is performed in this type of equipment. vacuum furnaces employing LPC are primarily insulated with only two or three inches of rigid graphite board or graphite felt. (99. This design attribute subsequently becomes a maintenance issue in LPC. I speculate. However. Gravity is the force that keeps our feet on the ground. 1013 millibar must have the air removed by a vacuum pump so that only 0. Heating elements now made from graphite were in 1950 made from tungsten or molybdenum ¼” rod. Atmospheric pressure on the moon’s surface is 1 x 10-11 millibar. LPC having acetylene gas thus the potential for soot (carbon) that is electrically conductive must limit the power to 24 volts AC. heat transfer to the steel vessel wall is low as well but the cold side of the graphite insulation is still very hot generally about 400°F to 700°F.9999 percent) of the air is removed. and since the pressure is very low. require a chamber capable of being evacuated to pressures approximating 0. AFC-Holcroft jacktitus In this installment of his column the author presents a discussion of the equipment used in the endo and low pressure carburizing processes. Then. IFB insulated furnaces are used in endo carburizing. having effectively very few gas molecules.032 inch thick molybdenum metal hot face and a few inches of ceramic fiber insulation.S. and nitrogen-methanol utilize refractory lined furnaces typically insulated with ceramic fiber or insulating fire brick (IFB). For LPC to work properly a vacuum vessel starting out at atmospheric pressure. graphite insulation was not yet invented. Don’t confuse barometric pressure with gravity. No pun intended. so perhaps a discussion of the equipment used in each is in order. Initially vacuum furnaces were primarily used for annealing and hardening small high-speed tools such as drill bits.S. since ceramic fiber was in use in atmosphere furnaces and HOTSeat Director of process and developmental engineering. likely reports barometric pressure in inches or millimeters of mercury.7 psi. more on furnace construction and types of heat treat equipment. some think removing that much air will allow parts to float around within the vacuum vessel. A developing low pressure weather system may be reported as 29 inches or 735 mm of mercury.. Vacuum furnaces. cold wall vessels with water jackets. and 760 mm of mercury.com]. except for a few locations atmosphere furnaces are heated with natural gas fired radiant “U” tubes. As indicated above. Commercial vacuum furnaces began as single chamber devices in the late 1950s with a 0. one bar = atmospheric pressure and for accuracy 1013 millibar equal one atmosphere. to a degree. Next month. multi-chamber vacuum furnaces began to appear.
com .COMPANY PROF ILE JLM Systems. Developer of oiLMiSeR technologies. this company provides clean and efficient fluid handling devices to customers found around the world. Ltd. By Russ Willcutt 26 gearsolutions.
and a dash of the entrepreneur. And when you’re talking about sawmills or mining operations. then an offline filtration kit featuring a kidney-loop design in 2003 and a color-coded filtration system the following year.” Gangnon says with a laugh. or visit online at [www. It was readily apparent to me that this contamination was responsible for the vast majority of equipment breakdown and downtime they were experiencing. introducing the products he’d been dreaming up in quick succession.com]. who is willing to take risks and harness new technologies. where I started learning about lubricants. In those days. and he continued launching new products as a sideline venture. and when it was time to change the fluid you’d just discard it. So that’s what I decided to do. Gangnon communicates with end-users all around the world who send him photos of their machines and systems so that he can suggest OILMISER devices that will meet their requirements. Just as the advent of the Internet enabled the launch of his company.com. “My background is in industrial engineering. the contaminants common in fluids at that time as a result of improper handling became concentrated. it’s likely to stay that way until somebody does something about it. The OILMISER Vapor Guard appeared in 2004. with their dedica tion to creating efficient systems. “and I’ll either sell it to them directly or to their preferred local vendor. slashing equipment uptime. The success of the FILLorDRAIN motivated him to consider other challenges he could help his customers overcome.” Gangnon has seen many changes over the years. which effectively “closed the loop” on airborne contamination between the drum and reservoir. when the price rose to more than a dollar a gallon and certain environmental regulations were introduced.” he says. when the price of hydraulic fluid was about 27 cents a gallon. “It would arrive in 55 gallon drums. it’s a very dirty environment. including the elevation of a job once referred to simply as “maintenance” to a highly specialized field made up of “reliability engineers” and technicians. “I began my career back in the mid-sixties in the wire rope business.” Gangnon recalls. Then a technology made its appearance that changed everything for him. people weren’t concerned about conserving it. eventually becoming director of hydraulic operations for a large industrial supplier. and I can tell them exactly what they need.oilmiser. that somebody is me!” TO LEArN MOrE: Call (888) 736-8645 or (604) 521-3248. supplies. in my case. Gangnon began devoting all his energy to JLM Systems in the late nineties. Today the company’s Web site features a wide selection of devices. “When you encounter inefficiency. who weren’t that interested in taking on new lines—and sell directly to the end user. who is president of JLM Systems and developer of OILMISER technologies. “And when it comes to hydraulic systems. and soon sample tubes.” After taking classes to learn about the Internet and Web-site design. he says his goal remains unchanged.” he says. In 2000 he launched a modified FILLorDRAIN for oil sampling. so the oil and the receptacles that held it were just filthy. and they would simply pour it into whatever bucket was available to transfer it to the machines. and then I went into hydraulics as a technical sales representa tive for several companies.W What’s the recipe for creating an innovator? In the case of Dick Gangnon you take one part engineer. “As it grew in popularity I realized it represented a way for me to eliminate the middleman—wholesale industrial suppliers. The system reservoirs were huge. . so I decided to do something about it.” says Gangnon. and suddenly everyone wanted smaller reservoirs on their hydraulic systems for less fluid usage. “People weren’t careful with their lubricants back then. it continues to play a major role in how it operates.” His solution was the OILMISER FILLorDRAIN. “At this point all I need to see is a picture of their setup. and sampling plugs and valves came on the scene. with their own set of professional certifications. who’s always dreaming up better ways of doing things. which he sold through the companies he represented as an outside salesman. e-mail info@oilmiser. reservoir aspirators. He established JLM Systems to manufacture the device. He also continued broadening his experience. ask a couple of questions. As for what motivates him today. and accessories that can be purchased directly or through a network of approved resellers. “It’s called the Internet. In addition to speaking on the subject to various companies that bring him in to educate to their employees. a smidgeon of the inven tor. so efficiency is what it’s all about. That changed in the seventies.” In smaller quantities.
Sroka. By Mark Michaud. low cost option for refurbishing both case carburized and nitrided gears. Benson .Refurbishing Wind Turbine Gears Isotropic superfinishing represents a value adding. Gary J. and Ronald E.
1. a foreign object debris (FOD) damage (c). However. grinding is utilized to refurbish these damaged gears. A case study on a sun pinion gear is presented. low-cost option for refurbishing both case carburized and nitrided gears.M Wear is greatest on the input stage. and fretting corrosion (e). AND AIR QUALITY.” ABRASIVE WEAR. many owners Fig. JUNE 2011 29 b d a c e . SURFACE CORROSION. the grinding process. chemically MULTI-MEGAWATT WIND TURBINE GEARBOXES OPERATE UNDER DEMANDING ENVIRONMENTAL CONDITIONS INCLUDING CONSIDERABLE VARIATION IN TEMPERATURE. introDuCtion Typical multiple megawatt (MW) gearboxes. 1: Micropitting or gray staining on gear flanks (a). evidence suggests that isotropic superfinishing imparts a finish that increases gear durability and service life in the field.5 MW and higher. however. WIND SPEED. Isotropic superfinishing removes light to moderate gear flank surface damage. THESE GEARBOXES EXPERIENCE SEVERAL TYPES OF REPAIRABLE DAMAGE INCLUDING UNCOMMON FOR GEARBOXES RATED FOR A MAINTENANCE FREE 20-YEAR LIFESPAN TO FAIL AFTER ONLY 20MICROPITTING OR “GRAY STAINING. accelerated vibratory finishing. especially on the sun pinion gear. However. nitrided gears cannot be ground and must be scrapped. are designed to operate for 20 years without requiring major maintenance to the drive train.08 mm or less. represents a value adding. heavy abrasive wear on gear flank and a SEM image of trail left by an abrading particle (b) . Historically. AND FRETTING CORROSION. Moreover. corrosion looking down on top land (d) . or isotropic superfinishing (ISF). The result is a surface with a non-directional pattern with a roughness of approximately 0. There including but not limited to high capital investment and the extraordinary amount of time and skill involved in are numerous drawbacks. Moreover. FOREIGN OBJECT DEBRIS (FOD) DAMAGE. IT IS NOT QUALITY A FEW YEARS.
Fig. leading to abrasive wear.com . 4: A crack on a used gear near the addendum of the tooth was revealed only after superfinishing. Finally.000 (USD) or more for a complete replacement by 2009 estimates . 5: Graphite tape lifts from damaged gear surface before (top) and after (bottom) superfinishing refurbishment. and air quality. Fortunately condition monitoring systems allow gearbox prob- Fig. 3: Ground surface (top) vs. dust and other foreign debris in the air can contaminate the lubricant during maintenance. Gears fail for several reasons. 30 gearsolutions.are experiencing gearbox failures after only a few years of service. 2: The superfinishing process. wind speeds. Fig. Fig. Gearbox repairs may cost $360. an isotropic superfinish surface (bottom). Wind turbine gears operate under extreme environmental conditions including highly variable temperature. During periods of low or no wind. Moreover. These conditions cause variable high loading and torque. corrosion and micropitting. the loading on slowly moving or stationary gears is exacerbated. moisture can contaminate the lubricant and condense on the gear surfaces forming sludge.
surface corrosion. This exposes the peak asperities of the metal surfaces to a second reaction (step 4).lems to be discovered before serious gear damage occurs [2. 3]. The burnish removes all remaining conversion coating (step 6) from the surface of the gear. At the start of the superfinishing process shown in step 1 of fig. 5]. size. The refurbishment process is a combination of reclamation and reconditioning of a used gear or bearing . 2. The process utilizes conventional vibratory finishing equipment and high density. burnishing soap is introduced into the vibratory machine. forming the first conversion coating (step 2) . reforming the complete conversion coating. the original metal surface reacts a first time with the active chemistry. producing a mirrorlike appearance while imparting a mild rust preventive to the surface. the active chemistry from the smoothing stage of the superfinishing process is drained away and a neutral. The initial selection of the proper media shape. This planarizing process is continued until the gears are smoothed to the required surface finish quality. Regrinding is necessary when lead and profile corrections are required on the working surfaces of the gear teeth . 1 [4. nonabrasive finishing media to produce isotropic surface finishes with a final surface roughness (Ra) below 0. and fretting corrosion. wind turbine gears experience several types of repairable damage including micropitting or “gray staining.” abrasive wear. and mixture is a significant part of the art to successfully superfinishing gears.com . or replacement with a new gear. Figure 3 shows a comparison of a ground gear surface versus a superfinished gear surface. An example of each is depicted in fig. thus planarizing the original rough machined or damaged surface. The Isotropic Superfinish. or ISF® pro- 32 gearsolutions. New gearing is expensive. cess—henceforward referred to as superfinishing—is an alternative time and cost efficient method of gear refurbishment. The final required surface finish governs the total number of cycles. The process of conversion coating reformation and removal (step 5) is continued through many successive cycles. There are three main approaches to repairing gear damage: refurbishment by regrinding. 2. foreign object damage (FOD). refurbishment by surface finishing. The superfinishing process is easily understood by referring to fig. The gear is ready for unloading and the superfinishing process is complete. The vibratory machine and nonabrasive media produce an effective rubbing motion on the surface of the gear (step 3). Media is specifically cho- bACkgrounD As mentioned. Once the required surface finish quality is achieved.10 mm. which makes surface finishing and regrinding the preferred low-cost alternatives.
There is sufficient material removal to reveal subsurface damage from micropitting. shape. T a risk that is associated with grinding. JUNE 2011 33 . • heprocessworksonnitridedaswellas T case carburized surfaces. the superfinishing process repeatedly finishes gears identically. of a used low-speed stage pinion before superfinishing: 2308 (b). The size. and alloy. Compressive stress slows the rate of surface wear and inhibits corrosion .50 mm.sen based on the following criteria: root diameter. • uperfinishingdoesnotdestroyresidual S compressive stress surface layers . Hence. gear mass. Once the media is chosen. • hereisnodiscolorationortemperburn. • uperfinishingremovesmetaluniformly S from every tooth of the gear with the ability to control total stock removal down to below 2. • he superfinishing process is an ideal T technique for improving the inspection c Fig. The superfinishing process possesses several ideal features. b Residual compressive stress is imparted on the surface during case hardening. scuffing and corrosion that may be masked by the texture of the used surface. 6: Surface trace of a new ground low-speed stage pinion before superfinishing: 2282 (a). of refurbished gears. characteristic Isotropic Superfinish on the flanks of the same assembly (b): photos courtesy Moventas. and therefore has a very low attrition rate. and density of the media remain stable over thousands of hours of vibratory machine a operation. and after superfinishing: 2282 (c). diametral pitch. 7: Superfinished intermediate gear assembly (a). the superfinished gear exhibits a superior surface versus used gears that are refurbished by grinding. gear size. The media is nonabrasive. Grinding a b Fig.
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Only after superfinishing did the crack become visible. 8: Sun pinion gear with several modes of damage including hard line micropitting (a). and the same gear after refurbishment (b). Consequently. this gear was scrapped and the potential catastrophic failure of the gearbox was avoided. 4 depicts a cracked gear tooth that was delivered by a customer and deemed suitable for refurbishment. For example. superfinishing can. it is apparent that some 36 gearsolutions. The deepest micropitting damage is approximately 150 mm (see arrows).a b Fig. In this instance. but also potentially going undetected by other inspection methods . In general. Figure 5 shows images of the graphite tape lift method that is used to measure and record the amount of micropitting on a gear flank .com . and in-service wear may cause a “smearing” of the metal on the gear surface resulting in subsurface damage not only being invisible to the naked eye. • uperfinishingcanalsoremovelight(I 25 Km depth) to modS erate (≤130 mm depth) damage from the gear tooth surface while maintaining geometric tolerances. fig.
First. Superfinishing has several distinct advantages over regrinding in terms of time and cost savings. sun.oilmiser. means increased reliability For more information visit our website www. as described superfinishing requires less setup time and potential complications versus grinding. typically the ring. It should be noted that customers frequently request complete refurbishment of the planetary gears and hollow wheel gear as well. 8a and b. Recently. and planetary drives • Ideal for mining equipment and off-road machinery • Replaces existing oil fill plugs. Fourth. No Maintenance. and (c) used gear after refurbishment via superfinishing. However.oilmiser. Gear refurbishment via superfinishing was evaluated for bending fatigue. especially an assembled intermediate unit. the process does not require engineering drawings. (b) used gear prior to refurbishment. Pre-finishing inspection is crucial as gears may be damaged during decommissioning and/or transport. GRI results suggest that “in all three tests. and scoring resistance tests on military helicopter gears by the Gear Research Institute (GRI) [14. Second. Consequently.com or telephone toll free: 1-888-RENU OIL (1-888-736-8645) E-mail: engineering@oilmiser. 2) The initial average surface roughness (Ra) was measured to • No Moving Parts. drain plugs and oil level plugs • The Hi-Flow / Hi-Viscosity sampling valve is always clean and accessible • No more sampling through an open port • More frequent oil sampling. in all likelihood. Importantly. Works 24 / 7 / 365 • Keeps Lubricating Oil On the Inside.com JUNE 2011 37 . Micropitting and light abrasive wear were noted. Figure 7 depicts a refurbished assembled intermediate stage gear. not progress to pitting and eventual spalling . However. For example. the peak asperities or “stress raisers” were removed and the existing micropitting will. Third.” Figure 6 depicts profilometer traces of (a) new ground gear. the cost per tooth is the same for a small gear with 59 teeth versus a large gear with 113 teeth. contact fatigue. The removal of all damage may have compromised the geometry of the gear. Not on the Outside • Extends the Life and The Efficiency of Gearbox Air Breathers • Cleaner Air means a Cleaner Workspace For more information visit our website www. The following protocol was used to refurbish this pinion gear: 1) After the gear was received it was inspected for damage.5 MW wind turbine gearbox. The low-speed sun pinion gear usually shows the most damage and will be used here to describe the superfinishing refurbishment process. The (Severe Duty) Oil Plug & Sampling Valve Quick. also can be superfinished with little additional expense since the entire gearbox is removed for maintenance. 15]. the gears of the intermediate stage. Clean & Reliable Oil Samples • Designed for wheel motors. all teeth are uniformly and simultaneously finished. the repaired gears met or exceeded the performance of the new gears. the turnaround time is rapid. gearbox manufacturers indicated between 150-250 mm can be safely removed without compromising gear geometry (maximum removal amount is per customer specifications). and pinion gears of the low-speed stage and the output pinions of the high-speed stage receive the most wear and are refurbished. The sun pinion gear is shown in figs.com or telephone toll free: 1-888-RENU OIL (1-888-736-8645) CAse stuDy A case study was performed on the input stage of a 1.micropitting remains after superfinishing.
the planet and hollow wheel (ring) gears were also successfully refurbished. Even if the micropitting is too deep to remove completely.com . However. Currently. All gears—with more than 2300 refurbished to date—remain within the required tolerance. and in-service performance superfinishing has several distinct advantages. In the majority of cases. all traces of micropitting and other moderate tooth damage can be successfully removed with superfinishing. 4) It was processed in active chemistry for a short duration and then carefully inspected for hidden serious damage such as cracks or deep pitting. Ongoing field tests. ConCLusions In terms of time. refurbishing wind turbine gears via superfinishing is in commercial operation as a viable replacement to regrinding by a major wind turbine gearbox manufacturer. No seri- ous damage was detected. The majority of damage sustained on in-service gears in wind turbine gearboxes can be successfully refurbished by superfinishing. Superfinishing is time efficient and economical since all teeth are finished simultaneously versus a few teeth 38 gearsolutions.31 mm (refer to Table 1). resuLts AnD DisCussion In the case study discussed. 3) The gear was placed in a vibratory finishing apparatus with an optimized media mixture to effect uniform stock removal on the flank. it is still advantageous to use superfinishing as the final step in order to impart a much longer service life. the peak asperities or “stress raisers” are removed and micropitting will not progress to pitting and eventual spalling. 6) The pinion was then burnished to remove all traces of the conversion coating. superfinishing will remove the raised lip around the lip of a FOD dent even if the valley of the damaged area is not completely removed. are being conducted to corroborate that superfinished wind turbine gears have equivalent or superior performance versus new ground gears. Gears with severe subsurface micropitting or in need of tooth profile correction must be reground first.be 0. 5) The gear was further processed in active chemistry and its surface roughness was periodically monitored with a skidded portable profilometer until the targeted Ra was achieved (a Hommel T1000 Basic with a skidded T1E probe and a 5 mm stylus was used for the case study. Moreover. 7) The Ra of the superfinished refurbished gear was determined to be 0. now more than two years old. with the profilometer cali- brated to ISO 5436 standard).07 mm (refer to Table 2). Customers utilize CMM to determine if the gears are still within tolerances after the parts are returned. cost.
Grzybowski. Technical Training Seminars: Gear Failure Analysis. K. Lifetime Prediction of Gear Teeth Regarding to Micropitting in Consideration of WEC Operating States. Springer: 2010. Winkelmann. M. Presented at DEWEK 2004: The International Technical Wind Energy Conference. Presented at the Printed with permission of the copyright holder. R. Fairfax Street. M.695 B2.Table 1: Ra and Rz measurements taken at different locations on the sun pinion prior to refurbishment. www. proprietary drawings or expensive reverse engineering is not required... P. Operations & Maintenance Real World Solutions. 1-35. Fundamentals of Chemical Milling. The Effect of Chemically Accelerated Vibratory Finishing on Gear Metrology. April 29. R. pp. 12) McNiff. large gears finish in the same amount of time as small gears. 5) Franke. and setup is simple and does not require extensive operator training... 1983. 5th Floor.remchem. 2005. 6 (6). 2007. S. Also. Errichello.windpower-monthly. Typically the ring. Repair of Helicopter Gears. www. 2009. Mach. May 2008. when regrinding may be the only way to remove the deep damage and reshape tooth geometry. and Gary J. E. 85-89. 14) Rao... 7) Schmid.windpower-monthly. L.. Windpower Monthly News Magazine (Supplement). 2007... American Gear Manufacturers Association. Previous studies by independent sources indicate that refurbishment of used gears by superfinishing results in extended operational life and reduced maintenance costs. referenCes: 1) Proactive Service Pays Dividends.. and nital etch inspection is unnecessary. Davim. 8) Arvin. May 2009. J. 9) Dini.-B. Also. R. K.. United States Patent 6.. P. Alexandria. American Gear Manufacturers Association. superfinishing can reveal pre-existing subsurface damage concealed by grinding or in-service wear related smearing.. Sroka and Ronald E. STLE 65th Annual Meeting and Exhibition Wind Turbine Tribology I.. 15) Rao. Marcel Dekker: New York. the gears of the intermediate and assembled intermediate stage can be refinished with little additional expense since the entire gearbox must be removed for maintenance. Table 2: Four Ra and Rz measurements taken at different locations on the sun pinion after refurbishment.W. Sroka. 113128. Benson are with the REM Research Group. Process for the Modification of Tooth Traces and/or for the Correction of Tooth Trace Deviations of a Gear.. Summers.. Gear Drives Systems. 1001 N.com 4) Errichello. Am.. at a time. the American Gear Manufacturers Association. Windpower Monthly News Magazine. However. Visit online at [www. Iron & Steel Technology.W. 128. Michaud. B. Bearing Repair Provides Valuable Alternative to Bearing Replacement for Heavy Industries. 13) Michaud. G.com]. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear Manufacturers Association. First quarter.. hence. Superfinishing Large Planetary Gear Systems. 1984. Ed. 10) Lynwander.. 2004. Suren B... Manesh. superfinishing afterward will result in more-durable surfaces and.. Documenting the Progression of Gear Micropitting in the NREL Dynamometer Test Facility.com 2) Dinwiddie. Journal of the Reliability Information Analysis Center. 2009. G. P. Surface Integrity in Machining. 2002. Sroka. European Patent EP1646477. 6) Flowers. May 22. 3) Juggling with Failure as an Option. AWEA. the equipment is inexpensive when compared to regrinding. May 2010. J. D. American Gear Manufacturers Association. Musial. McPherson. Repair of CH-46 Helicopter Gears. V. Virginia 22314. J. a gearbox with greater longevity in the field. And finally. J. sun.752. and pinion gears of the low-speed stage and the pinion gears of the high-speed stage that acquire the most wear are refurbished. ABOuT THE AuTHOrS: Mark Michaud is with REM Surface Engineering. 2002.. JUNE 2011 39 . 11) Astakhov. A.
Nagel Precision provides the details. By Sanjai Keshavan .Alternatives to Gear Grinding Honing and cup wheel superfinishing can be a cost-effective and higher-quality alternative to gear bore and face grinding.
to medium-volume production shops. 0. With ID grinding. In a high volume automotive environment. most gears used in high-load applications are following this trend. cup wheel finishing and honing are typically standalone processes. to cup wheel finishing and honing technology as a potential alternative to Especially in non-automotive environments.0002” bore size tolerance. when performed on a twin spindle machine this problem will be overcome as the part is held in the same position as the face and bore is ground. 0. BORE SIZE. • r after turning and heat treat. Honing and cup wheel superfinishing was devel• ores are first turned. pinion gears today are predominantly produced in the foldiameters and relatively deep bores—with length to diameter ratio of 2:1—honing has a real advantage in speed of material removal.S requirements. grinding is the final processing step for both faces and bores. BORE-TO-FACE PERPENDICULARITY TOLERANCES AND FLATNESS ON THE BORES. and then honed or ID ground. Faces are then double-disk ground to achieve final thickness and parallelism. In many of the gear manufacturing shops that we have seen. and a secondary finishing operation typically has to be instituted. In this method of processing the gear is cup wheel superfinished by clamping on the bore.and mediumvolume gear manufactures access to the same technology utilized by automotive OEMs. it was then lowered to 8 uin Ra in the 1990s. eliminating the need for multiple equipment. For low. heat treated (for hardened B gears). lowing ways: STRINGENT NVH REQUIREMENTS. The goal of this article is to expose manufacturing engineers. Integrating these two separate. If a finer bearing like plateau honed finish is desired. JUNE 2011 41 . grinding. Both processes have their advantages and disadvantages.0002” bore to face perpendicularity and under 20 uin flatness Increasingly. especially in shops specializing in small and medium production runs. and they have been utilized successfully in the automotive production environment for some time now. challenging the manufacturing engineers to produce higher quality gears. FACE FINISH. 1: Typical tight-tolerance pinion gear. however. for gears with smaller oped to address these problems. AND THE TREND TOWARD MINIATURIZATION TO SAVE WEIGHT AND SPACE ARE FORCING TRANSMISSION GEAR DESIGNERS TO INCREASINGLY TIGHTEN THE SURAND THRUST FACES OF TRANSMISSION GEARS. Surface finish Ra specifications of 20 uin was common in the 1980s. proven processes into a single system now enables low. this means two processes as opposed to one. HIGHER LOADS. It is not uncommon to see specifications like < 4 uin Ra for surface finish on bores and faces. and Fig. which results in increased NVH during operation. However. When the gear faces are double-disk ground there is no control over the bore-to-face perpendicularity. a twin spindle ID/ O face grinder is utilized to grind the bore and the face in the same setup. and over 5:1 deflection of grinding spindle will cause the bore to taper. Figure 3 illustrates a Nagel cup wheel superfinisher and bore honing machine. neither ID grinding nor double-disk face grinding can achieve it. BORE-TO - Figure 2 shows tightening of surface finish toltol erances over the last three decades for automoautomo tive pinion gears. AS ILLUSTRATED IN FIGURE 1.
For tighter thickness tolerances— in tenths of an inch—contact type in-process gauging can be integrated into the machine. A honing tool. Or the wear compensation can be accomplished with the touch of a button based on independent offline gage. and cup wheel positioning. should a part come off a hone a few microns too small it can be run again. Even more important is that the accuracy of the grinder is dependent on the machine’s positioning capability. The part can rotate up 3. and refurbishing are needed to ensure that positioning tolerances stay tight on a grinder. which could be inside or outside the Fig. yielding excellent bore-to-face perpendicularity. while that’s not possible with ID grinding. spindle stroking. The servo-driven machine positioning system can accomplish a part thickness tolerance of . This has proven to be a desirable Fig. while accuracy is mostly tooling dependent with a hone. then bores are honed by locating on the finished face. The tradeoff is that any given honing tool is very bore-size specific. an in-process process non-contact type air gage can be imbedded in the tool itself (fig. on the other hand. and make automatic adjustments to the honing program to correct the form error. For bore sizes over 20 mm.com feature for maintaining a hydrodynamic lubrication layer for rotating members. or barrel-shape. and the wheel up to 2.Fig. so more honing tools need to be stocked than grinding wheels. grinding can’t produce honing’s characteristic crosshatch pattern and plateau finish on the bore surface. Periodic checks. . 3: Nagel SPV 150 cup wheel face superfinisher and ECO bore honing system. 4: In-process gage embedded in Nagel ECO 40 honing tool. The stock removal is split equally between both the faces. Also. making them less sensitive to positioning accuracy. honing AnD iD grinDing Precision ID grinding machines are several times more expensive than an equally capable honing machine. The tool expansion servo can be integrated to machine in-process air sizing or post-process gauging system for automatic tool wear compensation. has float built into the tool or fixture. Unlike a grinding wheel on the end of an arbor. the part is turned 180 degrees and the other face is finished. cup wheel head rotation. calibration. The gage can detect the type of form error such as taper. the honing tool isn’t subject to spindle deflection. machine. hourglass. The SPV 150 cup wheel head is equipped with three servomotors for part rotation.600 rpm. Another important advantage of honing is that. and tool expansion. 42 gearsolutions.500 rpm. Smaller bores are measured by post process gages. And both honing and cup wheel superfinishing can yield bearing race-type mirror finishes.001” (25 um) or higher. 4). The ECO 40 honing head consists of three servo motors for spindle rpm. 2: Graph illustrating tightening of surface finish tolerances. The machine can be automated or tended manually. Upon finishing one face.
finishing. the dual expansion and in-process gauging that can be built in honing permits roughing. and all on one spindle. and gauging. Getting a fine finished bore starting with a heat-treated surface with one spindle is now a reality. Honing the parts twice—once with a coarser stone. 5: Illustrates . when dual expansion is not possible the part may have to be rerun with finer stone in a single spindle setup.05 um surface finish after hone. As it can be observed. Bore size permitting.001mm bore cylindricity and .Fig. For smaller bores with lower volumes requiring finer surface finish. the trace has deeper valleys and lower peaks. Figure 5 is a cylindricity trace illustrating 40 uin cylindricity (LHS) and 2 uin Ra plateau hone finish. and again with a finer stone—would create a finish with deeper valleys and lower peaks. JUNE 2011 43 . making it a surface suitable for bearings.
on the other hand. the cup wheel tool substantially overlaps the surface of the part during finishing (fig. and are not as dependent on machine accuracies as grinders are. To prevent variations in flatness or axial runout when finishing flat surfaces. If the gear is coming straight out of heat treat and a mirror-like finish is desired. The machine can remove as little as a few microns of stock to a few hundred microns very quickly. This automatically compensates for inaccuracies in the machine. During this operation. This can be achieved either by rerunning the part or by mounting an automatic cup wheel changer. which would change the wheel quickly and enable roughing and finishing in the same setup. Double-disk face grinding. The accuracy of ordinary grinding operations depends on rigid fixturing. Cup wheeL superfinishing AnD fACe grinDing The SPV 150 face finisher differs from conventional grinding operations. Cup wheel superfinishers can yield finer finishes. as well as the accuracy of the grinding wheel’s position relative to the part. 6: Schematic of Nagel SPV 150 cup wheeel finisher.Fig. IL 61109 Phone: 815-874-3948 • fax: 815-874-3817 For YOUR perfect teeth! Visit us at Gear Expo s a l e s @ r a y c a r g e a r. c o m w w w .com . Bore-to-face perpendicularity is comparable with a cup wheel finisher and ID grinder. Still waiting on your perfect teeth to arrive? Quality Parts Friendly Service On-Time Delivery Celebrating 20 years ISO 9001:2000 and AS 9100:2004 Certiffiified Complete Gear Manufacturing 4884 StenStrom road • rockford. 6). r a y c a r g e a r . the gear is clamped on the bore diameter and rotated in a direction opposite to that of the cup wheel at a high surface speed. whereas the SPV 150 utilizes free cutting cup wheels and the tools self dress and conform to the contours of the part. another pass may be necessary to accomplish the task. though. c o m 44 gearsolutions.
storloc.786.com .8769 email: email@example.com n.com STOR-LOC MODULAR DRAWER SYSTEM ® Modular Drawer System www. il 60901 toll free: 1. kankakee.7562 • fax: 1. Washington ave.
com]. ABOuT THE AuTHOr: Sanjai Keshavan is manager of the ECO Hone Division of Nagel Precision. Figure 7 provides a comparison of bore-to-face perpendicularity and flatness on a cup wheel finished face vs a double-disk ground face. Inc. yields a higher production rate and excellent parallelism between faces.and medium-volume environment. Call (734) 426-1812 or go to [www.Fig. 7: Comparision of bore to face perpendicularity and flatness after grinding and cup wheel face finishing. the honing and cup wheel processing that has long been the predominant way of making pinion gears in high-volume automotive applications is now possible in a lower.nagelusa.com . however. They do not impact the bore to face perpendicularity tolerance. In conclusion. 46 gearsolutions.
Gear Expo .
Reducing Gear Rattle The professionals at Muncie Power Products help you to address—and eliminate—gear noise/rattle one step at a time. By Mikel Janitz .
and endplay were recorded. or the lack of sufficient drag. Gear quality was the second-highest contributor to reduce noise. AND RATTLE ARE NOT NEW. WE CAN IMPROVE CUSTOMER CreAting A bAseLine The first step in the process was to create a baseline. internal backlash. gear quality. The reduction was not only measurable. CONSEQUENTLY. SATISFACTION. One additional feature affecting noise is the presence of drag. These are combined since they are so closely JUNE 2011 49 . which impacts noise and rattle in any form. ControLLing bACkLAsh The next step taken to reduce noise focused on internal backlash and centerline control. It was demonstrated that higher gear quality and gear pitch reduced noise. reduced noise. It is also noted here that the graph indicates that the features are additive. ADDRESSING THESE FEATURES IN DESIGN OR MANUFACTURING. WHINE. reduced gear quality. Each feature can therefore reduce noise by some amount. BASED ON THESE TESTS WE HAVE BOILED THEM DOWN THE FOLLOWING INFORMATION HIGHLIGHTS AND PRIORITIZES THE FEATURES WE DISCOVERED TO HAVE THE GREATEST IMPACT ON NOISE. The red line on the graph represents the unacceptable sound level from that test. backlash is controlled at installation and during gasket selection. The noise was unacceptable to customers due to many factors. smaller gear pitch. which depicts the impact on noise level as each feature is addressed. The design of backlash has its limitations. Noise can also be reduced proportionally to the number of features improved. This is in the control of the installer at this point. From this point the team started working on particular features to improve or reduce noise and rattle one step at a time. Consequently. Note that the gear quality went from a baseline of AGMA 8 to AGMA 10. GIVEN THAT THIS IS THE CASE. and a baseline established. It is important to understand the relationship of manufacturing cost vs. Baseline noise testing was conducted on a diesel-powered Class 3 cab with an automatic transmission (refer to the graph accompanying this article for details). install the gear set. The gear set was run at idle—approximately 700 rpm—the noise level recorded. DRIVING THE NEED FOR AXILLARY POWER TO DO THE SAME. THEY ARE MORE NOTICEABLE TODAY SINCE MOTORS AND POWERTRAINS ARE QUIETER. high internal backlash between gears. WORK TRUCKS ARE GETTING QUIETER. WHILE GEAR NOISE. All improvements are based on these measurements. Now let’s look at the graph. As you can see the baseline is well above the acceptable level. BY ONSEQUENTLY ONSEQUENTLY. It was discovered that one can change features.W TO THE TOP CULPRITS. but the backlash between the transmission gear and gear set must be addressed first or the other steps have minimal impact. the next feature worked on was gear quality. and therefore the second feature on the graph. WE CAN IMPROVE OR SIGNIFICANTLY REDUCE NOISE AND RATTLE. WE CONDUCTED TESTS TO IDENTIFY AND ISOLATE PARTICULAR FEATURES THAT CAUSE NOISE. Care must be taken to properly mount. Before the gear set was mounted measurements for external backlash. including excessive backlash between the transmission output gear and the input gear. and torque the fasteners to achieve optimal noise levels. and high bearing endplay. Improving gear quality can be costly. but also detectible to the human ear. Drag will be discussed last. After reducing the backlash between the transmission and gear set. gear centerlines at top of tolerance. MOREOVER.
but the results show that this had little effect in reducing rattle and noise that is detectible to the human ear.com . Accurate CNC equipment. The waves of sound come from vibration between the gear. 1: Baseline noise testing was conducted on a diesel-powered Class 3 cab with an automatic transmission. and bearing set. It is important to specify and control internal completely eliminated. but this step had the smallest impact on reducing noise of all those we addressed. however.003. the noise was reduced as well. When the endplay was reduced by 25 percent. This was an important finding. 50 gearsolutions. for example—the vibrations are more pronounced. and tooling must be used in manufacturing to hold and repeat tight centerline tolerances.backlash. and consequently the noise was unacceptable. Rattle and noise create sound waves that we feel and hear. and then you have a completely different issue to Fig. and the noise is noticeably louder. Testing indicated that it is necessary to control internal backlash before moving to the next step. Endplay cannot be related. programming. Rattle is a huge customer dissatisfaction issue. The baseline endplay was excessive. This is a cost-effective means to reduce noise. bearings would burn up. If it were. If the bearing set is loose—excessive endplay >. therefore rattle cannot be completely eliminated. shaft. the noise is reduced proportionally. If the endplay is reduced.
GEARING AHEAD TO MEET INDUSTRY'S DEMAND FOR PRECISION --Serving-Aircraft • Aerospace • Actuation Instrumentation • Optic Robotics • Radar • Medical Marine • Defense • Experimental Prototype • Production Hi-Performance Automotive Precision Gear Products (up to AGMA Q14): Spur Gears.stdgear. Call (800) 367-7867 or go to [www. Product design engineers are working with manufacturing engineers to produce the most-quiet gear set economically available. Worm Gears. and efficiency. for example. but it also shows that noise can be reduced by doing nothing other than adding drag. Metric Gears. And test engineers and lab technicians will keep testing and reporting results so that we can continually improve customer satisfaction. but there are other issues impacting rattle including gear size. The graph shows noise can be reduced to acceptable levels without drag.munciepower. drag element in series with other features discussed will reduce noise. It creates heat and requires power (uses fuel) to overcome resistance forces. Bevel Gears. A drag element by itself will reduce noise if the drag force is significant enough. as well. Unit 5 • West Bridgewater. Bearings need to be sized properly. Miter Gears. Serrated Shafts. excessive hydraulic fluid levels. Wormshafts. lubricated appropriately. Gear Assemblies. as well. These features were not addressed at present. 318 Manley St.contend with. Helical Gears. The downside of introducing a drag element is the inefficiency it creates. Face Gears. and geometry. Splines. and shaft loads. Worms. Gear Rack & Pinion. Internal Gears. STD Precision Gear & Instrument. Other designed parts can be introduced to create drag. tight bearings. Anti-Backlash Gears. The graph also indicates that noise was at an acceptable level with only a drag element without other features improved.com Web site: www. Cluster Gears. rattle.com JUNE 2011 51 . as well as cost. Endplay is last on the list to address. Inc. material. ConCLusion Noise and rattle are big customer concerns today. inertia. Idler Gears. Planetary Gears. and can operating costs justify the reduction in noise? Drag can come in many forms. weight.com]. introDuCing DrAg The last feature studied was the effect of drag on the noise in a gear train. A ABOuT THE AuTHOr: Mikel Janitz graduated from Oklahoma State University with a master’s degree in engineering management and is manager of engineering at Muncie Power Products. Drag was last on the list to work on because of the negative aspects associated with it. and allowed to expand while in use. Clutch Gears. The question then becomes whether the inefficacies can be tolerated. Gear manufacturers and users of gear sets are working together to balance noise. Spline Shafts. just to name a few. Gear Boxes. In the graph the orange line represents the baseline gear set with the addition of drag only. friction between clutch plates. MA 02379 (888) STD-GEAR or (508) 580-0035 Fax (888) FAX-4STD or (508) 580-0071 E-mail info@stdgear. as it would require significant time with simulation and 3D modeling to go down that path.
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Super turbo Chamfer mills from Seco tools Seco Tools has announced a new line of Super Turbo chamfer mills designed to provide high metal removal rates while reducing production costs. In addition. allowing manufacturers to increase the versatility of their operations without additional spare parts. CIMTECH 310 is low foaming and provides excellent rancidity control. Learn more at [www. The design increases tool life as compared to standard APxx style cutters. Designed for moderate.com].com/us]. The new cutters use the same inserts and hardware as standard Super Turbo square shoulder mills. manufactured by global supplier Cimcool Fluid Technology.com . The new chamfer mills use the same strong insert pocket design found in the rest of the Super Turbo family of products. helping to reduce cost per part. Call (248) 528-5444 or visit [www. 54 gearsolutions. including creep feed grinding on non-ferrous or ferrous metals. cimcool. The new Super Turbo chamfer mills feature a high positive cutting rake angle and positive helix angle to reduce power consumption. resulting in freer cutting and reduced harmonics.secotools.CImteCH 310 Synthetic metalworking Fluid CIMTECH 310®—a low-pH synthetic fluid designed to meet the stringent requirements of the automotive and aerospace industries—has become the standard metalworking fluid for many manufacturers. extending the life of the fluid and minimizing the need for additives. It is recommended for machining and grinding operations. it offers unmatched lubricity providing long tool life and outstanding surface finish. The product.to heavy-duty operations. passes all bi-metallic and aluminum (7075) “sandwich” corrosion tests.
5-foot (4.7 kg). farming.Upgraded HtA Honing System from Sunnen The new all-electric HTA hone brings increased part capacity and stroker torque to applications such as bore resurfacing of hydraulic cylinders. mining. extruder barrels. Both models handle parts with bore ID of 2. and the HTA-4100 for 13. The machine is available in two standard model sizes: the HTA2100 for 6. e-mail firstname.lastname@example.org – 533 mm) and maximum part OD of 24 inches (610 mm). Call (800) 325-3670.1 m) part lengths. JUNE 2011 55 . and forestry equipment.sunnen.or 4-meter parts.9-foot (2. or manufacture of gas flow meter tubes and repair of actuators for construction. and part weights to 8000 pounds (3628. and die casting shot tubes.1 m) part lengths.com. or go to [www. accommodating true 2.com].5 to 21 inches (63.
56 gearsolutions. Reflections or lack of contrast. which can impede the correct focusing of a camera. This sensor enables the measurement of parts that can’t be captured with a contact sensor or a camera.zeiss.o-INSPeCt multisensor measuring machine from Carl Zeiss The successful O-INSPECT Multisensor Measuring Machine from Carl Zeiss allows the very easy. very accurate. Learn more by going online to [www. and precision engineering. for medical and automotive technology. will no longer be a relevant factor. and thus very efficient inspection of complex parts. including very small and sensitive workapieces that feature a transparent. It can be used in the electronics and plastics industries. A chromatic white light sensor is now available for O-INSPECT. glossy or low-contrast surface.com .com].
com.twin Cutter Boring System from BIG Kaiser BIG Kaiser’s 319 SW series is an exceptionally rigid. users can switch between balanced and stepped cutting. and SP) and provide coolant-through direct to the cutting edge to improve chip evacuation and lengthen tool life. support. and boring mills. the 319 series reduces setup time and eliminates the need for a presetter due to fixed tool heights and a diameter scale on the tool.bigkaiser. FEELER lathes and turning centers are backed by Methods’ application expertise. By not introducing additional components or having to manually adjust insert height for different roughing methods.000” the tools utilize standard carbide inserts (CC. The Methods-FEELER CNC lathes and turning centers include the HT-Series. with a full range of equipment including vertical machining centers.787”-8. or visit [www. or visiting online at [www. bridge mills. The 319 SW series will replace the older 314 RW series. Call (847) 228-7660.methodsmachine. designed to provide users unsurpassed performance and value. and FT-Series. SC. These corrosion-resistant boring heads offer a unique feature. has introduced high performance FEELER milling lathes and turning centers featuring extensive design and engineering by Methods. and extensive network of technology centers. With a diameter range . e-mail sales@ methodsmachine. new style.com. Inc. JUNE 2011 57 . FTC-Series.com]. twin cutter rough boring system. by simply reversing the insert holders. More information is available by calling (978) 443-5388.com]. e-mail bigkaiser@bigkaiser.. a leading supplier of innovative precision machine tools. FeeLer milling Lathes and turning Centers from methods Methods Machine Tools.
” says Robert Strain. software. this location addition allows Siemens to offer its domestic customers several advantageous benefits. customs clearance. Ohio. facility. and fabrication of Electric Arc Furnace (EAF) components from its Milan. DOCS user training is generally two days.us]. ROMER’s tube inspection system utilizes the Data Overlay Camera System (DOCS) software platform.com . as compared to five to six days for traditional CMM software. Hexagon Metrology serves the high precision measurement and inspection needs of worldwide manufacturers with its extensive line of metrology hardware. Siemens also produces EAF equipment from its facility located in Monterrey. repair. reducing the process of trial and error associated with manual measurements. “The strategy of an OEM offering these services domestically is a great step for Siemens. Siemens is now the first EAF original equipment manufacturer to offer these services within the United States. However. EAFs are used to recycle scrap metals into usable product.< continued from page 18 start measuring immediately. so corrected bend data can be sent directly to the CNC bending machine. as well as offering service repair. Siemens can provide shorter turnaround times and varying cost-effective savings for customers based in the United States. The absolute encoders provide probing volumetric accuracy down to ±0. accessories and customer services. not to mention inspection and repair projects. including reduced logistical obstacles in freight costs. By manufacturing EAF components such as water-cooled panels. and will continue to use both plants based on the needs of its customers. Pictures can be taken with the arm’s onboard digital camera. Customers appreciate having the option 58 gearsolutions. and DOCS overlays the tube wire frame onto the digital picture. This enables the inspection report to show exactly how the tube was supported or fixtured during measurement. More information is available at [www. from its northwest Ohio facility. DOCS communicates with most CNC bender interfaces. account manager for Siemens Metallurgical Services. “We’ve already seen a significant increase in lower volume and short lead time water-cooled panel orders. and transit time which in the past often made repair jobs cost-prohibitive. The articulating arm also features low profile. Mexico. Siemens to Service electric arc furnaces in United States Siemens Industry’s Metallurgical Services Offline Maintenance business segment announces they are providing support.023mm depending on the model. hexagonmetrology. Zero-G counterbalance to stabilize its weight for one-handed operation and effortless control above and below its centerline.
They know the market well and we’re confident that the relationship with Mitsubishi will further cement their reach in the Oklahoma fabricating market as well..” says C4 President Ed Raschen. heavy fabrication. and profitability. will now represent the complete Mitsubishi product lineup. For more information visit [www.” says Mitsubishi Marketing Manager Pat Simon. of a quick turnaround while still receiving an OEM quality product.usa. and housing a comprehensive inventory of spare parts. and building technology solutions.com]. affiliate of Siemens’ global Industry Sector business—the world’s leading supplier of JUNE 2011 59 . consumables. lifting device fleet management.production. Inc. Siemens Industry. Inc. “C4 is recognized in the industry as a reliable source for manufacturing equipment. Until now C4 Incorporated represented Mitsubishi EDM and waterjet. Mitsubishi has the experience and equipment solutions to help U.com]. Also visit [www. and EDM. manufacturers achieve maximum productivity in every industry. sustainability.” Mitsubishi’s superior products are backed by industry-leading service and support. C4 Incorporated. com/industry]. C4 to Represent Complete Mitsubishi product Lineup MC Machinery Systems. transportation.siemens.S. With a total supply chain of complementary technologies.c4industrial. Learn more at [www. “We are excited to add a local presence for these lines in Oklahoma. The company’s integrated hardware and software technologies enable comprehensive industry-specific solutions for industrial and infrastructure providers to increase their productivity. engineering. “and by providing the complete Mitsubishi supply chain we’ll be able to deliver total manufacturing solutions to the full customer base in our territory.mitsubishi-world. is the U. Since 1972 C4 has been serving the machine tool industry with cutting tools. is pleased to announce that Oklahoma distributor.S..” The Milan facility is a full-service maintenance workshop that specializes in design.” “We are excited to expand our product offering. but the recent addition of Mitsubishi laser and press brake completes the offering.
867. ’42 Dbl Thrd REF#104 BARBER-COLMAN 16-36. ’53 Dbl Thrd. ’57 Sgl Thrd REF#104 BARBER-COLMAN 16-16. S/N 5407. 10" Dia.5DP REF#103 PFAUTER P-251 10” Dia. Dbl Thrd w/Jump Cut Cycle “ C” Style REF#104 BARBER-COLMAN 16-16. 36” Face REF#103 LIEBHERR #LC-502 6-Axis CNC Gear Hobber. S/N 184. 16” Dia. S/N 4631. 22” Dia. 42” Face. S/N 923. — REF #103 Phone: 704-872-8888 • Fax #:704-872-5777 Email: sales@rpmachine. 4" Max. ’77 Triple Thrd w/3” Hob Slide. 72” Face 1. S/N 635R. 12" REF#103 BARBER-COLMAN 2 1/2 -4. 2-Cut Cycle. 9. 16” Dia. ’57 Fine Pitch Prec Triple Thrd REF#104 BARBER-COLMAN 6-10. 4” Face REF#103 KOEPFER #153B. 18” Dia and 100” Length REF#103 KOEPFER #173B.5" OD. 15" Face. 20" Diam. 2 DP ‘09 REF#103 MUIR CNC Gear Hobber. 6-Axis. ’51 Sgl Thrd w/90 Deg Hd REF#104 BARBER-COLMAN 16-16. Gasher/Hobber. 10" Diam. 2.8” Dia. 15” Face.223. ’67 Dbl Thrd w/Hyd Live Ctr REF#104 BARBER-COLMAN 14-15 Dbl Cut. 5. 4 1/8” Bore REF#103 BARBER-COLMAN #16-56. 14” Face 3 DP REF#103 PFAUTER #P-3000. ‘94 REF#103 PFAUTER P400H. 4 DP REF#103 BARBER-COLMAN #14-15. All the Features.8” Dia. ‘57 REF#103 BARBER-COLMAN 10-12. Cap. 15” Face. 4 DP. 3.5” Dia REF#103 MIKRON #102.6” Dia. ‘82 REF#103 BARBER-COLMAN #3 HS. 188” Dia (5 Meter) REF#103 G&E #120GH. 800 RPM REF#104 BARBER-COLMAN 6-10. ‘70 REF#103 LIEBHERR #L-402. S/N 745. ‘67 REF#103 GE/Fitchuburg Pinion Hob 32” Dia. Differential REF#103 DAVID BROWN. 60” Dia REF#103 WANDERER GF 345 CNC Hobbing /Milling Machine 4-Axis 24" Swing x 240” Length REF#103 FITCHBURG Pinion Hobber 42” Dia. 5 DP. ’71 4-Thrd w/Sizing Cycle REF#104 BARBER-COLMAN 22-15. New ‘88 REF#103 SCHIESS 1 RF-10. 6” Dia. 72” Dia. 100” Dia REF#103 TOS FO-16. S/N 5148.5 DP REF#103 CRAVEN Horizontal . S/N 8079.com Website: www. 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S/N 4090. 2. ’68 Dbl Thrd w/4-1/8” Bore REF#104 BARBER-COLMAN 14-30 Dual Fd. 1/2 DP. 5-Axis. S/N 5259. S/N 396. ’75 Triple Thrd w/Auto Hob Shift REF#104 BARBER-COLMAN 6-10. 5” Face REF#103 NIHON-Kikai NDH-1200 50” Dia REF#103 PFAUTER P-900 36” Dia REF#103 SCHIESS RF 40/60S 240” Dia 100” Face REF#103 BARBER-COLMAN #25-15 25” Dia. S/N 5141. S/N 1261. 12” & 40” Dia REF#105 GEar Pinion HoBBErS & SPLinE MiLLErS HURTH #KF-32A 15” Dia. 24” Dia.mwgear. 3 DP REF#103 G&E #60S. S/N 3171.6” Face. S/N 4755. CNC. 9.. 16” Dia. ’60 Dbl Thrd w/Diff REF#104 BARBER-COLMAN 16-16. 27.com MaCHinErY Contact Gear Solutions at 800-366-2185 to list your machinery. 18” Face.25 DP REF#103 PFAUTER #P-630. ’62 Dbl Thrd. 4-Axis. 2. 7. ’73 4-Thrd w/Workclamp Cyl “C” Style REF#104 BARBER-COLMAN 16-16 Multicycle. 1 DP REF#103 G&E #96H. 118” Dia REF#103 LIEBHERR #L-252 3-Axis. S/N 110R. — REF #104 Phone: 815-968-4499 • Fax #:815-968-4694 Email: rpi@repair-parts-inc. 2 DP REF#103 LIEBHERR #L-252. 55” Face REF#103 GE/Fitchburg Hobber 32” Dia. 10” Dia.5" Face. Hob Sharpener. S/N 4473. 4" REF#103 BARBER-COLMAN #4-4HRS. 5" Length. 25" Max. S/N 5238. 5.5 DP Crowing.1” Dia.FEATUREDsuppliers Midwest Gear Corporation — REF #101 Phone: 330-425-4419 • Fax: 330-425-8600 Email: sales@mwgear. BARBER-COLMAN #16-36. 2. Face 60”REF#103 G&E #24H Universal Head. “C” Style End Brace REF#104 BARBER-COLMAN 16-36 Multicycle. Dia 60” 150” L. Dbl Thrd. ’65 Dbl Thrd w/New Hyd Sys REF#104 BARBER-COLMAN 14-15. 1. 8” Dia REF#103 G&E 120/188. ‘50’s REF#103 HAMAI #120.ca Website: www.7” Dia 11” Face. 48” Dia.4040 • Fax: 516. ’70 Triple Thrd.2 DP REF#103 MIKRON #79 1. S/N 5353.repair-parts-inc. 28" Grind Length. 4" Max. ’55 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 6-5. & Spiral REF#103 KAPP #AS204GT. ‘93 REF#103 G&E #60 S-2 CNC Gasher/Hobber REF#103 G&E #60SB-2C CNC. 138” Dia. ’59 Dbl Thrd w/Diff & Auto Hobshift REF#104 BARBER-COLMAN 16-16 Multicycle. up to 50 Degrees REF#103 KAPP #AS-305GT. 72” Face REF#103 MICHIGAN Tool #3237 REF#103 SCHIESS 1 RF-10. S/N 1371. 2.. S/N 4778R87. 12” Face.04 . ’62 Hi-Production Spur Gear REF#104 BARBER-COLMAN 6-10 SYKES. ’62 Dbl Thrd. 7” Face REF#103 PFAUTER #P-630R. S/N 1278. 26 DP REF#103 BARBER-COLMAN TYPE T REF#103 IUG –Craiova FD-3600 REF#103 LIEBHERR #L-401. 5-Axis. 9. REF#103 KAPP AS-410B REF#103 GLEASON #12 Sharpener. S/N 4232.8” Dia.. 12" Length. Dbl Cut REF#104 BARBER-COLMAN 16-11. Spanish Nameplates REF#104 BARBER-COLMAN 16-16. ’75 Dbl Thrd w/Gooseneck Slide REF#104 BARBER-COLMAN 16-16 Multicycle. 10” Face. 56” Face. “C” Style End Brace w/Diff REF#104 BARBER-COLMAN 16-16 Multicycle.com Website: www. S/N 4626. Differential REF#103 BARBER-COLMAN #22-15. S/N 3136R84. 5-Axis 26” Dia. 35” Face. 31. 4W Adj Ctr REF#104 BARBER-COLMAN AHM (36”). 10” Dia.5 Dia. 3-Axis REF#103 MITSUBISHI GD-20 CNC. 1 DP. C-Frame Style. Single Index REF#103 SCHIESS RFW-10-S 55” Dia REF#103 SHIBURA HHC-250A Single Index REF#103 OVERTON #HD-400.75” Face. ’82 Auto w/PLC Control REF#104 BARBER-COLMAN DHM. 3DP REF#103 G&E #36HS 36”Dia. 104” Dia. Recon ‘02 REF#104 BARBER-COLMAN 6-10. OD. 4-Axis.87" Max Dia Pitch 5. 4’ Dia. Gasher/Hobber. 14” Dia.newenglandgear.com Havlik International Machinery. Spark Out REF#103 FELLOWS #6SB. 72” Dia. 16 DP REF#103 KOEPFER #140 .5” Dia. ’63 Triple Thrd w/90 Deg Hob Slide REF#104 BARBER-COLMAN 6-10 Multicycle. 12 DP. Multi-Cycle. 12” Rotary Surface Grinder for Sharpening Sharper Cutters REF#103 BARBER-COLMAN #6-5. S/N 1131. 16"Dia REF#103 BARBER-COLMAN #3 (6-10). . ’68 Dbl Thrd “C” Style End Brace w/Diff REF#104 BARBER-COLMAN 16-56.27” Face. 16.com Repair Parts. 6 Multi-Cycle REF#103 G&E #36H Differential.6. S/N 938.rpmachine. CNC Gasher/Hobber.1195 Email: george@gqmachinery. 25” Dia REF#103 PFAUTER #2500. Fanuc 18MI REF#103 SYKES #H160. 17.5 DP. S/N 1055. 6” Dia. OD. S/N 6700045890. S/N 5394. 30” Face. Single & Triple Tread Worm HS REF#103 BARBER-COLMAN #6-10. S/N 3580. ’53 (Reb ’84).— REF #106 Phone: 516. 18” Face 2 DP. 72” Dia REF#103 CRAVEN Horizontal. Loading REF#103 LIEBHERR #L-652. S/N 4913. ’50 Dbl Thrd w/Vert DRO REF#104 BARBER-COLMAN AHM. All Parts Available REF#102 Tilt Tables for 10-2/10-4. 16” Face. S/N 1152. 4" REF#103 REDRING MODEL #SGH "PREIFORM" SHAVE CUTTER GRINDER/SHARPENER REF#103 STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#103 BARBER-COLMAN 2-2 1/2 . Single REF#103 LIEBHERR #ET-1802 CNC – 98” Dia Internal. 3 DP. Qty 2 REF#102 FELLOWS Parts Available For All Models REF#103 BARBER-COLMAN – PARTS AVAILABLE FOR ALL MODELS REF#103 G&E – PARTS AVAILABLE FOR ALL MODELS REF#103 GEar HoBBErS/CUttErS CnC LIEBHERR #LC-255 CNC. Triple Thrd REF#104 BARBER-COLMAN 6-10. ’68 Triple Thrd. S/N 2745. 6 DP. ’66 Wet w/Auto Dress & Sparkout REF#104 GEar aCCESSoriES. Differential. recontrolled 2008 REF#103 LIEBHERR #ET-1202 CNC . 14” Face. S/N 4170. CBN Wheels. New ‘07 REF#103 G&E #96GH. 48” Dia. 800 RPM REF#104 BARBER-COLMAN 6-10. ’55 Dbl Thrd w/Dwell REF#104 BARBER-COLMAN 14-15 Dual Fd.25DP REF#103 JF Reinecker 40” Dia 35” Face REF#103 LIEBHERR L-160-R 6. ’66 Dbl Thrd. ’79 “C” Style End Brace.5 Dia.com R. S/N 4665.7” Dia. 18” Dia and 100” Length REF#103 GEar HoB & CUttEr SHarPEnErS (incl CnC) ARTER #A-12. Inc..50 Face. S/N 4136. 12" Max Rotor Dia. 14” Face. S/N 1896. ’66 Dbl Thrd w/Hyd Tailctr REF#104 BARBER-COLMAN 14-15 Dual Fd. 29. 3-18” Cone REF#103 BARBER-COLMAN 2 1/2-2. ’60 (’87 Rebuild). ‘77 REF#103 LIEBHERR #L-650.5” Dia REF#103 KAPP #AST-305B. Universal REF#103 G&E #48H. 6" Dia.com Website: www. PartS & tooLinG FELLOWS Model #10-4/10-2.com GQ Machinery Inc.com Website: www. 6 DP REF#103 CHONG QIN #Y3180H. Inc. CNC. S/N 4659R. Triple Thrd w/Lever Operated Collet Assy REF#104 BARBER-COLMAN 6-10 B&C Ltd. 3 DP REF#103 FELLOWS FH-200 Max Diam 7. 4. 144” REF#103 BARBER-COLMAN #6-16. 800 RPM REF#104 BARBER-COLMAN 6-10 Multicycle. 59” Face. Str. 15. S/N 119. 6-Axis CNC. Gasher/Hobber. ’76 Dbl Thrd w/2 Cut Cycle REF#104 TOS OFA Series Conventional Gear Hobbers. S/N 105. 3 DP. ’66 Triple Thrd. Gooseneck Attachment REF#103 LEES BRADNER HH-144 16” Dia. 1 DP.70” Dia Internal. Sgl Thrd Hi-Spd REF#104 BARBER-COLMAN 6-10 M/C. ’42 Sgl Thrd w/3 Jaw Chuck REF#104 BARBER-COLMAN 16-16. 3. 2-Cut REF#103 BARBER-COLMAN #1600-36. S/N 3660. ’56 Triple Thrd Adj Ctr Assy REF#104 BARBER-COLMAN 6-10. 10” Face. Machine Enterprises. Helical Cutter Sharpener. New ‘70’s REF#103 MODUL #ZFZW 800. ’59 Triple Thrd w/MC Conversion REF#104 BARBER-COLMAN 6-10 Multicycle. Recontrolled ‘03 REF#103 G&E #160GH. Hob Sharpener.9” Face REF#103 LANSING #GH-50. S/N 16. 16” Cap. 26" Dia Cap. 4.75” DIa. Max Cut w/support 90” REF#103 PFAUTER P250 10” Dia REF#103 GE Hobber 200” Dia. 4-Axis CNC Hobber. CNC. 12 DP. ’42 Double Thrd REF#104 BARBER-COLMAN 14-15. 4” Face. ’58 Triple Thrd w/Power Down Feed REF#104 BARBER-COLMAN 6-10 M/C. 6” Dia. Dual Thread Worm and/or Single Thread Worm REF#103 G&E #48H 48” Dia. ’53 Dbl Thrd.08" REF#103 G&E #16H Gear Hobber. Excellent Condition REF#103 BARBER-COLMAN #14-30. 14” Dia.gqmachinery. 16" Dia. 9" Face. 1 to 4 Start Worm. Comp Reco REF#104 BARBER-COLMAN 14-15.25 DP REF#103 G&E #72H.25” Face. Several REF#103 BARBER-COLMAN #16-16. S/N 4701. Inc. Infeed. — REF #105 Phone: 519-624-2100 • Fax: 519-624-6994 Email: havlik@bellnet. Fact Reb REF#104 BARBER-COLMAN 14-15.com New England Gear — REF #102 Phone: 860-223-7778 • Fax #:860-223-7776 Email: jeff@newenglandgear. 50” Dia. Crowning. CNC 4-Axis.
7. 3-Axis REF#103 Michigan #873-24A.5”/’52 REF#103 MAAG #SH-600. Year 1965 REF#101 Springfield Vertical Grinder. 12” Dia. 6-7 DP REF#103 TOS OHA50 CNC 5 20” Dia 5” Face REF#105 Fellows 36-6 Shaper (2) 12. 2” Face. 5" Stroke. (10” Dia). 0-12” Risers. (10” Dia). Swing REF#103 HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88” REF#103 LEES BRADNER #HT12x102. 17. 80” Centers.5A Rail Type. Qty 1 REF#102 HYDROSTROKE #FS400-90. 4 DP REF#103 FELLOWS #4A Versa. 20” Dia. New ‘78 REF#103 DETROIT Gear Grinder #GGI-16x3A.# 75A. 0-12” Risers REF#103 FELLOWS #8AGS Vertical Gear Shaper. 11” Face REF#103 RED RING #SF-500 CNC Int/Ext. 4” Face REF#102 FELLOWS (200) 10-4 / 10-2 Shapers REF#102 FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009 REF#102 FELLOWS (1) #7 125A Face Gear Machine REF#102 FELLOWS (2) #3 Face Gear Machine REF#102 (1) 4ags with adjustable Helical Guide s/n 30634 REF#102 (1) #7 125A adjustable Helical Guide REF#102 FELLOWS (1) FS630-200 Hydrostroke Shaper s/n 36943 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009) REF#102 FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#102 FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009) REF#102 FELLOWS (1) 48-8Z Shaper w/ 14” throated riser (53” of swing) REF#102 FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#102 FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller s/n 34326 REF#102 FELLOWS (1) 36-10 Gear Shaper REF#102 FELLOWS (1) 10x6 Horizontal Z Shaper REF#102 FELLOWS (1) 36-6 Gear Shaper w/ 13” riser s/n 27364 REF#102 FELLOWS (1) 10-4 Shaper w/ 3” riser w/ 4 axis 21i Fanuc Controller (2009) REF#102 All Parts for 10-4/10-2 Fellows Gear Shapers REF#102 FELLOWS #36-8. 4 DP REF#103 FELLOWS #20-4. 7” Dia. 24” Dia. 1. 57" Dia. Extra Large Capacity REF#103 J&L AUTOMATIC THREAD GRINDER. Max Dia 197” REF#103 MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER. Fanuc 18MI REF#103 LORENZ # LS-180. Gear Grinder. #6A. #62AR/2CS. 12” & 40” Diameter REF#105 GEar SHaPErS CnC 36” Shapers. Model #264. 84" Between Centers REF#103 EXCELLO #39 Int. 13" Dia. 2.5" Max Dia.2”. 18” Face REF#103 RED RING #24 Twin Spindle Dia 4” REF#103 CROSS #55 Gear Deburrer. Dia 12” REF#103 BARBER-COLMAN #10-40. PC Control. 9” Cone. High Precision REF#103 FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY. Coniflex Straight Bevel REF#103 GLEASON 24A Straight Bevel REF#103 GLEASON 725-Revacycle.8 “ Dia REF#103 HECKERT WMW #ZFWVG REF#103 LEES BRADBER WORM MILLER REF#103 GEar tEStErS/CHECKErS (incl CnC) FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#102 FELLOWS (1) 24H Lead Checker s/n 32289 REF#102 GLEASON (1) #14 Tester s/n 31907 REF#102 GLEASON (1) #6 Tester s/n 19316 REF#102 FELLOWS (1) 20 M Roller Checker REF#102 FELLOWS (1) 20 M w/ 30” Swing Roller Checker REF#102 FELLOWS (1) #8 Micaodex s/n 36279 REF#102 David Brown #24 Worm Tester REF#103 Fellows 12H Gear Tester REF#103 Fellows #12M Gear Tester REF#103 Fellows 20M Gear Tester REF#103 Felows #24 Involute Measuring Instrument REF#103 Gleason #4.5” REF#103 MAAG #SH-75C. 1. #645A REF#103 FELLOWS #10-4. 7” Dia. 16" OD REF#103 MAAG SD-32-X REF#103 GLEASON #463. Qty 1 REF#102 FELLOWS #FS-180. 6" X 36". Twin Spindle.5 Spindle REF#103 GLEASON GTR-250 VG CNC 5-Axis REF#103 GRATOMAT #300L REF#103 GEar HonErS Fassler #K-400 CNC Hone 16" Dia REF#103 Fassler K-400A CNC Hone 16” Dia REF#103 Kapp #CX120 Coroning 4. Qty 2 REF#102 FELLOWS #20-4. 10 x 6 Dia 27.5A Rail Type.# Several REF#103 TOS OH-6. 3 DP REF#103 STANKO /RPM #48-8 Gear Shaper CNC. 480/3 Phase. Several Avail REF#103 MAAG #SH-180-300 . 5” Stroke REF#103 Red Ring #GCU-8 Shaver. 3” Max Dia. Qty 5 REF#102 HYDROSTROKE #FS630-125. 6" Face. 57” Dia. 2. Max Dia 31. 6” Dia REF#103 GLEASON #54 Str. 4 DP. Dia 12” /54” REF#103 MOREY-SHIELDS THREAD MILLER.6” Face. ‘50’s REF#103 MAAG #SH-100K 47”/12. 4-Axis CNC.45" cap REF#103 FELLOWS #36-6 Max Dia 36” 6” Face.7" REF#103 RP-GS 1500 CNC. Chamf/Deburrer.5” Dia REF#103 GLEASON 14. Coniflex. 6"Face REF#103 FELLOWS Model Z Shaper. 2. ‘70’s REF#103 MAAG #SH-100/140. 28” Dia. 615A. 7. 24” Dia. 18” Max Dia. 4-Axis. 70" Swing REF#102 REISHAUER ZA. 2” Stroke. 8” Face REF#103 FELLOWS #100-8 100” Dia. Single Spindle REF#103 CIMTEC #50 Finisher REF#103 RPM #GC-500 CNC 20” Dia.2Dia REF#103 GEar raCK MiLLErS/SHaPErS MIKRON #134 Rack Shaper. 8” Face REF#103 FELLOWS #612A. 18” Dia. Single Spindle REF#103 CROSS #75 Gear Tooth Chamferer. 30”/8”/2.87” Dia CNC Gear Grinder REF#103 GEar GrinDErS #27. 12” & 40” Diameter REF#105 TOS OFA Series CNC Gear Hobbers. 12” Dia. 10” Max Dia. Stroke 4” REF#103 GEar tHrEaD & WorM. 12" Dia.14" Dia. Deburrer/Chamfer. Qty 6 REF#102 FELLOWS #48-8Z. Single Spindle REF#103 FELLOWS #100-180/60 CNC Max Dia 180”. Tilt Table REF#103 REDIN #20D.Electronic Tester REF#103 Parkson #42N Worm Gear Tester REF#103 Fellows #24H Tester REF#103 Gleason #104 Tester REF#103 Vinco Dividing Head Optical Inspection REF#103 MiSCELLanEoUS WARNER & SWAYSEY #4A M-3580 Turret Lathe. 60” Cut Length. 6 DP. Fact Reb ‘83 REF#104 TOS OHA Series CNC Gear Shapers. 40" Length. 10" Max. 8" OD. #725A. 9. 33” Stroke REF#103 Red Ring #GCU-12.5 DP REF#103 RP-GS 400 CNC. 2 DP. and #463 Gleason Hypoid Spiral Bevel gear grinder generating Cams (2 full sets) REF#102 Springfield Vertical Grinder. 4” Face.4” Dia REF#103 NILES ZSTZ 06-800 CNC.8" SWING DIA REF#103 GLEASON Phoenix 200G Hypoid Grinder CNC REF#103 REISHAUER RZ-801 CNC.’09 REF#103 RP-GS 800 CNC. 3. 10” Dia. #62AR/2CS. 20" Grind Length REF#103 EXCELLO #33 Thread Grinder 6” Dia 18” Length REF#103 EXCELLO #35 and #35L Thread Grinder. 4" Face. 4DP. 12” Dia.75 Face REF#103 GLEASON #104 w/Helical Motion. Max Dia 49. 78. 4 DP REF#103 EXCELLO #31L. 36” Dia. 14” Dia. 11” OD. 4DP. 28 1/4 Swing.9” Face REF#103 MAAG #SH-350/500. 3” Face. #61S. Qty 3 REF#102 FELLOWS #10-4/10-2. 11” Face REF#103 NILES ZSTZ 08-800 CNC. Wet w/Auto Dress. 1. #715. #7A. 10” Dia. Gear Grinder REF#103 NILES ZSTZ-1250/5000 49. 3” Dia. 5” Stroke REF#103 Red Ring GCI 24. Max Dia 15” Face 4”./3GS.5” Dia. 5 DP REF#103 LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#103 LORENZ #LS-156 CNC Gear Shaper Dia 6” REF#103 FELLOWS FS400-125. 18” Dia. New ‘88 REF#103 LIEBHERR #WS-1.. 5” Face.1" Width. Internal Gear Grinding. 6-Axis. 5. 26” Dia.& Spiral. 4 DP. Bevel Planer.5" Risers 6" Stroke Mint YR 1969 id 3616 REF#106 GEar DEBUrrinG/CHaMFErinG/PointinG CROSS #50 Gear Tooth Chamferer. ‘38 REF#103 LEES BRADNER #HT 12"x 144" Thread Mill. 2” Face.25” Face.. 10" Dia. 4” Face REF#103 FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15. 5” Dia REF#103 GLEASON 2A. 7” Dia. 10” Dia. New ‘70’s REF#103 FELLOWS #10-2. Gear Shaper REF#103 FELLOWS #6. 3. 3. 4" Stroke. 118” Length REF#103 LEES BRADNER # LT 8” x 24” 8” Dia REF#103 HOLROYD 5A 24..7” Dia REF#103 Red Ring GHD-12. 10” Dia. Face 12”. 12” Spindle Hole 50/25 Motors.5 DP 5” Face REF#103 SCHIESS RS-20 S. 62" Table. 12. 5” Stroke REF#103 Nachi Raso CNC Shaver. 15” Dia REF#103 HOFLER BHS H1603-2000. 12. 16” Dia REF#103 HOLFER PROMAT 200 . 16” Dia. ‘82 REF#103 SAMPUTENSILI #SM2TA Gear Chamfering Mach. 5" OD. 4” Face. StraiGHt BEVEL GLEASON #37 Str. Deburrer/Chamfer REF#103 SAMPUTENSILI #SCT-3. S/N 643R83. 16. 10” Dia.BARBER-COLMAN 6-5. 118” Dia REF#103 FELLOWS #10-4 3-Axis (A/B). 72" Cut Length. 10" Dia. Max Dia 118”/ 16.0-72"OD. 70" Swing REF#102 GLEASON #529 Quench. ‘80 REF#103 SYKES VR-60 Vert Rack Shaper. Internal Attachment REF#103 FELLOWS #3-1. 1” Face. 3 DP REF#103 FELLOWS #HORZ Z SHAPER. PLC’s. 60” Dia REF#103 GLEASON #496 Straight. Qty 2 REF#102 HYDROSTROKE #20-8. REF#103 WALDRICH COBURG WHIRLING. Strait & Helix REF#103 RED RING #SGJ-18. 20” Dia. 4-Axis CNC.7” Dia REF#103 NILES ZSZT-3500. Straight Bevel REF#103 GEar GEnEratorS.6" Face REF#103 PFAUTER #SH-180 Shobber 7" capacity hobbing. Face 9”. 2” Face REF#102 FELLOWS #10-4. #13 and #17 Testers REF#103 Hofler EMZ-2602 Int/Ext Gear Tester 102” REF#103 Klingelnberg #PFSU-1200 Gear Tester REF#103 Klingelnberg #PFSU-1600 Gear Tester-2001 REF#103 Klingelnberg PWF-250 Tester REF#103 Kapp Hob Checker WM 410 REF#103 Maag #ES-430 Gear Tester REF#103 Maag #SP-130 Lead and Involute Tester REF#103 National Broach Gear Tester GSJ-12 REF#103 Oerlikon #ST2-004 Soft Tester REF#103 Maag #SP-60. 2 DP REF#103 GEar SHaPErS FELLOWS #10-2. #715.com .75” Dia. 4DP.. 6” Dia. 16” Cone REF#103 GLEASON #116. Ref. 9. 9” Face. 5” Face REF#103 FELLOWS #7. 10” Dia 4” Face REF#103 FELLOWS #20-4 3-Axis 10” Dia. 2 DP REF#103 GEar GEnEratorS.5 Stroke REF#103 Kapp #VAC65 Coroning 10” Dia REF#103 GEar SHaVErS Red Ring #GCX-24" Shaver. Dia 19. From 18”-35” Dia. Internal Attachment. ‘52 REF#103 REDIN #18. Bevel Planer. 8” Dia REF#103 Red Ring #GCY-12. 3. ’68.6”/1. 2" Stroke. SPiraL BEVEL (HYPoiD) GLEASON #645 Hypoid Generators REF#103 GEar GrinDErS CnC HOGLUND. Pinion Supp. 4 Spindle. 235” Dia 36”. Fanuc 18 REF#103 FELLOWS #10-4 2-Axis.5”.4" Length. 15” Face. 18” Dia.6 Face 8. 10” Face. ‘50’s REF#103 STAEHELY SHS-605.. #6. 4-Axis. #137. 31.5 Stroke REF#103 Red Ring GHG. 12” Dia. External Thread Grinder. 32” Dia. 31. 139” Dia REF#103 KAPP VAS #331.12. 8” Dia. Thread Grinder. S/N 433. REF#103 GLEASON/TAG – 400 CNC. (3) New ‘96 REF#103 REDIN #24 CNC Dia 4” Setup Gear Deburring REF#103 CROSS #60 Gear Tooth Chamferer.7” REF#103 FELLOWS #624A. 1DP REF#103 FELLOWS #4GS & 4AGS.Please Check Our Website To View Our Entire Inventory REF#103 TOS SU & SUS Series Conv Lathes REF#105 TOS SUA Series CNC Flat-Bed Lathes REF#105 62 gearsolutions. 3-5 Axis. 12” Stroke. 30” Dia. CNC Internal Gear Grinder REF#103 KAPP #VAS-482 CNC GEAR GRINDER.6" Face REF#103 LORENZ #SJV00. 2” Face. 4” Face. Qty 150 REF#102 HYDROSTROKE #50-8. 4 DP New . 6” Dia REF#103 GLEASON 726-Revacycle.7 ‘60’s Internal Attachment REF#103 MAAG #SH-150. 11. ’69 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 10-12. MiLLErS/GrinDErS LEES BRADNER #HT 12x54. 62" Table. 14” Throat Risers. 5. 16" Diameter REF#103 VERTICAL TURNING LATHES AND MORE .9 DP REF#103 SYKES VR-72 Vert Rack Shaper. Single Spindle REF#103 CROSS #54 Gear Deburrer. 53” of Swing.
com]. president of IACET and director of professional development at the American Speech-Language-Hearing Association. This year Boeing recognized 558 suppliers who achieved either a Gold or Silver level Boeing Performance Excellence Award. Beaver is one of only 141 suppliers to receive the Gold level of recognition.” says Jeff Duncan. ball screws and gears) are custom designed to fit virtually 64 gearsolutions. 30.org].” In order to achieve Authorized Provider status Danfoss completed a rigorous application process. which train more than 1. “Our continued partnership with IACET is a demonstration of our commitment to lifelong learning and high standards for all of our programs.” Beaver supplies ball splines to Boeing for the CH-47 Chinook helicopter. Go online to [www. installation. 2009 to Sept. “Danfoss is one of nearly 650 organizations around the globe that have had their programs vetted by third-party experts in continuing education to ensure the highest possible standards are met. with locations in more than 120 countries. Beaver aerospace & Defense receives Boeing performance excellence award Beaver Aerospace & Defense has received a 2010 Boeing Performance Excellence Award. In addition to setting the standard for highperformance quality variable frequency drives. Danfoss meets the needs of its customers through its EnVisioneering partnerships. Danfoss has pledged its continued compliance with the standard.” says Jason Ratcliffe. commissioning. energy efficiency. In addition. Beaver’s award-winning actuation systems and components (e. and servicing Danfoss VLT Drive products so they have the competency and skills to effectively and efficiently utilize our technology to its maximum potential. administration.com . Danfoss is now linked to the IACET Web site and is recognized as offering the highest quality continuing education and training programs. general manager. including a review by an IACET site visitor.g. development. The International Association for Continuing Education and Training (IACET) is a non-profit association dedicated to quality continuing education and training programs.danfossdrives. Danfoss is a leading manufacturer of precision mechanical and electrical components. marketing manager.Danfoss Re-approved as authorized CeU provider Danfoss VLT Drives has been re-approved by the International Association for Continuing Education and Training (IACET) as an Authorized Provider of Continuing Education Units (CEUs).. “Beaver Aerospace & Defense is honored to receive the Gold-Level Boeing Performance Excellence Award. focusing on developing new technologies for sustainable business growth through engineering innovation. The ANSI/IACET 1-2007 standard is the core of thousands of educational programs worldwide. and environmental responsibility. The recognition period extends for five years and includes all programs offered or created during that time.000 participants each year in all aspects of selecting. and we are very pleased to maintain our relationship with such a prestigious organization as well as an elite group of organizations that offer excellent continuing education and training programs. as well as a camera deployment actuator for the P-8 military aircraft. Learn more at [www. 1. and successfully demonstrated adherence to the ANSI/IACET 1-2007 standard addressing the design. IACET is the only standard-setting organization approved by the American National Standards Institute (ANSI) for continuing education and training. from Oct. The Boeing Company issues the award annually to recognize suppliers who have achieved superior performance.iacet. Beaver maintained a Gold composite performance rating for each month of the 12-month performance period. and maintains its authorization to use the IACET name and Authorized Provider logo on promotional course material. and evaluation of its programs.” “We are pleased to have Danfoss continue their continuing education and training work as an Authorized Provider organization. “Danfoss is proud of our education programs. 2010. “Beaver takes great pride in being recognized by a world-class company like Boeing and looks forward to continued success in the future.” says Karen Niles.
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Emerson Bearing provides solutions to a variety of industries including aggregate. and a CMM that is a productivity leader in the 1µm class. StRato-apex CMM from Mitutoyo The new STRATO-Apex® coordinate measuring machine from Mitutoyo America Corporation combines an advanced structure with newly developed high-performance control and scanning technologies. machine tools.g. California Brazing awarded aS9100 accreditation California Brazing is pleased to announce its official accreditation to the AS9100 international aerospace quality standard. machining. Mitutoyo’s nationwide network provides application. auto-leveling air springs and the newest compensation technology to support acceleration of 2. service. and process management. ball screws. Its award-winning actuation systems and components (e. Additionally. compressor. and a wide variety of programs supporting laser and vision probes.com]. along with its desire to meet and exceed the increasingly stringent industry requirements for aerospace related products and services. at jeffa@ californiabrazing.com. The program can also be linked to a higher-level network environment for enterprise-wide functionality. Call (630) 820-9666.23g (3D) and measuring scan speeds up to 3mm/s. general manager. Emerson Bearing has a staff of 22 and a 23. a vast inventory of bearings. speed.com . Emerson Bearing has converted its extensive online product catalog into a traditional 210-page print catalog. missile applications. MeasurLink STATMeasure Plus performs statistical analysis and provides real-time display of measurement results for SPC applications.beaver-online. marine. and testing services for all electromechanical actuators and ball screws. electric motor repair. which exhibit virtually no thermal expansion (coefficient of linear expansion of 0. a fixed price program. brazing. calibration. The controller is located outside the main unit to mitigate the effect of generated heat. worldwide sourcing. mining. New product Catalog from emerson Bearing Catering to OEM (original equipment manufacturers) and MRO (maintenance. medical. California Brazing is a manufacturer of critical components found at the heart of their customer’s complex products. or who simply prefer the print catalog over the online catalog. sensors. The free catalog is available upon request. For more information on the company and its line of products call (800) 225-4587. and can be found on some of the most advanced aircraft.any application. an offline teaching program. The STRATO-Apex features digital servo system control loops for position. and oil field. heavy construction. The ultra-high accuracy measurement units installed on each axis of the STRATO-Apex consist of high-performance reflective linear encoders that utilize ultra-high precision crystallized glass scales. power generation. a high-functionality general-purpose measurement program which is at the heart of MCOSMOS® (Mitutoyo Controlled Open System for Modular Operation Support) software. with current performance exceeding 99.8 percent. repair and educational programs. Additionally. higher acceleration. for contour measurement. vision. Visit online at [www.emersonbearing. MCOSMOS supports virtually every CAD format while providing routines for in-line measurement.com]. and operations) markets throughout the world. and mission-critical space exploration systems in the world. same day shipping and 24/7 service. pump. and it will also benefit their non-aerospace customers in the semiconductor. Space & Security. repair.598mm/s2 (3D). concrete.” says Ron Shelley.com. This makes it easy to implement various types of control algorithms. paper converting. the digital servo system has a wide dynamic range and is highly resistant to drift over time.000 square-foot facility to provide bearings ranging in size from 3mm to tunnel-boring 15-foot-diameter giants. The result is faster drive speeds. Additional software supported includes: CAT1000S® for freeform surface evaluation. overhaul. recreation. Mitutoyo Corporation is the world’s largest provider of measurement and inspection solutions offering the most complete selection of machines.01 x 10-5/°C). form and finish measuring machines as well as precision tools and instruments. wastewater treatment. as well as the alternative energy industry. food processing. or visit [www.com]. vice president of supplier management for Boeing Defense.com]. Nadcap aerospace brazing accreditation—AWS C3. and energy management markets.6—is scheduled for June of 2011. metal processing. and current. material handling. This certification reflects California Brazing’s ongoing commitment to continuous improvement. Due to demand. to top it off. Emerson Bearing has recently announced the availability of a new product catalog. robotics. With an online product catalog with over three-million bearings.mitutoyo. “Performance excellence is fundamental to the success of both our companies. Inc. data feedback. The scope of this accreditation includes heat treating. or visit [www. Mitutoyo’s proprietary statistical-processing and process-control program. printing. For more information contact Jeff Ager. e-mail info@ emersonbearing. Software packages include GEOPAK®. and metrology data management software. gears and splines) are custom designed to fit virtually any application. STRATO-Apex supports MeasurLink STATMeasure Plus®. And. a knowledgeable staff dedicated to delivering.—a subsidiary of Phillips Service Industries.” Beaver Aerospace & Defense. Beaver also provides expert repair. Emerson Bearing has become the leading provider of bearings to OEM and MRO markets in the United States. The extremely rigid STRATO-Apex CMM structure incorporates vibration-dampening.—is a global leader in the design and manufacturing of unique and broad-range actuation technologies for the aerospace and defense industries. The available software options enable the STRATO-Apex to tackle a wide variety of measurement applications. systems and services with a line encompassing CMMs (Coordinate Measuring Machines). Emerson Bearing offers customers a one-stop shopping experience. e-mail info@mitutoyo. wood products. transportation. The comprehensive print catalog better suits a number of Emerson’s bearing clients who may not have easy access to a computer. In a proud tradition. For more information visit [www. Inc.7 and AWS C3. 66 gearsolutions. packaging.com. “We extend our sincere congratulations to the employees of Beaver Aerospace & Defense for demonstrating their dedication to the high performance standards necessary to meet customer expectations and remain competitive in the global economy. serving commercial and military markets. and contract manufacturing.californiabrazing. SCANPAK®. the same families that started the company in 1957 keep Emerson Bearing rolling by specializing in bearings for OEM and MRO markets across the country. Beaver is the industry leader in on-time delivery. 0. The AS9100 certification will strengthen the company’s competitive position in the aerospace market. CAT1000P®. automation.
.............65 Micro Gear ....................67 Hermes Abrasives Ltd ...44 Repair Parts Inc ...............................................................................36 Sandvick Coromant ..................................................................47 Gear Manufacturing Inc .............................................51 Stor-Loc.....................50 Bourn & Koch .................65 Precision Gage Company ...... Allen Adams Shaper Services ..................................................................................................................................................................................... IFC KISSsoft USA LLC .........................................64 TMFM LLC ......................com CORPORATION JUNE 2011 67 ................................................................67 Broach House Manufacturing .............................9............................................................32 Process Equipment .........................................................................................................................................................................................................................................ADvERTISER iNDeX COMPANY NAME ..34-35 Forest City Gear ......................... 11......................................................................43 Clarke Gear Co .........................43 Riverside Spline & Gear Inc . IBC STD Gear ....32 Toolink Engineering . PAGE NO.....55 Banyan Global Technologies ................... BC New England Gear ...............................................................................................................52 Gleason Corporation ... 10................................................................................................................................................37 KAPP Technologies .......................................................................64 Gear Solutions Online ........................................65 Circle Gear and Machine .............13....................16 Gear Expo 2011 ...............45 The Broach Masters ..............................................................................................................................1 www.......7 Niagara Gear......17 Innovative Rack & Gear Co .........................................................65 AWEA 2011 ...........................................................................................................................................................46 Engineered Tools Corporation (ETC) ........................................14 Overton Chicago Gear .............................................................................64 Iosso Metal Processes ................................................................................hanikcorp...................................................................................................................................................................................50 Cole Manufacturing Systems Inc................................................................51 JLM Systems Ltd ...................................31 Hanik Corporation ..............46 Micro Surface Corp ............................38 Russell Holbrook & Henderson ...............................................44 Proto Manufacturing Ltd .................................................15......................12 Mitsubishi Heavy Industries America Inc ......2 Lawler Gear Corp ......60 Raycar Gear & Machine Co ...................................................................................................................................................................................................................12 Klingelnberg GmbH .....18 DT Technologies sa ...........58 R P Machine Enterprises Inc ...................................................................................................................63 Ingersoll Cutting Tools .....................................................................................................................................................65 Delta Gear ........................65 Hilco Industrial LLC .......65 Apollo Broach Inc ...............4 The Company Corporation ..................................................................
There’s such a need to make learning opportunities readily available and easy to access. among other positions. It’s very exciting. right when Henry Ford’s automobile assembly line was revolutionizing American manufacturing. into a value-adding component they can incorporate into the product they’re manufacturing. GS: Congratulations on being named chairman of the board of the American Gear Manufacturers Association. More than anything. so I’ve been with the company for 11 years and in this position for the past eight years. Cotta introduced what was known as the “constant-mesh shifting transmission. in addition to all that I’d learned while working toward my MBA. e-mail sales@cotta. So that experience. regardless of the application. graduating in 1991.” need their energy and input. That was in 2003. and it’s up to us to make a good case for why they should join the AGMA in addition to their primary responsibilities and concerns. and you’ll make friends you can rely on throughout your life and career. working in design engineering. or go to [www. 68 gearsolutions. so we will continue building on the great foundation that’s already been laid by the AGMA staff. We are a niche company. Another area involves recognizing the changing needs of the industry and its membership. especially those involving online training and education.com]. program management. and I’m honored to have the opportunity to serve the industry in this capacity. Could you tell us a little about its history and areas of expertise? MM: I’d be glad to. Charles Cotta was an engineer and inventor who established the company in the early 1900s. Also visit [www. so he brought me on in 2000.” which he was soon supplying to the emerging automobile and truck industry.com . What are your plans for the coming years? MM: Thank you. and strategic sourcing. positioned me well when the president’s position opened up. GS: How did you come to join the company? MM: After earning my bachelor’s degree in mechanical engineering from the University of Wisconsin-Madison I went to work for the Outboard Marine Corporation. and we design everything we make and make everything we design. and construction products. Cotta Transmission continues to be known for value-engineered solutions. We “AGMA members are an awesome group of people. purchasing. In the late forties Cotta began a shift to industrial. AGMA members are just an awesome group of people. heavy duty. So my advice to anyone who’s considering joining is to go for it. and in the sixties added a line of highspeed gearboxes.org]. because I can promise that you’ll be glad you did! TO LEARN MORE: Call (608) 368-5600. I’m going to do everything I can to help foster and promote the excellent programs that are already in place. so we need to be aware of their needs. He was looking for a vice president of operations and engineering.Q&a PRESIDENT matt MonDek COTTA TRANSMISSION COMPANy GS: Cotta Transmission has been in business for more than a century. and I’d studied with a gentleman who eventually became the president of Cotta Transmission. where I worked in the design department on the Evinrude and Johnson lines. and you’ll make friends you can rely on throughout your life and career.agma. and we’re here to help our customers meet the demands of their markets.cotta.com. While there I’d enrolled in the MBA program at Lake Forest Graduate School of Management. industrial. I was with OMC for nearly 24 years before they were forced to file Chapter 7. Today Cotta is a trusted manufacturer of precision-engineered premium transmissions in both stationary and mobile applications such as mining. and also those of the younger generation just beginning their careers in the industry. and marine. My personal conviction is that membership provides opportunities to meet and learn from industry leaders and to help develop the standards that govern our work. just before OMC filed for bankruptcy. One of our core competencies is our unique ability to transform our customer’s concepts. We have members located all around the world. of course. drilling. though. Over the years I’d made a point of exposing myself to as many different areas as possible.
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