GEAR SOLUTIONS MAGAZINE

THE EFFICIENCY OF A SIMPLE SPUR GEARBOX IN A THERMALLY COUPLED LUBRICATION MODEL

The Efficiency of a
SIMPLE SPUR GEARBOX

In a Thermally Coupled Lubrication Model

COMPANY PROFILE:
Lubrication
Engineers, Inc.
ROTARY BROACHING
With Machine Involute
Splines and Serrations

MARCH 2015

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

MARCH 2015

gearsolutions.com

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He once climbed the Matterhorn
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He has been known to

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But, when it comes

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FEATURES

The Efficiency of a Simple Spur Gearbox

Thermally Coupled Lubrication Model
By Athanasios I. Christodoulias, Andrew V. Olver, and Amir
Kadiric Imperial College London; Adam E. Sworski, Anant
Kolekar, and Frances E. Lockwood Valvoline/Ashland

This paper discusses how efficient a simple dip-lubricated

gearbox is in a thermally coupled lubrication model, which
includes elastohydrodynamic (EHL) friction losses in gear teeth
contacts as well as bearing, seal, and churning losses.

28

24

Company Profile: Lubrication Engineers, Inc.

42

Machine Involute Splines and Serrations

with Rotary Broach Tools

By Anna Claire Conrad

What was originally founded by three salesmen looking to provide a superior lubricant to the
manufacturing industry has grown into a successful, wide-reaching business with customers and
influence all over the world.

By Peter Bagwell
Rotary broaching is not just for machining hexagon holes in screws. Here, youll learn more
about the new product innovations and advanced techniques that continue to shape the
broaching industry today.
MARCH 2015

DEPARTMENTS

08 INDUSTRY
NEWS
Mitutoyo Announces Capital
Leasing Program for Measuring
Equipment

Heat Treating Industry

Veteran Ed Kubel Joins
Thermal Processing

BeaverMatic Supplies a New Carbottom

Furnace to an International Power
Generation Company

In this section, the premier supporter of gear manufacturing in the United States
and beyond shares news of the organizations activities, upcoming educational
and training opportunities, technical meetings and seminars, standards
development, and the actions of AGMA councils and committees.

18 MATERIALS
MATTER
Fred Eberle

13

48 PRODUCT
SHOWCASE

This month, well explore the factor of safety as a

statistical design variable in a Strength vs. Demand
model and how to use a reliability-based service factor to
best benefit you and your business.

Reports, data, and developments

to keep you aware of whats
happening with your colleagues in
the gear-manufacturing industry
around the country and world.

American
Gear Manufacturers
Association

56 Q &A
Chris Van De Motter,
The Ohio Broach & Machine Co.

20 TOOTH
TIPS
David Senkfor

Suggestions on how to deal with an order that has

been rejected by the customer and tips on how to
improve your process as a whole from start to finish.

HOT
22 SEAT
Jack Titus

Low-pressure carburizing (LPC) furnaces employ

strategically positioned jets, and atmosphere furnaces
must use the proper fan. However, all fans are not equally
able to handle the task.

23 TREND
TALKS

Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL
35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage
Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear
Solutions magazine, P.O. Box 1210 Pelham AL 35124. Publications mail agreement No. 41395015 return undeliverable
Canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond Hill, ON L4B4R6. Copyright 2006 by Media
Solutions, Inc. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopy, recording, or any information storage-and-retrieval system without permission in writing from the
publisher. The views expressed by those not on the staff on Gear Solutions magazine, or who are not specifically employed
by Media Solutions, Inc., are purely their own. All "Industry News" material has either been submitted by the subject
company or pulled directly from their corporate web site, which is assumed to be cleared for release. Comments and
submissions are welcome, and can be submitted to editor@gearsolutions.com.

Anna Claire Conrad

Suggestions and tips to help you regulate daily operations

at your company that can have a wide-reaching, beneficial
ripple effect.

MARCH 2015

VOLUME13 / NO. 03
MARCH 2015

LETTER FROM
THE EDITOR

David C. Cooper
PUBLISHER

Do croaking frogs still make you want to drink beer? Did

they ever make you want to drink beer? Did you name your
children Bud, Weis, and Er?
These are fair questions to ask in the wake of the 20th
anniversary of the introduction of arguably the three most
famous amphibians ever to grace the small screen.
Chances are, this has been the first time youve even thought about those little fellas in a decade. And while
you may look back on them fondly, its easy to discern the shift in marketing strategies with the passing years.
It was evident in the ads broadcast during Super Bowl XLIX. Advertisers now understand they have to
convey their messages in a relatable manner in order to influence the audience. A bond must be forged.
Puppy separated from his family? The audience relates, engages, and demands the reunion.
Its storytelling a return to the orthodox communication methods used by mankind for millennia.
I bought into the tactic at an early age. Ever since, the role of storytelling has evolved in my life from
bedtime stories to scary campfire tales to funny anecdotes from coworkers.
Now I tell other peoples stories for a living. And that starts with mastering the fundamental truth that
storytelling is a symbiotic relationship between teller and audience. To engage an audience, you must have
an audience.
When I tell the story of this magazine, I mention that Gear Solutions was built from the ground-up by a team
with decades of publishing experience. I say that we dont use the word goal because it implies satisfaction.
I cite the list of improvements weve made and continue to make since we started 12-plus years ago.
I tell people about the considerable expense and thousands of man-hours we put into the most comprehensive, most user-friendly website in the industry gearsolutions.com. I let people know about how we
created the only smartphone app of its kind in the industry.
I tell them how our print quality from our perfect binding to high-gloss UV cover stock to our inside
paper stock is second-to-none in the B2B publishing industry. I mention how the extensive amount of
energy, effort, and expense we put into our quintuple-audited BPA Brand Report ensures we go to the most
applicable, most responsive audience in the world for the gear manufacturing industry.
Then I brag about how Gear Solutions provides its readers with more quality, pertinent, technical articles,
columns, and features than any other information source in the industry, month after month every month.
Impressive stuff. But its not our story.
The Gear Solutions story involves the relationship with our audience, who can tell our story just as well or
better than we can. So we let them.
According to our recent 2015 Gear Solutions reader survey:
61 percent of respondents rated our technical content as Very Useful (an additional 33 percent
indicated Useful)
57 percent of respondents have bought or recommended a product mentioned in Gear Solutions
66 percent of respondents pass their copy of Gear Solutions on for others to read, with an average
3.1 readers per copy
98.7 percent of respondents rate our articles as reliable, with more than 60 percent responding
Very Reliable
81 percent of respondents rated the quality of Gear Solutions above other gear industry publications, with 40 percent indicating a quality Well Above other publications
Thats our whole story forged on the long-standing bond we share with our audience.

Chad Morrison

ASSOCIATE PUBLISHER

EDITORIAL

Stephen Sisk
EDITOR

Anna Claire Conrad

ASSOCIATE EDITOR

SALES

Chad Morrison

ASSOCIATE PUBLISHER

CIRCULATION

Teresa Cooper
MANAGER

Kassie Boggan
COORDINATOR

Jamie Willett
ASSISTANT

ART

Jeremy Allen

CREATIVE DIRECTOR

Michele Hall

GRAPHIC DESIGNER

CONTRIBUTING
WRITERS

MARY ELLEN DORAN

DAVID SENKFOR
FRED EBERLE
JACK TITUS
ATHANASIOS I. CHRISTODOULIAS
ANDREW V. OLVER
AMIR KADIRIC
PETER BAGWELL
Vertical Logo

Thanks for being part of the story.

PUBLISHED BY MEDIA SOLUTIONS, INC.

Stephen Sisk
Editor
Gear Solutions magazine
stephen@gearsolutions.com
(800) 366-2185 x209

P. O. BOX 1987 PELHAM, AL 35124

(800) 366-2185 (205) 380-1580 FAX
Dav id C. Cooper
PRESIDENT
Chad Mor r i son
VICE PRESIDENT
Ter esa Cooper
OPERATIONS

gearsolutions.com

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INDUSTRY
NEWS

New Products,
Trends, Services,
and Developments

Mitutoyo announces capital

leasing program for measuring
equipment

_____________________
www.mitutoyo.com

_____________________
Titutoyo America Corporation is now offering customers a capital leasing program as
an alternative to purchase. The program,
which features a variety of lease options,
customized financing solutions and flexible
terms (12-84 months), is available for purchases over $20,000 for measuring equipment including CMMs, vision measuring
systems, form measuring equipment, optical measuring equipment, automated mea-

suring solutions and precision measuring

instruments.
While financing precision manufacturing equipment can be a frustrating ordeal
for some businesses, the leasing program
offered by Mitutoyo America is simple
and fast. With the Fast Track Credit
Application, customers can submit a simple
online application for up to $350,000 in
financing, and they typically will get an
answer in 24 hours or less.
Many customers are looking to implement advanced measuring processes or
replace dated measuring equipment, but
are constrained by initial outlay costs or limited budgets, said Mark Izumi, marketing

group manager of Mitutoyo America. To

help our customers develop and expand
their businesses, Mitutoyo America is offering a flexible, simple, and rate-competitive
capital equipment lease program that significantly conserves cash and provides tax
advantages.
With the leasing program, customers
have access to Mitutoyos state-of-the-art
technology without having to make a large
capital expenditure. It also enables a company to leverage its available capital to
implement technology more broadly at
one time, rather than in stages over several
years.
Established in 1963, Mitutoyo America
Corporation offers turnkey metrology solutions and integrates measuring directly into
manufacturing processes via inline automation. The company is the first service
organization to have A2LA-accredited
field service technicians. To help develop
metrology solutions that best suit customers needs, Mitutoyo America operates nine
M3 Solution Centers across the country,
staffed with dedicated metrology specialists
providing expertise on the most advanced
technological equipment.
For more information on the capital leasing program from Mitutoyo America, visit
www.mitutoyo.com/financing or call (888)
648-8869.

Heat treating industry

veteran Ed Kubel joins
Thermal Processing

_______________________
www.thermalprocessing.com

_______________________
As part of its mission to serve the global
gear manufacturing community, Media
Solutions, Inc., a full-service marketing and media company and publisher
of Gear Solutions magazine, is pleased to
announce that heat treating industry veteran Ed Kubel, Jr. has joined its editorial

Companies wishing to submit materials for inclusion in Industry News should contact the Associate Editor, Anna Claire Conrad, at editor@gearsolutions.com.
Releases accompanied by color images will be given first consideration.

gearsolutions.com

staff. Kubel will serve as managing editor of Thermal Processing for Gear Solutions,
the biannual directory and supplement
to Gear Solutions on heat treating in the
gear manufacturing industry.
We are thrilled to welcome Ed to our
team, said David Cooper, president
and CEO of Media Solutions, Inc. His
wealth of knowledge and understanding
of heat treating is without question, and
we look forward to his leadership on
Thermal Processing for Gear Solutions moving forward.
After spending more than 15 years in
the metals industry as a metallurgical
engineer, Ed became involved in the
publishing industry serving in various
editorial capacities with several different
technical magazines. He has more than
30 years of experience in these editorial activities. His engineering background enabled him to cover a variety of
areas, including materials engineering,
manufacturing, thermal processing, and
materials testing and evaluation.
Finding someone with a breadth
of experience in both engineering and
publishing is a rare occurrence, said
Stephen Sisk, editor-in-chief of Media
Solutions, Inc. Its that unique characteristic that makes Ed the ideal choice to
serve the readers of Thermal Processing for
Gear Solutions.
Thermal Processing for Gear Solutions is
published in the Spring and Fall of each
year, and is co-distributed with Gear
Solutions. Its companion website can be
found at www.thermalprocessing.com.

BeaverMatic supplies a
new carbottom furnace
to an international power
generation company

_______________________
www.beavermatic.com

_______________________
An existing customer purchased its second BeaverMatic carbottom furnace.

The furnace is an essential duplicate

of a furnace manufactured several years
ago but was redesigned to operate in
Asia. It will be used for stress relieving
components ultimately used in the power
generation industry. The BeaverMatic
furnace is capable of processing 5-foot(1.5 meter) wide by 5-foot- (1.5 meter)
high by 8-foot- (2.4 meter) long work-

MARCH 2015

ment, guaranteed soak functionality, and

temperature control and recording. The
furnace is lined with energy efficient
ceramic fiber insulation. Parts are supported by grids on pre-cast workload
supports. A CE Marking was affixed to
the furnace to indicate that it complies
with the applicable international requirements. BeaverMatic personnel recently
supervised the installation of the furnace,
checked out its performance and operation during start-up and received final
signoff.
For more information, contact
Patrick Weymer, Product Manager, at
(815) 963-0005 or at Patrick.Weymer@
BeaverMatic.com.

loads that weigh up to 10,000 pounds (4.5

tons). It is electrically heated by rod overbend heating elements and features a car
driven by a motor a gearbox. Pneumatic
cylinders seal the car-mounted door to

the insulated frame. A forced convection

system results in 25F (6C) temperature uniformity from 1200F to 1550F
(649C to 843C). A Eurotherm nanodac instrument enables recipe manage-

Allen Adams Shaper Services, Inc.

was the subject of a Company
Profile in the January 2015 issue of
Gear Solutions magazine. The cover
of that issue misstated the company
name.

NEW RELEASE 03/2014

KISSsoft Highlights

KISSsoft USA, LLC

3719 N. Spring Grove Road
Johnsburg, Illinois 60051
Phone (815) 363 8823
dan.kondritz@KISSsoft.com

Strength calculation and 3D models of

beveloid gears
Simulation of flank wear based on
iterative calculation
Enhanced sizing for gear modifications
3D display of shafts and bearings
Efficiency and thermal rating in KISSsys
And many more ...
Get your free trial version at
www.KISSsoft.com

earSol_KISSsoft_Rel_03_2014_Highlights_92_25x123_83mm.indd 1

RUSSELL,
HOLBROOK &
HENDERSON, INC.

25 E Spring Valley Ave., Maywood, New Jersey 07607

P: 201-226-9000 F: 201-226-9004 E: geartools@tru-volute.com

Precision Gear Products

STOCK : HOBS : HSS & CARBIDE
STOCK : SHAPERS : Disc & Shank
STOCK : MASTER GEARS
RFQ on specials gear tools welcome
Diametral Pitch 12 and finer

CELEBRATING 100 YEARS IN BUSINESS

STOCK AVAILABLE

www.tru-volute.com
MARCH 2015
5/5/2014 10:57:35 AM

11

A Firsthand Look at Ipsens ATLAS

ATMOSPHERE

Questions & Answers

With Rene Alquicer, Manager Atmosphere Products
Ipsens newest atmosphere furnace is the ATLAS
single-chain model. What type of atmosphere
furnace is the ATLAS, and what does that mean
for users?
Ipsens single-chain ATLAS is a batch-type,
integral-quench furnace. This single-chain,
in-out-style furnace has a load size of 36 x 48
x 38 (W x L x H) and features all of the latest
technological advantages. The single-chain
model is configured for maximum compatibility
and utilizes the same push-pull chain loader as
the industry standard, allowing it to integrate
into existing lines for any brand of atmosphere
furnace with ease.*
When it comes to the atmosphere furnace
market, Ipsen has always been a strong leader
with one of the largest atmosphere furnace
installation bases in the U.S. several thousand
since being founded in 1948. In fact, our
founder, Harold Ipsen, was a pioneer in ...

Call Our Sales Team

800.727.7625
Ask for Rene, ext. 2695

From system integration to energy efficiency,

Ipsens batch atmosphere ATLAS furnace has the
answers. The ATLAS single-chain model features:
Ability to integrate into existing
atmosphere furnace lines (any brand) *
Intelligent controls with predictive process
capabilities Carb-o-Prof
Compact footprint
Ease of maintenance with a plug-type
heat fan assembly, shelf-mounted
quench oil heaters and oil circulation
pump, safety catwalks and more
Efficient combustion system,
which provides energy and
cost savings
Variable speed quench agitation,
allowing users to achieve and
maintain better quenching
control and uniformity

Where is the ATLAS single-chain model

manufactured for the North American market?
The ATLAS single-chain model is manufactured in
the United States at our facility in Cherry Valley,
Illinois. Our extensive U.S. Field Service network
provides support for atmosphere heat-treating
furnaces, including ...
* Compatible with most single-chain,
in-out-style atmosphere furnace lines

Read the full interview

here to learn more:
www.IpsenUSA.com/ATLAS-QA

www.IpsenUSA.com

American
Gear Manufacturers
Association

Mary Ellen Doran

Director, Electronic
Communications

How Are You Marketing on the Web?

By Mary Ellen Doran, Director, Electronic Communications
Did you see the article on the latest state
of manufacturing in this past Tuesdays
AGMA Industry News e-newsletter?
Chances are good, if you read the e-mail,
that you were viewing it on a mobile device,
most likely a smart phone.
For the past few years, AGMA has been
closely monitoring use of technology in our
industry. When we first started looking at
analytics back in 2010, less than 3% of all
e-mails were viewed on a mobile device. In
2014, the average was in the high 30% with
several e-mails clocking in at more than
40% of opened e-mails viewed on mobile
devices. Our data is showing that gear
manufacturing communication has moved
to the Internet in full force.
AGMA is making decisions for our
online presence based on our analytical research. Today, if you bring up
www.agma.org on your desktop, you will
continue to see our robust home page
with lots of industry news that is updated daily. But if you are using a mobile
device, you will see our new responsive
version of our site. It provides the same
great information just in a format that
is easier to use on your smaller devices.
Now, more than ever, manufacturing customers are going to the Internet to do research on products they seek and their corresponding suppliers, and theyre not just

looking for your websites. Having a wider

presence on the World Wide Web provides better search results for your company, and thus a better chance of getting
in front of potential buyers when they
type a term into a search engine. Does
this mean that you have to run out and
start a blog, post videos to YouTube, get a
presence on Facebook, and learn how to
tweet daily? While I will never discourage
the pursuit of social media - and the analytics are building more of a case for these
endeavors these require ongoing maintenance and valuable staff resources to
make them work correctly for your company. Look at Siemens USAs presence
on Twitter with over 20,000 followers
(AGMA has 508 followers as of when this
article was written). But these followers
have been earned over the course of six
years of Siemens work and 3,100 tweets.
While these numbers are impressive, you
can never lose sight of your own analytics
and follow that information in the direction that gets the most traction and ROI
for your individual company and the services and products you provide.
Right now, according to multiple sources, YouTube is the most popular among
source of social media among manufacturing marketers. Visual marketing has
been trending for several months with

these powerful smart phones everybody is

watching more video, but the how things
are made aspect of videos provide special interest. Horsburgh & Scott have several great videos on YouTube, as do many
more AGMA members and other gear
manufacturers. Loading videos is free,
and you can take the video you upload to
YouTube and place it on your website.
But do not forget about more traditional free and paid online advertising. Some
online buyers guides, such as the AGMA
Marketplace, have built-in search engine
boosts to the back end of their systems.
Our AGMA Marketplace listings utilize
Google Map It! and Google Site
Search not only to assist with people that
are using the Marketplace to find you, but
also to push your URL up in searches on
the back end.
Lastly, remember to take advantage of
all the other free opportunities that come
with your AGMA membership to spread
you across the web free job postings,
member news, and free e-newsletters
if you did not read the Tuesday AGMA
Industry News sign-up to start receiving for free by sending me an e-mail
doran@agma.org.
So, pick up your smartphones and tablets,
watch your analytics, and get the word out
about your products and services.
MARCH 2015

13

AGMA Foundation Offers Scholarships

The AGMA Foundation offers a $5,000 scholarship to assist engineering students whose programs focus on gear
technology or gear research. The scholarship is made possible by generous contributions to the Foundations Annual
Campaign.
The program is open to both undergraduate and graduate-level engineering students.
Help the AGMA Foundation alert studentsabout this scholarship opportunity by spreading the word.

The AGMA Foundation awarded four scholarships in 2014 to the following outstanding students:
Matthew Cane
A current employee in the gear industry, Cane is
enrolled in a weekend Bachelors program in Industrial
Technology at Southern Illinois University. Matt said,
With the AGMA Foundations support, Ill be able
to advance my knowledge, skills, and abilities even
further. In todays global economy, its not just companies that have to compete globally. The individuals
who make up those companies do, as well, and this
scholarship will definitely help me maintain my competitive advantage.

Ryan Hall
A senior at Valparaiso University, Hall is pursuing a
Bachelor of Science degree in mechanical engineering. He said he is grateful for the scholarship and

that, The AGMA Foundation Scholarship will help me

achieve my goals by relieving the financial burden of
my education and allowing me to focus on what I am
passionate aboutmy education and research. This
scholarship will allow me to dedicate more time to
my research, allowing me to make a more significant
contribution to the scientific community, specifically
renewable energy research.

Tyler OBrien
The AGMA Foundation is proud to have presented
a third scholarship to OBrien. OBrien said, I am
delighted to be continuing my education as a fourthyear student in the Mechanical Engineering Technology
program at Rochester Institute of Technology with
the help of the AGMA Scholarship Foundation. The

Foundations continued support of my education

allows me to participate in the extraordinary opportunities offered by RIT, such as cooperative education
work experience at various companies and hands-on
learning experiences both in class and in extracurricular activities.

Jacob Van Dorp

Jacob Van Dorp, a mechanical engineering student at
the University of Waterloo, received the second AGMA
Foundation Scholarship. He said, The cost of postsecondary education is high, but with the aid of this
scholarship provided by the AGMA Foundation, I will
be able to continue pursuing my degree. I look forward
to my continued education in mechanical engineering
and gear technology.

A printable brochure about the scholarship program is available at www.agmafoundation.org, which you can link to from your website,
LinkedIn, Facebook, and other social media outlets.
The 2015 scholarship application deadline is July 1, 2015 with award notification in August. For specific eligibility requirements
and application guidelines, please visit the AGMAs scholarship website, www.agmafoundation.org.

Speaker Added to 2015 Annual Meeting Lineup

Theo Maas, CEO of Siemens Mechanical Drives
Business Unit, has just been added to an all-star
lineup of presenters at the 2015 AGMA/ABMA Annual
Meeting this spring in Napa Valley, California.
His presentation will outline what global consumer
and B2B trends are on the horizon and how these
influence various industries, such as mass transportation, agriculture, marine, and wind. There will
also be information on what is happening in Europe
and in China - where they were, what happened, and
what is anticipated.
14

gearsolutions.com

Maas joins a distinguished list of presenters for this years

meeting, which includes:
Complete Champion Leadership: How Fast Can You Get Fast?
Derek Daly, International Racing Champion, Best-Selling
Author, and TVs Face of Motor Sports
Rethink, and Thrive
Michael Rogers, Author and Futurist-in-Residence,
The New York Times
Looking at the Reshoring Initiative
Harry Moser, President, The Reshoring Initiative
Economic and Market Outlook
Getting Old or Starting Fresh?
James P. Meil, Principal, Industry Analysis, ACT Research

CALENDAR OF EVENTS
Whether youre looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process,
AGMA has something to offer you. If you would like more information on any of the following events visit
www.agma.org or send email to events@agma.org.

APRIL

Powder Metallurgy Committee Meeting March 3 WebEx

Accuracy Committee Meeting March 4-5 Buffalo, NY
Helical Gear Rating Committee Meeting March 10-11 Chicago, IL
Metallurgy & Materials Committee Meeting March 12-13 Chicago, IL
Cutting Tools Committee Meeting March 16-17 Charleston, SC
Sound and Vibration Committee Meeting March 18 WebEx
Helical Gear Rating Committee Meeting (subcommittee 925) March 19-20 Chicago, IL
Vehicle Gearing Committee Meeting March 24-25 Indianapolis, IN
Vehicle Gearing Committee Meeting March 31 WebEx

Wormgearing Committee Meeting April 1WebEx

Wind Gearing Committee Meeting April 2 WebEx
Plastics Gearing Committee Meeting April 2 WebEx
Metallurgy & Materials Committee Meeting April 7 WebEx
Fine Pitch Committee Meeting April 8-9 Hartford, CT
Powder Metallurgy Committee Meeting April 22-23 Detroit, MI

MAY

MARCH

**Events are open to AGMA members only. Not a member? Send e-mail to membership@agma.org.

Bevel Gearing Committee Meeting May 5 WebEx

Mill Gearing Committee Meeting May 6 WebEx
Industrial Enclosed Drives Committee Meeting May 7 WebEx
Helical Gear Rating Committee (subcommittee 925) May 8 WebEx

Many of the presenters are in attendance for the entire three days, which gives
the attendees unprecedented access to these professionals.
Beyond the general session presentations, this years Annual Meeting
offers many opportunities for networking with old friends and meeting
colleagues in the industry while taking advantage of the unique Napa
Valley location.
This year, the meetings networking activities will take advantage of
the vineyard location to hold the first evening event in the Trinitas Estate Cave, located on the grounds of the Meritage Resort and Spa. Here
in the hushed serenity of the cave, the attendees can make new friends
and reconnect while sampling the Trinitas current releases.
Thursday night, April 30, attendees will have the experience of a lifetime with an off-site tour, wine tasting, and wine pairing dinner at
Artesa Vineyard in Napa. The trip will include a chance to taste and
compare the Artesa Estate Reserve and Limited Reserve wines in the
winery. Then, attendees will partake in a dinner in the barrel room where
these same wines will be served along with specifically paired courses
prepared by the chef and sommelier
The final networking event of the 2015 Annual Meeting will take place
at the Meritage Resort with a reception, dinner, and entertainment.
There will be a DJ, and comic Wayne Cotter who will provide the nights
entertainment. Once a computer engineer, Cotter is now a favorite of

the talk shows, having appeared dozens of times with both David Letterman and Jay Leno. A top nationally touring comedian, Cotter hosted the
Fox Television Network series Comic Strip Live and been nominated as
Best Standup Comedian in the American Comedy Awards.
A silent auction will take place during the Friday reception. Items will
include gourmet food, wine, sports, and travel packages along with other
tantalizing goodies that will entice attendees to open their wallets to benefit the AGMA Foundation. Proceeds will support the Foundations scholarship, training, and research programs which include a recent grant to
AGMA for the historical research and educational aspects of the AGMA
Centennial Celebration.
Throughout the annual meeting, the Meritage Resort and Spa promises
to be a comfortable and convenient setting for peer-to-peer interaction.
An active vineyard, complete with a tasting room and estate cave, surrounds the resort. The resort is only five miles from downtown Napa and
equal distance from the San Francisco, Oakland, or Sacramento airports.
This is a cant-miss event in a perfect setting, accompanied by interesting colleagues, exciting adventures, good wine, and delicious food all
wrapped up into a memorable three-day experience.
Further information about the joint meeting, including registration, hotel reservations, agenda, and program updates is located online at www.
agma.org. Any additional questions can be directed to AGMA at (703)
684-0211.
MARCH 2015

15

TWO POPULAR AGMA COURSES AVAILABLE ONLINE

Through generous support from the AGMA Foundation,
AGMA is able to provide gear engineers with two popular
seminars in a self-paced, online video format. The two
courses available are Ray Dragos Detailed Gear Design
program and Robert Errichellos Gear Failure Analysis
course. Not only are these video courses available as your
schedule allows, but by taking the course online, you save
time and money by avoiding travel costs.
The Detailed Gear Design seminar, taught by gear
expert Ray Drago, P.E., of Drive Systems Technology, Inc. is
divided into 15 one-hour segments and supporting training documents. Detailed Gear Design teaches students
about gear design and then walks students through carefully crafted problems that will demonstrate the practical
application of the optimization methods presented in this
seminar.
This program is best for gear engineers, gear designers, application engineers, people whoare responsible for
interpreting gear designs, technicians, and managersthat
want to better understand all aspects of gear design.
The majority of the course material is presented through
qualitativedescriptions, practical examples, illustrations,

and demonstrations,which require basic mathematical

and engineering skills.However, some familiarity with gear
design and application willenhance overall understanding
of the material.
After taking the Detailed Gear Design online course, you
will be able to:
Improve your gear designs

Better understand gear rating theory and analysis
methods
Investigate differences in stress states among various
surface durability failure modes
Discuss time dependent and time independent failure
modes related to tooth design

Use computer generated graphics to examine mesh
action and tooth interaction
The other program available online is Gear Failure
Analysis taught by Robert Errichello of GEARTECH. In this
program, students get the experience of the course through
11 segments consisting of a total of 10 hours of in-depth
discussion of gear failure modes and supporting training
documents. Gear Failure Analysis teaches students the

American
Gear Manufacturers
Association

causes of gear failure, how to prevent it from occurring,

and how avoiding gear failure can save thousands of dollars in repair costs.
In AGMAs Gear Failure Analysis online video training,
students examine the various types of gear failure, such as
overload, bending fatigue, Hertzian fatigue, wear, scuffing,
and cracking. Possible causes of these failures will be
presented, along with some suggested ways to avoid them.
Renowned gear instructor Bob Errichello uses a variety
of tools and methods lectures, slide presentations, and
Q&A sessions to give you a comprehensive understanding
of the reasons for gear failure. Errichello, holds Bachelors
and Masters Degrees in mechanical engineering and a
Master of Engineering degree in structural dynamics. He
has over 40 years of experience, has authored some 60
articles, and is a recipient of AGMAs prestigious Lifetime
Achievement Award.
The video presents a vast amount of knowledge not available elsewhere and is presented in a clear, well-organized
and easily understood manner.
For more information on either of these video courses, and
AGMAs other online education programs, visit www.agma.org.

1001 N. Fairfax Street | Suite 500 Alexandria, VA 22314

(703) 684-0211 |

www.agma.org

STAFF

Lou Ertel: Chairman

Kenneth J. Flowers: Owner and Vice President, Machine Tool Builders, Inc.

Overton Chicago Gear Corporation

Bill Gornicki: Vice President Sales & Marketing, ALDHolcroft Vacuum Technologies Co., Inc.

Matt Mondek: Chairman Emeritus

President/CEO, Mondek Solutions

Dean Burrows: Treasurer

President,Nixon Gear

John Strickland, Jr.: Chairman, BMEC

Fairfield Manufacturing Co.

John Cross: Chairman, TDEC

ASI Technologies, Inc.

Joe T. Franklin, Jr.: President

John E. Grazia: President, GearTec Inc.

BOARD OF DIRECTORS

EXECUTIVE COMMITTEE

AGMA LEADERSHIP

Sulaiman Jamal: Managing Director, Bevel Gears India

Steve Janke: President, Brelie Gear Company, Inc.
Jan Klingelnberg: CEO/CFO, Klingelnberg
Justin McCarthy: Vice President , Sales, Scot Forge Company
Mark Michaud: President, REM Surface Engineering
Brian L. Schultz: President, Great Lakes Industry, Inc.

Amir Aboutaleb: Vice President , Technical Division

Dylan Smith: President, VanGear

Jill Johnson: Director, Member Services

Wendy Young: President, Forest City Gear Company

General requests: webmaster@agma.org | Membership questions: membership@agma.org | Gear Expo information: gearexpo@agma.org
Technical/Standards information: tech@agma.org | AGMA Foundation: foundation@agma.org
16

gearsolutions.com

For the Last 60 Years,

Weve Never Stopped Learning
Searching for a higher gear-producing IQ? Make the smart choice today.
Your trusted source for
11715 Main Street, Roscoe, IL 61073
815-623-2168
www.forestcitygear.com

MATERIALS
MATTER

Fred Eberle

Technical Engineer
Hi-Lex Automotive Center

This month, well explore the factor of safety as a statistical design variable in a Strength
vs. Demand model and how to use a reliability-based service factor to best benefit you
and your business.
CLASSIC FACTORS OF SAFETY SOMETIMES CALLED SERVICE
FACTORS

According to NEMA, a Motor Service Factor (SF) is the percentage

of overload the motor can handle for short periods when operating
normally within the correct voltage tolerances. It is well known in AC
motors that a startup power spike is around 300% of rated load. This
type of load is considered a momentary-impact load.

Figure 1

Service factors for application load of motors and gearboxes

are based on uncertainty. This could come from any number
of individual components or the design process, including, but
not limited to, calculations, material strengths, duty cycle, and
manufactured quality. The value of the safety factor is related to
the amount of risk one takes in the design process. As engineers
and technical people, we never get all the information needed to
make risk-free decisions. In addition to the application and design
assumptions, there is true variation in every part of the design decision
tree. In mechanical engineering, the ultimate strength, yield strength,
and fatigue resistance are often used as base parameters in calculation
technique. However, these mechanical properties of the material have
corresponding bands of variation around the mean of 5% or more and
in the realm of metal fatigue it could be even higher. Additionally, the
applicability of the calculation theory and its probability to predict
reasonable design life can get ambiguous and complicated. In the
AGMA PM Gearing Committee, we are currently working on a
greatly expanded and refined document for the analysis of bending
life in powder metallurgy gearing. In the past, large factors of safety
and cautious assumptions have made the prior techniques significantly
conservative. More depth and clarity in addition to testing data are

resulting in a much greater understanding of the fatigue mechanisms in

powder metallurgy materials.
FACTOR OF SAFETY AS A STATISTICAL DESIGN VARIABLE

In the midst of all the design and process uncertainty, there is a

technique that can determine a statistical- and reliability-based factor
of safety analysis. This type of analysis is data-driven, and it is a much
more intelligent method to evaluate truth based assumptions. This
technique can be used as Capacity vs. Demand covariant analysis
often used within the theory of constraints. Historically, the technique
has been used for call center flow throughput resolution and inventory
velocity management. However, in mechanical design, we can use this
technique for a Strength vs. Demand analysis to determine design
and application risk and a corresponding reliability based Factor of
Safety.
In the following two examples, we will forgo all of the intensive
mathematical proofs to validate the simple results. There are however, a
couple of issues to discuss. A statistical service factor can be calculated
by assumed probabilities and a chosen level of reliability and confidence.
We are not going to do that because we would have to make a series of
probability assumptions based on experience, judgment, or educated
guesses. Instead, to get closer to truth based assumptions, we will
determine statistical reliability based on a limited amount of test data.
Consider an assembly line station that runs down bolts in magnesium
gear-reducer housings. In a Strength vs. Demand analysis, we want to
first know what the strength of the bolt or housing threads are. A 100piece sample of the components is set up to do a torque to failure test.
In this scenario, it is advantageous and economical to use surrogatehousing threads of the same cast material and thread engagement so
as not to do destructive testing on expensive housings. During the
test, only the housing threads stripped. A separate test of bolt strength
showed torsional failure about 20% higher than the housing joint. This
tells us two thingsthat the fasteners are robust and that we need only
to focus on the housing connection. The following data is taken:

Figure 2

ABOUT THE AUTHOR: Fred Eberle is a technical specialist in the development of gearing, drive motors, and power closure devices in the
automotive industry. He currently serves on the AGMA Plastic and PM Gearing Committees. Eberle has authored several papers on gearing,
measurement system analysis and process statistics. He can be reached at Fred_Eberle@hci.Hi-Lex.com.

18

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The next test is to determine what the variability is in the

Applied Torque where our production equipment runs
the bolts down to the drawing specification.
As a result of taking 100 bolts to failure, we know
something about the variation of the threaded joint and
by assembling 100 bolts to specification torque we know
something about the assembly variation also. The torque
gun gives accuracy in this range of +/- 1% or approximately
0.1 Nm in this range. This gives us our confidence level.
Therefore, we can make some statistical inferences about
the strength of these components and the process.
Determining the reliability results of our actual torque
specification relative to the capacity or strength of the joint
is as follows:
WHERE

SF , sSF = Strength of the joint, Standard deviation of the

failure sample
Stress, sSF = Applied load to the joint, Standard deviation
of the applied sample
Z = The standardized normal probability variable

However, instead of cyclic loading, the anvil is dropped from a fixture striking
a tooth near its tip at a predetermined height with specific gravitational
potential impact energy.
Des criptive Statis tics: Break Data, ImpactData
Variable
BreakData
ImpactData

Total
Count
60
60

Mean
12.203
8.190

StDev
1.100
1.743

Minimum
9.533
4.571

Maximum
15.051
11.919

Range
5.517
7.348

Figure 5

WHERE

BreakData = mean impact

energy to crack or shear teeth
ImpactData = impact resistance
required by specification

Figure 6

In this case, we can use Z to assess the amount of risk there is in damaging
gear teeth by application impact loads.
For Z = 2.97 there is only a (1-0.9985) = probability of failure of 0.15%
and corresponds to a sigma level of nearly 3.0

Figure 7
Figure 3

The histogram bears

Since most Z tables rarely go beyond (Z = 3.4), this out, also.
we easily conclude that the application and the
The tails of the
process are significantly robust to the joint strength. distributions cross
The histograms bear this out:
in the area under
the curve to reveal a
potential failure rate of
1.5 failures per 1,000
gears in service. This
gives us a reliability
based service factor
that gets closer to the
truth with just a short
and simple test of
tooth impact strength.
This
technique Figure 8
can be applied to
investigations of Capacity vs. Demand or Strength vs. Demand. Normality
of the data requirement is not as critical in this type of analysis as it is with
some capability studies. However, the technician needs to understand how
Figure 4
sample size and variation interact within the process under investigation.
Since the tails of the Applied and Failure distributions Standard deviation is everything. 1.5 failures in 1,000 may be totally
do not cross and based on the samples tested, the unacceptable in many applications. One way to improve that result is to
drive down the variation in tooth strength. Another way is to increase the
process should never result in a torque joint failing.
In this next example, a gear tooth impact test was strength of the gear. Either way, use a reliability-based service factor that gets
made. It is similar to single tooth fatigue testing. closer to the truth.
MARCH 2015

19

Senkfor
TOOTH David
President
TIPS

Top Gun Consulting

Below, youll find suggestions on how to deal with an order that has been rejected
by the customer and tips on how to improve your process as a whole from start to
finish.
YOU GOT THE CALL OR THE EMAIL, OR MAYBE THE BOX JUST SHOWED UP. One of your
customers rejected some parts. The box winds up in inspection and everybody wants to know what
happened. One of your inspectors or Quality Manager pulls a piece out of the box and checks the
validity of the rejection. Yep, theyre right. The part is bad, and now comes the fun part.
Does any of this sound familiar? This initial process is very common and is mentioned here
only because its a bit funny to watch. But now that you know the parts are deviant, do you have a
standardized process for dealing with this rejection?
I ask this question because in many companies, the way a rejected order is handled is completely
different than that of a regular order. True, a number of differences are to be expected. However,
there should be a process in place to deal with the particular nuances of any rejected order.
Without getting into the particulars of each subject, ask yourself the following questions to see if
your company has answers for each:

1) Once the rejection is verified by inspection, where does the paperwork go?
2) How and when does accounting get involved in the rejected order process?
3) How is the order entered and does engineering/quality and/or purchasing get to review the order
before it is released for rework/replacement or re manufacturing?
4) Who checks for other orders for this part in your system and what about any finished inventory
of these parts on your shelf?
5) Are similar parts you make for this or other customers examined to see if the same type of defect
exists on them as well? And if found, is the customer notified?
6) Once quality defines the type of rejection, is there a feedback to manufacturing to clarify or
change the existing process to positively correct the problem for next time or is this a one-time
event?
7) Is there some kind of internal tracking of rejects to see if there are trends within the manufacturing process that need correcting (training, machine issues, tooling issues etc.)?
8) Since these parts were deviant as shipped, is the inspection process examined to determine how
this defect was not detected?
Whatever your answers are to the above questions, tor me, they all boil down to four general areas:
PAPERWORK

The incoming paperwork has to be forwarded through order entry quickly and the type or response
(repair, remanufacture, or replacement) must be determined to allow the shop to turn the parts
around.
MONEY

This order must also make its way to the accounting department to allow them to handle the money
side of the order with the customer. Many customers will expect credits that they will take whether
or not you have that credit in your files or mail it to them. There is no accounting problem that your

accounts receivable clerk hates more than to

receive a check with a credit taken that they
are not aware of.
QUALITY

Your quality department will likely investigate

the matter to see if it is an isolated instance
and if any process changes are required. They
will also want to know how these deviant parts
got out of the plant without being found.
Transparency is important because it insures
that continuous improvement will occur to
correct any systemic or process problems
found.
TRACKING

Under no circumstances should parts be

touched without a routing to go along with
them. Seems a little rough, but think about
it. If the parts are not entered into the system,
somebody is trying to do an end around
the process. Im not a suspicious person but
without an order, youve got to question the
motives of those involved.
These questions and their answers barely
scratch the surface of what can be a daunting
affair if these sorts of orders are not handled
in a standardized manner regardless of the
type of remediation required to fix the parts.
Nowadays, with quality being assumed for
most vendor/customer relationships, any slip
may cause you a hit to your quality rating or
worst case, to lose orders. Quality must be
built into your process and verified by inspection along the way and at time of shipment.
Rejects are a pain, but if handled in a prescribed manner, the pain will be minimized
and youll be able to recover with the least cost
incurred.

ABOUT THE AUTHOR: David Senkfor is the president of TopGun Consulting, a manufacturing consultancy with a focus on helping companies improve their practices
and processes to increase the profitability and satisfaction of the owners of those companies. David has over 30 years of experience in manufacturing, more
specifically in the gear industry. Using his experience, David is able to quickly assess difficulties and recommend simple, yet effective, solutions to those issues. For
more information, contact David Senkfor at david@topgunconsulting.net or (602) 510-5998, or visit Top Guns website at www.topgunconsulting.com.

20

gearsolutions.com

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HOT

SEAT

Jack Titus

Director of Process and Developmental Engineering

AFC-Holcroft

Low-pressure carburizing (LPC) furnaces employ strategically positioned jets, and

atmosphere furnaces must use the proper fan. However, all fans are not equally able to
handle the task.
WHEN IT COMES TO CARBURIZING or protecting parts subjected to an atmosphere, fanand gas-injection methods become the critical
factor. Vacuum furnaces have air removed by
vacuum pumps, but by carburizing at lowpressure carburizing (LPC) pressures, fans are
ineffective because too few gas molecules to
circulate. Therefore, LPC with acetylene must
be introduced in a manner that will assure uniform carburizing and two primary methodologies that have been used.
Pulsed pressure is the oldest method, and it
was utilized by most OEMs. It involves injecting the gas for a preconfigured time increasing
the LPC pressure to some level. When that
pressure is achieved, the gas injection stops, and
a vacuum pump would evacuate the pressure
back to a starting point where the sequence
begins again until the initial case depth has
been reached. Following the last pressure pulse,
the vacuum pump evacuates to begin diffusion
resulting in the target surface carbon and case
depth.
Even though acetylene molecules (C2H2)
will disperse throughout the entire chamber
interior, only the gas contacting the parts
in the hot zone will receive carbon atoms.
Acetylene that is outside of the hot zone and
that is between the insulation and vessel wall
has no effect on the parts. As the acetylene
decomposes at the parts surface, hydrogen is
formed, as well as free carbon 2C + H2. Not
all of the carbon enters the steel. Some of the
acetylene is cracked from temperature alone.
This excess is responsible for the maintenance
required. As the steel surface becomes saturated
with carbon, less of it will enter the steel. The
hydrogen formed will dilute and reduce the
concentration of acetylene creating non-uniform carburizing. Evacuating the reacted gas

and pulsing fresh acetylene will improve uniformity. Evacuation in between pulses in addition to removing spent acetylene allows carbon
to diffuse into steel away from the parts surface.
If the evacuation time is too short to allow
enough diffusion, and if all of the unreacted
acetylene is not removed, the surface carbon
will be higher than anticipated by the control
model resulting in excess iron carbide (Fe3C).
To assist in distributing carburizing gas
throughout the load, most LPC hot zones
will have nozzles positioned around the hot
zone pointing at the load. The effectiveness of
nozzles can be argued since some will inevitably
plug and, consequentially, disturb the nozzle
jet flow. Evacuation between pulses tends to
ameliorate the uniformity.
Gas pulsing eliminates evacuation between
pulses and, instead, flows nitrogen between carburizing pules thereby, maintaining a constant
pressure during the LPC process. The vacuum
system continues to evacuate the vessel while
either acetylene or nitrogen flows. The transition from high acetylene concentration to zero
is much slower than with the pressure pulse
technique and may never completely remove
all of the diluted acetylene between pulses. The
pressure is controlled by a pressure sensor in the
evacuating manifold by varying the vacuum
boosters RPM.
Atmosphere furnaces rely on fans to circulate the atmosphere, but the type of fan used
can make a significant difference in results.
Furnace fans serve two purposesassisting in
heating parts in dense loads and improving
carburizing uniformity. However, not all fans
are equal or provide the same fluid motion.
In batch furnaces, roof-mounted radial fans
provide a defined circulation path for the carburizing gas. Gas is forced radially out from

the circumference of the fan to the sidewalls,

down along the walls, then up through the load
into the fan. Since fans operate at atmospheric
pressure, case depth uniformity is good even in
very dense loads. When vertical radiant tubes
are employed, the gas is also heated as it passes
over the hot tubes.
Since furnaces operate at high temperatures, the density of the gas is heavily reduced.
Therefore, the quantity of gas moved is
less than what it would be when it is cold.
Nevertheless, radial fans produce higher static
pressure more so than axial types and provide
the critical defined flow path. Propeller-driven
airplanes essentially have axial fans in the air is
moved along or parallel to the axil shaft. Roofmounted home exhaust fans are axial.
Radial fans will have straight blades that
create gas flow by compressing gas as it moves
along the blade length and produce a differential low pressure at the inlet and a higher pressure as the gas flies off the rotating blade tips.
Axial fans slice through the atmosphere with
very little compression of the gas as it slides
over the fan blades. Therefore, radial fans are
used where much higher system resistance is
encountered requiring higher static and velocity pressures from the fan.
Either fan type will function to some degree
without a plenum or directional vanes, but
the radial style will outperform an axial fan in
such a condition. Axial fans work much better
when moving an atmosphere through a duct
even a short oneto assist in keeping the gas
from sliding off the blades radially prematurely
before exiting in the direction required. Axial
fans with larger center hubs have a negative
characteristic that will short-circuit the fluid
back into the blades when no duct or plenum
is used.

ABOUT THE AUTHOR: Hot Seat columnist Jack Titus has an additional column in Thermal Processing for Gear Solutions in which he discusses
scheduled maintenance of furnaces, distortion control, and low-pressure carburizing. Jack Titus can be reached at (248) 668-4040 or
jtitus@afc-holcroft.com. More information can be found online at www.afc-holcroft.com or www.ald-holcroft.com.

22

gearsolutions.com

Anna Claire Conrad

Associate Editor
Gear Solutions Magazine

TREND

TALK S

Here, youll find suggestions and tips to help you regulate daily operations at your company
that can have a wide-reaching, beneficial ripple effect.
THIS IS MY FIRST REAL WORLD JOB
after graduating from college, and in the six
months Ive been here, Ive learned a lot more
about the gear manufacturing industry than I
ever thought Id need to know.
And while knowing the difference between
hobbing and milling is important, as the associate editor, my job requires a lot of quality
control.
According to SME Toolkit, a program of
the International Finance Corporation (IFC)
and member of the World Bank Group, the
American National Standards Institute (ANSI)
and the American Society for Quality Control
(ASQ) define quality as the totality of features
and characteristics of a product or service that
bears on its ability to satisfy given needs.
There are also two primary perspectives of
defining qualityone from the customer and
one from the producer.
The quality of design is from the point of
view of the customer. This involves incorporating quality characteristics and features into a
finished product.
Then, theres the quality of conformance,
which is from the manufacturers perspective.
This strives to ensure that the product received
by the customer is made according to its promised design. This can be achieved by improving
the design of equipment, materials, training,
and supervision starting at the shop floor.
Here at Gear Solutions, its my responsibility
to ensure that the quality of our product meets
the satisfaction of our readers. Its my duty to
find content, interview sources, edit articles,
send that editorial back for final approval, and,
with the help of my co-workers, put out the best
magazine I can every month.
Ive made a few mistakes along this journey,
none of which Im proud of, but like Ive found
with planning my wedding (as I mentioned in

my Letter from the Editor), the worst thing I

can do is become paralyzed by fear of failure.
On the other hand, the best thing I can do is
improve our processing of each issue from start
to finish to ensure that the product youre reading
right now reflects the hard work and long hours
that are put into it by everyone on the Gear
Solutions staff.
The same can be said about quality control
as it applies to the gear manufacturing industry.
Say you receive a returned part from a customer. Youre told it didnt work like you promised it
would, and the customer is left disappointed and
dissatisfied. Now, youre left with two burning
questionshow did this happen, and what can
I do to keep it from happening again.
This is a universal fear in any industry, especially in this tight-knit gear manufacturing community.
Here, well address how to adjust and improve
your processing flow of operations to keep something like that from happening or recurring.
As I said before, Ive only been involved in this
niche industry a short while, but one thing that
has stuck out to me throughout these months
has been how highly the customer is valued.
Gear manufacturers and service providers put
their customers needs first, whether that means
shipping them a replacement part, selling them a
new machine, or custom-designing a new product all together. To ensure your customers dont
stray, here are a couple of general tips on how to
optimize your quality control efforts based on
what Ive learned so far.
First, ask yourself if you value quality ? Are you
willing to make sacrifices for it, such as employing quality management personnel or updating
your technology? Is it something you currently
plan for?
Second, do you manage supplier quantities? In
Tooth Tips, David Senkfor listed several ways to

approach and comeback from a rejected order.

Its important to hold your suppliers accountable
to their products and the agreed upon deadlines.
Third, how do you involve your employees
with quality control? Are they trained on this subject. Do you encourage them to continue their
education and expand their knowledge on this
industry? Knowledge is power. Like we discussed
in our December issue of Gear Solutions, taking
advantage of educational and training opportunities is key to optimizing your human capital.
If you or your employees are at all like me, then
hands-on learning is the best way to go. If you
educate your people and keep them updated on
the latest methods and technology, youll put out
a better product and better serve your customers.
Fourth, is your communication streamlined?
If its not, have you explored ways to make your
communication more efficient? Direct communication is essential to ensuring effective communication between people working on a project,
and it will ultimately result in a smoother process.
Lastly, and perhaps the most important, are
your facilities organized? Have you implemented
a system of checks and balances to hold everyone
involved accountable for the final product? How
does your business measure and monitor quality?
Its important to, in a way, copy edit your work
before its distributed, like we do here at the
magazine. By that, I mean get as many fresh eyes
on your product as you can before it leaves your
facility. This may help catch small errors that can
have disastrous consequences.
These suggestions may seem simple but it
takes a great deal of hard work, organization,
and steadfast dedication to accomplish these
tasks. However, once you apply these tips to
your business and come up with a method that
works best for your company, youll witness a
high-quality end result that and a lot of satisfied
customers.

ABOUT THE AUTHOR: Anna Claire Conrad graduated from Auburn University with a Bachelors degree in journalism in August 2014 and joined
the Gear Solutions team in September as the associate editor. She can be reached at editor@gearsolutions.com or at (205) 380-1573, ext. 205.

MARCH 2015

23

COMPANY
PROFILE

Lubrication
Engineers, Inc.

24

gearsolutions.com

What was originally founded by three salesmen looking to provide a superior lubricant to the
manufacturing industry has grown into a successful, wide-reaching business with customers and
influence all over the world.
By Anna Claire Conrad
In 1951, three men took a risk. They
left the company they worked for behind and ventured out on their own
to provide the clients and industry
they served with a superior lubrication
product. Now, more than 60 years later, their legacy lives on at Lubrication
Engineers, Inc.
In the early years, the companys
products were manufactured by compounders/blenders. That lasted until
1979 when they built their own facility in Wichita, Kansas. Relocating
production to their own plant meant
one thing for these business pioneers
complete control over their product.
They did this so they could control
their own future as opposed to their
production being at the will of some
other company, said Scott Schwindaman, president and CEO of Lubrication Engineers. They went from being a marketing company to actually
being a manufacturer.
Since that time, LE has established
itself as a trusted reliability partner to
companies all over the world by manufacturing and distributing its own
high-performance lubricants. It has
also grown to include what Schwindaman refers to as engineering services,
which make up roughly 20 percent of
the business, including training people
at their respective facilities or at Lubrication Engineers facility, completing
asset surveys in plants to identify every
piece of equipment in need of lubrication, determining what the proper lubricant would be per the OEM manual, and identifying what the correct
drain interval should be.
According to Schwindaman, Lubrication Engineers enhanced lubricantswhich are made of highly
refined or synthetic base oils and proprietary additivesoutperform conventional lubricants in a wide variety

of industrial and automotive applications.

You have the commercial-grade
products that are available in the industry today, such as gear oils and greases,
Schwindaman said. We tend to build
our products to extreme specifications.
Where most commercial-grade products are built just to meet a minimum
specification, we look at the application
to see what we can do to build the very
best possible lubricant for that application. Thats because were looking at the
durability of the lubricant. We see the
lubricant not as a consumable, but as an
asset.
If you take care of the lubricant by
keeping it clean and dry, it should last for
an extremely long time. Theres no reason anyone should ever have to change
the lubricant out unless its at the end of
its useful life. Were also environmentally conscious in that we dont want to
waste natural resources. We want our
customers to get the maximum bang
for the buck out of that lubricant and
protect the lubricant as they would any

other asset. Its not unheard of for us to

have drain intervals that are four or five
times the length of commercial-grade
products in the same application. Thats
what makes our products different.
To help its customers take care of their
lubricants, Lubrication Engineers offers
a complete line of lubrication reliability
products and services, including solutions
for oil analysis, storage, handling and
transfer, contamination exclusion, contamination removal, and education.
We also started training our customers personnel at their locations to help
them understand the best practices of lubrication maintenance and application,
Schwindaman said. In addition, we did
some other types of informational training here in Wichita, which resulted in us
building a training room. Today, we have
approximately 100 different customers
who send people through our training
programs every year.
Since its inception, Lubrication Engineers has expanded into multiple
facilities. In Wichita, the company
houses its manufacturing, research
MARCH 2015

25

and development, financial, and marketing

operations. Sales and service personnel operate out of Fort Worth, Texas, which is where
the original home office was established more
than 60 years ago.
If you have a technical question, youre going to call our office in Fort Worth and speak
with a degreed engineer about your question on a particular piece of equipment, and
theyre going to be able to get the answers for
you there, Schwindaman said. Then, our
research and development and quality control
people here in Wichita will back up whatever
testing they may need done.
To accomplish timely shipments to customers, Lubrication Engineers has two regional
warehousesone in Knoxville, Tennessee,
and another out west in North Las Vegas, Nevadain addition to its warehouse in Wichita.
Because of where the warehouses are located, we ship 96 percent of the orders that
come into us within 24 hours. At 48 hours,
over 99 percent of everything is shipped to the
customer. There is no delay in shipments
whether its a pint bottle or a railcar lubricant.
Also, with roughly 70 international distributors, the company has extended its reach
26

gearsolutions.com

across the globe. Located outside of London

in Theale, England, Lubrication Engineers
International handles most of the companys
international clients.
With customers in a variety of industries
other than gear manufacturing, including
agriculture, food and beverage, oil and gas,
mining, and industrial equipment, Lubrication Engineers needs a lot of manpower to
meet the demand for their enhanced lubricants and reliability solutions.
According to Schwindaman, in the United States, the company has close to 150
employees and 64 independent consultants.
Of that total, nearly 90 are out in the field
taking care of customers on a regular basis.
When you factor in the international distributors and their employees, it adds up to
approximately 700 people under the companys employ.
In addition to the commercial work
we do for industrial customers, we also do
work for the U.S. Departments of Defense
and Energy, Schwindaman said. One of
the products we make is a proprietary dry
film lubricant, which is used in military and
space applications.

However, no matter how big LE is or may

grow to be, customer service and reliability
are engrained in its core and are its main
priorities.
According to Schwindaman, when a customer calls a company for a lubricant recommendation, it is typical for a major lubricant
manufacturer to cross-reference the lubricant
the potential customer is using with one of
their competitive products and just leave it at
that.
We dont do that, Schwindaman said.
In todays markets where equipment is being
pushed to extremes and, sometimes, beyond
its design capability, we actually go to look at
the piece of equipment, identify the proper lubrication for that equipment, and even sometimes go as far as looking at manufacturing
a new lubricant that will keep that piece of
equipment up and running due to the rigors
it must perform.
On the services side, we emphasize our
attentiveness to each individual customer
whether they need technical support, sales
support, or product delivery. Were all about
getting the product to them in a timely manner to put them back in operation because we
understand the costs associated with downtime.
Thats not to say that Lubrication Engineers
hasnt been met with its fair share of challenges. However, with each obstacle, the company
was able to rise to the occasion and successfully get its product to the customer in a timely
manner.
Take, for instance, the time when one of
Lubrication Engineers customersa mining operation in northern Texasfound out
that one of its gear sets that is supposed to be
greased and re-lubricated was not given the
attention it needed.
They had a failure one Saturday morning where they did not have any lubricants
there to get the unit back up and in operation, Schwindaman said. In that case, the
call comes in, and at 12:15 p.m. the next
day, 10 pails of product were delivered to
that customer to get them back up and in
operation.
Thats only one example of how the company heard one of its distressed customers
calling out for help and flew to the rescue.
Recently, there was an issue with a drilling
company in Alaska that was doing drain
intervals on the trucks they used to haul

thats what makes working at Lubrication Engineers so satisfying.

The great thing about LE is all of the
interesting stuff we get to do and see, and
how we get to help the customer. You never
have to apologize for the products because
they perform tremendously well. When
youre able to improve profitability for a

company to the magnitude were able to,

they become lifelong customers. Its not that
were just selling something. It becomes a
partnership.
FOR MORE INFORMATION, you can visit
Lubrication Engineers, Inc.s website at
www.lelubricants.com

Quality solutions since 1960

ISO 9001:2008

Our experienced Engineering staff coupled

with our skilled manufacturing technicians
will partner with you to produce your
product. From prototype to production.
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every application.

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Belts, Flanges, Pulleys & Pulley Stock, Sprockets and Chain
Component Mounting Accessories
Couplings, Clutches, Cams, Brakes, Universal Joints
Fasteners, Hardware, Assembly Tools
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crude oil from the well site to the oceanbound freighters in Prudhoe Bay. According
to Schwindaman, they were changing their
lubricants every 200 hours on a truck fleet
made up of roughly 1,500 tractors.
We extended their lubricant change interval time to 800 hours, Schwindaman
said. Weve also been analyzing the oil for
wear metals, which are dramatically lower
with that 800 hours than they were with the
commercial-grade product at 200 hours. And
were not done there. The next phase of the
test will be to take them to 1,000 hours. Well
continue to push that drain interval until we
see that were having an impact on the engines durability, and then well back off that
by 200 hours, and thatll become their drain
interval. Well always continue to monitor
those engines to make sure theres nothing going on with them. That particular customer
is saving somewhere around $12 million per
year, according to their own calculations.
These types of situations happen almost
every day, but, according to Schwindaman,

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MARCH 2015

27

The Efficiency of a Simple Spur Gearbox

Thermally Coupled Lubrication Model
By A
 thanasios I. Christodoulias, Andrew V. Olver, and Amir Kadiric Imperial College London;
Adam E. Sworski, Anant Kolekar, and Frances E. Lockwood Valvoline/Ashland

This paper discusses how efficient a simple dip-lubricated gearbox is in a thermally

coupled lubrication model, which includes elastohydrodynamic (EHL) friction losses
in gear teeth contacts as well as bearing, seal, and churning losses.
INTRODUCTION
The efficiency of drivetrain components is quickly becoming
a significant research area pushed by the intensifying quest
for improved fuel economy in automotive vehicles. Emissioncontrolling regulations are becoming stricter, owing mainly to
environmental issues, such as air contamination, but also due to
the depletion of oil deposits and the resulting high fuel prices.
Pursuing augmented efficiency of a drivetrain or its components
can also have the positive side effect of decreasing the frictional
heat that is generated inside the gearbox, differential, or axle
component therefore improving scuffing or pitting behavior.
The drive train in passenger cars absorbs around 6 percent of
the total fuel energy in combined city- highway driving, which
is equivalent to about 30 percent of the mechanical energy
delivered to the wheels [1]. The biggest part of this energy loss
ends up as heat in the axle or transmission lubricant resulting
from friction, windage and churning. As a result, the reduction
of lubricant-related losses in a vehicles drivetrain can lead
to significant improvements in both the fuel economy and the
environmental impact of the vehicle. Thus, this efficiency
increase is a much sought-after goal for lubricant suppliers of
OEM factory fill and aftermarket lubricants.

BACKGROUND
The efficiency of spur gears has started receiving significant
attention roughly since the 1980s with the work of Anderson
[2] [3]. Recent years have seen a boom in such publications,
mainly due to the energy crisis. Li and Kahraman [4] and,
more recently, Chang and Jeng [5] focused on a spur gear pair
while Michaelis [6] considered a more integrated approach
that included churning losses as well as bearing and seal losses.
Churning losses play a very important role in the prediction of a
dip lubricated components efficiency and recent studies from
Changenet and Velex [7] [8] have shown that the accurate
determination of churning losses and how these are affected by
design parameters is a challenging problem.
Thermal behavior of the components and thermal response
of lubricants are dominant factors of efficiency enhancement.

There are several published models of spur gear pairs that

analyze the thermal behavior of the pair like those developed
by Long and Lord [9] and Taburdagitan [10], which use finite
element methods to predict the overall temperatures and surface
temperatures. A more integrated approach by Changenet and
Velex [11] considered lump thermal elements to study and
model a six-speed gearbox, but with no experimental validation.
In addition, the thermal response of transmission lubricants
was extensively studied by Olver [12] who also developed a
comprehensive model to predict traction in Elastohydrodynamic
(EHL) contacts, which included thermal effects [13]. However,
there are currently no efficiency models that consider a full spur
gearbox, including the all-important thermal coupling, taking
into account the mesh and bulk temperature rise of all drivetrain
components or that of the oil surrounding them as well as all
sources of energy loss including bearings, seals, churning, and
EHL traction.
Additionally, the type of lubricant itself is a crucial factor in
determining the efficiency of a drivetrain. Despite this, there is
currently very limited ability to predict the relative fuel economy
arising from the use of different drive train lubricants. PetryJohnson [14] have included more than one type of lubricant in
their studies in an attempt to pinpoint the possible effect that
a specific combination of lubricant, component design and
operating condition may have on the overall gearbox efficiency.
The results from their studies showed a linear relationship
between the gear power loss and the rotational speed of the
gears. The results also highlighted the effect of surface finish
on the efficiency of the gearbox. Their lubricant comparison
used three different lubricants to indicate that there is a possible
change in overall efficiency depending on the lubricant type.
However, no complete method has been developed that is able
to simultaneously account for specific lubricant characteristics
under EHL contact conditions and relevant gearbox parameters.
Such an approach should be able to provide a more accurate
estimation of the possible efficiency gain.
The limitations of current approaches include limited
treatment of gear churning losses and not accounting for

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314. Statements
presented in this paper are those of the authors and may not represent the position or opinion of the AMERICAN GEAR MANUFACTURERS ASSOCIATION.

MARCH 2015

29

the transient conditions arising from variable

vehicle duty cycle. Kolekar and Olver [15]
have recently worked on this issue concentrating
on hypoid axles. A transient thermal model
coupled to a quasi-steady state lubricant
traction and churning formulation has been
used together with lubricant bench tests in
order to predict the energy that is dissipated
during specified drive cycles. The results
highlight the high influence that the properties
of axle oils have and that the ranking order of
lubricant composition and properties depends
greatly on the specified duty cycle, with high
Figure 1. The rules for determination of the mean shear stress [13]
viscosity, friction modified oils being favored (Do is Deborah number (= U/ (2Ge), S is non-dimensional strain rate (= g / ), * is non-dimensional shear stress (= / )
0
0 E
E
for high power use. In contrast, lower viscosity and c is the limiting shear stress)
fluids than are currently in use provide lower
losses for city and light highway duty.
In addition to only treating the axle, this work has other significant
shortcomings, including the lumped mass axle temperature that does
(1)
not capture the bulk lubricant temperature, and the lack of a change
gearbox model, as well as the lack of provision to determine the effect
of drive train efficiency on the engine behavior and therefore on fuel
(2)
consumption.
The present work is designed to offer significant improvements in the WHERE
is minimum EHL film thickness, m;
accuracy of efficiency predictions for simple spur gearboxes including the h0
effects of lubricant rheology on gearbox efficiency. The model accounts R x is reduced radius of contact, m;
is entrainment velocity, m/s;
for EHL friction losses in gear teeth contacts, bearing and seal losses,
and losses due to oil churning. The EHL friction losses are calculated
is gravitational acceleration, m/s2;
based on lubricant properties that have been obtained through extensive W

is total contact load, N;

measurements on a ball-on-disk tribometer, while also fully accounting hc
is central EHL film thickness, m.
for the effect of thermal coupling so that any increase in lubricant
temperature (and the corresponding change in lubricant properties) due
to power losses, is fed back to EHL friction calculations. The ambient
(3)
temperature of the lubricant in the gearbox is calculated using a multi
physics finite element model which includes all conductive and convective
(4)
heat transfers within the gearbox. Such a holistic approach, particularly

the inclusion of thermal coupling, will enable the model to account
for the transient conditions due to particular usage history and therefore
(5)
predict the efficiency for a given drive-cycle.

Where the non-dimensional parameters are the speed, load (L =
METHODS
line contact) and material parameter respectively.
This section first outlines the basics of the EHL model used to predict
tooth frictional losses, followed by the methods to predict bearing, seal, WHERE
and churning losses. Finally, the FEM approach used to calculate the
0 is inlet viscosity (at p = 0), Pa.s;
ambient (oil bath) temperature rise, which is fed back to the EHL model,
E is reduced modulus of elasticity, Pa;
is outlined.
is pressure-viscosity coefficient;
The experimental method used to extract lubricant characteristics that
W
L is total contact load in line of contact;
are used as input to the EHL model is also described.
L is length of EHL contact, m.

Basic EHL model

A thermally coupled EHL model was devised adopting the approach
of Olver and Spikes [13], which predicts the friction coefficient in the
rolling-sliding EHL contact of a lubricated disc pair.
The model uses the EHL regression equations developed by Chittenden
[16] to calculate the minimum and central film thickness:
30

gearsolutions.com

The mean shear stress is calculated based on the Ree-Eyring

approach as adapted by Evans and Johnson [17], and the traction
regime is decided using the following three-stage process described
by Olver and Spikes which is based on the non-dimensional Deborah
and S numbers (Figure 1).
The friction coefficient is then predicted by means of a convergence

loop; the loop is initiated by assuming an initial friction coefficient

0 and then the temperature rise due to shear heating of the lubricant
(Toil)av and contact of asperities (Tf)av are calculated using the
approach developed by Olver [13].

(6)

(7)

WHERE

h
is heat partition;
q
is heat generated by sliding in the contact,W;
A
is EHL contact area, m2;
k
is thermal conductivity, W/m-K;
1
is thermal diffusivity of material, m2/s;
0 is EHL semi contact width, m; B is transient thermal
resistance;
U s
is sliding velocity, m/s;
is shear stress, Pa;
koil is thermal conductivity of the oil, W/m-K.
Using these temperatures in conjunction with the skin (boundary)
temperature rise, TB, calculated using a heat partition h between
the two surfaces, the mean film temperature, T , can be calculated.

(8)

(9)

(10)

Figure 2. Flowchart of the EHL model algorithm

quoted by Muraki [19]. The ASTM equation based on the

ASTM D341-722 standard is used to calculate the low shear
rate viscosity of the lubricant, based on measurements at 40 C
and 100 C.
(11)

WHERE

v
b
c

is kinematic viscosity, m2/s;

is tooth face width, m;
is constant.

WHERE

M is steady state thermal resistance of contacting body.

The temperatures are repeatedly evaluated until the desired
convergence is achieved (usually within
0.1 C or less). Once these are known, the dissipated power
in the form of heat can be calculated by simply multiplying the
load with the friction coefficient and the sliding speed.
The EHL model assumes that the basic lubricant properties
do not change within the contact and are calculated either in
respect to the inlet conditions or to the mean film temperature
based on the assumption by Evans [18]. The lubricant properties
that are used are based on a synthetic 75W90 type gear lubricant
and they are calculated using a linear approach for the variation
of density and pressure viscosity coefficient with temperature.
The shear modulus is calculated using an exponential approach

The model can successfully predict the traction regime and

friction coefficient of a combination of materials and lubricants.
Roughness of the surfaces is also taken into account by means of
the non- dimensional lambda () value that necessitates the use of
a boundary modified friction coefficient of the form shown below,
suggested by Smeeth and Spikes [20] for m = 2.

(12)

WHERE

eff
f
b

is effective or mixed friction coefficient;

is fluid friction coefficient;
is boundary friction coefficient.
MARCH 2015

31

The model converges in less than 5 iterations for all but the most
extreme conditions and can be used as a base to simulate a lubricated
gear pair. The basic algorithm described here is summarized in the
flowchart of Figure 2.
Extracting lubricant rheology coefficients
The rheological characteristics of the lubricant play a crucial role in
determining the thermal and frictional behavior. Previous studies [13]
have shown that EHL contacts can operate at temperatures that are
significantly higher than the ambient oil bath temperature. Therefore, it is
necessary to produce an extended lubricant rheology database which will
include the typically high temperatures that are encountered in practice.
As stated earlier, the core of the EHL model is the Eyring model [21],
and it is therefore assumed that the lubricant is following the Eyring
behavior where the relationship between the shear rate and the shear
stress is described by the equation:

(13)

The viscosity in the second part of the equation is the high pressure,
in-contact viscosity which is in turn described by either the Barus [22]
or the Roelands equation. In this case, the complete equation originally
proposed by Roelands [23], which is both pressure and temperature
corrected was used:

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(14)

WHERE

P
is in-contact viscosity, Pa.s;

is viscosity constant (= 0.0000631 Pas);
r
is measured viscosity at atmospheric pressure;
p
is pressure;
pr
is reference pressure
Tr
is reference temperature.
135 is temperature constant where the viscosity becomes infinitely
high (-135C);
The atmospheric slope index, So , is calculated using the Roelands
chart [23] (p. 58) and the reference low shear rate viscosity at two (2)
temperatures. The measured values of r are listed in Table 1.
In order to extract the required coefficients for Roelands equation,
bench tests were carried out using an MTM ball-on-disc test rig to
measure the friction and an EHD rig to measure the film thickness of the
Lubricant

Type

40 C

100 C

Synth 75W90 gear oil

0.0751

0.013

Synth 75W90 gear oil

0.0926

0.0135

Table 1. Measured values of r

Figure 3. The MTM2 (above) and the EHD2 rig (below) by PCS Instruments that were used to measure friction and
film thickness respectively

lubricant under varying loads and temperatures. The former uses a steel ball pressed against a
steel disc to measure the traction coefficients under given conditions while the latter uses the optical
interferometry technique to measure the film thickness of the lubricant through a transparent
glass disc. The two rigs are shown in Figure 3.
The rheology coefficients namely the Eyring stress, E ,and the Roelands parameter, R ,were
then derived from the measured data using an approach similar to that outlined by LaFountain
[24]. This involves fitting the Eyring model to the measured traction curves obtained from
the MTM tests and then extracting the coefficients once the appropriate fit is achieved. The
coefficients were then incorporated into the EHD traction model to improve the accuracy of
the calculations. The lubricants modelled here are both fully synthetic 75W90 gear oils and are
believed to be of similar composition but they come from different manufacturers.
Spur gear pair design and modelling
With the rheology adequately modelled, the next step of the process involves designing a spur gear
pair for the required transmitted torque, desired life, and reliability. The gear design procedure
that is used is compliant with the British Gear Association and in accordance with international
design standards [25]. The gears and the bearings were designed for 12 months of continuous
operation which is equivalent to around 9000 hours. For simplicity, a 1:1 gear ratio was chosen.
After the rough design process is complete and the basic parameters of the gear pair are defined,
the geometrical parameters of the pair can be calculated according to appropriate standards [26].
The basic specifications of the selected gears are shown in Table 2. The gears that comprise the
gear pair are identical and are similar to the 23T gears mentioned in Petry-Johnson [14]. The
full model covers the geometry of spur and helical gears. However, in the presented study, only
spur gears have been considered. The load profile and the resulting pressure distribution of the
gear pair are shown in Figure 4. Note that the contact pressure for this application is in the high
end for a gear region at almost 2 GPa and that the slide roll ratio varies drastically along the path
of contact and is zero at the pitch point.
With the geometrical parameters defined, the EHL friction model can be applied to the
gear mesh to predict the coefficient of friction and the thermal parameters during the variable
conditions of a gear cycle.
The current tooth mesh cycle was used as a basis for the development of the model, and, in
each point of the line of contact, a sub-routine was applied to calculate the converging friction
MARCH 2015

33

Parameter
Normal module (mm)
Number of teeth
Pitch Diameter (mm)
Base Diameter (mm)
Root Diameter (mm)
Outside Diameter (mm)
Normal Tooth Thickness (mm)
Start of active profile (mm)
Face width (mm)
Tight mesh center distance (mm)
Centre distance (mm)
Pressure Angle (deg.)

Value
3.95
23
90.9
82.3
81.0
98.8
6.205
85.9
19.5
90.9
91.4
25

Table 2. The basic design parameters of the gear pair

Figure 4. The load and contact pressure distribution along the path of contact when input
torque is at the maximum of 800 Nm

coefficient and the resulting temperature rise inside the contact (mean
film temperature). As the roughness of the gears has also been taken into
account, a boundary friction coefficient of 0.11 was assumed in order to
also consider the boundary/mixed lubrication regime. The inputs that
have been used for the design and calculation of the gearbox are roughly
based on a 2013 Dodge Ram 3500 Semi Truck and are shown in Table 3.

Changenet and Velex [7]. Once the churning torque is calculated, the
churning losses are predicted using the rotational speed of the gears.
The series of equations used to calculate the churning losses based on
Changenets method are shown below:
(15)

TO HAN
UG D
HE LE
ST T
JO HE
BS
!

Modelling of losses due to bearing and seal friction

and churning
The remaining losses in a gearbox are those due to bearing and seal
friction and the churning of the oil. Churning losses are the largest of
these, and they are calculated using the set of equations developed by

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WHERE

Cch is churning torque, Nm;

is density, kg/m3;

is rotational speed, r/s;
Rp
is gear pitch radius, m;
Sm
is submerged surface area, m2;
Cm is dimensionless torque
Dp
is gear pitch diameter, m;
h
is gear immersion depth, m;
V0
is oil volume, m3;
Fr is Froude number dependent on the gear parameters (2 Rp/g)
Rec is critical Reynolds number ( Rp b/v)

Input

Value

Engine

6.7 L (408 in3) Cummins Diesel I6

Maximum power

350 (hp)/260 (kW)

Maximum torque

660 lbf. (900 Nm)

Design torque

1050 (Nm)

Gear roughness

0.32 (m)

Average lambda ratio

0.6
70 (C)

Ambient temperature of the oil bath

Table 3. The basic inputs for the design process and the model

has the same operational life expectancy, there are no over-designed

components. For simplicity, in this particular application, a 1:1 ratio
was chosen and, therefore, there is no need to design the bearings
individually.
Thermal coupling of the gearbox
To account for ambient temperature rise and incorporate
thermal coupling into the presented efficiency model, the
gearbox system was modeled using a multi-physics finite element
software tool. This FEM model calculates the conductive and
convective heat transfers within the gearbox itself and between
the gearbox and its surroundings. For the sake of simplicity,
the gears were approximated by rotating discs. The discs were
modeled in such a way as to sweep through the oil sump as
they would do in a real gearbox. The vehicle to which the
gearbox is attached is represented by a lump mass while air
is allowed to flow around the assembly at specified velocity

A linear interpolation between the two formulae is used when 6000

< Rec < 9000.
The calculation of the churning torque necessitates the definition of
a gearbox casing, where the hypothetical gear pair will operate. This is
essential so that the oil level inside the gearbox and the oil volume that is
being displaced by the gears can be calculated and taken into account.
Therefore, an arbitrary gearbox casing was defined and based on proper
clearances between the gears and the casing. Using Changenet [27]
as a guide, the value of 2 mn has been chosen for the radial clearance
and 1.5 mn for the axial clearance where mn is the normal module of
the gear. Once the casing is defined, the gearbox
churning losses can be modelled. Although
adequate clearances were defined, it should be
noted that in terms of size and shape the casing
defined here differs from that normally used in
the automotive applications. This is inevitable as
the current gearbox consists of a single stage only,
although the transmitted torque is representative
of automotive applications.
Bearing and seal losses were calculated using the
SKF bearing calculator tools [28] by considering
the selected bearing type and then calculating the
seal losses from the difference in losses between
the plain and the sealed bearings of the same
type. Bearing selection is an important design
parameter in a gearbox. A common design
procedure selects the bearings for each axle based
on the maximum load of the most heavily loaded
axle. Keeping in mind that the various axles in a
gearbox (two in the current simple single stage
application) rotate at drastically different speeds,
By utilizing any one of these controls
systems platforms (Siemens, Fanuc, NUM),
it is obvious that such an approach will lead to
MTB can improve your machine reliability.
one of the bearings to be over-designed and
that the system would be less efficient as a result.
Therefore, in order to improve the efficiency of
the system, ideally one should apply a procedure
that considers each component of the drivetrain
individually to ensure that while every component

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Figure 5. The multiphysics model of the simple gearbox

Figure 6. The coefficient of friction, minimum film thickness and mean film temperature
along the path of contact at 1600 rpm

causing forced convection and therefore simulating the moving

vehicle. The required inputs for the FEM model are obtained
from the numerical model presented above and include the total
dissipated heat from the teeth as well as the friction-induced
heat from the bearings. Figure 5 shows the modeled FEM
geometry and an example output of temperatures within a
gearbox.

the EHL conditions in the gear contacts at specified conditions

are shown, followed by magnitudes of individual losses in gear
contacts, bearings, and those due to churning. The total losses and
the relative contribution of each loss source are shown. Finally,
the model is used to compare the relative efficiency of the whole
gearbox for the two selected oils.

RESULTS AND DISCUSSION

This section shows example results obtained through the
application of the model described above. All results are for oil
A at the condition of 90% of maximum torque (800Nm). First,

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Friction in gear teeth contacts

The predicted friction coefficients, minimum film thickness and the mean
film temperatures along the path of contact for oil A and conditions
specified in Table 2 are shown in Figure 6. Friction reaches a maximum
value of 0.0593 at around 6 mm along the contact path and is minimized

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Figure 7. The efficiency of the gear pair along the path of contact at 1600 rpm

Figure 9. The individual and total losses of the modelled gear pair at 70 C

Bearings
The bearings that were selected for the application and the power loss
that results from their rotation at maximum load and at the corresponding
rotational speed are shown in Table 4. Note that single sealed bearings
were chosen because these use the internal lubricant and are only sealed
to prevent leakage to the outside of the shell.

Figure 8. The churning losses of the gear pair relative to the immersion depth of the gear
in a range of speeds typical of automotive applications

at the pitch point. It is also evident that the minimum film thickness
remains almost constant throughout the contact. The temperature
quickly rises as the slide roll ratio increases and is minimized at the pitch
point as may be expected.
Efficiency
Since it is assumed that the losses of the gear pair are predominantly in
the form of dissipated heat, the calculation of the heat combined with
the actual transmitted power can provide the efficiency of the gear pair
in each step. Figure 7 shows example of efficiency calculations along the
tooth contact path for oil A at gearbox conditions listed in Table 2. As
expected, the efficiency within the mesh cycle varies according to the slide
roll ratio with the values in the overall range of 98-100%.
Churning
Figure 8 shows how the churning losses vary with the rotational speed
and the immersion depth of the gear. As expected, the larger the portion
of the gear that is submerged the higher the churning losses are. It is
evident that increasing speed also increases churning losses. The rate of
increase in losses with speed depends strongly on the immersion depth
itself. In the example of Figure 8, it is clear that the speed has a much
bigger influence on losses for the bigger immersion depth of 12 mn.
The churning losses for this particular application, which can be seen
in Figure 4.4 were calculated for T = 70 C and immersion depth equal
to 6 mn ,which is relatively shallow. Since the most important parameter
for churning losses is the volume of the gear that is submerged in the oil,
and since the gears in this application are relatively small, the churning
losses are predictably only a small portion of the overall losses.
38

gearsolutions.com

Combined losses
The combined losses in the gearbox across the power range of the
engine can be seen in Figure 9. The calculations are carried out
through a set of conditions corresponding to actual spots on the
torque-power curve of the Diesel engine of the reference vehicle
at roughly 80-90% of accelerator pedal input.
It is evident that the EHL friction losses in the gear teeth contacts
provide by far the largest contribution to overall losses. However,
the relative magnitudes of each contribution differ for different
operating speed and torque conditions. In particular, the power
loss in bearings and those due to churning only become significant
at high rotational speeds, although they are still smaller than losses
in gear teeth contacts.
The overall efficiency, including all additional losses for
lubricant A under the specified conditions, is shown in Table 5.
The values are in the range of 99-99.15% and broadly agree
with the results of the experimental study of Petry-Johnson [14].
Shaft

Designation

Power loss (W)

1 (1600
rpm)

6212
6212 RS1 (sealed)
6212

74 2
99.3 (+ 25.3) 2
74 2

2 (1600
rpm)

6212 RS1 (sealed)

99.3 (+ 25.3) 2

Total losses (bearings + seals)

397.2 (296 + 101.2)

Table 4. The bearings of the single-stage gearbox and their respective power loss at 90%
torque for oil A
Condition

Efficiency (%)

400 Nm / 650 rpm

98.98

640 Nm / 1250 rpm

99.07

800 Nm / 1600 rpm

99.11

740 Nm / 2300 rpm

99.14

640 Nm / 2800 rpm

99.13

Table 5. The overall efficiency across the power range for lubricant A

Figure 10. The total dissipated heat due to gear friction for lubricants A and B

Figure 11. The effect of thermal coupling on the oil temperature prediction

Relative contributions of different loss sources shown here are also

generally comparable to those shown in the same study. However,
these previous results are not directly comparable to the current
study because they were obtained on a temperature-controlled,
jet-lubricated gearbox, which is significantly different than the
current dip-lubricated application.

and torque settings of 400 to 800 Nm corresponding to the particular

automotive application chosen. Figure 10 shows predicted gear friction
power losses for the two lubricants under these test conditions. It should
be noted that thermal coupling was not used when calculating the losses
in this particular case. The results clearly show that the predicted
gearbox efficiency for the two lubricants varies by about 1-2% depending
on the operating conditions.
These preliminary results are encouraging as they confirm that the
devised methodology is able to differentiate between different lubricants
in terms of their effect on transmission efficiency and that different
lubricant rheology is indeed an important factor in the overall transmission
efficiency. Therefore, the model will now be further refined and used to
provide a more extensive set of results.

Lubricant comparison
The described approach is capable of comparing different lubricants in
terms of their effect on the overall efficiency of the gearbox. To illustrate
this, the efficiency was calculated for the two lubricants described in Table
1, whose rheology was extensively characterized following the method
described earlier. The model was run in the range of 650 - 2800 rpm

MARCH 2015

39

Thermal coupling
The model described above is able to calculate
friction using an EHL algorithm and can
predict the ambient temperature rise resulting
from the heat loss in the contact. However,
if the model is not thermally coupled, the
accuracy of the method is suffering significantly
because even though the contact temperatures
are predicted using a feedback loop as illustrated

earlier, the ambient temperature receives no

thermal feedback from the code. However,
the addition of the multiphysics simulation
addresses this drawback by adding the missing
link of feedback.
As soon as the temperature rise in the contact
is calculated, it is fed back at the inlet of the
model. This loop continues until the model
reaches a state of thermal equilibrium where

the heat that is generated in the contact is being

dissipated away, resulting in zero temperature
rise. The model converges relatively quickly
due to its simple layout. A comparison of
the thermally coupled ambient temperature
prediction and the non-thermally coupled
prediction highlights the significance of the
coupling as can be seen in Figure 11. The
initial value of ambient temperature was 70
C in both cases and the simulated condition
was that of 90% of maximum torque at 800
Nm and 1600 rpm.
The temperature predicted using the
thermally coupled model is almost double
compared to the non- thermally coupled.
This is expected as the EHL code on its own is
essentially an in-contact code used to calculate
thermal gradients and temperature rise within
the contact while it lacks any information about
the thermal parameters outside the contact such
as the heat capacity of the assembly, the outside
air flow, and the complex thermal network
involved in the heat path. Past efficiency studies
[14] omit the temperature rise of the oil sump
and, instead, focus on efficiency and power loss,
keeping the temperature controlled at a specific
value via thermocouples. However, this may not
be the case in real-life application, where there is
a constant heat exchange between the gearbox
and the environment.

CONCLUSIONS
A simple thermally coupled one-stage gearbox
has been simulated using an EHL model to
calculate the friction within the teeth contact and
the resulting frictional losses. The present model
was based upon viscoelastic rheology, according
to the Eyring Maxwell theory and, crucially, uses
well-defined lubricant characteristics obtained
from extensive experimental tests. The EHL
traction is calculated using a fast, iterative
method. The model calculates the traction,
the temperatures, and the film thickness within
the contact as well as the ambient temperature
rise. The model includes full thermal coupling
by accounting for ambient temperature rise of
the oil in the sump and the effect that this has on
oil properties and, consequently on gear-teethcontact friction. The ambient temperatures
were calculated through the application of a
multiphysics FEM simulation which considers
all conductive and convective heat transfers in
the gearbox. Bearing, seal, and churning losses
are also considered. Preliminary results show
that the efficiency of the gearbox is strongly
40

gearsolutions.com

dependent on the lubricant rheology as well as

on the operating conditions. Changes in the
lubricant composition can therefore provoke
changes in the relative fuel economy of a
vehicle. The high temperatures that have been
predicted even for relatively mild operating
conditions highlight the need for accurate
lubricant data at such high temperatures. The
current model has been successfully used to
highlight the differences between two lubricants
with similar formulation and slightly differing
rheology. Work is underway to elucidate the
effects of lubricant properties on the overall
gearbox efficiency.

REFERENCES
1. Baglione, M., Duty, M., Pannone, G., Vehicle
system energy analysis methodology and tool for
determining vehicle subsystem energy supply and
demand, SAE Technical Paper 2007-01-0398,
2007, SP-2072, http://www.fueleconomy.gov/
feg/atv.shtml.
2. Anderson, N.E., and Loewenthal, S.H., Spur-Gear
Efficiency at Part and Full Load, NASA Technical
Paper 1622, AVRADCOM, 1980.
3. Anderson, N.E., and Loss, P., Effect of Geometry
and Operating Conditions on Spur Gear System,
no. 80, 1981.
4. Li, S., and Kahraman, A., Prediction of Spur
Gear Mechanical Power Losses Using a Transient
Elastohydrodynamic Lubrication Model,
Tribology Transactions, 53:4, 554-563, 2010.
5. Chang, L., and Jeng, Y.R., Modeling and Analysis
of the Meshing Losses of Involute Spur Gears
in High-Speed and High-Load Conditions,
Transactions of the ASME, Journal of Tribology,
Vol 135, 2013.
6. Hhn, B.-R., Michaelis, K., and Hinterstoier,
M., Optimization of Gearbox Efficiency, Gear
Research Centre FZG, Technische Universitt
Mnchen, Germany, 2009.
7. Changenet, C., and Velex, P., A Model for
the Prediction of Churning Losses in Geared
Transmissions - Preliminary Results, Journal of
Mechanical Design, 129(1), pp. 128133, 2007.

8. Changenet,, C., and Velex, P., Housing Influence

on Churning Losses in Geared Transmissions,
Journal of Mechanical Design, Vol 130, pp.
128133, 2008.
9. Long, H., Lord, A.A., Gethin, D.T., and Roylance,
B.J., Operating temperatures of oil-lubricated
medium-speed gears: numerical models and
experimental results, Proceedings of the I MECHE
part G: Journal of Aerospace Engineering, 217 (2).
pp. 87-106, 2003.
10. Taburdagitan, M., and Akkok, M., Determination
of surface temperature rise with thermo-elastic
analysis of spur gears, WEAR 261 pp. 656-665,
Elsevier B.V., 2006.
11. Changenet, C., Oviedo-Marlot, X., and Velex, P.,
Power Loss Predictions in Geared Transmissions
Using Thermal Networks-Applications to a SixSpeed Manual Gearbox, Journal of Mechanical
Design, vol. 128, no. 3, p. 618, 2006.
12. Olver, A.V., Testing transmission lubricants: the
importance of thermal response, Proceedings
of the Institution of Mechanical Engineers, Part
G, Journal of Aerospace Engineering, 1991,
206(G1), 35-44.
13. Olver, A.V., and Spikes, H.A., Prediction of
traction in elastohydrodynamic lubrication,
Proceedings of the Institution of Mechanical
Engineers, Part J: Journal of Engineering
Tribology 1998 212: 321.
14. Petry-Johnson, T., Kahraman, A., Anderson,
N.E., and Chase, D., An Experimental
Investigation of Spur Gear Efficiency, Journal of
Mechanical Design, DOI: 10.1115/1.2898876,
2008.
15. Kolekar, A., Olver, A.V., Sworski, A.E., and
Lockwood, F.E., The efficiency of a hypoid
axle - a thermally-coupled lubrication model,
Tribology International, Volume 59, March
2013, pp 203209.
16. Chittenden, R.J., A Theoretical Analysis of the
Isothermal Elastohydrodynamic Lubrication of
Concentrated Contacts, Direction of lubricant
entrainment, Proceedings of the Royal Society
A: Mathematical, Physical and Engineering
Sciences, 397, 271294. 1985.

17. E
 vans, C.R., Johnson, K.L., The rheological
properties of elastohydrodynamic lubricants,
Proceedings of the Institution of Mechanical
Engineers. C200, pp. 303-312, 1986.
18. Evans, C.R., Johnson, K.L., Regimes of traction
in elastohydrodynamic lubrication, Proc.
Institution of Mechanical Engineers, Part C,
Journal of Mechanical Engineering Science,
1986, 200(C5), pp 313-324.
19. 
Muraki, et al., Influence of temperature
rise on non-Newtonian behavior of fluids in
EHD conditions, In Proceedings of the Fifth
International Congress on tribology (Eds K.
Holmberg and I. Nieminen), Espoo, Finland,
1989, Vol. 4, pp. 226-231.
20. Smeeth, M. Spikes, H.A., The influence of
slide roll ratio on the film thickness of an EHD
contact operating within the mixed lubrication
regime, Presented at the Twenty-second LeedsLyon Symposium on Tribology, The Third
Body Concept, Lyon, France, 5-8 September
1995.
21. Eyring, H., Viscosity, Plasticity, and Diffusion
as Examples of Absolute Reaction Rates, The
Journal of Chemical Physics 4, 236.
22. Barus, C., Isothermals, Isopiestics and Isometrics
in Relation to Viscosity, American Journal of
Science, 3rd Ser. 45, pp. 87-96, (1893).
23. Roelands C.J., Correlational aspects of the
viscosity-temperature-pressure relationship of
lubricating oils, University of Delft, 1966.
24. LaFountain, A.R., Johnston, G.J., and Spikes
H.A., The Elastohydrodynamic Traction
of Synthetic Base Oil Blends, Tribology
Transactions, 44, 648-656 (2001).
25. Hoffman, Dieter A., British Gear Association
Teaching Pack, Module 4.
26. Hoffman, Dieter A., British Gear Association
Teaching Pack, Module 3.
27. Changenet, C., and Velex, P., Housing Influence
on Churning Losses in Geared Transmissions,
Transactions of the ASME, Journal of
Mechanical Design, Vol. 130, 062603-1, 2008.
28. http://www.skf.com/group/knowledge-centre/
engineering-tools/skfbearingcalculator.html

ABOUT THE AUTHORS: Dr. Amir Kadiric is a senior lecturer in the Department of Mechanical Engineering and a member of Tribology Group.
He also leads the SKF University Technology Centre for Tribology at Imperial College. He obtained his MEng degree in Mechanical Engineering
followed by a PhD in Tribology from Imperial College in 2005. He subsequently took a post at SKFs Engineering and Research Centre in the
Netherlands where he worked on rolling bearing research, before returning to Imperial. Kadirics research focuses on efficiency and reliability
of mechanical systems, including damage accumulation in rolling/sliding contacts through mechanisms of rolling contact fatigue, micro pitting
and scuffing; frictional losses and efficiency in transmission systems; contact mechanics; and surface coatings.
Athanasios Christodoulias is a PhD student in the Department of Mechanical Engineering and a member of Tribology group at Imperial
College London. He obtained his Diploma in Mechanical Engineering and Aeronautics from the University of Patras, Greece in 2010. His
research focuses on the efficiency of drivetrain components utilizing numerical simulation, finite element and experimental methods.

MARCH 2015

41

Machine Involute Splines and Serrations

with Rotary Broach Tools
By Peter Bagwell

Rotary broaching is not just for machining hexagon holes in screws. Here, youll
learn more about the new product innovations and advanced techniques that
continue to shape the broaching industry today.
Of the many ways to machine a form suitable for a gear, rotary
broaching is not often the first considered. Precision grinding,
broaching, EDM, and hobbing all have advantages in various
features. Yet, innovation in rotary broaching tools is still alive
and should be considered for various forms including small
involute splines and serrations.
Rotary broaching tools were first patented more than 100
years ago by H.E. Warren in 1914. The concept involves using
a machine to wobble a cutting tool from one corner to the
next at a slow feed rate into a pilot hole. As the broach reaches
the bottom of the hole, the complete form has been machined
in a fast cycle time without a secondary operation.
In the 1950s, commercial rotary broach tool holders were
adapted into turning machines and screw machines. These
tools were suitable for small hexagon, square, and polygon
forms. However, interest began to grow and various other
shapes, such as serrations and splines, were manufactured by
rotary broaching.
Enter the 21st century and, now, rotary broaching tools
for CNC machines have advanced features such as sealed
bearings, pressure relief holes, and improved cutting tool
steel. Ease of use has relaxed the skills needed to install the
tools in the machine and more operators have become aware
of their use. Today, rotary broaches are routinely used for
making hexalobular and involute forms in precision-machined
products in the standard lathes and mills found in nearly every
machine shop.
However, the most significant challenge for rotary broaching
has been the limited amount of material that can be removed
in each pass of the broach. The average amount of material
that can be removed with a rotary broach is approximately
.025 per side. Improved techniques are helping to break
through this barrier.
For example, if you have a half-inch diameter involute spline
with tooth height of .025 per side, you should be able to rotary
broach the form on your CNC machine. However, a one-inch
diameter form with a .050 tooth height cannot typically be
done due to the tooth height. New techniques are solving this
problem and allowing more forms to be manufactured by
rotary broaching.

Rotary Broach Dog and Guide Post Fixture

Rotary Broach Brake, Tool Holder and Custom Rotary Broach

One method is to use a new tool called a rotary broach

brake. The brake attaches to the broach holder and holds the
broach in position in between turning cycles. This tool allows
the operator to remove the broach, drill out chips that are
increasing pressure on the operation, and reinsert the broach
into the hole in the same position it was removed.
The aligning of the broach to the partially broached hole
could not be done previously because free turning rotary
broach spindles do not include alignment features. The broach
brake may also be used to align the involute form to another
feature on the part. If there is a missing tooth in the form that is
aligned with a perpendicular screw hole, the brake is manually
adjusted to align the form properly.
The broach brake might also be used to align multiple
broaches. Just as conventional broaches use multiple teeth to
MARCH 2015

43

cut the form in a part, multiple broach holders

with brakes could be used to machine a part
larger than .025 per side. The earlier
example of a form with .050 material
removal might be machined using three
different broaches starting with the smallest
and ending with the final form.
However, rotary broach brakes are not
always the ideal choice for rotary broaching

these larger gear forms. Manual adjustments

and larger work envelope space may rule
out its use. Another option is the use of a
dog and guide post.
The dog is attached to the rotary broach
holder spindle and will rest against the
guide post when the tool begins turning.
The guide post will always align the broach
to the pilot hole in the same position and

Choose from one of our portable

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help keep it cutting straight in the hole.

This fixture can often be assembled using
standard screws and plates.
Setting up a rotary broach dog and guide
post is more work and will take longer than
setting up the rotary broach brake. However,
the guide post is a more rigid set-up and can
be relied on for longer sessions of unattended
machining. The broach brake requires more
attention, but can be set up to begin broaching
very quickly.
Innovation in rotary broaching tools has not
been limited to the tool holders. Many rotary
broaches are now made with standard pressure

Rotary Broach Brake, Tool Holder and Custom Rotary Broach

Case Study: Rotary Broaching for the Next Generation

relief holes to prevent hydraulic pressure from

building in blind holes. New broach materials
and coatings are constantly being tested to
improve tool life.
Rotary broach forms are typically
manufactured to a tolerance within .0005
and cut accurately. Limitations due to grinding
and EDM may require .005 maximum radii
in the sharp corners, but this area of the form
is also removed from the part and is usually an
acceptable compromise. Slightly oversize pilot
holes for internal broaching and undersize
diameters for external broaching needed to

For more than 30 years, the Society of Automotive Engineers (SAE)

has held an annual competition
known as Formula SAE. The goal
is to design and build a formulastyle racing car, and then compete
against similar race cars from
all over the world. University of
Washington Formula Motorsports
students needed to make a hole to
match the serration of one of their
drive components.
The serration had a major diameter of 11.35mm, a minor diameter
of 10mm, and 30 teeth. Students
contacted rotary broach manufacturer Polygon Solutions Inc. to
determine if the form was suitable.
After confirming the suitable mate-

rial removal per side and the shallow depth of the hole the custom
serration broach was ordered.
An approval drawing was sent
to the students to confirm all of
the required dimensions and the
broach was manufactured and
delivered shortly after. The racing students achieved an early
victory and were able to quickly
and easily machine the complex
form in a milling machine using a
standard adjustment free broach
holder and custom designed
rotary broach. Future broaching
projects are also planned with
the new partnership developing
between the students and engineers at Polygon Solutions.

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MARCH 2015

45

create individual chips often eliminate the radii

portion of the form and make this limitation
irrelevant.
Many customers wanting to make mating
parts for spline shafts and other gear related
forms often expect to find standard serrations
and splines available off the shelf. However,
the wide variety of international standards and
standards between various trades makes this

unrealistic. Most multi-toothed rotary broaches

will be made to your custom dimensions
within a short period of time. Some time may
be required to generate working or approval
drawings needed to manufacture the tools.
Some modification to the forms can be
made after the broach is manufactured. Due
to the back-taper needed to allow the broach
to wobble in the hole, rotary broaches

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are not typically sharpened. If the broach

was sharpened, the form would drastically
decrease in size.
If the internal form is at the high side of the
tolerance, and the fit is too loose, the broach
may be able to be slightly ground or dusted
on the end resulting in a smaller form. When
broached, this will result in a smaller hole and
tighter fit. Sharpening and modifying the form
by grinding the end of the broach should be
done with caution as modern adjustment free
versions of rotary broach holders designed for
CNC machines rely on the fixed length of the
standard broaches to keep the form on center.
Many of the limitations for rotary or
on-machine broaching are changing,
and it may be worthwhile to revisit some
manufacturing processes or product designs
to see if your parts are candidates. Eliminating
secondary operations and reducing cycle times
are very effective means of reducing costs
and utilizing idle turning machines. Contact
your rotary broach supplier to see if you can
machine your involute splines and serrations
with rotary broach tools.
ABOUT THE AUTHOR: Peter Bagwell is a
Rotary Broach Product Engineer at Polygon
Solutions, Inc. in Fort Myers, Florida, and
a board member of the Southwest Regional

www.McInnesRolledRings.com

Manufacturers Association. Peter shares over

1.800.569.1420

expert technical support with thousands of

gearsolutions.com

10 years of experience in broaching and

Polygon customers and can be reached at
peter@polygonsolutions.com.

Vacuum Heat Treating

...because quality is critical

We know high quality gears and automotive
components are vital to performance. Our leading
edge vacuum technology and expertise provides
precise control and repeatability for consistently
superior parts.
Low Pressure Vacuum Carburizing (LPVC)
High Pressure Gas Quenching (HPGQ)
Vacuum Stress Relieving

Advantages

Uniformity of case depths

Minimized distortion
No IGO (Intergranular Oxidation)
Parts returned clean, free of soot eliminating
downstream cleaning processes

For more information or an immediate quote,

call 1-855-WE-HEAT-IT or visit solaratm.com

AS ISO

9001:2008
9100C

Heat Treating | Brazing

Hardness Testing

Philadelphia Los Angeles

Pittsburgh South Carolina

VACUUM PROCESSING

registered

Heat Treating Brazing Carburizing Nitriding

PRODUCT
SHOWCASE

HONING MACHINE OPTIMIZES GEAR FINISHING

Available from German Machine Tools of
America, the Prwema SynchroFine 205 HS gear
honing machine features direct-driven, digitally
controlled spindles for the tool and the workpiece,
enabling precise, rigid synchronization
Now available from German Machine Tools of
America (GMTA), the Prwema SynchroFine 205
HS gear honing machine features direct-driven,
digitally controlled spindles for the tool and the
workpiece, enabling precise, rigid synchronization.
The Prwema Honing gear finishing process
produces quality comparable to grinding results
for spur and helical gears, as well as shafts. The
machines software checks the stock allowance and
workpiece runout and then optimizes the X-axis
approach distance. Measuring the workpiece does
not affect the cycle time and the process can reduce
cycle times by 3 to 5 sec.
The machine features a pick-up design to enable
automation. The workpieces and dressing tools are
loaded and unloaded by the workpiece spindle.

48

gearsolutions.com

The large X-axis travel enables placement of

additional stations adjacent to the loading/
unloading station inside the machine, such as a
two-flank roll-checking device. External robots
and conveyor systems can also be integrated by
GMTA engineering.
The honing machine is constructed on a
natural granite bed to promote stability and
control thermal fluctuations. The X and Z axes
are equipped with linear motor drives. The cutting
tool is clamped with a hydraulically operated
system and the tool spindle can be swiveled into a
vertical position, enabling easy access. Additional
options are available for machining oversized
drive shafts as long as 850 mm and the Prwema
SynchroFine 205 HS-D model, equipped with
two spindles, is offered for further reduction of
cycle times.
For more information, please contact GMTA
by phone at (734) 973-7800, or by email at
scott@gmtamerica.com.

www.gmtamerica.com

NEW FLANGE COUPLINGS DELIVER

HIGHER TORQUE CAPACITY
Ringfeder Power Transmission is now offering its new RfN 5571
series of flange couplings for heavy duty applications. These
couplings offer easy installation and have higher torque capacity
than standard press fits.
Equipped with Ringfeder shrink discs, the RfN 5571 flange
couplings can be integrated into machines without any heating or
cooling, making them easily installable for engineers. They are slip
fit and come with either hexagon-head or hexagon socket-head
cap screws. Other advantages include:
No wear parts.
Backlash-free shaft-hub connections.
High true running accuracy.
Elimination of additional components such as keyways or
shims.

www.ringfeder.com

A COMMON SENSE APPROACH IN

THE MANUFACTURING OF WORLD
CLASS GEARS
Raycar manufactures high
quality smooth running gears
offering competitive pricing
and quick turn around.
CNC GEAR BLANKING
CNC GEAR SHAPING
CNC GEAR HOBBING
CNC GEAR GRINDING
ANALYTICAL CHARTING
EQUIPMENT

RfN 5571 flange couplings are ideal for mining applications,

general gearbox designs and plant manufacturing.
For more infor mation from Ringfeder Power
Transmission USA, call (201) 666-3320 or by email at
sales.international@ringfeder.com

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, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears,
Clutch Gears, Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, Bevel
Gears, Miter Gears, Metric Gears, Internal Gears, Idler Gears, Gear Rack &
Pinion, Worms, Wormshafts, Splines, Spline Shafts, Serrated Shafts.

STD Precision Gear & Instrument, Inc.

WE WANT THE OPPORTUNITY TO MAKE YOUR NEXT HIGH QUALITY GEAR
SEND YOUR QUOTES TO:
Raycar Gear & Machine Co.
6125 11th Street
Rockford, IL 61109

Phone: 815.874.3948
www.raycargear.com
sales@raycargear.com

318 Manley St. Unit 5 West Bridgewater, MA

02379
(888) STD-GEAR or (508) 580-0035
Fax (888) FAX-4STD or (508) 580-0071
E-mail info@stdgear.com
Web site: www.stdgear.com

MARCH 2015

49

SUMITOMO MACHINERY CORPORATION OF AMERICA

LAUNCHES NEW CUSTOM EQUATION SOLVER APP FOR IOS
Sumitomo Machinery Cor poration
of America, U.S.A. headquarters for
Sumitomo's Power Transmission and
Control Group, is proud to introduce PT
Equate, a custom equation solver. The

new equation solver mobile app, available

exclusively for Apple iOS, offers users the
capability to create their own equations
with customizable variables and a visual
editor to represent the equation and its

SOLVE
YOUR MOST
CHALLENGING
MANUFACTURING
15SUES
AeroDef Manufacturing 2015
Dallas, Texas, USA | April 2023, 2015
Exhibits: April 21-22, 2015
AeroDefEvent.com/GS

WITH

MEDIA PARTNERS

PART OF ADVANCED MANUFACTURING MEDIA

Access the leaders and the

technologies in aerospace
and defense manufacturing.
AeroDef Manufacturing 2015.
Manufacturers are challenged by
increasing demands and pressure to
drive innovation. AeroDef Manufacturing
brings together the best and the
brightest leaders in the industry to
openly discuss the issues we all face in
the extended manufacturing enterprise.
Join us! Learn more about new ideas
and technologies to meet the
challenges ahead.

EXECUTIVE COMMITTEE

50

gearsolutions.com

Aero15_ISSUES_4.875x7.875".indd 1

12/10/14 5:31 PM

www.sumitomodrive.com

components through sketches, drawings,

photos or diagrams.
PT Equate is preloaded with
equations commonly used in the Power
Transmission industry, such as Torque to
Electric Power, Cyclo Overhung Load,
Rotational to Linear Velocity and Torque
to Accelerate Inertia. Users can create
custom equations and corresponding
visual aids through the equation builder
functionality of the app.
The contact options of PT Equate
enable users with a data network or
wifi connection to email Sumitomo,
locate their nearest Sumitomo Drive
Technologies' sales representative, or
visit Sumitomo's global website or online
product Configurator.
Designed to visualize and solve custom
equations, Sumitomo's PT Equate is a
universal app available on the Apple
App Store in English for devices running
iOS 6 or later, and features an interface
optimized for iOS 7.
For more information, or to contact
Sumitomos marketing department directly,
send an email to marketing@suminet.com.

TOOL MANAGEMENT TO GO
ZOLLER has just launched three new apps for
each of its TMS Tool Management Solutions
software packages to give users access to their
tool data at any time from any location. Master
data, graphics, warehouse information, and
more can be accessed remotely, warehouse
inventory, and tool service lives or reasons
for replacement can be documented on an
iPhone or iPad. All information is transparently
displayed and easy to use, which is what users
expect from their iPhones and iPads.
The right application for each package
The app for the BRONZE TMS package
enables users to view the single components,
the setting sheets and the tools. The software
identifies the detailed data and drawings, tools
and single components via the mobile device's
built-in camera using the barcode or QR code
and data matrix.

www.zoller-usa.com

Decentralized inventory transaction

The SILVER app makes part list printouts
obsolete. All tools can be put into and taken
out of storage and the storage location selected
remotely. Users now no longer have to go to
the main computer in the warehouse and,

instead, can conveniently enter stock items in the

warehouse system from anywhere. Moreover,
users receive not only information on precisely
where their tools are located, a three-dimensional
graphic additionally displays the storage location
of the tools in the cabinet. Lastly, users can
manage how certain types of tools are stored,
for example, new or re-machined tools.
Mobile query for tool service lives and reasons for replacement
With the GOLD app, users can additionally
create tool service life entries, which means
the service lives can be queried directly on the
machine and reasons for replacement defined.
The corresponding statistics on tool service lives
or information on suppliers and delivery times
are available remotely.
This gives users access to their tool data at all
times, from any location and without having to
worry about time-consuming installation.
The app can be used with any company-wide
wireless connection or at any preferred location
with Internet access. It is available from the App
store for the iPhone and iPad with iOS 7 and 8.
For more information, contact Dr. Karin
Steinmetzer at steinmetzer@zoller-usa.com.

MARCH 2015

51

MACHINERY
FEATUREDSUPPLIERS
GQ Machinery Inc. REF #101
Phone: 516-867-4040 Fax: 516-223-1195
Email: george@gqmachinery.com
Website: www.gqmachinery.com
Gibbs Machinery Company REF #102
Phone: 586-755-5353 Fax: 586-755-0304
Email: rj@gibbsmachinery.com
Website: www.gibbsmachinery.com
Havlik International Machinery, Inc. REF #103
Phone: 519-624-2100 Fax: 519-624-6994
Email: havlik@bellnet.ca
Website: www.havlikinternational.com
Midwest Gear Corporation REF #104
Phone: 330-425-4419 Fax: 330-425-8600
Email: sales@mwgear.com
Website: www.mwgear.com
New England Gear REF #105
Phone: 860-223-7778 Fax: 860-223-7776
Email: jeff@newenglandgear.com
Website: www.newenglandgear.com
R. P. Machine Enterprises, Inc. REF #106
Phone: 704-872-8888 Fax: 704-872-5777
Email: sales@rpmachine.com
Website: www.rpmachine.com
Repair Parts, Inc. REF #107
Phone: 815-968-4499 Fax: 815-968-4694
Email: rpi@repair-parts-inc.com
Website: www.repair-parts-inc.com

GEAR ACCESSORIES, PARTS & TOOLING

FELLOWS Model #10-4/10-2, All Parts Available REF#105
Tilt Tables for 10-2/10-4, Qty 2 REF#105
FELLOWS Parts Available For All Models REF#106
BARBER-COLMAN PARTS AVAILABLE FOR ALL MODELS REF#106
G&E PARTS AVAILABLE FOR ALL MODELS REF#106

GEAR HOBBERS/CUTTERS CNC

PFAUTER #PE-150, 6-Axis CNC, 6 Dia, 5 DP, 6 Face, Fanuc 18MI REF#106
G&E #60 S-2 CNC Gasher/Hobber REF#106
BARBER-COLMAN #16-36, 16 Dia, 4-Axis, 6 DP, 36 Face REF#106
MUIR CNC Gear Hobber, 4-Axis, 118 Dia REF#106
LIEBHERR #L-252 3-Axis, 9.8 Dia, recontrolled 2008 REF#106
LIEBHERR #ET-1802 CNC 98 Dia Internal, 3-Axis REF#106
G&E #120GH, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42 Face, 94 REF#106
PFAUTER P400H, 5-Axis, 18 Dia, 1 DP, Recontrolled 03 REF#106
G&E #96GH, CNC, Gasher/Hobber, New 09 REF#106
PFAUTER PE 300 AW CNC 6-Axis REF#106
Pfauter PE150, 15MB Fanuc, Chip Conveyor, Auto Load REF#102
Pfauter PE150, Siemens 3M, Magnetic Chip Conveyor, Oil Chiller REF#102
Pfauter PE150, Fanuc 15, with light hob slide 8 REF#102
Pfauter PE80, 15MB Control, Auto Load, Light Curtain REF#102
Liebherr LC82 15M Fanuc Control, Auto Load REF#102

GEAR HOBBERS/CUTTERS
PFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#105
PFAUTER (1) RS-00 s/n 17593 REF#105
BARBER COLEMAN (1) 16-36 multi cycle s/n 4404 REF#105
BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm and/or Single Thread Worm
REF#106

52

gearsolutions.com

Contact Gear Solutions at

800-366-2185 to list your machinery.

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

G&E #48H, 48 Dia, 35 Face, 3 DP, Gooseneck Attachment REF#106
BARBER-COLMAN #6-16, 6 Multi-Cycle REF#106
G&E #36H Differential, Excellent Condition REF#106
BARBER-COLMAN #14-30, 14 Dia, 30 Face, 3.5DP REF#106
BARBER-COLMAN #14-15, 14 Dia, 15 Face, 1 to 4 Start Worm, Several REF#106
BARBER-COLMAN #16-16, 16 Dia, 16 Face, 6DP REF#106
BARBER-COLMAN #16-36, 24 Dia, C-Frame Style, 4 1/8 Bore REF#106
BARBER-COLMAN #16-56, 16 Dia, 56 Face, Differential REF#106
G&E #24H Universal Head, Infeed, Tailstock, Differential, 50s REF#106
LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New 70s REF#106
G&E #16H Gear Hobber, 16"Dia REF#106
BARBER-COLMAN #6-10, 6 Dia, 10 Face, 16 DP REF#106
KOEPFER #140 , 2.75 DIa, 4 Face REF#106
LANSING #GH-50, 50 Dia, 17.75 Face, 2 DP REF#106
LIEBHERR #L-252, 9.8 Dia, 7.9 Face, 4.2 DP REF#106
BARBER-COLMAN TYPE T REF#106
G&E #36HS 36Dia, 14 Face 3 DP REF#106
PFAUTER #P-3000, 120 Dia, Single Index REF#106
SCHIESS RFW-10-S 55 Dia REF#106
SCHIESS 1 RF-10, Dia 60 150 L, .50 DP REF#106
G&E #40TWG, 48 Dia, 18 Face, 3 DP REF#106
G&E #60S, 72 Dia, 14 Face, 1.25 DP REF#106
G&E #72H, 72 Dia, 24 Face, 1 DP REF#106
G&E #96H, 104 Dia, .50 Face, 1.25 DP REF#106
PFAUTER #P-630, 25 Dia REF#106
PFAUTER P250 10 Dia REF#106
GE/Fitchburg Hobber 32 Dia, 72 Face 1.25DP REF#106
JF Reinecker 40 Dia 35 Face REF#106
LIEBHERR L-160-R 6.5 Dia REF#106
MIKRON #102.04 , 4 Dia, 5 Face REF#106
PFAUTER P-900 36 Dia REF#106
BARBER-COLMAN #25-15 25 Dia, 15 Face, 2.5 DP REF#106
PFAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#106
BARBER-COLMAN 2 1/2 -4, S/N 119, 62 Hi-Production Spur Gear REF#107
BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#107
BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#107
BARBER-COLMAN 6-10, S/N 4626, 57 Triple Thrd 3 Hob Slide REF#107
BARBER-COLMAN 6-10, S/N 4659R, 56 Triple Thrd Adj Ctr Assy REF#107
BARBER-COLMAN 6-10, S/N 4665, 57 Fine Pitch Prec Triple Thrd REF#107
BARBER-COLMAN 6-10, S/N 4701, 58 Triple Thrd w/Power Down Feed REF#107
BARBER-COLMAN 6-10 M/C, S/N 4755, 59 Triple Thrd w/MC Conversion REF#107
BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, 60 (87 Rebuild), Sgl Thrd Hi-Spd REF#107
BARBER-COLMAN 6-10 M/C, S/N 4913, 63 Triple Thrd w/90 Deg Hob Slide REF#107
BARBER-COLMAN 6-10 Multicycle, S/N 5055, 66 Triple Thrd, 800 RPM REF#107
BARBER-COLMAN 6-10, S/N 5141, 67 Triple Thrd w/Prec Hob Shift REF#107
BARBER-COLMAN 6-10 Multicycle, S/N 5148, 68 Triple Thrd, 800 RPM REF#107
BARBER-COLMAN 6-10 Multicycle, S/N 5259, 75 Triple Thrd w/Auto Hob Shift REF#107
BARBER-COLMAN 6-10, S/N 5353, 77 Triple Thrd w/3 Hob Slide, 800 RPM REF#107
BARBER-COLMAN 6-10, S/N 5394, 81 Fine Pitch Triple Thrd w/Dwell & Hob Rev REF#107
BARBER-COLMAN 6-16 M/C, S/N 5238, 70 Triple Thrd, Recon 02 REF#107
BARBER-COLMAN 6-10, S/N 5407, 82 Auto w/PLC Control REF#107
BARBER-COLMAN DHM, S/N 105, 42 Double Thrd REF#107
BARBER-COLMAN 14-15, S/N 635R, 53 Dbl Thrd, Fact Reb REF#107
BARBER-COLMAN 14-15, S/N 745, 55 Dbl Thrd w/Dwell REF#107
BARBER-COLMAN 14-15 Dual Fd, S/N 938, 62 Dbl Thrd, Comp Reco REF#107
BARBER-COLMAN 14-15, S/N 1055, 65 Dbl Thrd w/New Hyd Sys REF#107
BARBER-COLMAN 14-15, S/N 1131, 66 Dbl Thrd w/Hyd Tailctr REF#107
BARBER-COLMAN 14-15 Dual Fd, S/N 1261, 67 Dbl Thrd w/Hyd Live Ctr REF#107
BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, 68 Dbl Thrd w/4-1/8 Bore REF#107
BARBER-COLMAN 14-30 Dual Fd, S/N 1371, 71 4-Thrd w/Sizing Cycle REF#107
BARBER-COLMAN 22-15, S/N 923, 62 Dbl Thrd, Dbl Cut REF#107
BARBER-COLMAN 16-11, S/N 184, 50 Dbl Thrd w/Vert DRO REF#107
BARBER-COLMAN AHM, S/N 1896, 42 Sgl Thrd w/3 Jaw Chuck REF#107
BARBER-COLMAN 16-16, S/N 2745, 51 Sgl Thrd w/90 Deg Hd REF#107
BARBER-COLMAN 16-16, S/N 3171, 53 Dbl Thrd, Spanish Nameplates REF#107
BARBER-COLMAN 16-16, S/N 3580, 59 Dbl Thrd w/Diff & Auto Hobshift REF#107
BARBER-COLMAN 16-16 Multicycle, S/N 3641, 60 Dbl Thrd w/Diff REF#107
BARBER-COLMAN 16-16, S/N 3660, 57 Sgl Thrd REF#107
BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, C Style End Brace w/Diff REF#107
BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle C Style REF#107
BARBER-COLMAN 16-16, S/N 4473, 73 4-Thrd w/Workclamp Cyl C Style REF#107
BARBER-COLMAN 16-16 Multicycle, S/N 4520, 75 Dbl Thrd w/Gooseneck Slide REF#107
BARBER-COLMAN 16-16 Multicycle, S/N 4631, 79 C Style End Brace, 4W Adj Ctr REF#107
BARBER-COLMAN AHM (36), S/N 1152, 42 Dbl Thrd REF#107

BARBER-COLMAN 16-36, S/N 4090, 66 Dbl Thrd, C Style End Brace REF#107
BARBER-COLMAN 16-36 Multicycle, S/N 4232, 68 Dbl Thrd C Style End Brace w/Diff REF#107
BARBER-COLMAN 16-56, S/N 3136R84, 53 (Reb 84), Dbl Thrd REF#107
BARBER-COLMAN 10-20, S/N 6700045890, 76 Dbl Thrd w/2 Cut Cycle REF#107
TOS OFA Series Conventional Gear Hobbers, 12 & 40 Dia REF#103
TOS OHA Series Conventional Gear Shapers, 12 & 40 Dia REF#103
TOS FO-16 with single index 72 cap. REF#101

GEAR PINION HOBBERS & SPLINE MILLERS

HURTH #KF-32A 15 Dia, 59 Face, 67 REF#106
GE/Fitchuburg Pinion Hob 32 Dia, 72 Face REF#106
MICHIGAN Tool #3237 REF#106
FITCHBURG Pinion Hobber 42 Dia, 72 Dia REF#106
Craven horizontal 36 dia 96 length 73/4 hole REF#101

GEAR HOB & CUTTER SHARPENERS (incl CNC)

BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, 57 REF#106
FELLOWS #6SB, Helical Cutter Sharpener, 6 Dia, up to 50 Degrees REF#106
KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#106
KAPP #AS204GT, 10 Dia, Wet Grinding, CBN Wheels, 82 REF#106
REDRING MODEL #SGH "PREIFORM" SHAVE CUTTER GRINDER/SHARPENER REF#106
STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#106
BARBER-COLMAN 2-2 1/2 , 2.5 Dia REF#106
KAPP #AST-305B, 27.5 Dia, REF#106
KAPP AS-410B REF#106
GLEASON #12 Sharpener, 3-18 Cone REF#106
Red Ring Shaving Cutter sharpener Periform REF#106
Star #6 Gear Cutter Sharpener REF#106
Star 4HS Hob sharpener REF#106
Star HHS Horizontal Hob Sharpener CNC, Max Dia 10 Max length 12 New 1990 REF#106
BARBER-COLMAN 2 1/2-2, S/N 16, 66 Wet w/Auto Feed REF#107
BARBER-COLMAN 6-5, S/N 110R, 55 Wet w/Auto Dress & Sparkout REF#107
BARBER-COLMAN 6-5, S/N 396, 66 Wet w/Auto Dress & Sparkout REF#107
BARBER-COLMAN 6-5, S/N 433, 69 Wet w/Auto Dress & Sparkout REF#107
BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC Control, Fact Reb 83 REF#107
TOS OHA Series CNC Gear Shapers, 12 & 40 Diameter REF#103
TOS OFA Series CNC Gear Hobbers, 12 & 40 Diameter REF#103

GEAR SHAPERS CNC

36 Shapers, 14 Throat Risers, 53 of Swing, Qty 3 REF#105
FELLOWS #10-4/10-2, Qty 150 REF#105
HYDROSTROKE #50-8, Qty 2 REF#105
HYDROSTROKE #20-8, Qty 5 REF#105
HYDROSTROKE #FS630-125, Qty 1 REF#105
HYDROSTROKE #FS400-90, Qty 2 REF#105
FELLOWS #20-4, Qty 6 REF#105
FELLOWS #48-8Z, Qty 1 REF#105
FELLOWS #FS-180, 3-5 Axis, 7 Dia, 1.25 Face., 6 DP, New 88 REF#106
LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#106
LORENZ # LS-180, 4-Axis CNC, 11 OD, 2 Stroke, 5 DP REF#106
LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#106
FELLOWS FS400-125, 16 Dia, 3.5 DP 5 Face REF#106
FELLOWS #10-4 3-Axis (A/B), 10" Dia, 4" Face, 4 DP New .09 REF#106
FELLOWS #10-4 2-Axis, 10 Dia 4 Face REF#106
FELLOWS #20-4 3-Axis 10 Dia, 4 Face REF#106
FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15.7" REF#106
Fellows 20-8, CNC Gear Shaper, Remanufactured and recontrolled REF#106
Fellows Model Z gear Shaper REF#106
Lorenz SN4 Gear Shaper, Max OD 7, 2 Face, Max 6 DP with Loader REF#106
RP/ Stanko 48-8 Remanufactured Gear Shaper, Fanuc 3 Axis, 18i M Control, new 2010 REF#106

GEAR HOBBERS
Barber Colman Model 4-4HRS, Hob Sharpener 4 Max OD, 4 Length REF#106
Fellows FH 200 Gear hobber, universal hobbing Machine REF#106
Barber Colman 6-10, CNC, CRt 5 Axis, 6 Dia, 10.5 travel, 6 DP REF#106
Barber Colman Hobber Type T REF#106
Barber Colman model #14-15 Gear Hobber, horizontal Heavy Duty REF#106
Barber Colman Model #16-36 GearHobber REF#106
Barber Colman Model #16-56, 16 dia, 56 Face, adj. Air Tailstock REF#106

Barber Colman Model 2.5-2 gear hobber, 2 length Manual Dresser REF#106
G&E Model 5.2 CNC Internal Gear gashing head REF#106
Jeil JDH-3, Gear hobber, Max Dia 31.5, 3DP, 22.8 Table Diameter REF#106
Jeil JDP-2, Gear hobber, Max Dia 26, 4 DP, 19.5 Table Dia, Differential and tailstock REF#106
Liebherr ET 1802, Internal Gashing head, Fanuc 16i Control, 98Max dist 17 Face
REF#106
Liebherr L-402 Gear hobbing Machine, New 1977 REF#106
Liebherr LC 752, 6 Axis CNC Hobber, Max OD 29.5, Max Face width 23.6 REF#106
Micron Model 120.01 w/bevel Cutting Attachment, New 1975, 1.6 dia, 25.4 DP REF#106
Nihon Kakai Model NTM-3000, Spline Hobbing Machine, Max dia 400mm, 3150mm
between Center REF#106
Pfauter P900 Reman and Recontrolled, Max OD 120 REF#106
Pfauter Model PE125 CNC Gear hobber REF#106
Pfauter model PE300 CNC, Max OD 12, Max gear face 15, 3 DP, 6 Axis REF#106
Reinecker Heavy Duty Gear Hobber REF#106
Scheiss Model RF10 Horizontal Hobber, 60 dia, 144 face, 180cc, 8 DP REF#106
G&E 96H, roughing & finishing 104 dia. REF#101
TOS FO-16 single index 80 dia. Yr 1980 REF#101
Craven spline & pinion hobber 36 x 96 REF#101
G & E 48H 48 dia. Diff, OB, change gears REF#101
Pfauter hobber P-1800 70 dia. 29 face yr 1980 REF#101
Lees Bradner 7VH, 8PD, 10 Face, , Magnetic Chip Conveyor , Hob Shift REF#102
Lees Bradner 7VH, 8PD, 4PD, Magnetic Chip Conveyor, Hob Shift REF#102
Mitsubishi Model GH300, 15.7, 3 DP, Differential, 2 Cut REF#102
Tos 32A, 320mm Gear Dia.,3.6 DP, Differential, 2 Cut REF#102
Gleason 775 8PD, High Helix Head, Infeed, Very Light Use REF#102
Barber C. 16-15, 7 Hob, Crowning, Differential, 2 Cut REF#102
Barber Colman 14-15, 2 Cut, Fast Approach, 4 Bore REF#102
Barber Colman 16-36, Type A Very Good, Double Thread Index REF#102
G & E Model 48HS 48PD, 18 Face, 2.5 DP REF#102

GEAR SHAPERS
FELLOWS #10-2, (10 Dia), 2 Face REF#105
FELLOWS #10-4, (10 Dia), 4 Face REF#105
FELLOWS (200) 10-4 / 10-2 Shapers REF#105
FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/
6 axis 16iMB Fanuc (2009) REF#105
FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/
6 axis 16iMB Fanuc (2009 REF#105
FELLOWS (1) #7 125A Face Gear Machine REF#105
FELLOWS (2) #3 Face Gear Machine REF#105
(1) 4ags with adjustable Helical Guide s/n 30634 REF#105
(1) #7 125A adjustable Helical Guide REF#105
FELLOWS (1) FS630-200 Hydrostroke Shaper s/n 36943 w/
6 axis 16iMB Fanuc (2009) REF#105
FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc
Controller (2009) REF#105
FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#105
FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/
6 axis 16iMB Fanuc (2009) REF#105
FELLOWS (2) FS400-170 Hydrostroke Shaper w/
6 axis 16iMB Fanuc (2009) REF#105
FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6
axis 16iMB Fanuc (2009) REF#105
FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis
21i Fanuc Controller (2009) REF#105
FELLOWS (1) 48-8Z Shaper w/ 14 throated riser (53 of swing) REF#105
FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#105
FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB
4 axis Fanuc controller s/n 34326 REF#105
FELLOWS (1) 36-10 Gear Shaper REF#105
FELLOWS (1) 10x6 Horizontal Z Shaper REF#105
FELLOWS (1) 36-6 Gear Shaper w/ 13 riser s/n 27364 REF#105
FELLOWS (1) 10-4 Shaper w/ 3 riser w/ 4 axis 21i
Fanuc Controller (2009) REF#105
All Parts for 10-4/10-2 Fellows Gear Shapers REF#105
FELLOWS #36-8, 36 Dia, 8 Face REF#106
FELLOWS #100-8 100 Dia, 8 Face REF#106
FELLOWS #612A, 615A, #645A REF#106
FELLOWS #10-4, 10 Dia, 4 Face, 4 DP REF#106
FELLOWS #4A Versa, 10 Dia, 3 Face, 4 DP, New 70s REF#106
FELLOWS #10-2, 10 Dia, 4 Face, 4 DP REF#106
FELLOWS #20-4, 20 Dia, 4 Face, 4 DP, 70s REF#106
FELLOWS #3-1,/3GS, 3 Max Dia, 1 Face, Pinion Supp, High Precision REF#106
FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#106
MAAG #SH-150, 57" Dia.12.6" Face REF#106
PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#106
FELLOWS #36-6 Max Dia 36 6 Face, 3 DP REF#106
FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5 REF#106
FELLOWS #4GS & 4AGS, 6 Dia, 2 Face, 4DP, 68, Ref.# Several REF#106

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

FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7 Dia, 0-12 Risers,
Several Avail REF#106
MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#106
FELLOWS Model Z Shaper, 5" Stroke, 50s REF#106
STAEHELY SHS-605, Gear Shaper REF#106
FELLOWS #6, #6A, #61S, From 18-35 Dia, 0-12 Risers REF#106
FELLOWS #8AGS Vertical Gear Shaper, 8 Dia, 2 Face, 6-7 DP REF#106
TOS OHA50 CNC 5 20 Dia 5 Face REF#103
Fellows 36-6 Shaper (2) 12.5" Risers 6" Stroke Mint YR 1969 id 3616 REF#101
Fellows 36-6, shaper W/6 riser, change gears REF#101
Magg shaper SH4580-500S, 206dia. 26 face REF#101
Magg shaper SH250, 98 dia. 26 face REF#101
Fellows #10-4,7 riser yr 1980 REF#101
Fellows 3, 6, 7, 10, 18, 42, 100, Some CNC REF#102

GEAR DEBURRING/CHAMFERING/POINTING
CROSS #50 Gear Tooth Chamferer, 18 Dia, Single Spindle REF#106
REDIN #20D, 20 Dia, Twin Spindle, Deburrer/Chamfer REF#106
SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14 Dia, 5 Face, 82 REF#106
SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10 Max Dia, (3) New 96 REF#106
REDIN #24 CNC Dia 4 Setup Gear Deburring REF#106
CROSS #60 Gear Tooth Chamferer, 10 Dia, Single Spindle REF#106
FELLOWS #100-180/60 CNC Max Dia 180, Single Spindle REF#106
CIMTEC #50 Finisher REF#106
CROSS #54 Gear Deburrer, 30 Dia, 18 Face REF#106
RED RING #24 Twin Spindle Dia 4 REF#106
GLEASON GTR-250 VG CNC 5-Axis REF#106
Gleason- Hurth Model ZEA 4, Max Dia 250mm, Max Module 5mm REF#106
Redin Model 36 universal Chamfering and Deburring Machine, Max OD 36, Twin
spindle, Tilt table REF#106
Samputensili SCT3 13.7, SM2TA 10, (5), 2003 REF#102
Mitsubishi MA30 CNC, 11PD, Fanuc, Powermate, 1999 (2) REF#102

GEAR HONERS
Kapp #CX120 Coroning 4.7 Dia REF#106
Red Ring GHD-12, 12 Dia, 5.5 Stroke REF#106
Red Ring GHG, 12 Dia, 5.5 Stroke REF#106
Kapp #VAC65 Coroning 10 Dia REF#106

GEAR SHAVERS
Red Ring #GCX-24" Shaver, 24 Dia, 33 Stroke REF#106
Red Ring #GCU-12, 12 Dia, 5 Stroke REF#106
Red Ring #GCY-12, 12 Dia, 5 Stroke REF#106
Red Ring GCI 24, 12.75 Dia, 5 Stroke REF#106
Kanzaki model GSP 320 Gear shaver REF#106
Red Ring GCU 12 Crowning, 1956 to 1988 (6) REF#102
Mitsubishi FB30, 12.2 CNC Fanuc, 1997 REF#102
Sicmat Raso 100, CNC Fanuc 16M, New, Guarantee REF#102

GEAR GENERATORS
GLEASON #37 Str. Bevel Planer, 6 Dia REF#106
GLEASON #496 Straight.& Spiral. 7.5 Dia REF#106
GLEASON 725-Revacycle, 6 Dia REF#106
GLEASON 726-Revacycle, 5 Dia REF#106
Farrel Sykes Model 12C herringbone max dia 264, max face width 60 REF#106
Farrel Model 5B herringbone gear generator. REF#106
Gleason 529 gear quench press, Auto cycle 16 Diam, New 1980 REF#106
Gleason 614 hypoid finishing machine, 10.5 pitch, dia 5.25 Max cone dist
REF#106
Oerlikon/klingelnburg Model C28, Max dia 320 mm, Max Module 7.5 mm REF#106
Gleason Model 26 Quench press and Hypoid Generator Max OD 16, Max face Width Air
Cylinder REF#106
Gleason Model 36 Gear Quenching Press, Max Ring 28 OD, 8 Face, Universal REF#106
Gleason Model 450 HC CNC Hypoid Cutter, Face width 2.6, fanuc 150 Controls REF#106
Gleason 24 Rougher, Gears, Finishing Tool Holder REF#102
12 Gleason, Gears, Gauges Tool Blocks REF#102
Gleason 116 Rougher & Finisher (6) REF#102
Gleason Phoenix 175HC CNC 1994 REF#102
Gleason 22 Rougher & Finisher (8) REF#102
Gleason 610 Combination Rougher & Finisher, 1988 REF#102
Gleason 608 & 609 Rougher & Finisher REF#102
Gleason 7A, 7PD Helical Motion, Gears & Cams REF#102
Gleason Cutters, 3 to 25 in stock, 1000 REF#102

GEAR GRINDERS
#27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder
generating Cams (2 full sets) REF#105
Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#105
REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#106
GLEASON #463, 15 Dia REF#106
Hofler model Rapid 2000L, CNC Grinder, Max OD 78, CNC Dressing REF#106
Matrix model 78, Reman CNC Thread grinder, 24 Dia, 86 grind Length, 106
between centers REF#106
Mitsu Seiki Model GSW-1000 Gear Grinder REF#106
Reishauer RZ 362 AS, CNC Grinder, Max Dia 360mm REF#106
Sundstrand/Arter Model D12 Grinder REF#106
Teledyne-Landis Gear Roll Finishing Machine, 5 Diam, 42k lbs Rolling Force REF#106
Reishauer RZ301AS CNC, 13 Measuring System (3) REF#102
Reishauer ZB, 27.5 PD Gears, Coolant REF#102

GEAR RACK MILLERS/SHAPERS

MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#106
SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, 80 REF#106
Fellows 4 60 Rapid Traverse, 2 Cut REF#102

GEAR THREAD & WORM, MILLERS/GRINDERS

BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#106
EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#106
EXCELLO #33 Thread Grinder 6 Dia 18 Length REF#106
HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88 REF#106
LEES BRADNER #HT12x102, Extra Large Capacity REF#106
LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#106
LEES BRADNER # LT 8 x 24 8 Dia REF#106
HOLROYD 5A 24.8 Dia REF#106 LEES BRADBER WORM MILLER REF#106
Dranke CNC Internal Ball Nut Grinder REF#102

GEAR TESTERS/CHECKERS (incl CNC)

FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#105
FELLOWS (1) 24H Lead Checker s/n 32289 REF#105
GLEASON (1) #14 Tester s/n 31907 REF#105
GLEASON (1) #6 Tester s/n 19316 REF#105
FELLOWS (1) 20 M Roller Checker REF#105
FELLOWS (1) 20 M w/ 30 Swing Roller Checker REF#105
FELLOWS (1) #8 Micaodex s/n 36279 REF#105
David Brown #24 Worm Tester REF#106
Gleason #4, #6, #13 and #17 Testers REF#106
Hofler EMZ-2602 Int/Ext Gear Tester 102 REF#106
Klingelnberg #PFSU-1600 Gear Tester-2001 REF#106
Kapp Hob Checker WM 410 REF#106
Maag #ES-430 Gear Tester REF#106
Maag #SP-130 Lead and Involute Tester REF#106
National Broach Gear Tester GSJ-12 REF#106
Oerlikon #ST2-004 Soft Tester REF#106
Maag #SP-60- Electronic Tester REF#106
Parkson #42N Worm Gear Tester REF#106
Vinco Dividing Head Optical Inspection REF#106
Gleason model 511 Hypoid tester Max Dia 20, max spindle centerline 3.5
REF#106
Klingelnberg Model PFSU-1600 63 Dia, 1.02 DP, Rebuilt REF#106
MAAG ES401 Pitch tester With Process Computer REF#106
Fellows 12 & 24M Involute, 12 & 24 Lead REF#102
Fellows 36 Space Tester, Hot Pen Guaranteed REF#102
Gleason 17A Running or Rebuilt Guaranteed REF#102
Gleason 511, 20 Reconditioned in 2010 Guaranteed REF#102
Gleason 27, 26, Guaranteed REF#102
Gleason 515, 24 REF#102
Gleason 523, 20 Reconditioned, 2010 REF#102

MISCELLANEOUS
WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80 Centers, 12
Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#104
Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#105
GLEASON #529 Quench, 16" Diameter REF#106
Klingelnberg Model LRK-631 Gear Lapper REF#106
VERTICAL TURNING LATHES AND MORE - Please Check Our
Website To View Our Entire Inventory REF#106
TOS SU & SUS Series Conv Lathes REF#103
TOS SUA Series CNC Flat-Bed Lathes REF#103
Change gears for G & E hobber REF#101

MARCH 2015

53

KOROfor Quality

Hob Sharpening Service

Quick Turnaround 2 Day Service

MARKET

Spur Shaper Cutter Sharpening

HSS & Carbide Hob with center hole
and straight flutes
Thin Film Coatings
Length up to 7 inches

PLACE

Manufacturing excellence through

quality, integration, materials,
maintenance, education, and speed.

Diameter up
to 5 Inches
Precise rake
and spacing guaranteed
to AGMA standards
RUSH SERVICE AVAILABLE
Koro Sharpening Service
9530 85th Ave North
Maple Grove, MN 55369
763-425-5247
info@koroind.com

SHARP HOBS
Change Downtime To Productivity

You Need Your Tools Back FAST

Eliminating Downtime &
Tuned To Meet or Surpass
Original Design Specs
and Thats Where We Come In

Stripping & Re-Coating

Gear Shaper Sharpening
Milling Cutter Sharpening
Gear Tool Certifications

Tel: 216-642-5900 Fax: 216-642-8837 5755 Canal Road Valley View, OH 44125
Email: gallen@gallenco.com WWW.GALLENCO.COM

Tooth
Finishing

Technology Experts

Custom gear racks in AMERICAN and

METRIC standards, STRAIGHT and
HELICAL, VARIOUS materials, FINE
and COARSE pitch (254 D.P. 0.5 D.P.;
0.10 Module 50 Module); hard-cut
(up to 60 Rc) and soft-cut (up to 40
Rc); 32 face width; Up to 82 lengths
longer lengths through resetting
Custom gears in AMERICAN and
METRIC standards (3 D.P. 72 D.P.,
10 Diameter)
Precision Quality up to AGMA 12
Prototype & Production quantities
Breakdown Service Available
Reverse Engineering
Unique Tooth Configurations
Heat Treating
Complete CNC Machining
RETROFITTING REBUILDING CUSTOM MACHINES

www.newenglandgear.com
p. 860-223-7778

54

gearsolutions.com

Geared to make things move.

sales@kapp-usa.com
www.kapp-niles.com

ADVERTISER
INDEX
COMPANYNAME

PAGE NO.

Advent Tool..........................................................................................45
AeroDef Manufacturing '15..................................................................50
ALD Thermal Treatment Inc.................................................................40
All Metals & Forge Group.....................................................................33
Allen Adams Shaper Services Inc........................................................54
Bourn & Koch Inc.................................................................................55
Broaching Technologies LLC...............................................................34
Circle Gear & Machine Co Inc..............................................................55
Colonial Tool...........................................................................................9
Encoder Products Co...........................................................................51
Engineered Tools Corp.........................................................................21
Forest City Gear...................................................................................17
Gleason Corp.......................................................................................37
GMTA (German Machine Tools of America)...........................................2
Index Technologies..............................................................................54
Innovative Rack & Gear........................................................................54
Ipsen USA............................................................................................12
KAPP Technologies....................................................................... IFC,54
KISSsoft USA LLC...............................................................................11
Koro Sharpening Service.....................................................................54
Lawler Gear Corp.................................................................................54
Lubrication Engineers Inc.....................................................................10
Machine Tool Builders..........................................................................35

CIRCLEGEAR and MACHINE

STRAIGHT BEVEL

McInnes Rolled Rings..........................................................................46

MicroGear.............................................................................................51
Mitsubishi Heavy Industries America Inc............................................BC

GEARS

.25 to 34 Diameter

New England Gear............................................................................7,54

32 DP to 1.5 DP

Nordex Inc............................................................................................27

.5 Module to 16 Module

P & G Machine & Supply Co Inc.....................................................48,54

Penna Flame Industries........................................................................32
Pentagear Products.............................................................................39
Pinson Valley Heat Treating..................................................................32
Polygon Solutions................................................................................45

SPIRAL

BEVEL GEARS

Proto Manufacturing Ltd......................................................................44

.25 to 33 Diameter

Raycar Gear & Machine Co.................................................................49

32 DP to 2 DP

Repair Parts Inc....................................................................................48

RP Machine Enterprises Inc...............................................................IBC
Russell Holbrok & Henderson Inc........................................................11
Solar Atmospheres...............................................................................47
STD Precision Gear & Instrument Inc..................................................49
The Broach Masters Inc.........................................................................4
TMFM LLC...........................................................................................34

.5 Module to 12 Module
Since 1951 Circle Gear has served
Chicago land as a full service gear
manufacturing facility. In addition
to bevel gears Circle Gear also
provides spur gears, helical gears,
herringbone gears, worm and gear
sets, internal gears, splines, racks
and sprockets.

Toolink Engineering Inc..........................................................................1

Ty Miles Inc...........................................................................................45
United Tool Supply...............................................................................36
Walker Forge........................................................................................36

MARCH 2015

55

Q&A

Chris Van De Motter

President
The Ohio Broach & Machine Co.

Could you give us a look into the history of

Ohio Broach?
In 1955, my father Charles Bud Van De Motter
started Ohio Broach in my grandfathers four-car
garage, and it was incorporated in 1956. He worked
as an engineer for Cleveland Broach back after the
war for roughly seven or eight years before going out
on his own. He bought a couple of machines and
continued sharpening broaches. Back then, it was
small machines and a small group of customers
people they knew and who they had worked with
at Cleveland Broach.
In 1974, he moved out to Willoughby, Ohio,
which is where were located now. He bought a
20,000-square-foot building that he had tailored to
put a pit in for big machines. Since that time, weve
had five expansions. Now, we occupy a building
about 50,000-square feet.
Bud has been a part of this company for his
entire career, about 58 years or more. He retired
from active duty in 2009, and now serves as the
chairman of the board.
I took over around 2007 and became president,
and Bud became CEO. Before that, I became the
general manager in 2001, and Bud was president.
When the downturn hit in 2008, we were hit
especially hard. Now, we have approximately 35
employees. Since 2009, we have increased our sales
approximately 8-10 percent per year. It has been
difficult, but it has been a big plus.
It sounds like your dad created a family business
when he started Ohio Broach. Can you tell us
more about that aspect of the company?
Yes, it is a family business. Back when my father
started the company in his fathers garage, drafting
was done on a board with a pencil. We did our basic
machines from that point, and then grew into the
2-D and 3-D CAD.
I grew up in the business. I went to college
at Marquette University and graduated with an
engineering degree in 1976. Then, I went back to
school to get my MBA at Cleveland State University
in 1987. I started working at Ohio Broach in 1977
in the engineering department. I worked my way
up at the company by doing everything in the shop
from sweeping floors to running around and setting

up machines. I was raised up in the business. Ohio

Broach is where I started, and its where I ended up.
What is your companys relationship with its
customers like?
We service automotive, aircraft, medical, defense, fire
arms, agriculture, hand tools, and broaching is a very
small part of those types of industries. When you
think about machining , you think of turning and
milling, but there are some operations that can only
be done by broaching, like an internal involute spline.
Broaching allows you to get high-quality production
and maintain a high tolerance. Broaching is a onepass operation. You rough it out and finish it all in
one pass.
Normally, broaching is meant for a large volume
of parts where batch processing is used extensively,
but sometimes broaching is the only way to machine
a part.
We have customers all over the world. We sold
equipment to companies in France, Holland, Israel,
South Korea, Mexico, Canada, Ireland, and the
Philippines. We have equipment everywhere. Its
all broach machine equipmentsurface broaching
and horizontal broachingall for different styles of
broach equipmentlike manufacturing, automotive
parts, fire arms parts, and defense partsall for
different places. We make the tools and the broach
tool holders for those. We can do a turnkey package,
completely tool up a person, come in, run it off, and
have them come in and take it to go from there.
Broaching is a niche industry. We provide service
in that area, and we have to keep on top of that.
Obviously, its very competitive. We have a number
of competitors. Its a matter of staying with your
customer and giving them the service they need,
whether it be sharpening the tools, providing delivery,
or helping them with their problems.
What are some new products Ohio Broach has
been working on?
In 2013, we came up with a CNC shaping machine.
The intent of this machine was to machine or shape
blind splines. A blind spline means that the hole in
the part doesnt go all the way through. We need
a little relief on the bottom. We sold a couple of
these shaper machines in production. Its doing

an automotive part with a sixspline form in it. Cycle time is

approximately 30 seconds per
part. It is advantageous in that
normally a blind spline requires a
multi-station as well as multi-tool
machine. These machines run up
somewhere around $750,000.
This particular machine that
were selling is about $200,000.
So, there is an advantage on
the capital equipment side. On
the tooling side, a set of tools
for the blind spline-broaching
machine runs around $25,000
to $30,000, depending on the
size and the capability. We use a
carbide insert with our tools that
is specially formed, and its $150
to $200. You get an advantage in
that respect, also. However, the
disadvantage is that they get a
part off every 15 to 20 seconds,
and we require a slightly longer
time to do that. Its cost effective
as far as equipment and tooling
goes. If you have a crash with
ours, you may only have to
replace the tool holder and the
tool. Thats $500 to $1,000 versus
$30,000.
Were advertising on our
website, and were exploring a
lot of different avenues to get
experience. Were getting more
and more confident in how we
use this machine.

FOR MORE INFORMATION: Contact The Ohio Broach & Machine Co. at (440) 946-1040 or visit the companys website at www.ohiobroach.com.

56

gearsolutions.com

USED

Fellows Remanufactured

We understand each of our customers have unique gear cutting requirements, that is why we carry such a large gear
machine inventory. We carry such brands as Gleason, G&E,
Fellows, Barber Colman, Liebherr, Pfauter, and many more.
You will find hundreds of machines on our website at all
times; from gear cutting machines to finishing and inspection machines. Dont forget, if you cant find what you need
on our website, let us know and we can try and find it for you.

SERVICE

At R.P. Machine, we understand that its about more than

supplying gear machines. Thats why we provide a wide
range of service on many types of machine tools. Our stateof-the-art facility and experienced staff allow us to handle
service of all sizes. Our service abilities do not stop at just
gear equipment, we can also assist you with machines
such as large capacity lathes and mills, no matter the
size. We offer preventive maintenance packages, rebuild ing and corrective service, retrofitting, machine and plant
relocation, training, and replacement parts. Our goal is to
provide the highest quality of service so each of our cus tomers can achieve their maximum production potential.

Keep pace with technology advances - without the expense of buying

new equipment - with our full line of Fellows remanufactured CNC
gear shapers. These gear shapers are completely remanufactured
using the latest components from manufacturers such as
Heidenhain, FANUC, Allen Bradley, and many others. Each machine is
equipped with a new reliable CNC control with all the latest
technology. These solid core machines are brought up to date with
many additional options available. Each machine is remanufactured
to your individual part requirements.

866.256.3708
F: 704.872.5777

820 Cochran Street Statesville, NC 28677

sales@rpmachine.com www.rpmachine.com

Our Technologies, Your Tommorow

HOBBING

SHAPING

S H AV I N G

GRINDING

Increased
Capacity is
AVAILABLE NOW
for Immediate
Delivery...
...FROM THE WORLDS LARGEST INVENTORY
OF CNC GEAR CUTTING MACHINES.
No need to scour the globe searching for a machine in order to
quickly ll increased production needs. With our vast inventory of
new machines right here in the U.S.A., Mitsubishi Heavy Industries
America can deliver the machine you needin perfect condition,
optimized for maximum output and all at a moments notice.

2014 Mitsubishi Heavy Industries America

Learn more about the world-class Mitsubishi

gear machines available from stock at

www.mitsubishigearcenter.com
or contact sales at 248-669-6136.