A Division of U.S.

EQUIPMENT COMPANY

ROTO-FLO
INSTRUCTION
MANUAL
 TABLE OF CONTENTS
Section 1 – Roto-Flo Capabilities
Detroit Facility 5
Swannanoa Facility 6
Spline Rolling Capabilities 7
Optional Equipment 12

Section 2 – Terminology
Machine Terminology 13
Spline Terminology 17
Effective Size 21

Section 3 – Spline Data

Spline Design Consideration 24

Section 4 – Quality Capabilities

Process Control Consideration 29
Effective Variations 30
Spline Tolerances 32
Spline Inspection 33

Section 5 – Machine Set-Up

Machine Set-Up 37
Machine Set-Up Form 41

Section 6 – Process Troubleshooting

Indexing Errors 43
Lead Errors 44
Variation of Tooth Thickness 44
Excessive Tooling Wear & Breakage 44

Section 7 – Machine Maintenance

Checking Centers for Runout 46
Checking Machine Opening & Vernier Accuracy 46
Correcting Excessive Backlash 52
Checking Center to Center 53

Section 8 – Lubrication
Forms of Lubrication 57
Functions of Lubrication 57
Lubrication Troubleshooting 60

1
 TABLE OF CONTENTS (cont.)

Section 9 – Machine Cycle Troubleshooting

Machine Cycle Troubleshooting 64

Section 10 – Hydraulic Troubleshooting

Hydraulic Troubleshooting 66
Servicing the Hydraulic Reservoir 67
Preventative Maintenance Schedule 69

Section 11 – Rack Maintenance

Function of Coolant 71
Rack Maintenance 71

2
 SECTION 1

INTRODUCTION

ROTO-FLO and U.S. GEAR TOOLS

CAPABILITIES

3
SECTION 1 – INTRODUCTION

U.S. Equipment has two facilities involved in the design and manufacture of ROTO-
FLO machinery and tooling. Because of Roto-Flo experience and expertise, we offer
complete accountability for your spline rolling systems.

Our machine manufacturing facility in Detroit, Michigan and our tooling facility in
Swannanoa, North Carolina give Roto-Flo total control of items critical to the spline
rolling process.

In Detroit, Roto-Flo has 75,000 square feet of floor space and employs approximately
60 people.

At Roto-Flo, the FEA (Finite Element Analysis) CAD system is used by our
engineering group to analyze critical machine structures and model our process to our
customer needs.

Roto-Flo engineering group works with a variety of PLC’s including Allen Bradley,
Modicon, and others. They also work with a variety of peripheral devices such as
servo controllers, BASIC modules and display terminals.

- Roto-Flo utilizes manufacturing methods that ensure our customers are provided
equipment that is of the highest quality.

- Machine components are inspected with a Coordinate Measuring Machine to

ensure proper manufacture.

- All measuring devices at Roto-Flo and U.S. Gear Tools are under scheduled
calibration.

- During the manufacture and testing of the ROTO-FLO machine, Roto-Flo utilizes a
22-page inspection report.

- Our service engineers are trained to assist you in all areas should you have a
problem with either the machine or the process of spline rolling.

4
The Swannanoa North Carolina facility (located in the western part of North Carolina,
7 miles east of Asheville) has 34,000 square feet of floor space and employs
approximately 40 people. At this facility, U.S. Gear Tools designs and manufactures
ROTO-FLO racks from start to finish.

Computer aided design, CNC grinding machines, and top grade tool steels all
contribute to quality racks and on time delivery.

The Swannanoa facility has a complete inspection department designed especially for
the complete forming racks inspection. Also available are three ROTO-FLO cold
forming machines. These machines are used for the certification of the forming racks.
Certification means that customer supplied parts are rolled using the newly
manufactured or reground racks and measuring the rolled parts to assure they meet or
exceed customer specifications. These machines are also used for short production
runs and prototype rolling.

The experience and expertise of the engineering and manufacturing people are
available to assist you in all your manufacturing needs.

CONTACTS

TOOLING

Dan Carter Phone: 828-686-5486

Email: dcarter@usgeartools.com

Dan Olszewski Phone: 828-686-5486

Email: dolszewski@usgeartools.com

TOOLING Sales

Don Ritter Phone: 313-526-8300

Email: dritter@usgeartools.com

MACHINES

Paul Simon Phone: 313-526-8300

Email: psimon@roto-flo.com

5
 FIGURE 1.1

In the spline rolling process, parts are progressively formed by displacement of metal in
the periphery of the part. The part rotates between racks traveling in opposite directions.
Racks are designed so that each tooth penetrates progressively deeper into the part
throughout the ramp section of the rack. Then in the finish section of the rack, parts
make several revolutions to assure size and surface finish.

ADVANTAGES

Cost Savings - Due to the fact that cold forming is much faster than machining splines,
there is a great reduction in cost per piece to manufacture. The process also is
"chipless" and no waste metal is produced. Cold rolling also enhances the metal being
rolled by increased tensile strength, metal hardness and surface finish. Cold forming
reduces the need for additional machining of the parts rolled.

Density - During the rolling process, the density of the splines increase due to the
compression of the metal. This increases the life of the spline because the grain of the
metal has not been removed as in cutting the spline during hobbing (Fig. 1.2). During
rolling the parts are work hardened, which can increase the strength of the part by as
much as 35% depending on the geometry of the part, chemistry, and any subsequent
heat treatment.

6
 FIGURE 1.2

FIGURE 1.3 FIGURE 1.4

Finish - The rolled spline also offers the advantage of having a higher finish of the tooth
surface, usually running from 3 to 15 R.M.S. This offers two advantages. First, where
the members have to slide under load, it can be done with less effort. Second, the
formed part has no generation scallops such as created in the hobbing process, and thus
maintains its fit characteristics throughout its entire life. The initial fit with hobbed parts is
on the high points, which soon get worn and result in increased backlash.

Capacity - Frequently, the use of dual racks on a single machine permits the forming of
several operations in a single pass. In general, maximum part diameter is controlled by
face width, diametral pitch (tooth depth), number of teeth and material hardness.

Tool Life - Varies with hardness of material and with pressure angle. For 200 BHN
(Brinell) and a 45° pressure angle, tool life may average as high as 200,000 pieces. For
320 BHN and a pressure angle of 30°, tool life may be as low as 12,000 pieces. In each

7
case, the tool cost is below that of other methods of producing a similar part. Each rack
may be reground several times.

Versatility - Many ROTO-FLO machines are used today to produce different parts on a
job-to-job basis. Change over of the forming tools is both quick and easy.

Automation - With the long life of ROTO-FLO racks, the machines lend themselves
ideally to automation, producing thousands of parts with a minimum of attention. A
ROTO-FLO machine is particularly suitable to gravity loading; lift and carry walking beam
type, or overhead transfer automation systems.
MACHINE OPERATION

FIGURE 1.5

The principle involved in the ROTO-FLO process is that of metal displacement. On a

given spline to be formed, a circle must be found that creates the condition where the
area of the space below the circle equals the area of the tooth above the circle (Fig. 1.5).
This circle is then the pre-roll diameter (the diameter of the shaft before rolling). For best
results, this diameter should not vary more than 0.002.

FIGURE 1.6

8
 FIGURE 1.7

The shaft to be rolled is held between centers (Fig. 1.6). The pre-roll diameter must run
true with the centers.

FIGURE 1.8

Forming racks are made so the linear pitch of the rack corresponds to the pre- roll
diameter. The tops of the teeth on the starting end of the racks are tapered (Fig. 1.8), so
the initial bite is very slight and metal is gradually displaced as the racks traverse the
part. The racks are made in pairs and the two racks in a pair carry a common serial
number. (Example: RF-l23)

9
 FIGURE 1.9

The forming racks are mounted in rack fixtures, which are secured to sturdy slides, which
travel in opposite directions and are powered by identical hydraulic cylinders (Fig. 1.9).
The cylinders are supplied by a common four-way valve, assuring equal flow and
pressure.

The movement of the slides is mechanically synchronized by mounting identical

synchronizing racks along the center portion of each slide (Fig. 1.10). These racks are in
mesh with a precision synchronizing gear, bearing on the O.D. of a rigid spindle housing
(which also carries the headstock center).

10
 FIGURE 1.10

These operating components are all encased in a rugged "C" type frame, further
strengthened by extra heavy tie bars. Extending from the base is the underarm (or an
overarm) (Fig. 1.11). These hold the tailstock unit and the tailstock slide cylinder.

FIGURE 1.11

11
 FIGURE 1.12 FIGURE 1.13

Optional Equipment:
1. Motorized headstock adjustment. (Fig. 1.13)
2. Servo controller for headstock adjustment. (Fig. 1.12)
3. Heavy duty model for rolling large splines or hard material. This includes
hardened bronze liners, secured to the slides, to prevent scoring of the ways and
slides.
4. Capability for mid-stroke headstock adjustment.
5. Capability for turning part at mid-stroke for rolling both ends of a shaft.
6. Walking beam loading and unloading systems.
7. Overhead part transfer systems.
8. Gravity load and unload systems.
9. Tailstock rotation motor (starts to rotate part before engaging forming racks to
reduce part slippage).
10. Multiple rack set-up (roll multiple splines, threads or oil grooves on one part during
the same pass).
11. Rack loading fixture to assist in holding heavy racks.
12. Quick change rack fixtures.

12
 SECTION 2

TERMINOLOGY

13
SECTION 2 – TERMINOLOGY

FIGURE 2.1

Forming Rack - Precision, hardened tool used in the cold forming process to form
splines, threads, oil grooves and serrations into a round bar.

Spacers - Parallel steel bars used to offset the forming racks from back of the rack
fixture, or from each other when rolling two separate splines.

Ways - Hardened ground steel structures on which the slides traverse.

Slides - Part of the machine which is attached to the slide cylinders and which carry the
rack holding fixture.

Slide Cylinders - Two matching cylinders used to move the slides in opposite directions.

14
Headstock - Unit located on the inside of the ROTO - FLO® machine which contains the
headstock center and part present limit switch actuator.

Headstock Center - Part of the headstock, which holds and locates the part axially into
position between the racks.

Headstock Motor - Optional motor used to adjust the setting of the headstock center for
the proper positioning of the part to be rolled to the forming rack.

Tailstock - Unit located on the outboard side of the ROTO - FLO® machine which holds
the tailstock center.

Tailstock Center - Part of the tailstock, which functions to secure the part axis into
position parallel to the rack tooth surfaces.

Overarm - Outboard structure holding the tailstock when it is located above the machine
rolling center point.

Underarm - Outboard structure holding the tailstock when it is located below the
machine rolling center point.

Spindle - Unit located in the center of the machine which contains the headstock center
and upon which the synchronizing gear turns.

Synchronizing Gear - Precision gear used to synchronize the movement of the slides.

Heel Block - Unit located on the rack fixture, which is designed as the stop for locating
the forming rack to assure proper location to the centers. Also contains set screws to
lock down the forming rack to the rack fixture.

Toe Block - Unit located on the rack fixture at the opposite end from the heel block from
which the forming rack is pushed against the heel block. Also contains set screws to
lock down the forming rack to the rack fixture.

Verniers - Graduated scales mounted on the adjusting wedge to set the proper height of
the forming rack to the centers. Adjustments should always be made equally between
the top and bottom verniers.

Adjusting Wedge - Tapered wedge used to adjust the height of the forming racks.

15
 FIGURE 2.2

Rack Fixture - Unit that holds the adjusting wedge and the forming racks.

Synchronizing Racks - A matched set of racks, one of which is bolted to each slide.
The racks are in mesh with the synchronizing gear producing precise synchronized
movements between the racks in relation to the part.

FIGURE 2.3

16
EXTERNAL SPLINE TERMINOLOGY

Gear - Machine element consisting of integral keys (teeth) and keyways (spaces) equally
spaced inside a circle. A gear transmits torque from one shaft to another.

FIGURE 2.4

Spline - Machine element consisting of integral keys (spline teeth) or keyways (spaces)
equally spaced around a circle or portion of a circle. A spline always transmits torque
along the same axis or shaft. Two of the more common rolled splines are: serrated and
involute.

FIGURE 2.5

External Spline - A shaft with equally spaced teeth, of straight sided or involute shape
capable of transmitting torque to the mating member along the same axis.

Serrated Spline - Also called "straight sided angular". The teeth on this type spline are
small and able to transmit only small amounts of torque. This type of spline has little
surface contact and is subject to rapid initial wear, thus increasing the clearance fit
between mating parts.

Involute Spline - Spline having teeth with involute profiles. This type of spline presents
the most surface contact and is not subject to rapid wear.

17
Involute Profile - Form or shape of the gear tooth, which is controlled by the base circle.
The involute form is not a Curve or radius, which can be calculated by an easy
mathematical formula, but, is simple to describe. Attach a string on a cylinder (Fig. 2.6).
Bring the string over the top to point "A". Where the string contacts point "A" will be point
"B" on the string. Keeping the string tight, pull away from the cylinder. The line made by
point "B" is the involute of that cylinder.

FIGURE 2.6

Diametral Pitch - Number of spline teeth per inch of pitch diameter. The diametral pitch
determines the circular pitch, tooth thickness and tooth spacing.

Stub Pitch - Number used to denote the radial distance from the pitch diameter to the
major diameter.

On spline prints, process sheets and inspection

forms, the diametral and stub pitch is shown in
the form of a fraction such as 24/48. The
numerator (top number) is the number of teeth
per inch of pitch diameter. It can also be
stated as the number of teeth, which will fit into
Pi (3.14159") since the circumference of a 1"
diameter circle is 3.14159". The denominator
(bottom number) is the stub pitch, which is the
height of the tooth from the pitch diameter to
the major diameter. The height is one (1)
divided by the denominator.

Using the above mentioned fraction of 24/48

on a one inch pitch diameter shaft means that
there are 24 teeth on the shaft, and the
distance from the pitch diameter to the major
diameter is .0208" (1 divided by 48). FIGURE 2.7

18
Working Depth - Depth from the major diameter of the external spline to the minor
diameter of the internal spline.

Base Diameter - The generating diameter or origin of the involute helicoid, which
determines the tooth profile.

Pressure Angle - Angle between a line tangent to an involute surface and a radial line
through the point of tangency (Fig. 2.8).

Pitch Diameter - Reference circle from which all transverse spline tooth dimensions are
defined.

Form Diameter - Circle, which defines the deepest part of the involute profile requiring
control. Located near the minor diameter of an external spline.

Major Diameter - Circle formed by the tips of the teeth on an external spline.

Minor Diameter - Circle formed by the innermost part or root of the spline teeth.

Circular Pitch - Distance along the pitch diameter between corresponding points of
adjacent spline teeth.

Root Fillet - Concave portion of the tooth profile, which is at the bottom between two
adjacent teeth.

Tooth Flank - The surface of the spline tooth from the pitch diameter to the root
diameter.

FIGURE 2.8

19
Tooth Face - The surface of the spline tooth from the pitch diameter to the major
diameter.

Side Fit - Fit where the external and internal teeth contact each other for both centering
and driving. The minor and major diameters are clearance dimensions.

Major Diameter Fit - Contact for centering is made at the major diameter of both the
external member and the internal member. The minor diameter of both members are
clearance dimensions. The sides of the tooth surface are for driving only.

Helix - The angle of the spline to the axis of the part.

FIGURE 2.9

Parallelism - Correlation of one spline to another. A line drawn the length of two splines
to infinity will never meet if they are parallel to each other.

Parallelism Variation - Any variation in the parallel direction of one spline tooth to any
other spline tooth.

Out of Roundness - Variation of the spline from a true circular form.

Lead Variation - Any variation in the parallel direction of the tooth spline to the reference
axis.

Index Variation - Any variation in the distance from one spline tooth to another spline
tooth.

Total Index Variation - Greatest difference in any two teeth (adjacent or otherwise)
between the actual and the perfect spacing of the tooth profiles.

20
Effective Variation - Accumulated effect of the spline variations on the fit with the
mating part.

INTERNAL

MIN EFFECTIVE SPACE

MIN ACTUAL SPACE
MAX ACTUAL SPACE

EXTERNAL

MIN ACTUAL T.T.

MAX ACTUAL T.T.
MAX EFFECTIVE T.T.

FIGURE 2.10

Effective Size - The effective tooth thickness or space width of a component is an

important spline element because it is this size, which determines the fit between the
spline and the mating part, and hence it's load carrying capability.

It is not only the tooth thickness or space width, which determines the resultant fit
between an external and internal spline fit. This is because splines have multiple
engaging surfaces. Each of these surfaces is subject to an error of either profile, index
or parallelism, which must be allowed for if a fit is to be guaranteed. This allowance is
determined by allocating each of these elements a maximum permissible tolerance. The
sum of these tolerances is referred to as the error allowance. It is generally accepted by
most engineering spline standards that all elements will not be on their maximum value;
and an error allowance of 60% of the sum of twice the positive profile error, index error,
and lead errors for the length of engagement is allowed.

Max Effective - The maximum tooth thickness, which will allow the external spline tooth
to fit the space width of the mating part at the pitch diameter.

Max. Actual - The upper limit allowance of the tooth thickness measured at pitch
diameter.

Min. Actual - The lower limit allowance of the tooth thickness measured at pitch
diameter.

Effective Clearance - The effective space width of the internal spline minus the effective
tooth thickness of the mating external spline.

21
Class of Tolerance - One of four classes of tolerance in space width and tooth thickness
used in spline standards. Class five (5) tolerance is shown in Table 5. To achieve class
four multiply the tolerances by 0.71, for class 6 multiply by 1.4 and for class 7 multiply the
tolerances by 2.0. All tolerance classes have the same minimum effective space width
and maximum effective tooth thickness limits so that a mix of classes between mating
parts is possible.

22
 SECTION 3

SPLINE DATA

23
SECTION 3 – SPLINE DATA

Spline Design Considerations

1. Pressure Angle: 30°, 45° and 37 1/2° pressure angle members all have the same
effective fit (backlash) characteristics. The pressure angle should be chosen to
satisfy function and economy. If the assembly requires that the members slide under
load, or if one or both of the parts have a thin walled tubular section, then function
dictates the use of a 30° pressure angle to reduce shift effort and bursting forces.

If the member is to deliver torque only and if bursting forces are not detrimental, then
economy should dictate the use of a 45° pressure angle. The 45° pressure angle
yields at least 50% more tool life than 30° pressure angle tools.

The 37 1/2° pressure angle spline offers a compromise between the 30° and the 45°
pressure angle members. This is suggested if the shaft material is too hard to
consider use of a 30° pressure angle, and function prohibits use of the 45° pressure
angle.

2. Piece Part Chemistry:

Most carbon steel and alloys may be roll formed. It is desirable that the material be
homogeneous and have good ductility. Sulfurized steels are not recommended
although they are being rolled in some applications where generation is not severe,
using the 45° pressure angle.

Examples of some of the steels being roll formed are:

(A.I.S.I. SPECIFICATION)
1020 1330 4340 8620
1040 3140 4620 9310
1050 4027 303 STAINLESS
1117 4130 410 STAINLESS

TABLE 1

In addition to steel, brass and some aluminum alloys can be formed. In some cases,
parts may be rolled after hardening to eliminate dimensional variations arising in heat-
treating. However rack life is shorter than when heat-treating is done after rolling tile
part. Material hardness should range from 180 to 220 Brinell, but can be up to 340
Brinell.

24
 FIGURE 3.1

3. Material Hardness:
The maximum yield strength and hardness of material, which can be economically
cold formed, varies according to the pressure angle. The approximate limits are
shown below.

P.A. YIELD STRENGTH APPROX. BHN

30˚ 60 kg/mm2 / 90,000 PSI 265
37 ½˚ 85 kg/mm2 / 90,000 PSI 340
45˚ 90 kg/mm2 / 90,000 PSI 365

TABLE 2

4. Diametral Pitch:
The module/pitch chosen should also provide a sufficient number of teeth to assure
continuity of contact between tools and the work piece so proper control and
repeatability are maintained. The choice must be consistent with the minimum
number of teeth shown in each section of the dimensional portion of the spline
standards.

The module/pitch chosen should also provide the necessary strength and fatigue
resistance to suit its application, remembering that with a common major diameter or
a common pitch diameter, the finer the pitch the greater the strength. This is also
advantageous to ROTO-FLO tool life. Less metal displacement is required and tool
life is extended with a finer pitch.

5. Splining Into Undercuts:

25
 FIGURE 3.2

Shafts may be prepared and splines formed as shown in Figure 3.2. These designs
allow the forming tools to extend both effective ends of the spline. The shaft shown
on the left, when properly designed, has increased fatigue resistance. The design
shown on the right permits a mating part to locate against the shoulder.

6. Splining With Radius Runout:

FIGURE 3.3

Parts may be prepared without undercuts at the inboard

end as shown on the left (Fig. 3.3). The mating part
can locate against the shoulder by providing a clearing
chamfer at that end of the internal spline.

When forming racks are made for such parts, the

standard radii on the tools are ground as shown in
Figure 3.4. The dimensions are shown in Table 3.
FIGURE 3.4

DIAMETRAL
MODULE B R
PITCH
0.794 / 0.397 32/64 1.5 / 0.060 2.00 / 0.085
1.058 / 0.529 24/48 2.5 / 0.100 3.50 / 0.140
1.270 / 0.635 20/40 2.5 / 0.100 3.50 / 0.140
1.587 / 0.794 16/32 3.0 / 0.170 4.30 / 0.170
TABLE 3

7. Major Diameter Fit:

Caution should be used when considering this fit for the following reasons:

26
 1. When allowances are made for eccentricities, and when present, the torque load
is borne by only a few teeth.

2. When eccentricities do not occur, excess backlash is present. Further

consideration must be given to the major diameter of the external spline. A part
can be rolled to form a spline to a standard major diameter, and then ground down
after heat treating leaving a stub addendum for the major diameter. Forming
racks designed to roll a part large enough to provide grind stock on the major
diameter can also be ordered.

Since a roll formed spline cannot provide a chamfer at a major diameter, it must
be machined into the internal spline with a broach to provide the necessary comer
clearance (Fig. 3.5).

FIGURE 3.5

8. Major Diameter Fall-Off:

An inherent condition on a roll formed spline is the fall-off of the major diameter at the
ends. This is caused by the material following the path of least resistance, some
flowing axially out the ends rather than extruding up to form the full major diameter.

The appropriate amount of fall-off and the suggested accommodating chamfers on

the blank part are shown in Fig. 3.5. The dimensions for the fall-off are detailed in
Table 4.

dch df L
MODULE D.P. DEPTH OF CHAMFER DEPTH OF LENGTH OF
(+0.25mm, -0.0mm) / (+0.010, -0.000) FALL-OFF FALL-OFF
0.794 / 0.397 32/64 0.89 / .035 0.25 / .010 7.62 / .300
1.058 / 0.529 24/48 1.14 / .045 0.38 / .015 8.89 / .400
1.270 / 0.635 20/40 1.40 / .055 0.51 / .020 10.16 / .400
1.587 / 0.794 16/32 1.78 / .070 0.64 / .025 11.43 / .450

TABLE 4

27
 SECTION 4

QUALITY CAPABILITIES

28
SECTION 4 – QUALITY CAPABILITIES

I. PROCESS CONTROL CONSIDERATIONS

The following is a general list of the parameters that must be considered when seeking
complete process control.

1. Machine functions:
A. Machine centers and part holding devices.
B. Machine ways and slides.
C. Machine heel blocks.
D. Backlash (synchronizing gear and racks).
E. Machine opening.
F. Parallelism of tools and spacers.

2. Part preparation:
A. Concentricity.
B. Pre-roll size control.
C. Rollability of material.
D. Consistency of hardness.

3. Tool Function:
A. Capability of design.
B. Tool manufactured to design specifications.
C. Tool manufactured to necessary quality standards.

4. Other:
Quality of coolant.
Temperature control of coolant.

29
III. EFFECTIVE VARIATIONS

Allowed inherent variations involved in spline manufacture are individually listed and
defined below. No one individual variation should be cause for piece part rejection.

1. Profile Variation - Positive profile variations affect the fit by reducing effective
clearance. Negative profile variations do not affect the fit but reduce the contact area.
A deviation, measured as profile variation from the desired form, is permitted due to
manufacturing conditions and piece part functionability. The zero point from which
profile variation is measured occurs at the contact point of the measuring pins that
are used to establish the actual tooth thickness, preferably at the mid-point of the
active profile. These measurements do not determine the fit between mating parts,
but may be used as a part of analytical inspection of splines to evaluate the effective
tooth thickness by approximation. The diameters of measuring pins are usually
selected to contact the tooth approximately at the mid-point of the tooth profile, but
the location of contact may be adjusted depending on the function of the piece part.
The profile for parts with low number of teeth, range 22 and under, will show a
condition in the minor diameter, fillet area of the tooth, where the form of the tooth will
have an under-cut condition that extends approximately three (3°) degrees of roll
angle above the form diameter.

2. Lead Variation - These variations cause clearance variations affecting the fit by
reducing looseness or increasing interference. An inherent condition on a roll formed
spline is a fall-off at the end of the part, caused by a diminishing axial flow of material
that causes an "end easing". This is a desirable condition as it assists in assembly
and permits load carrying at the center of the members, yet retaining all the
predetermined fit characteristics. The effect of this "end easing" is very slight on 30°
pressure angle members and those having short lengths. This condition will vary with
different materials and the end chamfers that are on the pre-roll diameters.

3. Index Variations - The greatest difference in any two teeth (adjacent or otherwise)
between the actual and the perfect spacing of tooth profiles, cause the clearance to
vary from one set of mating tooth sides to another. Since the fit depends on the
areas with minimum clearance, index variations reduce looseness or increase
interference.

30
III. Effective Size

The effective tooth thickness or space width of a component is an important spline

element because it is this size, which determines the fit between the spline and the
mating part, and hence it's load carrying capability.

It is not only the tooth thickness or space width, which determines the resultant fit
between an external and internal spline fit. This is because splines have multiple
engaging surfaces. Each of these surfaces is subject to an error of either profile,
index or parallelism, which must be allowed for if a fit is to be guaranteed. This
allowance is determined by allocating each of these elements a maximum
permissible tolerance. The sum of these tolerances is referred to as the error
allowance.

It is generally accepted by most engineering spline standards that all elements will not be
on their maximum value; and an error allowance of 60% of the sum of twice the positive
profile error, index error, and lead errors for the length of engagement is allowed.

31
 MAXIMUM TOLERANCES FOR SPACE WIDTH AND
TOOTH THICKNESS OF TOLERANCE CLASS 5 SPLINES
TOLERANCES IN TEN THOUSANDTHS (0.0001)
(REF. ANSI B92.1-1996)
2.5/5 4/8 6/12 10/20 16/32 24/48 64/128
P
and and and and and and and 128/256
Ps
3/6 5/10 8/16 8/16 20/40 48/96 80/160
N Machining Tolerance
10 15.8 14.5 12.5 12.0 11.7 11.7 9.6 9.5
20 17.6 16.0 14.0 13.0 12.4 12.4 10.2 10.0
30 18.4 17.5 15.5 14.0 13.1 13.1 10.8 10.5
40 21.8 19.0 17.0 15.0 13.8 13.8 11.4 --
50 23.0 20.5 18.5 16.0 14.5 14.5 -- --
60 24.8 22.0 20.0 17.0 15.2 15.2 -- --
70 -- -- -- 18.0 15.9 15.9 -- --
80 -- -- -- 19.0 16.6 16.6 -- --
90 -- -- -- 20.0 17.3 17.3 -- --
100 -- -- -- 21.0 18.0 18.0 -- --
N Variation Allowance
10 23.5 20.3 17.0 15.7 14.2 12.2 11.0 9.8
20 27.0 22.6 19.0 17.4 15.4 13.4 12.0 10.6
30 30.5 24.9 21.0 19.1 16.6 14.6 13.0 11.4
40 34.0 27.2 23.0 21.6 17.8 15.8 14.0 --
50 37.5 29.5 25.0 22.5 19.0 17.0 -- --
60 41.0 31.8 27.0 24.2 20.2 18.2 -- --
70 -- -- -- 25.9 21.4 19.4 -- --
80 -- -- -- 27.6 22.6 20.6 -- --
90 -- -- -- 29.3 23.8 21.8 -- --
100 -- -- -- 31.0 25.0 23.0 -- --
N Total Index Variation
10 20 17 15 15 14 12 11 10
20 24 20 18 17 15 13 12 11
30 28 22 20 19 16 15 14 13
40 32 25 22 20 18 16 15 --
50 36 27 25 22 19 17 -- --
60 40 30 27 24 20 18 -- --
70 -- -- -- 26 21 20 -- --
80 -- -- -- 28 22 21 -- --
90 -- -- -- 29 24 23 -- --
100 -- -- -- 31 25 24 -- --
N Profile Variation
All +7 -10 +6 -8 +5 -7 +4 -6 +3 -5 +2 -4 +2 -4 +2 -4
Lead Variation
Lg, in. 0.3 0.5 1 2 3 4 5 6 7 8 9 10
Variation 2 3 4 5 6 7 8 9 10 11 12 13

TABLE 5

For Classes:
Class 4 = 0.71 x tabulated value
Class 5 = as tabulated value
Class 6 = 1.4 x tabulated value
Class 7 = 2.0 x tabulated value

32
SPLINE INSPECTION

Types of Gages

1. Composite spline gages – A gage having a full compliment of teeth

a. GO composite Spline Ring Gage – This gage

is what we refer to as a functional gage. The
Go Ring Gage is used to ensure we do not
produce a tooth thickness with effective
errors larger than the max effective. If the Go
Ring Gage does not go, we are either
producing our tooth thickness too large, or
our effective errors are too great.

FIGURE 4.1

b. Variable composite gage – Sometimes called the max effective gage, this
gage will measure and give a value for max
effective. By being a composite variable gage,
and having a full compliment of teeth, this gage
measures tooth thickness and effective errors
simultaneously.

FIGURE 4.2

c. Go Composite Major Diameter Fit ring gage – This gage is required for
major diameter fit splines. Like the standard Go gage, it is a functional
gage with one difference, the gage is designed to confirm the relationship
between the major diameter and the pitch diameter is correct.

33
2. Sector spline gages – A gage having two diametrically opposite groups of teeth.

a. NO GO sector Spline Ring Gage – This is a

functional gage. The No Go ring gage is
used to ensure we do not produce a tooth
thickness less than the min actual. Being a
sector gage, this gage is not inclusive of
effective errors.

FIGURE 4.3

b. Variable sector gage – Sometimes called the min actual gage, this gage
will measure and give a value for min actual.
By being a variable sector gage, having two
diametrically opposed groups of teeth, we do
not measure effective error. With this gage we
get a true reading for min actual tooth
thickness.

FIGURE 4.4

3. Measuring Pins – The use of measuring pins allows the

measurement of tooth thickness. Two pins, placed 180
degrees apart, contact the tooth at about the mid-point of
the profile. The pin diameter must be greater than the
major diameter but large enough to not contact the root
radius of the part.
a. Dimension Over Pin gage – A gage designed to
check the DOP of a given spline. The DOP can be
used to calculate a tooth thickness for a given
spline. The DOP check is an actual check, non

34
 inclusive of effective error.
FIGURE 4.5
4. Major GO and NO-GO ring gages – A set of gages used to ensure the OD of a
given spine is produced within limits.
These gages are produced at the high
and low limits of major. Major diameter
ring gages are also considered functional
gages.

FIGURE 4.6

5. Span Measurement – A process where progressive block tooth measurements

are taken around the
spline. This process
will give a good
indication of the
quality of a given part.
This is not index,
however, it is a good
method to determine
variation in tooth
spacing.

FIGURE 4.7’
6. Analytical Gear Measuring Machine – This type of FIGURE 4.8
machine is capable of measuring all the parameters of involute
splines, both straight and helical. When so desired the print
out will show the tooth profile, tooth thickness, tooth index,
taper, concentricity, lead of the spline and parallelism. Once
the machine is set up, it will do all these measurements
automatically.

35
 SECTION 5

MACHINE SETUP

36
SECTION 5 – MACHINE SETUP
To Set-Up Tooling For The ROTO-FLO Machine

1. Measure, with micrometers, the height

of the bottom ROTO-FLO forming rack
at its starting point. Also measure the
riser shim if present (Fig. 5.1). Record
these measurements using a form
such as shown on Page 43. Be sure
that both racks are of the same set,
i.e., have the same serial number
(RF___).

FIGURE 5.1

FIGURE 5.2 FIGURE 5.3

37
 FIGURE 5.4

2. Repeat Step 1 for the top forming rack.

3. Record the pre-roll diameter.

4. Add the measurements from Steps 1, 2 and 3.

5. Subtract this from the maximum opening of the machine (the distance between the
upper and lower rack fixture with the verniers set at zero).

6. Half of this amount is the theoretical setting for each vernier. Some additional
compensation will have to be made for machine springback, usually .002" to .003" on
each vernier.

7. Example: For a machine with a 139.7mm opening, the racks measure 57.100, the
part measurement is 25.40.

A. Double the rack measurement = 114.20

B. Add the pre-roll diameter of 25.40
C. This equals 139.6
D. Subtract this amount from the maximum machine opening of 139.7 equals 0.100
E. Divide this by two equals 0.050
F. On larger pitch splines, add 0.025 needed for machine deflection.
G. Thus, the final reading is 0.050 mm for both the upper and lower vernier setting.

8. With the adjusting screw, set the size adjusting wedges to this predetermined vernier
setting.

38
 FIGURE 5.5

9. Before installing the racks, check the starting end of the racks. The smaller end is the
starting end of the rack and is sandblasted. First install rack spacers if required then
set the racks in place. The lower rack sets in the machine with the starting end to the
right, and the upper rack with the starting end to the left. Be sure that the rack serial
numbers face to the outside of the machine (Fig. 5.5).

10. Using the hold down screws provided; snug the racks to the slide, to the heel block,
and against the back of the rack fixture (Fig. 5.5).

11. Tighten the heel block screws, then tighten the screws to hold the rack to the slide
and the back of the rack fixture.

12. Check the position of the tailstock so the stroke of the cylinder brings the tailstock at
least 1/4" closer to the headstock than when a part is in place, otherwise the travel of
the tailstock cylinder will not be great enough to actuate the "Part in Position" limit
switch located in the rear of the machine. This limit switch ensures that the part is
properly located before rolling.

13. Check the test part for correct pre-roll size and tolerance.

14. Next, load a part between centers, checking to see that the part is positioned so the
spline will be rolled in the proper location with respect to length of spline, proximity to
shoulders, etc.

15. If the location of the part needs to be changed, this is accomplished by moving the
location of the headstock. This can be done on some machines with a manual
adjusting screw located at the rear of the machine. On some machines there is an
electric motor, which turns the adjusting screw (Fig. 5.6). Each turn of the headstock
adjusting screw moves the headstock center one/tenth (0.1") of an inch. On

39
 machines with the electric headstock motor, the adjustment can be made with a
selector switch at the operator's control station.

FIGURE 5.6

16. The machine is now ready for the initial tryout, roll the first piece using the following
operating cycle.

A. Start the hydraulic pumps.

B. Start the coolant pump. Coolant nozzle must be clear of the forming racks and
coolant is directed on the work area.
C. Load the part.
D. Advance the part support. (Push advance part support and two hand safety
pushbuttons)
E. Roll the spline. (push the advance racks and two hand safety pushbuttons)
F. Retract the part support. (push return part support and two hand safety
pushbuttons)
G. Remove the part.
H. Return the racks to the starting position. (Push the return racks and two hand
safety pushbuttons)

17. Check the spline for size. If adjustments are necessary, loosen the heel block
screws, rack holding screws and the screws holding the rack to the back of the rack
fixture, and adjust the size of the adjusting wedge to the new vernier settings. A
higher number on the verniers will decrease the distance between the forming racks,

40
 resulting in a smaller over the pin measurement. Be sure to set both top and bottom
verniers to the same setting. Retighten the screws as in Steps 8 and 9.

18. Roll another part following step 13, check this part for size. If the size is correct the
machine is ready for automatic cycling.

41
 U.S. GEAR TOOLS RACK SET-UP FORM

Date

Tool #

Part #

Customer

Operator

MEASURE AND ADD ALL OF THE FOLLOWING:

Starting end height, bottom rack.

Riser shim, if present.

Starting end height, top rack.

Riser shim, if present.

Pre-Roll diameter of part.

TOTAL*

LIST AND SUBTRACT THE FOLLOWING:

Machine opening.

Subtract total from above.

Difference.

Divide by two (2) (half for each vernier).

Add approx. 0.002" (for machine springback).

Setting for top and bottom verniers.

*TOTAL MUST BE SMALLER THAN THE MACHINE OPENING!!

42
 SECTION 6

PROCESS TROUBLESHOOTING

SECTION 6 – PROCESS TROUBLESHOOTING

It should be noted that most process errors occur after a tooling change or a change in
source of incoming material.

Indexing Errors - (Variation in or incorrect spacing of teeth on the part)

1. Incorrect pre-roll diameter.

Inspect incoming parts for proper pre-roll diameters in relation to tool drawing.

2. Part must be rolled to the proper tooth thickness in relation to tool drawing.

3. Excessive part runout.

Part must run true within 0.0015".

4. Bent or loose machine centers (headstock or tailstock).

Inspect centers. Replace as necessary.

5. Improper rack installation.

Be sure that racks are firmly seated against the heel blocks.

6. Improper fixture alignment.

Remove tooling and check mounting surfaces. Check distances from heel block
to the center.

7. Racks are not matched.

Check first tooth of forming rack to machine centers. Racks should be within
0.0005" of each other. Contact rack supplier.

8. Top and bottom racks not equally distanced from the machine centers.
Change vernier setting to bring racks within 0.001" of each other.
(Measure from bottom of rack fixture to machine centers)

9. Tailstock not aligned properly with the centerline of machine.

Check and correct the alignment.

10. Inconsistent part hardness.

Check with part supplier.

43
Lead Errors - (part teeth not parallel to part centerline
1. Part bent.
Inspect incoming parts.

2. Excessive runout.
Part must run true to within .0015".

3. Splines have crosstaper (measurement over pins not consistent over length of spline

4. Bent or loose machine centers (headstock or tailstock).

Inspect centers and replace as necessary.

5. Racks not parallel to slide ways.

Check tool installation.
(Loose screws and/or dirt or burrs between rack and back of rack fixture.)

6. Possible lead condition ground into the forming racks.

Contact rack supplier.

7. Inconsistent part hardness.

Check with part supplier.

Variation of Tooth Thickness - (part to part inconsistency)

1. Variation of part pre-roll diameter.

Inspect incoming parts for size consistency and taper.

2. Variation in part hardness.

Inspect incoming parts for part hardness.

3. Bolts and dowels loose on machine tie bars.

Retighten bolts and replace dowels with larger size.

Excessive Tooling Wear or breakage

1. Part too hard.

Inspect incoming parts (180 -220 Brinell recommended).

2. Incorrect or contaminated coolant.

Change coolant and/or filters.

3. Tooling improperly set. (excessive lead or indexing errors).

Reset tooling

44
 SECTION 7

MACHINE MAINTENANCE

45
SECTION 7 – MACHINE MAINTENANCE
Checking Centers for Runout.
To test live center for runout, remove center from the machine and place it in a vise. Set
an indicator on the vise, place the indicator near the point of the center. Slowly turn the
center. The indicator should not move more than 0.001". Next turn the center around so
that the live center is now in the vice and indicate as before. The indicator should not
move more than 0.001". If the indicator readings are more than the amount allowed,
replace the live center and/or the shank.

Checking Machine Opening and Vernier Accuracy.

For this procedure use the following items:
1. Straight turned setup shaft (no more than 0.0005" runout)
2. Planer gage
3. Toolmaker jack (or screw jack)
4. Micrometer

FIGURE 7.1

Forming racks must be removed from the machine, and verniers set at zero.

1. Place setup shaft between headstock and tailstock centers.

46
2. Move the slides until they are even with one another.

3. Shut off machine.

4. Place a toolmaker jack between the slides (Fig. 7.2). Open the toolmaker Jack until
the slides are firmly seated. This eliminates any sag in the upper slide, which could
cause false readings.

FIGURE 7.2

5. Place a planer gage between the slide and the setup shaft (Fig. 7.2).

6. Open the planer gage until firm contact is made. Lock gage in position.

7. Measure the height of the gage using the micrometers. Record this dimension.

8. Repeat Steps 5, 6 and 7 for the remaining slide.

The total of the two planer gage readings plus the

diameter of the setup shaft must equal the "daylight"
opening of the machine. If the readings do not equal
the opening of the machine, or if the top and bottom
readings are not equal, adjust the slides by using the

47
size adjusting screws. Reset the verniers.
FIGURE 7.3

Checking Distance of Heel Blocks to Machine Centers. For this procedure use the
following items:
1. Straight turned setup shaft (no more than .0005" runout)
2. Planer gage
3. Micrometer

Forming racks must be removed from the machine.

1. Place setup shaft between headstock and tailstock centers.

2. Move the slide forward until distance from heel blocks to the setup shaft are within the
capacity of the planer gauge.

3. Shut off machine.

48
4. Place planer gage firmly on the slide between heel block and the setup shaft (Fig.
7.4).

FIGURE 7.4

5. Open planer gage until contact is made between

the heel block and the setup shaft (Fig. 7.4). Lock
gage in this position.

6. Measure gage using the micrometer (Fig 7.5).

Record this dimension.

7. Repeat Steps 3, 4 and 5 on the remaining heel block. FIGURE 7.5

8. Move the slides back and forth several times and repeat Steps 1-7 to ensure
consistency of your readings.

9. Compare the distances between the heel blocks. If the readings are not the same on
both top and bottom heel block, then the heel block with the lowest micrometer
reading will have to be ground equal to the difference. This amount must be removed
from the locating face of the heel block.

10. After grinding the heel block recheck the measurements by following Steps 1-7.

NOTE: If in step 8 the readings do

not repeat, you may have
excessive backlash in your
synchronizing gear and
synchronizing rack.

49
 FIGURE 7.6

11. Clean the slides of all dirt, chips and burrs (the area which holds the timing racks).

12. Place the slides so these are centered on the headstock center.

13. Place a toolmaker jack between the slides to remove slack in the upper slide (Fig.
7.7).

FIGURE 7.7

14. Place the planer gage between the synchronizing rack locating surface of the lower
slide and the headstock spindle housing. Open the planer gage and lock in this
position.

15. Measure the planer gage using the micrometer.

Record this dimension.

16. Repeat Steps 14 and 15 for the upper slide.

Remove the toolmaker jack.

FIGURE 7.8

50
17. Take the synchronizing rack for the lower slide to a surface plate and place the
synchronizing gear in mesh at the center of the synchronizing rack (Fig. 7.9).

FIGURE 7.9

18. Measure the distance from the surface plate to the gear bore diameter (Fig. 7.9).
Record this dimension.

19. Subtract dimension of Step 18 from Step 15, add 0.002" for preload. The result is the
dimension for the synchronizing rack spacer.

20. Repeat Steps 17, 18 and 19 for the upper slide.

21. Install synchronizing racks plus the spacers to the respective slides. Tighten bolts
securely. Be sure that the bolt heads do not protrude into the tooth openings.

22. Install synchronizing gear and replace the gear cover plate.

23. To check for proper preload, fasten a magnetic base indicator and indicator assembly
to the machine base, placing the indicator needle on top of the headstock center.

24. Advance lower slide only until the synchronizing gear is at the center of the
synchronizing rack. The indicator should read between 0.001" and 0.002" deflection.

25. Disengage the lower rack from the synchronizing gear and repeat Step 24 for the
upper rack. Place toolmaker jack under upper rack to remove machine clearance
before taking indicator reading for preload. Remove jack after taking reading.

26. After verifying the proper preload from the indicator readings, engage both slides at
the same time.

27. Replace slide end brackets, reconnect hydraulic cylinder rods and replace the end
guards.

28. Recheck the heel block to machine center.

51
Correcting excessive backlash.
If tooth indexing problems and heel block to center measurements are inconsistent, the
problem is caused by excessive backlash in the synchronizing gear and the
synchronizing rack.

Items you will need for this procedure:

1. Planer gage
2. Toolmaker jack (or screwjack)
3. Micrometer
4. 2x4 (at least six feet long)

The following corrective procedure assumes the forming racks have been removed from
the machine.

1. Place the slides so they are centered with the headstock center.

2. Shut off machine.

3. Remove both end guards. This allows the synchronizing racks to be disengaged
from the synchronizing gear.

4. Loosen, but do not remove, (use 1/2" impact wrench) the nut from the upper and
lower hydraulic slide cylinder. Remove the dowel pins from the slide end bracket,
which hold the slides to the cylinder.

5. Start the machine. Bring the slides to the returned position.

6. Remove the cylinder rod nuts. Remove the end brackets.

7. Separate the slides (using 2x4) to disengage the synchronizing racks from the
synchronizing gear.

8. Remove synchronizing gear cover plate and synchronizing gear.

9. Remove both synchronizing racks and spacers.

10. Thoroughly clean and inspect synchronizing rack teeth and synchronizing gear
bushing for wear. Replace racks and gear as required.

52
Checking Center to Center:
There are two conditions, which may cause problems such as runout, taper and indexing
errors. The first is the headstock and tailstock centers are out of perfect alignment. The
tailstock could be higher, lower, or off to a side from the headstock. The second is the
tail stock being at an angle to the headstock. This could be angled up, down or
sideways. These conditions can be caused by having loose outboard support mounting
bolts or broken dowel pins. If the bolts are loose, movement could be created to cause
the dowel hole to enlarge its size, thus losing the ability to maintain position of the
outboard unit to the headstock center.

If the tailstock or the tailstock slide have been changed, and there have been no previous
problems running parts, only the first procedure needs to be performed.

For this procedure you will need:

1. Small based magnetic indicator.

NOTE: For this procedure the forming racks must be removed from the machine.

1. Advance the tail stock to the end of the stroke.

2. Extend the headstock as far as possible.

FIGURE 7.10

53
3. Attach the magnetic base indicator to the tailstock center (Fig. 7.10).

4. Position the indicator to read zero.

5. Rotate the tailstock center so the indicator reads all the way around the headstock
center.

6. The location of the highest reading indicates the direction the tailstock is out of
alignment with the headstock. (Example: if the reading is highest at the top, the
taiIstock is low). Correct accordingly.

If you are experiencing problems with indexing, runout, taper or lead errors and have
eliminated everything it could be, then the tailstock is out of angular alignment with the
headstock. For testing this you will use the following items.

1. Small base magnetic indicator.

2. A centered 12" test bar (Maximum .0005 runout).
3. A centered 24" or 36" test bar (depending on the length of the outboard arm).

For this procedure the forming rack and spacers must be removed from the rack fixture.
Clean the rack fixture and stone off the back of the rack fixture to remove any burrs or
high spots.

1. Place the 12" test bar between centers.

2. Place the magnetic indicator so the back of the rack fixture can be reached with the
indicator (Fig. 7.11).

FIGURE 7.11

3. Turn the test bar 360º as to indicate both top and bottom rack fixtures.

54
4. Record the readings, top, bottom and both sides.
5. Remove the 12" bar and replace it with the longer bar and repeat Steps 2, 3 and 4.

6. The location of the highest reading on the indicator is the direction the tailstock is off.
(Example: if the highest reading is at the bottom, the tailstock is angled downward
from a level condition. Try to increase the tension of the support holding the
underarm. In case of an overarm, the unit must be shimmed.)

55
 SECTION 8

LUBRICATION

56
SECTION 8 - LUBRICATION
Proper lubrication is essential to keeping the ROTO - FLO machine operating. Almost
every machine and tool requires lubrication to protect its moving parts and ensure
smooth operation.

A Lubricant is a substance that provides a smooth, slippery surface. It is usually an oil or

grease, which can be made from animal or vegetable fats, but most often is made of
crude oil. To lubricate means to apply a lubricant or to make smooth and slippery.

Lubricants provide a thin film between two parts, which allow those parts to move
smoothly past one another.

There are four general forms of lubricants:

1. Liquid lubricants - These are oils generally made from crude oil, but can be made
from animal or vegetable fats.
2. Semisolid lubricants - These are various greases which are made by adding a
thickening agent to mineral oils or synthetic oils.
3. Solid lubricants - These are forms of metals or chemicals and used in extremely high
or low temperature conditions.
4. Gaseous lubricants - These are used in applications requiring highly accurate
separation of moving surfaces. They are also used in extreme temperature
conditions where grease and oil would not be practical.

There are five primary functions for lubrication. They are:

1. Reduce friction.
2. Reduce wear.
3. Cool moving surfaces.
4. Prevent corrosion.
5. Seal out contaminants.

FIGURE 8.1

A lubricant reduces friction between two surfaces by providing a film for the two surfaces
to travel on (Fig. 8.1).

Friction and wear are always present between two sliding surfaces due to the fact that no
surface is perfectly smooth. Any surface has many high and low points, as shown

57
(greatly exaggerated) (Fig. 8.2). Wear occurs because the high points of each sliding
surface will break off during movement. How much wear occurs depends on how rough
the surfaces are and the amount of lubrication between the two surfaces. If the film is
not thick enough the wear rate is high. If the film is sufficient, the two surfaces may not
contact each other at all and the wear rate is very little.

FIGURE 8.2

The cooling action of a lubricant is another purpose for lubrication. Lubricants reduce
friction, which is the primary cause of heat generated from two surfaces sliding past one
another. The lubricant can carry heat away from the points where heat is generated.

The prevention of corrosion is the result of lubrication giving a machine surface a

protective film, which acts as a barrier between the surfaces and most corrosive
elements, which may be present.
The last purpose of lubrication is to function as a seal against contamination. As a
lubricant works its way out from between two surfaces, it prevents the entry of
contaminants by flushing them away.

Proper use of lubrication and routine lubrication will also protect moving parts and keep
parts moving freely; ensure smooth and proper operation of machines; and will ultimately
prolong the useful life of machinery.

The primary lubrication system used on the ROTO - FLO® machine utilizes a piston
pump, which is solenoid operated, feeding lubrication to a master block. The master
block in turn feeds lubrication to a series of secondary feeder blocks. These blocks
determine the amount of lubrication delivered to every point on the machine (Fig. 8.3).

58
 FIGURE 8.3

This type of system can also be referred to as a "single line progressive lubrication
system". In this system (Fig. 8.4), there is no need for a separate source of pressure to
reverse the action of the pistons in the master and feeder blocks.

The dispensing pistons are each connected to the main pump successively. Through
internal valving, each piston is in turn moved by the flow from the pump. The first piston
must move before the second, which in turn must move before the third etc., until all of
the pistons have cycled in one direction at which time lubrication flow is automatically
diverted to the opposite end of the piston in the manifold. Each piston then moves
successively in the opposite I direction. The cycling is continuous as long as there is
flow in and out of the feeders. The pump develops the pressure required to deliver the
lubricant to the various points on the machine. Therefore, each piston moves
consistently during the course of each cycle. If one piston cycles, then all pistons must
be cycling normally. If one piston is prevented from moving, due to a blockage or foreign
matter in the feeder block, the cycle of all of the pistons will stop. The pump will continue
to pump and build up pressure in the inlet line until a rupture disc is blown. The oil will
then move an indicator pin actuating a limit switch. The limit switch actuates a lube fault
light and can prevent the machine from recycling, depending on the machine electrical
circuit. The system will not lubricate the machine until the rupture disc is replaced.
Should the disc rupture again, the cause for the high pressure condition must be located
and repaired.

59
 FIGURE 8.4

Lubrication Troubleshooting

1. No lubrication from the pump:

A. Reservoir empty.
B. Loss of power to activate the solenoid.
C. Low air or hydraulic pressure.
D. Solenoid failure.
E. Pump damaged internally.
F. Pump is air locked.

2. Pump keeps rupturing blowout disc:

A Blocked mainline, blocked feeder block, or tight bearing.
B. Rupture disc pressure rating too low.
C. Air or hydraulic pressure to the pump set too high, causing surges to the pump.

3. Pistons do not cycle:

A. High pressure down stream.
B. Broken line to block.
C. Piston stuck in block due to contamination.

4. Lubricant leaks from between sections:

A. Valve block screws loose.
B. “O" rings not installed.
C. Damaged "O" rings.

60
5. Excessive lubrication on machine:
A. Stroke of the lubrication pump is too long.
B. Pump cycling too often.

6. Excessive lubrication at one area of machine:

A. Distribution block number too high.
B. Broken lubrication line allowing fluid to puddle.

The determination of a blockage can be seen on the lubrication system pressure gage.
During normal operation the pressure will cycle between zero PSI and 1000 PSI. When
the pressure does not drop back down, a blocked I condition has occurred. The following
steps can be taken to locate and free I a blockage in the lubrication system. Caution
must be taken that all work done on the system be done in a clean area to prevent
contamination of the system.

Connect a manual pump with a gage, to the inlet port of the master block attempt to
cycle the master block. If the master block has indicator pins and the blockage is down
stream; one of the pins should be extended, and the blockage is in the line common to
the extended pin. If the master block will not cycle and no pins are out, the blockage is
within the master block.

If the master block has no indicating pins, remove (one at a time) the outlet plug,
which is common to the outlet port. The pressure will drop when the blocked port
plug is removed. Attempt to cycle the master block with the affected line plug
removed. If the master block then cycles when oil is pumped in, the blockage is in
the line with the removed plug. If the master block does not cycle even with all
plugs removed, the blockage is in the master block and will have to be taken apart
to determine the cause of the blockage.

If it is determined the blockage is down stream of the master block, proceed to the
affected block and remove the outlet plugs one at a time until the pressure drops.
Go to the master block and remove the plug from the port common to the line to
the affected feeder block and connect the manual pump. Pump up the pressure.
If the system now cycles, the blockage is in the port with the removed plug. If not,
the blockage is in the secondary feeder. If the blockage is down stream from the
secondary feeder, look for a crushed line, improperly drilled fitting, or a blocked
injection point.

If it has been determined that the blockage is in the secondary feeder, it must be
repaired or replaced as no other point in the system will receive any lubrication.
To save time prior to taking the feeder block apart, take the piston enclosure plugs out,
and try to move the pistons back and forth with your fingers; this may dislodge the cause
of the stuck piston. If all the pistons can be moved back and forth, replace the enclosure
plugs and retest the system.

61
If the feeder block must be repaired, remove the unit from the machine and disassemble
the block in a clean area to prevent dirt from contaminating the block at reassembly.
Upon finding the stuck piston, blowout the affected section. Attempt to again move the
piston with your fingers; if you are able to move it, reassemble the block and test it with
the manual pump
prior to placing, it back on the machine. If the piston still does not move, take a small
brass rod and lightly tap the piston in the direction where the piston is closest to the
outside of the block. If it does not move attempt to move it in the other direction. If the
piston is now free, remove it from the body and clean the section with air or solvent.
Inspect the piston and body for signs of damage. If there are score marks, the section
should be replaced. Once the section has been repaired, test it with the manual pump
and replace it on the machine.

It is recognized that preventive maintenance is something everyone agrees "should be

done" but the pressures of production make this difficult at times. However, a carefully
planned and executed preventive maintenance program can actually save money in the
long run by eliminating unplanned production interruptions from machine breakdowns.
Most importantly, preventive maintenance will greatly increase the useful life of your
machine while maintaining its superior accuracy.

The single most important system on a machine of such simplicity and accuracy is the
lubrication system. Machine accuracy depends on close mechanical tolerances. Close
tolerances require precise and continual lubrication. The automatic lubrication system on
this machine provides this function automatically. Regular monitoring is suggested to
detect and repair minor system malfunctions before severe mechanical damage occurs.

Second only to the lubrication system is the hydraulic system. It is necessary to devote a
major portion of your preventive maintenance to areas, which will reduce hydraulic
problems to a minimum. Maintain proper fluid level and temperature. Use only fluid with
the correct viscosity and composition. Most importantly, replace filters regularly. Fluid
contamination and neglect can be a major source of machine failures. Dirty oil causes
sticky valves, erratic operation, increased wear on hydraulic components, and loss of
machine performance. It is imperative that regular fluid testing and filter changes are
part of the preventive maintenance program.

The following recommended preventive maintenance schedule and procedures will aid in
obtaining maximum reliability from your ROTO - FLO machine.

62
 SECTION 9

MACHINE CYCLE TROUBLESHOOTING

63
SECTION 9 - MACHINE CYCLE TROUBLESHOOTING
There are many causes for a machine cycle interruption. Some of the more common are
listed here, and are listed in order of probability.

Racks Will Not Advance:

1. Coolant pump not turned "On".
2. "Coolant Fault" light on.
3. "Part Between Centers" limit switch not actuated.
4. Machine guard limit switch not actuated.
5. "Machine Lube Fault" light is on.
6. "Rack Advanced" limit switch stuck in actuated position.
7. "Tailstock Returned" limit switch stuck in actuated position.
8. Rack advance solenoid valve failure.
9. No hydraulic pressure.

Racks Will Not Return:

1. "Tailstock Returned" limit switch not actuated.
2. "Part Between Centers" limit switch not released.
3. Rack return solenoid failure.
4. "Racks Returned" limit switch stuck in actuated position.
5. No hydraulic pressure.

Tailstock Will Not Advance:

1. "Racks Returned" limit switch not actuated.
2. "Machine Lube Fault" light is on.
3. Tailstock advance solenoid failure.
4. "Racks Advanced" limit switch stuck in actuated position.
5. No hydraulic pressure.

Tailstock Will Not Return:

1. "Racks Returned" limit switch not actuated.
2. Tailstock return solenoid failure.
3. No hydraulic pressure.

Rack Stalls During the Rolling of the Part:

1. Too large part pre-roll diameter.
2. Roll pressure set too close to roll pressure requirement. This should be set to 75
PSI above what it takes to roll a part.
3. Hydraulic oil too hot causing pressure loss.
4. Rack advance solenoid failure.

64
 SECTION 10

HYDRAULIC TROUBLESHOOTING

65
SECTION 10: HYDRAULIC TROUBLESHOOTING
The following represents some of the more common problems, which may be
encountered while troubleshooting the hydraulic system. If more than one cause is
listed, these will be in order of probability.

No Machine Movement:
1. Failure to actuate proper limit switches.
2. Failed solenoid valve.
3. Flow control valves shut off.
4. No pressure.

Erratic Movement:
1. Erratic pressure.
2. Air in hydraulic fluid.
3. Worn or damaged hydraulic cylinders.
4. Inadequate lubrication of machine slides or ways.

Slow Movement:
1. Insufficient pressure.
2. Incorrect setting of flow control valves.
3. Worn or damaged cylinders.
4. Inadequate lubrication of moving members.

No Pressure:
1. Relief valve solenoid not energized.
2. Relief valve solenoid failure.
3. Relief valve worn out.
4. Motor/pump coupling broken.
5. Pump shaft broken.

Low Pressure:
1. Relief valve set too low.
2. Hydraulic flow passing over relief valve.
3. Damaged or worn relief valve.
4. Damaged or worn pump.
5. Hydraulic fluid bypassing in cylinders.

Erratic Pressure:
1. Air in hydraulic fluid.
2. Contamination of hydraulic fluid.
3. Damaged or worn relief valve.

66
Excessive Heat of Hydraulic Fluid:
1. System pressure set too high.
2. No water to the heat exchanger.
3. Unloading valve set too high or malfunctioning.
4. Hydraulic fluid level low.
5. Hydraulic pump worn allowing fluid slippage.

Excessive Noise in Relief Valve:

1. Relief valve setting too low.
2. Relief valve setting too close to another.
3. Worn or damaged valve.

Excessive Noise in Pump:

1. Cavitation due to low fluid level or hole in inlet line.
2. Air in fluid due to cavitation or air being sucked past a cylinder rod seal.
3. Misalignment of the pump/motor coupling.
4. Worn or damaged pump.
5. Vane installed backwards during pump rebuilding.

Excessive Noise in Motor:

1. Misalignment of the pump/motor coupling.
2. Pressure too high in the system.

Servicing the Hydraulic Reservoir:

The primary function of a hydraulic reservoir is to hold the system's hydraulic fluid. It
'also serves to cool the fluid, allow contamination to settle and air to escape. The major
elements of a reservoir are illustrated (Fig. 10.1).

Proper maintenance of the hydraulic system should consist of the following:

1. Maintain proper fluid levels at all times.

2. Check pressure settings no less than weekly.

3. Clean or replace filter elements and clean filter housings every six months.

On a Yearly Basis:

1. Completely drain and flush the hydraulic reservoir. Remove the clean out cover and
clean reservoir with steam or suitable solvent. Dry the reservoir completely before
closing reservoir.

67
 FIGURE 10.1

2. Disassemble and clean heat exchanger.

3. Remove, clean and/or replace breather cap.

4. Check pump cartridge for wear. Rebuild or replace as necessary to avoid

unscheduled downtime.

5. Lubricate main drive motor. (See manufacturer's recommendations).

6. Refill the reservoir with fresh hydraulic fluid.

68
PREVENTIVE MAINTENANCE SCHEDULE
Daily
Inspect safety guards and interlocks
Check lubricant level in reservoir
Check lubrication lines for leaks and damage
Check slide ways for lubrication and damage
Check hydraulic fluid in reservoir
Check hydraulic fluid temperature
Check hydraulic fluid for aeration
Check hydraulic pressure settings
Check hydraulic filter monitors
Check for hydraulic fluid leaks
Change or clean hydraulic fluid filters
Clean hydraulic reservoir breat
Change coolant filters
Change coolant
Clean heat exchanger water trap
Clean heat exchanger
Inspect slide cylinders for leakage
Inspect slide wipers
Clean machine
Tighten all bolts
6
Weekly Monthly Yearly Operator Maint
Months
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
TABLE 6
69
 SECTION 11

RACK MAINTENANCE

70
SECTION 11 – RACK MAINTENANCE
COOLANT

The proper use of coolant is critically important to the spline rolling process. Roto-Flo
U.S.E recommends an oil-based coolant called ROTO-LUBE, however oil-based
coolants may not be desirable in some applications. Water-based coolants are
becoming increasingly more popular. These coolants are very appealing because a
wash operation is not necessary after spline rolling. The following precautions must be
used when using water based coolants:

1. Make sure the coolant flow is directed toward the part.

2. Make sure acceptable levels of concentration are maintained.
3. Periodically inspect coolant lines to ensure proper coolant flow.
4. Do not turn down coolant pressure to avoid splash.

RACK

Rack maintenance is very important to the life of the tool. Proper attention to the rack
will ensure the user gets full benefit out of the tool. The following steps are very
important:

1. Use proper Set-up procedure.

2. Use precaution not to damage racks.
3. Make sure fines are periodically brushed out of the rack teeth.
4. When changing set-ups:
- Clean removed racks
- Spray with rust inhibitor (WD-40)
- Package carefully back in U.S. Gear Tools box

FIGURE 11.1 FIGURE 11.2

71
 A Division of U.S. EQUIPMENT COMPANY

SWANNANOA OPERATIONS
US 70 & LYTLE COVE ROAD, SWANNANOA, NC 28778
PHONE: 828 686-5486
FAX: 828 686-5977

ROTO-FLO U.S.E
20580 HOOVER ROAD
DETROIT, MICHIGAN 48205
PHONE: 313-526-8300
FAX: 313-526-5303