Tooling & Workholding • Inspection & Metrology

GEAR SOLUTIONS MAGAZINE

BONUS SECTIONS

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

ISSUE FOCUS
Heat Treating | Innovative Technology
THERMAL LEAD CORRECTION FOR HIGH-SPEED GEARS

THERMAL LEAD
CORRECTION FOR
HIGH-SPEED GEARS
COMPANY
PROFILE

SINTO AMERICA, INC.

JULY 2021

JULY 2021
gearsolutions.com
 AMORPHOLOGY

NASA BORN
PATENT DRIVEN

PRECISION GEAR MANUFACTURING

 COMPACT ROBOT MACHINE TENDING

HOBBERS & SHAPERS

INT/EXT WORM GRINDING

GEAR GRINDERS GANTRY & STOCKER

MACHINE TENDING

GREAT IDEA!
Precision Products for Gear Manufacturing

www.toolink-eng.com

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 Smart.
Gleason non-contact laser
scanning is revolutionizing gear
inspection. Use the GMSL to
speed new gear development,
or take countless hours out of
in-process, high volume gear
inspection, and even lead
measurement, with the GRSL.
All supported with precision
tooling, Closed Loop networking,
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www.gleason.com/laser

BOOTH #3115

2     gearsolutions.com
© Gleason Corporation. All rights reserved.
FEATURES

28
A COMPARISON OF AN ANALYTICAL AND
FEA APPROACH IN DETERMINING THERMAL
LEAD CORRECTION FOR HIGH-SPEED GEARS
A simplified approach for quick and reliable heat analyses for thermal lead
correction of single-stage double helical high-speed gears has been developed.

HEAT TREATMENT BUILD RESILIENCE BY GIVING FORM TO

OF GEARS
The benefits of close interaction
between gear designers and heat-
treat specialists can lead to total cost
and quality optimization.
36
MONETIZING VALUE
Uncover the factors, technologies,
and financial models that can help
make a business more predictable
and future-proof.
42
PROCESS MATERIALS
COMPANY PROFILE Sinto
America, Inc. provides high quality,
cost effective, and innovative
equipment and solutions to a variety
of industries throughout North
America. 46

BONUS SECTIONS

TOOLING & WORKHOLDING INSPECTION & METROLOGY

54 72

SOFTWARE THOUGHT BACKWARDS GROWING ROLE OF METROLOGY IN EV

When using the proper design software, manufacturers are Advanced technologies will be needed to produce complex
able to go from the desired gear to the perfect skiving tool. surface features in gear teeth to enhance efficiency.

62 PRODUCTS & NEWS 65 SUPPLIER LISTINGS 80 PRODUCTS & NEWS 83 SUPPLIER LISTINGS

July  2021     3
 Reliability begins
with a cup of coffee.
Relationships are built by taking the The solutions we provide delivers the
highest quality in the world at a reliable
time to sit down with you, and Lowest Cost Per Piece, GUARANTEED!
discovering what keeps you awake An industry first. What do you
at night. take in your coffee?

CINDUSTRY-
olonial isn’t typical in the BROACH
our main focus is to establish
customer relationships that are a perfect fit with
our decades of service providing broaching
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looking for experience
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EXPERIENCED • RELIABLE • INTERNATIONAL

United States • Canada • Mexico • 1-866-611-5119 • info@colonialtool.com • www.colonialtool.com

4     gearsolutions.com
 JULY 2021  •  VOLUME 18, NUMBER 7
DEPARTMENTS
INDUSTRY
8 NEWS
Reports, data, and developments to keep
you aware of what’s happening with your
colleagues in the gear-manufacturing
industry around the country and world.
Schwarze-Robitec is gearing up for KHK USA Inc. announces extensive line of
Fabtech 2021. metric internal ring gears.

17
In this section, the premier supporter of gear manufacturing in the United American
States and beyond shares news of the organization’s activities, upcoming
educational and training opportunities, technical meetings and seminars, Gear Manufacturers
standards development, and the actions of AGMA councils and committees. Association

MATERIALS TOOTH HOT

22 MATTER 24 TIPS 26 SEAT
JIM ALBERTSON & JOHN TABELLION BRIAN DENGEL D. SCOTT MACKENZIE

MATERIALS MATTER – AND SO DOES MAXIMUM ALLOWABLE TORQUE PRECIPITATION HARDENING

TOTAL COST OF OWNERSHIP
Energy efficiency is critical to many of
today’s end markets. Next-generation
gear-system designs and, specifically,
new propulsion powertrains, demand
performance at the lowest possible cost.
What is the maximum allowable torque of STAINLESS STEELS
a gear and why does it matter? The top alloy groups have seen increased
growth in application because of corrosion
resistance, strength, and low distortion upon
precipitation hardening treatment.

PRODUCT Q&A
50 SHOWCASE 88
New products, trends, services, and
developments in the gear industry.

RESOURCES
86 MARKETPLACE

87 ADVERTISER INDEX STEVE YOUNG

Co-president at Exact Metrology

COVER PHOTO: SHUTTERSTOCK

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 website, which is assumed to be cleared for release. Comments and submissions are welcome, and can
be submitted to editor@gearsolutions.com.

July  2021     5
 FROM THE
EDITOR David C. Cooper
PUBLISHER

EDITORIAL
Bonus sections, company Kenneth Carter
listings, and much more! EDITOR

Jennifer Jacobson
A s the world slowly returns to some sense of normalcy, Gear Solutions is here to give you
some amazing articles and information to help get you through one more month. And
has been our tradition, our July issue is offering even more than usual.
ASSOCIATE EDITOR

Joe Crowe
CONTRIBUTING EDITOR
For a long time now, the July issue of Gear Solutions has been a source of news and
information about four important aspects of the gear-manufacturing industry: tooling
& workholding and inspection & metrology. SALES
This issue includes articles, product announcements, and listings for these topics that Dave Gomez
will serve as a valuable resource and a quick guide that can be used throughout the year. NATIONAL SALES MANAGER
It’s basically a mini-Buyer’s Guide for these gear-manufacturing areas.
Similar to previous years, we have included these topics as bonus sections within our
standard issue. It’s an easy, one-stop-shopping way to check out the information, as well CIRCULATION
as the company listings you’ve come to expect. Teresa Cooper
By focusing on tooling, we hope to bring you some in-depth knowledge on machine MANAGER
tooling, improving efficiency, performance, and precision in gear manufacturing. Jamie Willett
Improvements in tooling are happening all the time, it seems, so we want you to stay ASSISTANT
informed of the latest news and developments.
Inspection and metrology markets have been making a lot of strides in automation,
data collection, and results analysis. Whether it involves a large OEM, major tier supplier, DESIGN
or a small job shop, these technologies can benefit practically any company. Rick Frennea
As important as these topics are, this issue isn’t just about them. The regular part of CREATIVE DIRECTOR
our July issue also offers several interesting looks at gear manufacturing. Don’t miss some Michele Hall
fascinating articles on heat treating and innovative technology to aid in making businesses GRAPHIC DESIGNER
build resilience by monetizing value. Our regular columnists are also bringing you some
can’t-miss info on the mechanics of the industry as well.
I’ve said it before, but it bears repeating: This is why Gear Solutions exists. We are here CONTRIBUTING
to be a visible and viable tool you can use in order to get your message out to the industry.
WRITERS
Let us be your eyes, ears, and, most importantly, your voice. We are here, first and fore- JIM ALBERTSON
most, to shine a spotlight on your valuable products, services, and know-how to a market ZITA BADER
that continues to have limited avenues available to discover it. GUNEET BEDI
ANDREAS BEINSTINGEL
Gear Solutions is here to serve you. With that in mind, if you have any suggestions or
REBECCA BRINKLEY
would like to contribute, please contact me. I’m always looking for exciting articles to
BRIAN DENGEL
share. BILL DISLER
As always, thanks for reading! ERIC FELKEL
CRAIG A. FISCHER
MICHAEL HEIDER
D. SCOTT MACKENZIE
STEFFEN MARBURG
BURKHARD PINNEKAMP
MICHAEL SCHMIDT
DANIEL STIERLI
KENNETH CARTER, editor JOHN TABELLION
Vertical Logo
editor@gearsolutions.com
(800) 366-2185 x204

Coop w
CALL FOR ARTICLES Have a technical paper or other work with an PUBLISHED BY MEDIA SOLUTIONS, INC.
educational angle? Let Gear Solutions publish it. Contact the editor, P. O. Box 1987 • Pelham, AL 35124
(800) 366-2185 • (205) 380-1580 fax
Kenneth Carter, at editor@gearsolutions.com for how you can share
your expertise with our readers. David C. Cooper Teresa Cooper
PRESIDENT OPERATIONS

6     gearsolutions.com
 FELLOWS 10-4 GEAR SHAPERS REMANUFACTURED IN 2021

We have the world’s largest stock

of used late-model Fellows Gear Shapers
WE OWN WHAT WE SELL, AND WE KNOW WHAT WE’RE SELLING!

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343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776 • JEFF@NEWENGLANDGEAR.COM
July 2021     7
 INDUSTRY
NEWS
The fully equipped, fully electric CNC 80 E TB MR multi-radius tube bending machine is perfectly matched to the
requirements of the automotive industry.
Schwarze-Robitec
gearing up for
Fabtech 2021
Fabtech 2021 in Chicago September 13-16 is
expected to be one of the first major events
where metalworkers from all over the world
will meet again after a long pandemic
break. Schwarze-Robitec, the tube bend-
ing machine manufacturer from Cologne,
Germany, is presenting the fully equipped,
fully electric CNC 80 E TB MR multi-radius
tube bending machine, an absolute all-
rounder for tube bending.
Designed for high volumes, short cycle
times, and resource-saving material han-
SEND US YOUR NEWS Companies wishing to submit materials for inclusion in Industry News should contact the editor,
Kenneth Carter, at editor@gearsolutions.com. Releases accompanied by color images will be given first consideration.
8     gearsolutions.com
NEW TRENDS, SERVICES & DEVELOPMENTS
dling, the highly efficient CNC 80 E TB MR
is perfectly matched to the requirements
of the automotive industry, for example.
Production time is reduced by up to 40 per-
cent compared to conventional machines,
depending on the component and the desired
tube geometry. Material waste is reduced by
90 percent. The contact pressure can always
be optimally gauged, while tool costs and
changing times are reduced. Overall, the
use of the CNC 80 E TB MR increases repeat-
ability and process reliability.
These advantages are possible thanks
to numerous features of the machine from
Schwarze-Robitec’s high-performance series.
It bends and cuts tubes in a single work step
thanks to an integrated fully electric cutting
device. With extended vertical transport car-
riage, this is also possible despite the multi-
stack bending tool. A vertically adjustable
pressure die moves to the different levels for
bending synchronously with the tube. The
intelligent NxG control checks the interac-
tion of all machine axes for each bending
sequence and simultaneously prepares all
axes for subsequent steps. In addition, the
CNC 80 E TB MR is equipped with the Quick-
Tool- Unlock tool changing system in com-
bination with a rapid clamping system for
the bend former. This makes it easy to open
and close the tension bars for tool changing,
while no bolts are required to fasten the
bend former to the turntable.
So, after the worldwide pandemic-
induced trade fair break, Schwarze-Robitec
is now fully gearing up with the fully
equipped CNC 80 E TB MR. The tube bending
machine manufacturer is looking forward
to meeting customers and interested parties
from application industries such as automo-
tive and aerospace, plant engineering and
shipbuilding, again for direct exchanges at
Fabtech. At booth D45954, Schwarze-Robitec
will illustrate the competitive advantages
that its bundled competence in tube bend-
ing brings to its users.
MORE INFO www.schwarze-robitec.com
KHK USA Inc. announces
extensive line of metric
internal ring gears
KHK USA Inc., a factory-owned distributor
of the market-leading KHK® brand of met-
ric gears, offers an extensive line of metric
internal ring gears. KHK’s large selection of
internal ring gears are designed for use in
planetary gear trains and are suitable wher-
ever high-speed reduction is required.
Internal gears, also known as ring gears,
are cylindrical disks which have involute-
shaped teeth cut into their interior face. KHK
internal ring gears are offered in carbon
At KHK, a large selection of off-the-shelf products and customized solutions can be ready within five business
days. (Courtesy: KHK USA Inc.)
steel, with many configurations of modules
and numbers of teeth. All KHK internal ring
gears allow for secondary operations such as
adding through or tapped holes in the face.
KHK’s quick customized products can be
ready within five business days.
Two categories of KHK internal gears
are available. KHK steel internal gears (SI),
typically with 50 to 100 teeth, are a low-cost
option that is suitable for many applications.
KHK steel ring gears (SIR) are larger in size
and number of teeth, typically between 120
and 200 teeth, and can be cut to make seg-
ment gears and corner racks.
The production process of KHK cylindrical
gears, including internal ring gears, depends
on consideration of tooth size expressed in
module or DP (diametral pitch), configura-
tion, material, heat treating, method for
finishing the tooth surface, precision of the
gears, and manufacturing quantity. The typi-
cal production sequence involves cutting off
material, blank making on a lathe, tooth cut-
ting on a hobbing machine, and deburring.
KHK also offers a new method in which a
5-axis machining center is used in combi-
nation with gear manufacturing software.
MORE INFO www.khkgears.us
Gleason sets stage for
future virtual shows with
successful ‘emotions’
Gleason Corporation’s first-ever virtual show,
called ‘emotions’, drew visitors from 39 coun-
tries representing manufacturers from all
the major gear industries. The 12-day global
event will serve as the launch pad for subse-
quent Gleason virtual events, making it easi-
er for visitors around the world to engage on
the most important gear technologies and
developments.
‘Emotions’ showcased the latest gear tech-
nology innovations for cylindrical and bevel
gear design, manufacture, and inspection.
Visitors from around the world accessed four
showrooms with different themes, ranging
from e-drives to industrial gears, closed loop
manufacturing, in-process inspection, and
detailed gear noise analysis.
Each showroom was accompanied by a
special event presentation by an industry
expert. After each opening event, partici-
pants could browse through the respec-
tive showrooms to experience the featured
technologies, with or without a guided tour.
Gleason’s technology experts and product
July 2021     9
INDUSTRY
NEWS
Gleason Corporation’s ‘emotions’ virtual show included an extension of the event due to great demand.
(Courtesy: Gleason Corporation)
managers were available through the dura-
tion of the virtual event to answer questions
and provide additional information.
“We thank the many customers that
joined us for this special event,” said
Christian Albrecht, director corporate mar-
keting at Gleason Corporation. “While we
were unsure about what we could expect
from a digital show, we are extremely
pleased with the positive feedback from our
global customer base. We are already in the
planning stage for adding additional capabil-
ities and new content for future events. For
those that were not able to participate, some
of the content is available on our website or
can be obtained by requesting through our
global sales network.”
Dates for upcoming Gleason events includ-
ing the Gear Trainer Webinar Series, online
training, trade shows, and more are available
on the Gleason Corporation website.
MORE INFO www.gleason.com
Krebs & Riedel offers
innovative grinding
technology since 1895
The cornerstone of the Krebs & Riedel grind-
ing wheel factory in Bad Karlshafen was
laid some 125 years ago. Today, the family-
owned company operates worldwide as a
manufacturer of individually manufactured
precision grinding wheels and innovation
and solution-oriented application technol-
ogy advice. Customers from the automotive,
aerospace, mechanical engineering, medi-
10     gearsolutions.com
cal technology, and wind power sectors rely
upon the high-precision products manufac-
tured by Krebs & Riedel. In addition to con-
ventional grinding wheels, cutting wheels,
cup grinding wheels, and grinding segments
with ceramic and synthetic resin bonds,
Krebs & Riedel also manufactures CBN and
diamond tools with ceramic bonds, as well
as honing rings.
At Krebs & Riedel, high-quality products
are created with special quality standards
and maximum safety. Krebs & Riedel is a
member of the VDS (Verband Deutscher
Schleifmittelwerke e.V.). As a founding
member of the oSa (organization for the
safety of abrasives), safety comes first. The
Krebs & Riedel offers solutions
from continuous generating
grinding to single-profile grinding,
and bevel gear grinding to power
honing applications. (Courtesy:
Krebs & Riedel)
production program includes corundum
and silicon carbide wheels with a ceramic
bond and synthetic resin bond for most
industrial grinding applications up to 900
mm outside diameter for round, flat, tool,
centerless, gear, and rough grinding appli-
cations. Products include cut-off wheels in
synthetic resin bond with and without fiber
reinforcement up to 800 mm outside diam-
eter for chop cut, pendulum cutting, and
rotary cutting; roughing and pendulum
grinding with and without fiber reinforce-
ment for the cleaning shop and the foundry
industry; grinding wheels for pendulum
grinding machines, grinding wheels for
bench grinders, and grinding wheels for
grinding manipulators; and diamond and
CBN grinding media in vitrified bond with
a working speed of up to 200 m/s for inter-
nal, flat, circular, tool grinding, and special
grinding processes.
Krebs & Riedel is a specialist in the
field of gear applications and supplies top
gear manufacturers around the globe.
These grinding wheels are used on many
gear-grinding machines, including those
from the manufacturers Gleason, Kapp-
Niles, Klingelnberg, Liebherr, Mitsubishi,
Reishauer, and Samputensili.
Krebs & Riedel’s experience ranges from
grinding the smallest gears in the field of
medical technology to large planetary gears
in wind turbines. From continuous gener-
ating grinding to single profile grinding,
and bevel gear grinding to power honing,
it also offers customized grinding solutions
to increase productivity, improve tool life,
or optimize surface finishes.
The company produces a wide range of
Supertec chooses NUM on their cylindrical grinders.
NUMgrind simplifies the creation of G
dressable grinding worms with a ceramic for CNC cylindrical code programs for CNC grinding machines
bond for customers’ gear machining. All
specifications guarantee the highest profile grinding machines through the use of a highly intuitive graphi-
cal human machine interface (HMI), and
accuracy with the lowest thermal loads on Supertec Machinery Inc., one of Taiwan’s unlike conventional CAD/CAM workstation
the workpieces. The combination of Krebs leading machine tool manufacturers, has tools, it is designed specifically for use by
& Riedel grinding worms with fine-grain chosen to base new versions of its renowned shop floor personnel in a production envi-
or polishing worms creates powerful tools Plunge type of CNC cylindrical grinding ronment.
that enable grinding and polishing in one machines on NUM’s Flexium+ CNC platform. After evaluating the software, Supertec
application. Founded in 1954, Supertec Machinery Inc. immediately raised a purchase contract with
Krebs & Riedel offers a carrier variant has grown to become one of Taiwan’s top NUM. Betty Chu, Supertec’s assistant general
for CBN and diamond abrasives. The propor- machine tool manufacturers. The company manager, said, “NUM has an excellent repu-
tion of carbon fiber guarantees maximum specializes in precision grinding automation tation in the grinding industry. Much like
strength with the lowest weight. The body is and produces a diverse range of centerless, Supertec, this has been earned over many
up to 75 percent lighter than a comparable cylindrical and surface grinding machines. years. And the latest version of NUMgrind,
steel body. In addition to easy handling dur- Supertec operates sales and support facilities which accommodates non-circular grinding,
ing assembly, it runs quite smoothly. This at strategic locations throughout Asia and is a natural fit for our CNC cylindrical grind-
means that the load on the grinding spindle Europe, as well as in the United States and ing machines. We also now benefit from very
is lower. With the new CBN worm grinding South America. responsive local support – NUM’s Taiwan
wheels, an increase in productivity can be Supertec has traditionally used Fanuc facility is less than 15 kilometers away from
achieved through increased stock removal CNC systems for most of its machine tools. our factory.”
with an improved service life. The working However, when NUM added non-circular Supertec’s Plunge type of CNC cylindri-
speeds are up to 100 m/s. Depending on the grinding functionality to its popular cal grinding machines offer a choice of
composition, higher working speeds can also NUMgrind cylindrical grinding software six capacities, covering distances between
be achieved. in June 2020, the company realized that centers from 500 mm to 2,000 mm. The
this innovative CNC technology provided machines can also accommodate grinding
MORE INFO www.krebs-riedel.de exactly what many of its customers needed diameters from 300 up to 430 mm (3 sizes),

PERFECTION
PERFECTION
RHH, Inc.
CREATED
PERFECTION
CREATED
BY PRECISION. Quality since 1915
CREATED
BY PRECISION.
BY PRECISION.
www.heat-treatment-services.com
TRU-VOLUTE
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ALD is a leader in vacuum

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Global service centers treatment services.and heat
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Port Huron, MI, USA 48040 ▪ Prototype and trials
United States ALD Port Huron
Cell Number +1 (810) 300-1437 Edwin Orozco, Sales Director – Mexico
ALD Thermal
Thomas Treatment
Chris Totten,
Lord,Sales Inc.
SalesLeader
Director AntonioGarcia,
Moises Vasquez, Sales
Sales Director
Director
Email: tlord@aldtt.net Office Phone +52 844 866 9791
2656 Phone
24th Street
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300-1437 Phone: +52
Phone: +52 11 (844)
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277-2257
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ctotten@aldtt.net
Email: tlord@aldtt.net
Port Huron, MI, USA 48040 Email: mgarcia@aldtt-mexico.com
Email: avasquez@aldtt-mexico.com
Christopher Totten, Sales – Canada / USA, ventas@aldtt-mexico.com
Cell Number +1 (810) 300-1437 Edwin Orozco, Sales Director – Mexico

SPECIALISTS IN PRECISION FINE-PITCH GEAR PRODUCTS

OfficeChris
Phone +1 810 357 Leader
0634 Inc. eorozco@aldtt-mexico.com
Email:ALD Thermal
Totten,
tlord@aldtt.net Treatment
Sales ALD Tratamientos
Antonio
Office Vasquez,
Phone +52 Termicos
Sales 866S.A.
844Director
9791de C.V.
Cell Phone
Phone: +11 (810)
2656 24th 810 300 3601
300-3601
Street Phone:
Blvd. +52 1 (844)
CellOmega
Phone No. 1277-2257
+522270,
844 Parque Industrial
277 2257
e-mail: sales@aldtt.net
Email:
Port ctotten@aldtt.net
Huron, MI USA 48060 Moises
Email:
Santa Garcia – Sales Director - Bajio
avasquez@aldtt-mexico.com
Maria
Christopher Totten, Sales – Canada / USA, ventas@aldtt-mexico.com
Office Phone +1 810 357 0634
MexicoALD Thermal
ALD Treatment
Tratamientos Inc.
Térmicos S.A. de C.V.
Ramos
ALD
Arizpe,+521
Cell Phone Coahuila,
(844) Mexico
eorozco@aldtt-mexico.com
277 2254C.P. 25901
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STOCK : HOBS : HSS & Carbide RFQ on special gear tools welcome
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Mexico
2656 24th Street
e-mail: sales@aldtt.net
ALD
Port Tratamientos
Huron, Térmicos S.A. de C.V.
MI USA 48060
Blvd. Omega No. 2270, Parque Industrial
Moises Garcia – Sales
ventas@aldtt-mexico.com
Santa Maria Director - Bajio STOCK : SHAPERS : Disc & Shank Diametral Pitch 12 and finer
Mexico ALD Tratamientos Térmicos S.A. de C.V.
Cell Phone
Ramos Arizpe,+521 (844)Mexico
Coahuila,
ventas@aldtt-mexico.com
277 2254
C.P. 25901
STOCK : MASTER GEARS STOCK AVAILABLE

201-226-9000 • tools@tru-volute.com • www.tru-volute.com

July 2021     11
INDUSTRY
NEWS

grinding wheel speeds up to 1,390 rpm, and
workhead spindle speeds from 30 to 350 rpm.
The new versions of these machines are
based on NUM’s Flexium+ 8 CNC platform
and use NUM’s high performance MDLUX
drives and brushless servo motors for the X,
Z and C axes. In addition to the NUMgrind
HMI, the software that is being supplied by
NUM includes the Flexium 3D simulator,
which can be used offline or online, and
an application-specific profile editor which
enables users to import DXF files.
Johnny Wu, general manager for NUM
Taiwan, said, “The ability to use the Flexium
3D simulator both offline and online pro-
vides Supertec’s customers with a distinct
advantage. CNC programs can obviously be
prepared offline and checked for potential
problems such as collisions before being
transferred to the machine. But the simu-
lator can also be used online. This enables
operators to gain vital visibility of the grind-
ing process – which is normally obscured by
the flow of oil.”

Supertec’s latest plunge type CNC cylindrical

grinding machine is based on NUM’s Flexium+ CNC
platform. From left, Betty Chu, general manager
of Supertec, and Adrian Kiener, CSO Asia NUM.
(Courtesy: Supertec)

GEARING AHEAD TO MEET

The new machines will be introduced to
the public at the next opportunity, which
will likely be TMTS in 2022 due to Covid-19

INDUSTRY’S DEMAND restrictions.

FOR PRECISION
MORE INFO www.supertec.com.tw
www.num.com

– SERVING – Exsys expands inventory,

Aircraft • Aerospace • Actuation speeds delivery
Instrumentation • Optic
Robotics • Radar • Medical
at Florida facility
Marine • Defense • Experimental To ensure customers the shortest delivery
times possible and cost-effective pricing,
Prototype • Production
Exsys Automation has significantly expand-
Hi-Performance Automotive ed its inventory capacities at its facility in
Florida. The company now has ample room
to stock its wide range of product offerings
CNC Thread Grinding that includes its popular Preci-Flex modu-
lar tooling system and associated adaptors
Nadcap Accredited: Heat Treatment, Induction Hardening, Passivation along with other tool holding solutions and
gear box systems.
Precision Gear Products (up to AGMA Q14): In addition to providing tooling repair
services and applications expertise, the
Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, company will also house in stock its BMT
Clutch Gears, Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, style gear hobbers, dual Y-axis live holders,
Bevel Gears, Miter Gears, Metric Gears, Internal Gears, Idler Gears, Gear Rack 0-180-degree angle adjustable holders and
high-speed live holders along with dual, dou-
& Pinion, Worms, Wormshafts, Splines, Spline Shafts, Serrated Shafts.
ble static holders, and other special tooling
as part of its expanded inventory capacity.
For today’s manufacturers, Exsys
STD Precision Gear & Instrument, Inc. Automation offers new high- qualit y
318 Manley St. • W. Bridgewater, MA 02379 Eppinger products designed to revolution-
ize chip making, maximize productivity,
(888) STD-GEAR or (508) 580-0035 and reduce per part costs to boost their
competitiveness.
Fax: (888) FAX-4STD or (508) 580-0071 EXSYS Automation, Inc. is the exclusive
E-mail: info@stdgear.com • Web site: www.stdgear.com importer of German-made Eppinger auto-
mation solutions, high-precision live and
12     gearsolutions.com
 visualize 3D CAD data on the shop floor
within a very short time. For the execution
of CAM-generated CNC programs for free-
form surface machining, One Dynamics 3-
and 5-axis milling packages offer the Top
Surface and Top Speed Plus CNC functions
for excellent motion control and perfect
workpiece surfaces.
With Top Surface, the geometric data
from the CAM system is checked and opti-
mized during processing on the CNC using
an intelligent algorithm. This ensures high
surface quality when milling complex free-
form surfaces. This is particularly advan-
tageous for geometrically complex mold
components that place special demands on
surface quality, mold accuracy, and produc-
tion efficiency — for example in tool- and
mold-making, aircraft construction, or
medical technology. Top Speed Plus ensures
with new filter technology that increased
dynamics are made possible without activat-
ing mechanical vibrations of the machine
and that the contour accuracy is reliably

Exsys Automation offers a variety of different

toolholders, gold-standard tooling repair, and Rings 4”-144” OD · DiSCS up to 60”
applications expertise to manufacturers throughout
CARBON • ALLOY • STAINLESS VISIT US AT
North America. (Courtesy: Exsys Automation)
Motion+Power 2021
Booth #2333

FORGING
fixed toolholders for CNC turning centers,
modular adapter systems for quick lathe
tooling changeovers, and gear box solutions
for a wide range of applications. With head-
quarters near Tampa, Florida, and support
offices in California, Canada, and Mexico;

AHEAD
Exsys Automation offers a variety of differ-
ent toolholders, gold-standard tooling repair,
and applications expertise to manufacturers
throughout North America.

MORE INFO www.exsysautomation.com

OF THE PACK
Sinumerik One Dynamics
offers powerful new
technology packages
Siemens recently launched three power-
ful technology packages exclusively for its
new Sinumerik One control system. The
Sinumerik One Dynamics packages are
available in three different variants: One
Dynamics Operate, One Dynamics 3-axis
milling, and One Dynamics 5-axis milling.
The software functions contained in each
technology package support users from
machine-oriented programming in the job Fast.
shop to high-performance machining of
CAD-CAM-programmed workpieces with
No Fine Print.
high surface quality. No Premium.
The One Dynamics Operate package
supports the machine tool user in efficient
At McInnes Rolled Rings, we provide quality
programming in the machine shop with products, shipped in as few as 4 days. And we
the proven Sinumerik machining cycles partner that with exceptional customer service to
and high-quality CNC simulation for mill- forge the perfect partnership with our customers.
ing and turning applications. In addition,
the user is given a wide range of options for
accessing NC programs and workpiece doc-
umentation. Users have the option of paper-
1.877.695.0301 · www.McInnesRolledRings.com
less manufacturing and can, for example,
July 2021     13
INDUSTRY
NEWS

maintained. Depending upon the specific functions, no intervention at the machine

application, this can reduce machining
times by up to 30 percent. As a result, unit
costs for milling with CAM-generated CNC
programs can be reduced and production
efficiency increased.
With a few exceptions, the functions of
Sinumerik One Dynamics do not require
any commissioning effort by the machine
tool builder. Once activated, they are avail-
able to the user for immediate use on the
CNC machine. Since they are CNC software
or in the machine’s mechanics is required.
For users who have particularly challenging
requirements when it comes to machining
quality and speed, the machine tool builder
can add additional optional CNC functions
of the Sinumerik control that go beyond the
Sinumerik One Dynamics packages. These
additional functions must then be activated
and parameterized by the machine builder
for the user’s individual machine and adapt-
ed to the machine statics and dynamics.

Siemens’ Sinumerik One Dynamics offers three

technology packages that increase CNC machine
users’ efficiency when programming in the machine

The
shop and executing CAM-generated CNC programs.
(Courtesy: Siemens)

The new digital-native CNC from Siemens,

Power Sinumerik One, is setting new productivity

benchmarks with its digital twins — the new

of One2
hardware platform and innovative technol-
ogy functions.

MORE INFO www.usa.siemens.com/

sinumerik-one
Your Objective:
One face in perfect alignment with another. For infinity.
West Ohio Tool
announces new
production leadership
Custom PCD and carbide cutting-tool maker
West Ohio Tool hired production and train-
ing expert Chad Mahurin as production
manager and a member of the company’s
No problems. No distress. No delays. leadership team.
That’s the same objective you have for choosing your gear producer. Mahurin brings more than 20 years of
Circle Gear’s objective is to engage with every customer’s objectives. experience in tool grinding and cutting,
grinding-machine programming, support,
 One to 1000 gears
training, and ser-
 Customer designed or reverse engineered vice. At West Ohio
 Gearbox repair, rebuild or redesign Tool, Mahurin will
contribute to the
 OEM or end-users
expansion of the
 ISO 9001:2015 Certified company’s custom
product lines and
assist in guiding
1501 S. 55th Court, Cicero, IL 60804
(800) 637-9335
workflow processes
(708) 652-1000 / Fax: (708) 652-1100
as well as efficien- Chad Mahurin
sales@circlegear.com cy initiatives. His
www.circlegear.com understanding of tools and tool production
will benefit West Ohio Tool and its custom-
Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears • ers with technical insights and an advanced
Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears • understanding of how to obtain the best
Worm and Worm Gears • Racks • Sprockets • ISO Certified
results from industry technology.
Partnering with QualityReducer to provide West Ohio Tool’s hand-selected team of
Gearbox repair, rebuilding and reverse-engineering. experts in engineering, tooling, innovation,
and advanced machining geometry devel-
14     gearsolutions.com
ops special drills that have been exceeding
expectations for more than 30 years, with
delivery times up to 75 percent faster than
industry standards. The firm’s innovations
include the patented edgeX4, the cross-cen-
ter tipped drill that runs up to three times
faster and 10 times longer than carbide. As
an experienced PCD and carbide cutting tool
maker, West Ohio Tool focuses on building
long-term partnerships with customers
based on problem solving, technical support
and better, faster, longer-running drills.
with the announced registration phase.
The next important milestone for exhibi-
tors at AMB 2022 is the start of the planning
phase in October.
Around 90,000 international trade visi-
tors and 1,500 exhibitors are expected at the
twentieth AMB, which will be held at the
Stuttgart Trade Fair Centre. On an exhibi-
tion area of more than 120,000 square meters
(gross), the focal points will be innovations
and further developments for metal-cutting
machine tools, metal-removing process
machine tools, precision tools, measuring
systems and quality assurance, robots, work-
piece and tool handling technology, indus-
trial software & engineering, components,
assemblies and accessories. AMB 2020 will
be backed by the promotional supporters,
i.e. the VDMA Precision Tools Association,
the VDMA Software and Digitalisation
Association, and the German Machine Tool
Builders’ Association (VDW). 
MORE INFO www.amb-expo.de

MORE INFO www.westohiotool.com

SIGHTIA SURFACE EVALUATION

Registration begins Increase reliability and quality assurance of your shot peening process by
for AMB 2022 integrating surface evaluation devices into the shot peening process
international trade fair and inspecting all products in-line!
After the suspension of last year’s event, MATERIALS MACHINING HEAT TREATMENT BEFORE PEENING QUALITY CHECK
AMB — the international exhibition for
metal working — will get back into its regu- FLO
W
lar cycle and take place again at the Stuttgart
trade fair center September 13-17, 2022. All
major exhibitors from the metal working
and processing industry will present their
innovations and further developments to
the interested professional visitors over five
trade fair days.
“We’re really excited to finally be able
to stage trade fairs again,” said Gunnar
Mey, department director industry at FLO
Landesmesse Stuttgart GmbH. W
The Trade Fair Advisory Board supports
the project team in its endeavor. At the kick-
off meeting in June, all companies pledged
their full backing for the trade fair. The com-
panies present in the meeting were DMG
MORI, INDEX-Werke, HAHN+KOLB, EMCO,
GF Machining Solutions, CHIRON Werke, PRE-PEENING QC CHECK POST-PEENING QC CHECK
FFG Europe, KASTO, GÜHRING, CERATIZIT,
ISCAR, Hartmetall-Werkzeugfabrik Paul ECNI-I PSMX-II
Horn, MAPAL, NAGEL Werkzeug-Maschinen, Non-destructive Eddy Non-destructive xray diffraction
Ilg + Sulzberger, and Römheld. “The trust Current Peening Inspection residual stress measurement.
placed in us from exhibitors and partners
As low as 10 second measurement
makes us extremely proud and confirms us
time depending on part.
on our way to a great AMB 2022,” said Mey.
The current market data presented by PEENING AFTER PEENING QUALITY CHECK FINISHING
the promotional supporters of AMB includ-
ing the VDMA Precision Tools Association, TM

the VDMA Software and Digitalization

Association, and the German Machine Tool www.sinto.com
SINTO AMERICA
Builders’ Association (VDW) approve the SINTOKOGIO, LTD.
impressions of the Trade Fair Advisory Board www.sintoamerica.com sales@sintoamerica.com
150 Orchard St. Grand Ledge, MI 48837
and give a positive outlook on the current Tel 517.371.2460 Fax 517.371.4930
economic developments. Increases in incom-
ing orders are good signs for a successful
restart of AMB, which gathers momentum
July 2021     15
 CHUCKS - ARBORS - MANDRELS - COLLETS - FIXTURES

LEADERS in GEAR WORKHOLDING

An Expert In Design and Build

With 70 years of experience, we can handle all your custom workholding needs.
Drewco Corporation is a family run business led by a team of engineers and machinists.
We are backed by original patents, years of experience, and proven effective designs.

service@drewco.com
www.drewco.com Office (262) 886-5050 3745 Nicholson Rd
Franksville,WI 53126

16     gearsolutions.com
 American Rebecca
Jenny
AGMA
Blackford
Brinkley
Vice President
Director,of
Gear Manufacturers Communications
Member
AGMA
Engagement

Association

Why a trade association might be

that missing piece for your company

I
s there something missing in your business strategy? Do you Make sure the association gets to know you and your business. If you
find that you have a great product, a strong workforce, and some want to hear testimony, ask for a board or committee member from
advertising channels, but you still feel that your name isn’t get- the association to tell you why they joined. Do not be afraid to ask
ting the attention it deserves? Often times, that missing piece questions and to fully understand what your investment gets you.
is the industry intel and networking that you can only get through The competition out there is tough, especially for manufacturing.
being an association member. Supply chains are global, the trade laws are changing all the time,
AGMA has always been a member-driven trade association. The hiring economists and getting a real look into the future of technol-
board of directors, the committee involvement, events, and even the ogy is not easy, and can be very expensive. But, when you belong to
strategic plan is led by member volunteers who work directly in the an association, that work is done for you.
power transmission supply chain. For those of you in the gear industry who do not yet belong to
AGMA and its members drive power transmission innovation — AGMA, contact Rebecca Brinkley at brinkley@agma.org. Let us show
it’s a bold vision, crafted with care by members, for members, as we you how being a member of our association can give you that missing
collaborate together and shape the future of AGMA and our industry. piece to your business and, hopefully, help you grow.
Why is this important to your business?
Well, if you are not part of an association,
you are not involved with those who are
making decisions on behalf of your industry.
Additionally, you are not establishing your-
self or your team as experts in your sector.
Joining a trade association can truly help get
your name out there and connect you to the
full supply chain. Being a part of an associa-
tion means you are a part of the big picture,
and the investment you make into member-
ship will add great value to your bottom line.
Membership benefits include:
 Direct connection to industry experts
and peers.
 Exclusive access to important economic
data and reports.
 Opportunity to join active and engag-
ing committees that develop standards,
policy, and events for industry.
 Marketing platforms and tradeshows
that enhance your company’s abilities to get
your products into the right hands.
 Discounted education courses to help
train your workforce and develop professionally.
 Establishment of your company as a leader and contributor to
the future of your industry.
AGMA and its members drive power
 A team of people always looking for the best ways to support transmission innovation — it’s a bold vision,
you and your company.
Membership is an incredible tool, but it isn’t free. It is important to crafted with care by members, for members, as
do your research and to set up a meeting with the association before
joining. Bring your team members who touch different aspects of
we collaborate together and shape the future
your business and find out what resources you will have access to. of AGMA and our industry.
July 2021     17
Upcoming Education
Fundamentals of Gear Design & Analysis (In Person)
July 20-22, 2021
Gain a solid and fundamental understanding of gear geometry, types
and arrangements, and design principles. Starting with the basic defi-
nitions of gears, conjugate motion, and the Laws of Gearing, learn the
tools needed to understand the inter-relation and coordinated motion
operating within gear pairs and multi-gear trains. Basic gear system
design process and gear measurement and inspection techniques will
also be explained.
This course is IACET accredited and worth 1.7 CEUs.
This course is taught at Ranken Technical College. A shuttle bus is
available each day to transport students to and from the hotel. Class
are 8 a.m.-5 p.m. each day.
American
Gear Manufacturers
Association
18     gearsolutions.com
Basic Inspection for Operators (In Person)
August 10-11, 2021
This course will provide a solid foundation for anyone going into
gear inspection. Learn the common, current, and basics of the tools
and techniques used to measure and inspect gears. Understand the
four main categories by which a gear is evaluated and classified. Gain
proficiency in understanding gear quality by learning the numerical
scale on which gear design, manufacture, and inspection are based,
and more.
This course is taught at Daley College. A shuttle bus is available
each day to transport students to and from the hotel. Class are 8
a.m.-5 p.m. each day.
This course is IACET accredited and worth 1.3 CEUs.
Upcoming Webinars
When Discussing Electric Vehicles You Must Talk About
the Consumers
August 4, 2021 | 1-2 p.m.
We continue to discuss the paradigm shift in automotive manufac-
turing. The future is uncertain. In order to have a comprehensive
picture, one must include the consumers. Escalent’s EVForward™
is the largest EV study of the next generation of EV buyers. Mike
Dovorany and his team talked with 10,000 new vehicle buyers. Come
and listen to what they discovered from this research as we work to
move forward in this space.
Latest Trends in Trade Secrets Protection and
Enforcement for the Bearing and Gear Industries
July 14, 2021 | 1-2 p.m.
This webinar will survey recent developments in trade secrets pro-
tection and enforcement and issues affecting the bearing and gear
industries. Topics include:
Corporate best practices for managing and protecting trade
secrets.
Remote workforce risks and mitigation issues, post-pandemic
lessons learned, and new protective measures.
Patent vs. trade secret protection.
Trade secret audits and tracking.
Restrictive covenants and non-competes, new challenges.
Employee lifecycle: Tips for employee on-boarding and exit
interviews.
Interplay between cybersecurity and trade secret protection.
Use of cybersecurity tools to detect external and/or internal
threats.
Managing risk with JV partners, vendors, and independent con-
tractors.
AGMA has over 1,000 Twitter followers! Join the conversation @agma
1001 N. Fairfax Street | Suite 500 | Alexandria, VA 22314 | (703) 684-0211 | www.agma.org
AGMA’s Emerging Technology Efforts – What’s Next?
September 1, 2021 | 1-2 p.m.
The goal of the AGMA Emerging Technology committees is to Identify,
investigate, and inform AGMA members of Emerging Technologies
that may disrupt or significantly affect the power transmission
industry. As we enter our fourth year of work in this space, join us
for an overview of what we have accomplished and a roadmap of
where we hope to go next.
Your Suppliers Will
be at Motion + Power
Technology Expo
WHY ATTEND MOTION + POWER TECHNOLOGY EXPO
Make powerful partnerships, preview, touch,
and learn about emerging trends and tech-
nology, and take home proven solutions for
the year ahead. Read more about who comes,
what you’ll see and do, and why MPT Expo is
a “don’t miss” on your calendar of events.
ALL MOTION AND POWER TRANSMISSION INDUSTRY SECTORS
Motion + Power Technology Expo covers the full range of power trans-
mission solutions using mechanical power transmission, pneumat-
ics, hydraulics, electric motors, and drives. Read how professionals
from each industry sector will benefit from attending.
MORE INFO motionpowerexpo.com
July 2021     19
 CALENDAR OF EVENTS
Whether you’re 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 an email to events@agma.org.

July 15 — Nomenclature Committee Meeting — WebEx

July 19 — Materials 7 Metallurgy Committee Meeting — WebEx
JULY

July 20 — Fundamentals of Gear Design & Analysis Course — St. Louis, Missouri
July 29 — TDEC FTM Review — Chicago, Illinois

August 4 — Lubrication Committee Meeting — WebEx

August 4 — Emerging Technology Webinar — WebEx
August 5 — Gear Accuracy Committee Meeting — WebEx
August 5 — IIoT Committee Meeting — WebEx
August 10–11 — Basic Gear Inspection for Operators Course — Chicago, Illinois
AUGUST

August 12 — Plastics Committee Meeting — WebEx

August 17 — Powder Metallurgy Committee Meeting — WebEx
August 18 — AGMA Board of Directors Meeting — Alexandria, Virginia
August 19 — Nomenclature Committee Meeting — WebEx
August 20 — 3D Printing Committee Meeting — WebEx
August 24 — Metallurgy & Materials Committee — WebEx
August 24–26 — Detailed Gear Design Course — Chicago, Illinois
August 31 — Robotics & Automation Committee Meeting — WebEx

AGMA LEADERSHIP

Greg Schulte: Chairman Craig Burriss: Industrial Gear Group

EXECUTIVE COMMITTEE

Bonfiglioli USA
Michael Cinquemani: Treasurer Zen Cichon: Innovative Rack & Gear Company
Master Power Transmission Brian Coclich: CGI, Inc.
BOARD OF DIRECTORS

Michael McKernin: Chairman, BMEC

Milans Machining and Gear Manufacturing Greg Estell: The Estell Group LLC
Todd Praneis: Chairman, TDEC Adam Gimpert: Helios Gear Products
Cotta Transmission Company, LLC
John Cross: Chairman Emeritus Mushtaq Jamal: Bevel Gears India, Pvt, Ltd.
ASI Drives
Ruth Johnston: Croix Gear & Machining
Scott Miller: Caterpillar, Inc.
Matt Croson: President
Eric Van Rens: Schafer Industries
Amir Aboutaleb: VP, Technical Division
STAFF

Jenny Blackford: VP, Marketing Robert Rye: Cincinnati Gear Co.

Randy Stott: VP, AGMA Media Sara Zimmerman: Sumitomo Drive Technologies
General requests: webmaster@agma.org | Membership questions: membership@agma.org | AGMA Foundation: foundation@agma.org
Technical/Standards information: tech@agma.org | MPT Expo information: mptexpo@agma.org
20     gearsolutions.com
 9001:2015
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AS
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Solution Treat and Age (STA) • Annealing • Stress Relieving • Harden and Temper • Degassing • Brazing

We know high quality gears and components are

vital to performance. Our leading edge vacuum
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• Low Pressure Vacuum Carburizing (LPVC)

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For more information or a quote,

call 1-855-WE-HEAT-IT
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Eastern PA California
Western PA South Carolina VACUUM PROCESSING Heat Treating • Brazing • Carburizing • Nitriding
July 2021     21
 MATERIALS JIM ALBERTSON
MATTER
SENIOR MANAGER OF SUPPLY CHAIN STR ATEGY
& OPER ATIONS ADVANCEMENT   TIMKENSTEEL
Materials matter – and so does total cost of ownership
Energy efficiency is critical to many of today’s
end markets. Next-generation gear-system
designs and, specifically, new propulsion
powertrains, demand performance at the lowest
possible cost.
G ear designers have options when exploring cost reductions within
a component, from using different material grades and leaner
processing to incorporating less-proven offshore suppliers. While
individually, these options may provide lower costs, consequently
they might drive higher costs in other areas of the supply chain. It’s
important to look holistically at the supply chain and focus on total
cost of ownership.
Whether you are managing a supply chain or partnering with an
experienced company like TimkenSteel to do so, you should recog-
nize that each stopping point in the creation of your gear presents
an opportunity for performance and savings. For example, if your
application requires a more costly raw material, you may discover
savings by customizing that material to your downstream suppliers’
equipment or processing capabilities.
Ring gears manufactured in
TimkenSteel’s St. Clair Plant
in Eaton, Ohio. (Courtesy:
TimkenSteel)
22     gearsolutions.com
Using integrated systems to improve the flow of information and
materials within the supply chain can dramatically reduce inventory
costs and investment in working capital.
Remember these points to help control costs within the supply
chain:
Consider all the capabilities of the supply chain when making
sourcing decisions. Make sure you’re conducting due diligence to
select the right suppliers for the right roles. Look at factors such as
their physical location, technical and management expertise, dem-
onstrated process capabilities, planned lead times, historical quality
performance and warranty claims data, etc.
Understand material utilization, projected scrap rates and how much
material is needed to manufacture the desired components. Ask your-
self if there are opportunities in the design phase of the project to
minimize material requirements.
Understand how to communicate well and help facilitate a smooth
transition between suppliers. Know the handoff points and understand
how you can automate the communication process and share informa-
tion electronically between compatible systems.
Consider where you can eliminate redundancies. For example, can
you sequence or combine inspections while ensuring quality?
Identify opportunities to utilize open capacity in the supply chain
JOHN TABELLION
SENIOR PRODUC T MANAGER, VALUE-ADDED
AUTOMOTIVE   TIMKENSTEEL

versus making investments in new capital equipment.
Be careful to manage working capital and take advantage of trusted
regional or localized supply partners. Evaluate safety stock, required
WIP and planned delivery times carefully to manage the inflow inven-
tory and conserve cash.
Continuously analyze and manage logistics costs for each part of
the supply chain and combine freight pick-up and delivery destina-
tions where possible.
Design raw material thermal treatment for optimal machinability
within the supply chain and for customer gear cutting and finishing,
which ultimately affects gear performance.
Review options to combine operations within the supply chain.

Suppliers like TimkenSteel offer turnkey processing from melt-to-
component manufacturing, which could allow you to focus on core
competencies.
The most important part to managing a complex supply chain is
having the expertise to know where you can improve. This includes
identifying and mitigating problems early in the process, reducing
inefficiencies and sources of variation and devoting resources to drive
out costs. Open, proactive communication with suppliers and custom-
ers is also key to identify and implement comprehensive continuous
improvement initiatives and reduce the total cost of ownership. 

ABOUT THE AUTHOR

Jim Albertson is Senior Manager of Supply Chain Strategy and Operations Advancement for TimkenSteel. He spearheads supply chain strategy
and supplier development programs for a broad range of outsourced conversion services. He joined TimkenSteel in 2001 and has held various
leadership positions. He holds a bachelor’s degree in marketing from The University of Akron and is a member of the American Society for Quality.
Contact him at 330-471-3134 or james.albertson@timkensteel.com.
John Tabellion is Senior Product Manager, Value-Added Automotive at TimkenSteel. He began his career with the company in 2001 as an
engineering analyst and has held a variety of analytical and engineering roles, predominantly in value-added product capacities. Most recently,
he served as an account manager on TimkenSteel’s sales team. He holds a bachelor’s degree in mechanical engineering technology from The
University of Akron. Contact him at 330-284-0810 or john.tabellion@timkensteel.com.
This article first appeared in the December 2020 issue of Gear Solutions.

July 2021     23
 TOOTH BRIAN DENGEL

TIPS GENER AL MANAGER   KHK-USA

Maximum allowable torque

What is the maximum allowable torque
of a gear and why does it matter?

W hen participating in a competitive sport, there is a strong desire to

maximize the physical output of your body. Whether it is running
faster or leaping higher, we all strive to push the boundaries of how we
were designed. Sometimes these activities result in spectacular imagery,
such as when we leap high into the air and catch a football in the end
zone, scoring the game winning touchdown. Other times, they result
in spectacular failure, such as when we land from that amazing catch
and our femur cracks under the pressure. Engineers typically push the
physical limits of gearing in a similar way to what athletes do to their
bodies.
In order to properly size a gear for a specific application, design
life is critical. If a gear needs to operate for a short cycle, perhaps one
hour, then the applied torque can be significantly higher than if the
same gear needs to operate for six months or more. A common design
Figure 1: As the gear begins to rotate, the dynamic torque capacity decreases.
standard for gearing is 2,600 hours. This benchmark represents a
gear being in service for eight hours per day,
five days per week, for one full year, with a
factor of safety of 1.25. With this time frame
established, annual preventative mainte-
nance can be scheduled on the mechanism
to check for wear and other issues.
As torque capacity is inversely proportion-
al to the operational speed of a gear train,
the maximum allowable torque will vary
depending on the speed of the driven gear.
When a gear is not rotating, the maximum
allowable torque is equal to the static torque.
As the gear begins to rotate, the dynamic
torque capacity decreases as noted in the
Figure 1.
Just as the speed is important to the
value of the maximum allowable torque,
so is the definition of maximum allowable
torque itself. Most engineers only consider
the maximum allowable torque due to bend-
ing strength. This is the maximum applied
torque that will cause an instantaneous fail-
ure of the gear. Another torque to consider is
the maximum allowable torque due to sur-
face failure. The failure mode, also known as
bearing failure, is defined as the allowable applied torque that mini- life of 107 cycles, then the maximum allowable torque due to bend-
mizes surface wear, thus allowing the gear to perform as designed ing strength is 46 Nm. However, the maximum allowable torque due
for the desired life span. These two torque capacities are independent to surface failure is only 2.83 Nm. With this gear, the surface torque
and can vary significantly. capacity is only 6 percent of the bending strength torque.
Let us consider the following situation: If we choose a module 2, 40 tooth, carbon steel spur gear, with a
If we choose a module 2, 20 tooth, carbon steel spur gear, with a 20mm face width, operating at 100 rpm, symmetrically supported
20mm face width, operating at 100 rpm, symmetrically supported by by bearings, properly lubricated, driven by a uniform load and a
bearings, properly lubricated, driven by a uniform load and a desired desired life of 107 cycles, then the maximum allowable torque due
24     gearsolutions.com
 Just as the speed is important to carburizing, or induction hardening. Each of these processes
increases the surface durability of the tooth flank but they also
the value of the maximum allowable reduce the bending strength.
Using the same gears detailed above and induction hardening
torque, so is the definition of the tooth areas, we are able to significantly improve the maximum

maximum allowable torque itself. Most allowable torque due to surface failure. For the 20-tooth example,
although the bending strength torque capacity drops from 46 Nm
engineers only consider the maximum to 38.3 Nm, the maximum allowable torque due to surface durabil-
ity increases from 2.83 Nm to 16.6 Nm. For this gear, a 17 percent
allowable torque due to bending decrease in bending strength results in a six-fold increase in sur-
face durability. For the 40-tooth example, the bending strength
strength. This is the maximum torque capacity drops from 118 Nm to 98.3 Nm, and the maximum

applied torque that will cause an
instantaneous failure of the gear.
to bending strength is 118 Nm. However, the maximum allowable
torque due to surface failure is only 12.5 Nm. With this gear, the
surface torque capacity is slightly better at 10.5 percent of the bend-
ing strength torque.
In order to improve the surface durability, a heat treatment
is typically applied to the tooth surfaces. Dependent on the base
material, the heat-treatment method could be laser hardening,
allowable torque due to surface durability increases from 12.5 Nm
to 72.1 Nm.
As noted earlier in this article, if the desired life is shorter, then
the maximum allowable torque values will be higher, and if the
operating speeds are increased, then these values would be lower.
The maximum allowable torque is never one static value. The
designer must always consider all of the operating conditions in
order to properly calculate the maximum torque values. Athletes,
like gears, can suffer from bending strength failures, resulting in
broken bones, and they can suffer from surface failures, resulting in
hip and knee replacements. When operated properly, the service life
of both athletes and gears can exceed their design life. 

ABOUT THE AUTHOR Brian Dengel is general manager of KHK-USA, which is based in Mineola, New York. Go online to www.khkgears.us

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 HOT D. SCOTT MACKENZIE, PH.D., FASM

SEAT
SENIOR RESEARCH SCIENTIST–METALLURGY   
QUAKER HOUGHTON INC.

Precipitation hardening stainless steels

The top alloy groups have seen increased
growth in application because of corrosion
resistance, strength, and low distortion upon
precipitation hardening treatment.
formation. Aging at temperature allows the precipitation hardening
mechanism to occur.
AUSTENITIC PRECIPITATION HARDENING
STAINLESS STEELS
This group of alloys has lower mechanical properties than the other
two groups of precipitation hardenable stainless steels but has good

I n this column, we will discuss precipitation hardening steels and

their physical metallurgy.
Precipitation hardened stainless steels are a class of stainless steels
creep resistance and holds their properties to temperatures to as high
as 704°C (1,300°F). Precipitation occurs during aging at 650°-750°C.

that can be hardened to significant strength levels by heat treatment. PHYSICAL METALLURGY
These alloys were first introduced in 1946 [1] to fill the need of high- There are predominantly two different crystal structures for
strength, corrosion-resistant alloys that would be capable of operating precipitation hardening stainless steels – ferrite and austenite.
at elevated temperatures. Since their initial
creation, numerous different alloys have Common Type Typical Chemical Analysis %
been created. These alloys are now widely Name C Mn Cr Ni Mo Cu Al Ti Others
used in aerospace, marine, automotive,
A 286 Austenitic 0.04 1.45 15.25 26.00 1.25 – 0.15 2.15 V 0.25,
paper, nuclear, petrochemical, and other
B 0.007
applications. These alloys are used whenever
a combination of high strength, corrosion 17-10PH Austenitic 0.07 0.75 17.20 10.80 – – – – P 0.28
resistance, and toughness is required. 13-8Mo Martensitic 0.05 0.10 12.75 8.00 2.25 – 1.25 – –
Precipitation hardening is achieved by the
addition of copper, molybdenum, aluminum, 17-4PH Martensitic 0.05 0.75 16.50 4.25 – 4.25 – – Nb 0.3
and titanium. These alloys are generally Custom 455 Martensitic 0.05 0.50 11.50 8.50 0.50 2.00 – 1.10 Nb + Ta 0.4
solution heat treated at the mill, fabricated at
17-7PH Semi-austenitic 0.06 0.70 17.25 7.25 – – 1.25 – –
shop (forming and machining), then aged to
achieve the desired mechanical properties. AM-350 Semi-austenitic 0.09 0.80 16.50 4.30 – 2.75 – – –
The age hardening step then precipitates PH 15-7 Mo Semi-austenitic 0.06 0.70 15.50 7.25 2.60 – 1.30 – –
the hard intermetallics that significantly
increase hardness and strength. Table 1: Typical compositions of some precipitation hardening stainless steels.
Precipitation hardening stainless steels
are divided into three main groups of alloys: martensitic; semi- Ferrite is a body centered cubic structure while austenite is a face
austenitic; and austenitic. Typical chemistries of common alloys in centered cubic structure. Chromium, molybdenum, vanadium, and
each group are shown in Table 1. niobium are ferrite stabilizers. Nickel, manganese, copper, and cobalt
are austenite stabilizers.
MARTENSITIC PRECIPITATION HARDENING Solubility of the alloying elements increases at higher tempera-
STAINLESS STEELS tures, meaning that the martensite start and finish temperatures
These stainless steels are typically used as bar or forging stock, but can can be controlled by the solution heat-treating temperatures. At high
be available as castings, sheet, or plate. Cold forming of these alloys is solution heat-treating temperature, the alloy content of austenite is
difficult because of the untampered martensitic structure developed increased, and the martensite start temperature is depressed. At lower
during solution heat treatment. Alloys in this condition have relative solution heat-treating temperatures, the austenite is leaner in alloy
low ductility and high strength. Hardening by a single aging treatment content (less in solution) and upon cooling transforms to martensite.
will produce yield strengths from 1,170 MPa to 1,376 MPa (170-200 Ksi). These alloys are called semi-austenitic precipitation hardenable alloys.
These alloys can be used at temperatures up to 482°C (900°F). The effect of alloying content on the type of alloy is shown in Figure 1.
The primary precipitation hardening elements in these stainless
SEMI-AUSTENITIC PRECIPITATION HARDENING steels are aluminum, titanium, and copper. There are three basic steps
STAINLESS STEELS to hardening these alloys. While there are differences between the
These alloys are predominantly produced as sheet because the aus- different groups, they all follow the same scheme.
tenitic structure after solution heat treatment provides excellent First there is solution heat treatment. As with aluminum alloys,
formability. Mechanical deformation after solution heat treatment this temperature is chosen to dissolve all the solute atoms in solution.
transforms the austenite present from solution heat treatment to a The amount of time, and the temperature are chosen depending on
martensitic structure. Refrigeration can also drive martensite trans- the alloying elements present. As indicated previously, time and
26     gearsolutions.com

Figure 1: Effect of alloying content on the transformation temperature of
precipitation hardening stainless steels [1].
Figure 2: Effect of aging temperature on the yield strength of a typical martensitic
precipitation hardening stainless steel [3].
temperature can be adjusted to change the martensitic transformation.
Secondly, a supersaturated solid solution must be created. This is
accomplished by quenching. If the alloy transforms to martensite upon
quenching, greater supersaturation occurs because of limited solubility
of the alloying elements in martensite. This means the surrounding
matrix has a greater alloying content, and greater supersaturation.
This martensite reaction can be driven to completion by refrigeration
to below the martensite finish temperature.
The last step in the process is precipitation hardening or aging.
Since the diffusion rate is so slow because of the temperatures
involved, natural aging does not occur. Upon application of elevated
temperature, diffusion occurs, and fine precipitates occur along crys-
tallographic planes of the matrix. A highly strained matrix results,
with a mismatch occurring between the matrix and the precipitate.
As in aluminum, the size and morphology of the precipitates can be
controlled by different times and temperatures. Long exposure at low
temperatures creates many fine precipitates which, in turn, increases
the strength. Intermediate temperatures can still achieve maximum
strengthening, but a shorter cycle. At high temperatures, the precipi-
tates lose coherency with the matrix. The precipitates shear, reducing
the strain between the matrix and the precipitate, and the structure
becomes overaged.
MARTENSITIC PH STAINLESS STEELS
This material is typically solution heat treated at 1,037°±13°C (1,900°F)
and quenched at the mill. Product forms are bar, plate, sheet, and billet.
This solution heat treated and quenched thermal treatment is called
ABOUT THE AUTHOR D. Scott MacKenzie, Ph.D., FASM, is senior research scientist-metallurgy at Quaker Houghton Inc. For more
information, go to https://home.quakerhoughton.com/
“Condition A.” In this condition, the material is readily machined to
the desired shape. After machining, the part is aged to the desired
properties. One of the advantages of precipitation hardening stainless
steel is the ability to readily machine parts in Condition A, and age
them at moderate temperatures to the final strength. The typical con-
traction from hardening this group of alloys during aging is extremely
small. Aging from Condition A to 900°F, the resulting contraction is
0.0004-0.0006 inches per inch. The contraction from aging Condition
A at 1,150°F is 0.0009-0.0012 inches per inch [2].
SEMI-AUSTENITIC PRECIPITATION HARDENING
STAINLESS STEELS
These steels are austenitic in the solution-treated condition, and trans-
formed to martensite either by mechanical working or by thermal
treatment. Additional strengthening occurs during aging. An addition-
al austenite conditioning step is required before aging. Refrigeration at
-100°F after rapid cooling from the conditioning step helps to achieve
the desired peak strength. These alloys have a much more complex
heat-treatment cycle and mechanical working to achieve the very high
strengths. Space does not allow a full discussion of the interactions
between austenite conditioning, aging, and mechanical deformation.
AUSTENITIC PRECIPITATION HARDENING STEELS
In these alloys, sufficient austenite stabilizers are present (such as
nickel) to maintain an austenitic structure. The martensite start
temperature is lowered, so that it is room temperature or below. This
group of alloys contains titanium and aluminum, and hardens by the
formation of Ni3 (Al,Ti) during precipitation hardening.
The heat treatment of this group of alloys consists of solution treat-
ment at 982°C (1,800°F), and cooling rapidly (typically an oil or polymer
quench) to Condition A. The alloy is then fabricated, and subsequently
aged at 704°C (1,300°F) for 16 hours, then air cooled [4]. These alloys
have a much lower yield strength (620 MPa) than the martensitic or
semi-austenitic grades.
CONCLUSIONS
In this column we introduced the different types of precipitation
hardening stainless steels, and briefly discussed the thermal
treatments and physical metallurgy of the three alloy groups within
the broader precipitation hardening grades of stainless steels.
These alloys have seen increased growth in application because
of corrosion resistance, strength, and — importantly — low distortion
upon precipitation hardening treatment. 
REFERENCES
[ 1 ] C. J. Slunder, A. F. Hoenie and A. M. Hall, "Thermal and Mechanical Treatment
for Precipitation-Hardening Stainless Steels," NASA, Washington D.C., 1967.
[ 2 ] AK Steel International, ARMCO PH 13-8 MO Stainless Steel Product Data
Bulletin, Barcelona, Spain, 2019.
[ 3 ] Allegheny Technologies International, Stainless Steel 17-4 Precipitation
Hardening Alloy, Pittsburgh, PA, 2006.
[ 4 ] L. Zubeck, "A Technical Review of Precipitation Hardening Steel Grades,"
Springs, no. January, pp. 14-16, 2006.
[ 5 ] Allegheny Technologies, AM350 Technical Data Sheet, Pittsburgh, PA, 2012.
[ 6 ] AK Steel, 17-7 PH Stainless Steel, West Chester, OH, 2020.
July 2021     27
ISSUE HEAT TREATING / INNOVATIVE TECHNOLOGY
FOCUS

A COMPARISON OF AN ANALYTICAL
AND FEA APPROACH IN DETERMINING

THERMAL LEAD
CORRECTION
FOR HIGH-SPEED
GEARS

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. (AGMA) This paper was presented October 2020 at the AGMA Fall Technical Meeting. 20FTM02

28     gearsolutions.com
A simplified approach for quick and reliable heat
analyses for thermal lead correction of single-stage
double helical high-speed gears has been developed.
By ANDREAS BEINSTINGEL, BURKHARD PINNEKAMP, MICHAEL HEIDER,
DANIEL STIERLI, and STEFFEN MARBURG

F
or high-speed applications, gears of large
dimensions and high-power density are used.
Temperature distribution in those rotors is
much different in operation as compared to
manufacturing. Therefore, the tooth contact as it
can be validated by blue ink during assembly is not
only affected by distortion and bending under load
but also by non-uniform thermal growth. As power
density and specific load are continuously increasing
over time, for highly sophisticated applications, this
influence should be accounted for with suitable lead
modification, as it is demanded by the
latest version of API 613.
For many years, RENK-MAAG has
been using empirical methods for
thermal lead corrections based on
measurements and experience. Lately,
the authors carried out complex finite
element calculations to numerically
investigate the influence of tempera-
ture distribution on tooth contact. This
kind of detailed finite element model-
ing for tooth contact analyses requires
a strong effort with respect to the cor-
responding finite element meshing as
well as extended computation time.
Therefore, the numerical method was
further enhanced. As a result, a simpli- Figure 1: Schematic visualization of mechanical deflection and thermal distortion
fied approach for quick and reliable in a pinion shaft [2].
heat analyses for thermal lead correc-
tion of single-stage double helical high-speed gears
was developed. The paper describes the theoretical
background and gives a comparison of the results with
the different calculation approaches.
INTRODUCTION
Under operation, a part of the transmitted mechanical
power is lost as thermal energy. Therefore, heat gen-
eration in a gearbox is related to the overall power loss
consisting of gear mesh, bearings, seals, and auxiliary
losses [1]. The total gear-power loss can be further dis-
tinguished in load-dependent losses and load-indepen-
dent losses. The first category is related to frictional
rolling and sliding energy dissipated during power
transmission, whereas the latter one considers dissi-
pative effects due to the rotational movements of the
wheel bodies; in detail, windage power loss and oil
power losses due to oil injection impacts, oil squeezing
during gear meshing, and oil acceleration. It is obvi-
ous that, especially for high- speed applications with
larger dimensions, these power losses and their result-
ing heat generation can become significantly high. As
a result, thermal distortion of the gear blanks needs
to be considered in addition to bending and torsional
deflections when designing profile modifications for
high-speed gears. A schematic draft of the mechani-
cal deflections and the thermal distortion of a pinion
shaft is illustrated in Figure 1.
Already in the 1970s, MAAG published its philoso-
phy on how to compensate for thermal deflection by
specific lead modification [2]. The determination of
the steady-state temperature distribution in a gear
blank was investigated experimentally in [3,4] and
simulated numerically in [5] and [6]. RENK-MAAG,
a subsidiary to RENK AG, adopted these methods
and has, for many years, been using thermal modi-
fications, continuously improving the application
through experience. The computational approach in
[7] also focuses on the radial deformation of the gear
teeth. In this article, a simplified calculation strategy
is presented to determine the thermal condition of
the gear wheel bodies as well as the resulting thermal
profile correction along the path of contact in the nor-
mal direction relative to their corresponding tooth
flanks. The underlying computational model of this
technique considers only the pinion and wheel body
as a basic cylinder volume without an explicit descrip-
tion of the gear-teeth geometry. The quality of this
approach is tested against a detailed finite element
analysis of the same gear type and is finally compared
to design values of experience.
July 2021     29
1 THEORETICAL BACKGROUND
OF THERMAL LOAD ANALYSIS
The computational approach to determine an optimum thermal lead
correction basically consists of three sequential steps:
Calculation of temperature distribution in pinion and wheel.
Calculation of thermal growth due to the temperature change
in pinion and wheel.
Derivation of thermal lead corrections by superimposing the
results of pinion and wheel.
In the first step, the thermal situation in the pinion and wheel
body is determined by solving the heat equilibrium equation [8]
using the thermal boundary conditions defined in the next section
as impact on gear backlash, center distance, bearing load distribu-
tion, and alignment are not considered in this article.
In this specific area, the main heat generation consists of the
power loss of the gear mesh and the power loss of the adjacent bear-
ings. The thermal heat input related to the bearings is here assumed
to primarily dissipate through the housing and hence no additional
temperature exchange at the shaft surfaces Fs takes place in the
following investigations. As a result, the only heat input into the
wheel bodies is the corresponding heat flux acting on the respec-
tive surface F due to the gear power loss Pv, which consists of two
parts [1]: a load-dependent power loss Pz and a load-independent
power loss Pz0

Equation 1 Equation 4

where The load-dependent power loss Pz is the result of the frictional

T is the current temperature [K].
t is the time [s].
l is the material conductivity [W/m/K].
c is the specific heat capacity [J/kg/K].
r is the material density [kg/m3 ].
·q is an external heat flux [W/m2 ].
losses along the path of contact during power transmission, where
rolling as well as sliding friction occurs during the gear-meshing pro-
cess. As sliding friction dominates, the rolling friction is neglected
and the power loss Pz is finally given [10,11]
Equation 5

Then, the gained result — in form of a temperature distribution where

— serves as the boundary condition for the structural analysis in the pet is the transverse pitch [m].
second step. Here, the thermal expansion ua and ur in axial and radial FN is the normal force [N].
direction, respectively, caused in a cylindrical body by a temperature μ is the frictional coefficient [-].
change is given as follows [9] vg is the sliding velocity [m/s].
The frictional coefficient μ is determined according to [12,13].
Equation 2 The calculation of the normal load distribution FN along the path of
contact is based on [14].
The load-independent power loss Pz0, related to the rotational
Equation 3 movements of the wheel bodies consists of windage-power loss and
where oil-power losses caused by oil injection impacts, oil squeezing, and
r is the radial coordinate [mm]. oil acceleration. Therefore, the amount of the power loss Pz0 increases
z is the axial coordinate [mm]. with the gear dimensions and the rotational speed and can thus
u is the Poisson’s ratio [-]. move significantly into the foreground for high-speed applications. It
b is the gear width [mm].
ra is the tip radius [mm].
ath is the thermal expansion factor
[1/K].
T0 is the initial temperature [K].
Finally, the deformations occurring on
the active flanks of the pinion and wheel can
be determined. As schematically illustrated
in Figure 2, a subsequent superposition of
these resulting thermal expansions deliv-
ers the effect of actual thermal distortion Figure 2: Schematic representation of the thermal expansion of pinion and wheel and its effect on the gear
on the total gear meshing. As a result, a two- meshing process.
dimensional thermal lead correction field
along the gear flank and the path of contact
— from point A to point E — can be derived.

2 DETERMINATION OF BOUNDARY
CONDITIONS OF THERMO-
MECHANICAL MODEL
As the focus lies on the temperature balance
of the pinion and wheel body, only the two
corresponding components of the complete
gearbox are considered in all computations.
Moreover, these subdomains can be further
reduced with respect to their axial- and lon-
gitudinal-symmetric design, see Figure 3.
Any further effects of thermal growth such Figure 3: Computational sub model within its boundary surfaces.

30     gearsolutions.com
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can be determined by a computational fluid dynamics (CFD) analysis
[15] or by an approximation according to [10] and/or [16]. The latter
method is the approach of choice in this article.
Finally, the total power loss Pv serves as the basis for the thermal
heat input into the surfaces F for the pinion and for the wheel, respec-
tively. Under consideration of the gear ratio u = z2 /z1, the respective
portion of the pinion power loss Pv,1 and of the wheel power loss Pv,2
can, as an approximation suggested by the authors, be calculated by
the following equations:]

Equation 6
Besides the heat absorption of the gear cylinder surfaces F, both
the pinion body and the wheel body are in constant thermal inter-
action with the surrounding air/oil mixture. In detail, the front
side surfaces Ff, the gear cylinder surfaces F, and the gap surfaces
Fg between the helices. All interactions at these particular areas are
specifically described by means of forced convection heat-transfer
coefficients. While the cylinder surfaces F and Fg are approximated
by flat plates with longitudinal flow [17,18], the front side surfaces
Ff are interpreted as a rotating disk in a stationary fluid according
to [6, 19,20,21]. Therefore, an individual calculation is required for
the corresponding Nusselt numbers Nu.

Equation 7

Equation 8
where
Re is the Reynolds number [-].
Pr is the Prandtl number [-].
k is an exponent-constant according to [19] [-].
With the definition of the physical properties of the surround-
ing air/oil mixture, the forced convection process at the two-wheel
bodies is initially described. Hereby, a complete atomization of the
injected oil is assumed due to the high circumferential velocities
in high-speed applications. As a result, the specific fluid properties
fmix of the homogenous two-phase flow inside the gear housing are
calculated with the following formula
Equation 9
where
fmix is the fluid property to be determined.
fair is the corresponding property of air.
foil is the corresponding property of oil.
x is the oil/air-ratio [-].
Since the oil-to-steel contact in the gear meshing means a fur-
ther significant heat transfer for the two-wheel bodies, this cooling
process is also considered by an additional forced convection heat-
transfer coefficient interacting with 100 percent oil at the top sur-
faces F and Fg in the mesh sector of the circumference. In addition, a
representation of the fling-off effect according to [22] is considered.
As the intermediate surface Fsym represents the symmetric split of
the double helical gear, symmetric boundary conditions are applied
for all thermal and structural analyses.
Finally, the thermal boundary conditions can be summarized in
a basic manner as follows:
Pressure angle α = 20°
Helix angle β = 30°
Module mn = 8.5 mm
Number of teeth z1, z2 = 42, 101
Tip diameter da1, da2 = 428.35, 1006.17 mm
Face width b = 2 x 280 mm
Gap width bg = 85 mm
Rotational speed n1 = 7500 rpm
Power P = 50 MW
Oil type ISO VG 32
Oil inlet temperature 54 °C
Ambient temperature 75 °C
Integral temperature 94 °C
Oil/air ratio ξ = 0.08
Young’s modulus E = 206e3 N/mm²
Poisson’s ratio v = 0.3
Thermal expansion αth = 11.5e-6 1/K
Density of steel ρ = 7800 kg/m³
Thermal conductivity λ = 42 W/(mK)
Specific heat capacity c = 490 J/(kgK)
Table 1: Gear geometry data and material properties of investigated gearbox.

32     gearsolutions.com
 Tamb is the ambient temperature of the air/oil mixture [K].
Equation 10
Toil is the oil temperature [K].
q· is the external heat flux due to the gear power losses [W/m2 ].

Equation 11
3 APPLICATION AND RESULTS
Equation 12 The procedure from Section 2 to determine the thermal lead cor-
rection, under consideration of the boundary conditions defined in
Equation 13 Section 3, is now carried out by means of an example. The computa-
tion is done once by applying the finite element method and then
where again by using a highly simplified analytical approach. The obtained
n is the unit vector normal to its corresponding surface [-]. profile modifications of these two methods are finally compared
hdisk is the convection coefficient according to rotating disk with each other to validate the analytical model on the basis of the
theory [W/(m2K)]. finite element calculations. In addition, a reference is made to the
hplate is the convection coefficient according to flat plate theory results of an empiric formula developed and proven over the years
[W/(m2K)]. at RENK-MAAG.
hflo is the convection coefficient according to fling-off theory In all the investigations covered by this article, only the steady-
[W/(m2K)]. state temperature distribution of the two wheel bodies is taken into
hoil is the convection coefficient considering thermal output account, and, hence, the time dependency in Equation 1 does not apply.
during gear meshing [W/(m2K)]. All calculations and results refer to the gear data and the material
properties listed in Table 1. While the ambi-
ent temperature inside the housing is here
assumed by experience, the integral tempera-
ture is calculated as suggested in [13].
As indicated in Figure 4, the finite element
approach maps the complete wheel body in
three-dimensional space, including their
exact tooth geometry. Therefore, the bound-
ary conditions of the previous sections can be
applied directly to the corresponding surfaces
— for example: the heat input due to the gear
power losses is directly applied to the active
flank surfaces. Accordingly, the thermal
expansions of the active tooth flanks, in nor-
mal direction, also are determined automati-
Figure 4: Finite element model of pinion. cally by the finite element analysis.
In contrast, the analytical approach of
the present work computes the temperature distribution and the
structural deformations of a wheel body by describing its complete
geometry as a simple cylinder without gear teeth. For this reason,
the thermal boundary conditions are adjusted to take account of
the difference in the surface area. In a subsequent step, the result-
ing thermal expansions of the cylinder — Equation 2 and Equation
3 — are transferred to the thermal expansions of the active gear
flanks in normal direction by basic geometry operations.
Once the thermal expansions of the active flanks are available
for pinion and wheel, the thermal lead correction from the super-
imposed thermal distortion between pinion and wheel is derived
identically for both calculation approaches. The results for one half
Figure 5: Thermal lead correction based on finite element approach. of the double helical gear are shown in Figure 5 for the finite ele-
ment approach and in Figure 6 for the analytical approach, respec-
tively. The colors in the figures correspond to equivalent scales. For
this reason, Figure 5 and Figure 6 can be put directly in relation
to each other.
It can clearly be seen that basically the finite element analysis
aligns with the analytical approach. Both thermal lead corrections
propose their highest peak at about 80 mm in longitudinal direction.
Furthermore, they have their minimum value located in the area
of the tooth gap of the double helical gear. However, minor deviations
show up along the path of contact at the beginning and at the end of
the gear meshing. This can probably be referred to the fact that the
exact tooth geometry is not considered with the analytic approach.
Figure 6: Thermal lead correction based on analytical approach. Figure 7 shows an extract of these results — Figure 5 and Figure 6
July 2021     33

Figure 7: Thermal lead correction at pitch radius.
— along the longitudinal axis at pitch radius. In addition, a thermal
lead correction design based on the empirical formula as described
in Section 1 is depicted in Figure 7.
As it can be expected, the curves are not identical. However, the
general shape and amount of modifications align sufficiently well.
The first validation of finite element approach and analytic method
with the empiric values covered by experience is successful. Applying
and continuously improving the calculation methods will even
increase the reliability and provide confidence to even extrapolate
the results beyond the actual area of experience.
4 CONCLUSION
In addition to mechanical distortion, the temperature distribution
in the gears demands for a specific thermal lead correction for high
performance high-speed gears. Sophisticated calculations with the
finite element method are compared to a much easier-to-apply ana-
lytical method developed by the authors. The results not only align
satisfactorily with each other but also with empirical formulae that
have been used for decades and match well with experience.
Therefore, the newly developed calculation method is considered
suitable for actual gear designs even if they extend the scope of cover-
age of the existing empirical methods. Further research and valida-
tion by practical experience will give the basis for further improve-
ment of the calculation approach.  USA.
BIBLIOGRAPHY
[ 1 ] Michaelis, K., Höhn, B., Hinterstoißer, M., 2011, “Influence factors on gear-
box power loss,” Industrial Lubrication and Tribology, 63(1), pp. 46-55.
[ 2 ] RENK-MAAG GmbH in Switzerland, Parallel Shaft Gearboxes, from https://
renk-maag.ch/wp- content/uploads/post_151/RENK_MAAG_Turbo_
Gearboxes.pdf.
[ 3 ] Martinaglia, L., 1973, “Thermal behavior of high-speed gears and tooth
correction for such gears,” Mechanism and Machine Theory, 8(3), pp. 293-
303.
[ 4 ] Amendola, J. B.., Amendola III, J. B., Yatzook, D., 2011, “Longitudinal
ABOUT THE AUTHOR
Andreas Beinstingel, Burkhard Pinnekamp, and Michael Heider are with RENK AG. Daniel Stierli is with RENK-MAAG GmbH. Steffen Marburg is
with the Technical University of Munich.
34     gearsolutions.com
Tooth Contact Pattern Shift,” AGMA Fall Technical Meeting, Cincinnati,
Ohio, 11FTM18.
[ 5 ] Patir, N., Cheng, H. S., 1979, “Prediction of the bulk temperature in spur
gears based on finite element temperature analysis,” Asle Transactions,
22(1), pp. 25-36.
[ 6 ] Long, H., Lord, A., Gethin*, D., Roylance, B. J., 2003, “Operating tempera-
tures of oil-lubricated medium-speed gears: numerical models and experi-
mental results,” Journal of Aerospace Engineering., 217(2), pp. 87-106.
[ 7 ] Arana, J. B., Iñurritegui, A., Larrañaga, J., Ulacia, I., 2018, “Influence of
thermal distortion on load distribution, transmission error and premature
contact,” International Conference on Gears 2018, Lyon, France, 2018.
[ 8 ] Greenberg, M. D., Advanced Engineering Mathematics, Edition 2, Prentice
Hall, New Jersey, USA.
[ 9 ] Szabo, I., 2001, Höhere Technische Mechanik, Edition 6, Springer Verlag,
Berlin Heidelberg New York, Germany.
[ 10 ] Niemann, G., Winter, H., 1983, Maschinenelemente Band II: Getriebe allge-
mein, Zahnradgetriebe - Grundlagen, Stirnradgetriebe, Edition 2, Springer
Verlag, Berlin Heidelberg New York Tokyo, Germany.
[ 11 ] Gurd, C., Wink, C., Bair, J., Fajardo, C., 2019, “Computing Gear Sliding
Losses,” AGMA Fall Technical Meeting, Detroit, MI, 19FTM10.
[ 12 ] International Organization for Standardization, 2017, “Calculation of load
capacity of spur and helical gears - Part 20: Calculation of scuffing load
capacity (also applicable to bevel and hypoid gears) - Flash temperature
method,” ISO/TS 6336-20.
[ 13 ] International Organization for Standardization, 2017, “Calculation of load
capacity of spur and helical gears - Part 21: Calculation of scuffing load
capacity (also applicable to bevel and hypoid gears) - Integral temperature
method,” ISO/TS 6336-21.
[ 14 ] Schmidt, G., 1973, “Berechnung der Wälzpressung schrägverzahnter
Stirnräder unter Berücksichtigung der Lastverteilung” Ph.D. thesis, Gear
Research Center (FZG), Technical University of Munich, Germany.
[ 15 ] Concli, F., Gorla, C., Stahl, K., Höhn, B., Michaelis, K., Schultheiß, H.,
Stemplöinger, J. P., 2013, “Load independent power losses of ordinary
gears: numerical and experimental analysis,” World Tribology Congress,
Torino, Italy.
[ 16 ] Schröder, W., Leimann, D. O., 1980, “Ermittlung der Getriebeverlustleistung,”
ant-antriebstechnik, 19(11), pp. 532-535.
[ 17 ] Stephan, P., Kabalec, S., Kind, M., Mewes, D., Schaber, K. Wetzel, T., 2019,
VDI-Wärmeatlas, Edition 12, Springer Vieweg, Düsseldorf, Germany, Chapter
G4.
[ 18 ] Bergman, T. L., Lavine, A. S.,Incropera, F. P., Dewitt, D. P., 2011,
Introduction to heat transfer, Edition 6, John Wiley & Sons, New Jersey,
[ 19 ] Northrop, A., Owen, J. M., 1987, “Heat Transfer Measurements in Rotating-
Disc Systems Part 1: The Free Disc,” International Journal of Heat and Fluid
Flow, 9(1), pp. 19-26.
[ 20 ] Popiel, C. Z. O., Boguslawski, L., 1974, “Local Heat-Transfer Coefficients on
the Rotating Disk in Still Air,” International Journal of Heat and Fluid Flow,
18, pp. 170-174.
[ 21 ] Hartnett, J. P., Deland, E. C., 1961, “The Influence of Prandtl Number on
the Heat Transfer From Rotating Nonisothermal Disks and Cones,” Trans.
ASME, J. Heat Transfer, C83, pp. 95-96.
[ 22 ] DeWinter, A., Blok H., 1974, “Fling-off cooling of gear teeth,” Trans. ASME,
J. Engineering for Industry, 96(1), pp. 60-70.
 September 14-16, 2021 | St. Louis, Missouri

HEAT TREAT 2021 IS THE EVENT THAT BRIDGES

RESEARCH WITH INDUSTRY!
Heat Treat is the premier conference and expo for heat treating
professionals, attracting global innovators, researchers, influencers, and
decision makers from around the world. Next year’s conference and expo
will feature:
• Three days of face-to-face networking opportunities with approximately
200 heat treat exhibitors and companies. All of the top companies and
big names in the heat treating industry will be represented!
• Latest research and industry insights will be offered during more than
125 technical presentations
• “Basics of Heat Treating” education courses
• VIP guided industry tour
• Initiatives for students and emerging professionals
• Continued co-location with AGMA’s Motion + Power Technology
Expo 2021
• And much more!

WHAT’S NEW FOR 2021?

Co-location with ASM’s Annual Meeting, International Materials, Applications,
and Technologies (IMAT) Conference and Exposition, featuring:

• Access to 200 additional materials-related exhibitors in the co-located

exhibit hall
• Access to an additional 600 technical presentations and workshops,
featuring special crossover keynotes and sessions with Heat Treat
• Joint networking events
• Access to comprehensive programming and events for students and
emerging professionals
• Joint Heat Treat / IMAT programming in the Solutions Center on the
Show Floor

heattreatevent.org
July 2021     35
 HEAT
TREATMENT
OF GEARS

36     gearsolutions.com
The benefits of close interaction between gear
designers and heat-treat specialists can lead to total
cost and quality optimization.
By BILL DISLER
O
ften the options of heat treat may feel
pre-defined when looked at from a gear
designer’s perspective. There are options,
but both gear designers and some heat-treat
manufacturers are constrained by limited exposure
to the fundamental physics that drive the process
performed by the equipment available. The heat-treat
industry is old and rich with experience, but it moves
slowly without the proper incentives to change. It is
important to recognize the benefits of
early, constructive dialogue between
gear and powertrain designers and heat-
treatment experts to advance system
features and designs to the overall
benefit of cost-effective performance
of quality powertrain systems.
The objective of this article is to
touch on some of the key elements of
heat treatment at the fundamental
levels to impress upon readers the
benefits and limits of commonly
discussed methods. In some cases, older
methods with newer packaging can be
a foundation for progress. The science Figure 1: Changes in heat transfer rates for multi-phase quenchants – oil and
of our processes has not changed much water.
over the last several decades. The focus
of this article is carburized gears, but most of the
fundamentals discussed can be applied in other heat-
treat processes when the benefit can bring value.
A REAL-WORLD EXAMPLE – LARGE DEEP
CASE GEAR OPPORTUNITIES MISSED
In this case we’re talking about wind-turbine gears
— gears that can weigh in excess of 1,500 pounds
(680 kilograms). The pressure created by surface
winds apply extreme force to the turbine nacelle
and the structure supporting the gears and rotating
gear mass. Gears, no matter the application but
especially in wind turbines, are expected to operate
with as little noise as possible. To effectively operate
in such harsh conditions, most wind-energy gears
are carburized and quenched. The most common
equipment used is pit furnace systems. The driving
force in selecting this technology is the very long
carburizing time related to quench utilization.
Multiple pit carburizing furnaces can be serviced
by one shared quench tank. When carburizing
times are measured in days, utilizing multiple
carburizing chambers with one quench tank is
logical. However, when the overall gear design is
taken into consideration to include both heat-treat
and hard-grinding processes, opportunities exist
to significantly improve manufacturing cost and
overall quality.
The fundamentals of this carburizing and quench
process are sound, but the physics of the mechanisms
are not being considered. Keep in mind that thousands
of these systems are being used for large gear processing
around the world today. Carburizing en masse for
deep-case parts makes sense. Beyond the awkward
material handling and the undesirable product-to-
fixture load ratios, the quench configuration is the
true weakness. These systems use oil to quench the
parts, which is a time-tested and proven process. Here
is where physics comes in and the problems grow.
The oil quench system used is a vertically elongated
quench chamber. It is simply not possible with such
massive loads to get uniform high volume oil flow
from the bottom to the top of such loads. Since oil
boils when it gets too hot, there is an inevitable non-
uniform cooling of these gears that leads to dramatic
distortion. The more uniform the heat transfer during
quench, the lower and more predictable the distortion
you will see. Gears can be designed to compensate for
predictable distortion.
Oil by nature is a multi-phase quenchant when
used in heat-treat quench applications. This means
there will always be more than one type of heat
transfer occurring in a load, no matter what we
do in quench designs: the heat transfer of liquid
oil (convection), film boiling heat transfer, and the
heat transfer into oil vapor (bubbles) when it all out
boils. The differences of these heat transfer rates are
dramatic (Figure 1).
For those of a less technical mindset, consider
July 2021     37
thawing something frozen for dinner. Let it
thaw in air (vapor) or put it in water (liquid).
The same physics principles are involved.
All oil quench tanks have agitation — or
they should — to minimize the formation
of vapors that create non-uniform cooling
of the parts. In an optimum situation, you
want enough flow to absorb heat into the oil
and take the oil away (convection) before it
gets to a temperature of phase change. There
are also detrimental effects from too much
agitation, so we really want a sweet spot of
2-3 feet/second in an optimum world. (See
Figure 2)
The quench tank in a pit furnace setup
is the worst-case scenario, as the agitation is
from the bottom to the top of the elongated
tank. There is no way, regardless of how
aggressive the agitation may be in the
bottom of that tank, to have any uniform,
much less laminar, flow through the load.
Even with high flow at the bottom, the
top of the tank will act closer to still oil.
In addition, the mass of the gears creates Figure 2: Laminar quench flow in optimized quench tank design.
voids of flow between themselves due to the
needed vertical fixture. (See Figure 3)
The way the parts are configured within
a load is very important to the uniformity
of any quenchant’s flow. By using CFD flow
modeling, fixturing can be optimized to
improve flow. As an equipment supplier,
I can say with experience this technology
is seldom used early in a project, but often
used to solve problems later in production.
Figure 4 shows how CFD modeling can help
with progressive quench system designs.
Imagine what a flow model would look like
if applied to a pit furnace quench tank. (See
Figure 4)
During tests done in a conventional
sealed quench batch furnace with a much
more optimized oil quench configuration,
it was found that a decrease in distortion
could have a substantial impact in reducing Figure 3: Typical configuration of fixtured parts in pit quench system.
the amount of costly hard grinding needed
for these gears. It could also allow a decrease of carburizing time by
almost one day — more than 20 hours of furnace time. The reason Heat treat systems tend to
is the gear could be designed with less planned waste material,
as the reduced distortion would minimize that requirement
evolve slowly compared to other
due to the improved quench method applied. Of course, using
conventional sealed quench batch furnaces, each with their own
technologies such as metal cutting
quench tank, is not a cost-effective or practical solution for a number
of reasons. However, the lessons learned can lead to new designs
and automation, but they do evolve
of equipment applying conventional technology in a new package. and can do so in the most efficient
These alternatives exist and bring with them improved automation,
improved quality of the parts, and much lower overall part costs. way when gear designers engage and
But today, pit furnaces remain the primary solution purchased
for heat treating such large, extremely deep case gears as are explore options together with their
used for wind energy. Why? To take advantage of this change in
heat treatment approach, the actual gear design, upstream of heat suppliers. Much of what can be done
treatment, must be changed. In many companies, there is not an
optimal channel of communications, and the actual Value Add that is limited by physics.
38     gearsolutions.com
could be seen is not easily conveyed.

THE HEAT-TREAT BUILDING BLOCKS

GEAR DESIGNERS (AND FURNACE
ENGINEERS) SHOULD UNDERSTAND
1. Heating and holding parts at temperature
during carburizing and other processes.
a. Temperature specification for a process
chamber may be common, but what the
actual part experiences in one system vs.
another is not the same — and it can matter.
b. When comparing a continuous furnace
to a batch furnace, regardless of process
(atmosphere carburizing, LPC, nitriding,
tempering, etc.), parts will experience more
uniformity in continuous furnaces.
c. In addition, in a comparison of a
processes, parts experience better uniformity
with a continuous process vs. a batch process.
The reason is that although the chambers
may be validated to common uniformity
specifications, a part/load moves through a
Figure 4: Quench flow CFD model through fixtured parts.
continuous furnace, and, hence, the parts
experience an averaging effect of the highs
and lows within the acceptable specification
band. In a batch chamber, the parts are
stationary and one part vs. another in the
same load will experience the full variance
of the tolerance allowed.
C on side r a ± 10°F te mp e rat u r e
specification in the typical carburizing
furnace. That is a 20°F total spread. Although
the significance to the quality results of what
the parts see will vary based on case depth
and process, consider that a change of 100°F
in carburizing temperature either doubles or
halves the case depth. If you are striving for
higher and higher quality, this might matter.
2. Atmosphere options for carburizing —
conventional endothermic gas vs. LPC-based Figure 5: Heat transfer rates of common quench media.
approach — understand the pros and cons of
both. 1. LPC processes come with a price, so be certain the IGO benefit
a. Endothermic carburizing gas, either created by a generator or applies to the application; often, it does not due to the failure
through a blend of nitrogen and methanol directly in the furnace, points of the gear or the post-process grinding requirements.
is controlled via sensors inside the furnace throughout the cycle, iv. Acetylene carries about six times more carbon than conven-
allowing compensation for load size variations. tional endo atmosphere and can offer faster cycle times for
i. These processes displace air in the chambers with the gas, but light-case parts.
will have trace levels of oxygen remaining. 1. After a short carburizing time, the benefit of this surface
ii. Cycles are fairly “text book” with respect to carbon potential carbon activity is overridden by carbon diffusion physics within
and case-depth creation. the part. In mid- to deep-case carburizing, it is unlikely that the
b. LPC uses alternating acetylene and nitrogen throughout the process times will differ in a significant way.
cycle to carburize, with no sensors inside the furnace involved 2. The same can be expected for case uniformity when measured
throughout the process. from the root to the face of a gear — with a shallower case, the
i. LPC chambers use vacuum to remove air from the chambers benefits are likely to be more pronounced; with a deeper case,
and backfill with carbon-rich gas; hence, virtually no oxygen it will be less so.
remains in the chamber. v. Viable temperature increases to shorten carburizing times, and
ii. Cycles can be simulated, but testing is required to dial in the their adverse effect on microstructure apply to both LPC and
exact process for each specific load of parts — the results depend conventional atmosphere systems.
on exact load surface area each time, so partial loading is not c. Complications are created when using vacuum in continuous
possible. furnaces, so LPC is typically constrained to batch only processes.
iii. With no trace air, inner granular oxidation (IGO) can be elimi- 3. Quench media and load size — key considerations to minimize
nated, and this can be a benefit in some cases. distortion (a newer way to look at this topic).

July 2021     39
 a. Quench media, in my opinion, should
be grouped into two main categories:
i. Multi-phase quench media: oil, water,
polymer.
1. Each of these will experience phase
changes during quench, which leads to
non-uniform heat transfer in the parts,
regardless of what is done in machine
design.
2. Although oil is a multi-phase quen-
chant, when used properly, it remains
a high-quality, flexible solution that
meets the needs of many gears and
other components.
ii. Single Phase Quench Media: Compressed
Gas or Molten Salt
Figure 6: Future modular system with salt quench.
1. These will not experience a phase
change during quench and, therefore,
will provide the most uniform heat
transfer from the part during quench.
2. Compressed gas, typically nitrogen or
helium (which has a better heat transfer
coefficient but is no longer viable), has
very limited heat-transfer properties.
3. Salt has better heat-transfer proper-
ties and is often blended with small
amounts of water if even higher heat
transfer rates are required.
iii. In all cases, circulation is a major con-
sideration.
b. The smaller the load, the better quench
uniformity can be in all cases. This again is
the intersection of physics regarding how one
can get flow uniformly through the load.
c. Figure 5 shows approximate heat trans- Figure 7: Re-deployable heat-treat systems.
fer rates for common quench media options.
Some words about using salt as a quench media: It has a stigma to its mechanical properties, it may be worth considering.
from the past of being a nasty media with all kinds of safety and envi- I encourage gear designers to reach out and explore the evolu-
ronmental issues. Often, when I mention salt quenching, I get looks tion of heat-treatment processes. Heat-treat systems tend to evolve
from seasoned heat-treat experts like I am crazy. It is very important slowly compared to other technologies such as metal cutting and
that people understand salts better to open opportunities for the automation, but they do evolve and can do so in the most efficient
future. The salts being referred to in this article are 99-plus percent way when gear designers engage and explore options together with
recycled, and what is left can be easily discarded, unlike oil. Salt used their suppliers. Much of what can be done is limited by physics, but
in these quench systems is very green and environmentally friendly. creative packaging will allow for much more flexible and accommo-
Further, with new sensors being developed, the heat-transfer rate of dating systems in the future. Although not explored in this article,
salt with small amounts of water added can be controlled and become changes are coming with other aspects of heat-treatment systems. As
an added factor to tailor many processes. Demand for salt quench an example, consider the modular system shown in Figures 6 and 7.
systems is growing. In some cases, this is because it can do things This system is designed for fast installation on flat floors, is easily
no other media can, like quench to bainite with a 700°F quench re-deployable similar to CNC machines, can process moderate sized
temperature. In other cases, it is being considered for martensitic loads to balance flexibility and cost per part, has small load quench
quench processing to provide better heat-transfer rates for those who benefits, and uses salt quench for environmentally friendly, low
have seen the benefits of gas quench systems but do not want to deal distortion quenching. Change can happen when gear designers and
with the poor heat-transfer rate limitations. Like everything, it has heat-treat equipment experts work together to develop a vision of
limitations and aspects to be considered for its application, but due their future needs. 

ABOUT THE AUTHOR

Bill Disler is president and CEO of AFC-Holcroft L.L.C. He also held a previous concurrent title of chairman of the Board of ALD-Holcroft, a joint
venture between ALD GmbH and AFC-Holcroft. Previous positions include leading the opening of an induction heat-treatment business unit for
a major Japanese company through its Gear Technology Center and an industrial cleaning company serving the metal cutting equipment in gear
centers and other powertrain related systems. Since 1916, AFC-Holcroft has been a leading manufacturer of industrial furnace systems used in the
heat treatment of ferrous and non-ferrous metals. AFC-Holcroft has been a part of the AICHELIN Group since 2016.

40     gearsolutions.com
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Give us a call to learn
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July 2021     41
THE BRIGHTEST SOLUTIONS THROUGH INGENUIT Y PROUDLY MADE IN THE USA
 BUILD
RESILIENCE BY
MONETIZING
VALUE

Business resiliency is vital for

protection from unexpected
disruptions, market fluctuations,
and macroeconomic issues.
(Courtesy: relayr)

42     gearsolutions.com
Uncover the factors, technologies, and financial
models that can help make a business more
predictable and future-proof.
By GUNEET BEDI
U
nforeseen disruptions, market fluctuations,
and macroeconomic issues. The last year alone
has exposed the unpredictable nature of the
market and supply chains.
Even new competitors popping up from other
industries — think Google competing with CNC
machine providers, a pump OEM, or a water fixture
manufacturing company — can make or break a busi-
ness. Finding ways to make your business more resil-
ient has become imperative, and those who can do that
while creating more value will be even more primed
for success.
Improving resiliency is a huge undertaking, and
if you’re like many people, you’re probably unsure of
where to start.
In this article, I’ll walk you through the different
factors that can help build resiliency at your business,
how advanced technology can enable it, common hur-
dles to watch out for, and some of the top advantages
you can gain from doing the work.
WHAT MAKES A RESILIENT
BUSINESS MODEL?
First, let’s go over what we mean when we talk about
business resiliency. Relayr has identified nine differ-
ent points of resiliency that manufacturers can lever-
age and capitalize on:
Revenue. Ideally, you’ll want revenue to be recur-
ring, long-term, and predictable to manage through
any macroeconomic or market issues effectively.
Failure Risk Exposure. Is your failure risk exposure
Before jumping into a business transformation, determine business outcomes, create a culture shift and account for older parts.
(Courtesy: relayr)
from you and your customers? Have you either covered
some of this risk or monetized the risk? It’s also essen-
tial to determine if your accrued risk on your balance
sheets is possible to be covered by a partner like a spe-
cialty re-insurer.
Remote Equipment Visibility. This is constant moni-
toring of your equipment. Do you have access to the
data outputs? Are you aware of what’s happening with
the equipment and how it’s being operated? Can you
help your customers operate the equipment better to
capture more equipment lifetime?
Maintenance Repair Costs. Ideally, you’ll want any
maintenance or repairs to be predictable, proactive,
and remote.
Operation Cost. Similar to repairs, can you predict
your operation costs?
Spare Parts. How many spare parts do you still
have in your inventory, and why? Do you need to have it
in your inventory? Instead, can you offer it on demand?
Utilization. An idle machine is a monetization
opportunity. How are your machines being used, and
can they be deployed elsewhere?
Product Improvements. If you’re gathering data
from your gear, your product department can work
on a more accurate, real-time basis to provide better
machines for your end customers.
Remaining Useful Life. Lastly, what’s the lifetime
value of your assets? How often do you interact with cus-
tomers? When do they come back to purchase a new
machine? Can you make the machines remain useful for
longer or replace them so that downtime is minimized?
July 2021     43
Integrating a pay-per-use business model opens a new line of revenue for manufacturers and guaranteed up-time for customers. (Courtesy: relayr)
All these factors are opportunities for your business to harness,
ensuring you can proactively and predictively harbor any storm.
HOW ADVANCED TECH PLAYS A ROLE IN MONETIZING
You’re probably familiar with the Industrial Internet of Things (IIoT),
artificial intelligence, machine learning, and big data. While these
technologies are more enhanced than ever, they’ve also turned into
buzzwords with promises of exponential business growth and pros-
perity.
IIoT, in particular, has been around for more than three decades,
yet the concept still means something different to everyone. Many
people define it as the connection of assets to gather data, such as
smart home devices. However, the benefits of IIoT go well beyond that
to address inefficiencies and other pain points in industrial settings.
But technology is only an element of a monetizing business trans-
formation. In fact, technology investments should come well after
you’ve defined your overall business strategy.
In general, people are done with piloting, and they’re finished
with failed IIoT projects. They’re looking for business-impacting tech-
nology more than anything else. This leads us to the crucial question:
How do you get there?
COMMON HURDLES FOR SUCCESSFUL
BUSINESS TRANSFORMATIONS
Any fundamental shift in how you do business requires a lot of
upfront work and planning before you ever flip the switch on any
technology. While every manufacturer is different in terms of mar-
ket, size, etc., there are common factors that can get in the way of
your success.
NOT STARTING WITH THE BUSINESS OUTCOMES
Remember: This type of transformation is not about technology. It’s
not about digitization either. The manufacturers who are getting this
process right — the ones with greater resiliency — take a step back
and approach their monetization efforts through a business lens.
Determining your desired business outcomes first helps you out-
line yours and your customers’ challenges and how you will solve
them. Starting with the outcome will dictate all the technology
architectures to follow.
Additionally, this overarching strategy will allow you to determine
micro-goals or the smaller, incremental steps you’ll take throughout
44     gearsolutions.com
the process. Not only do these goals help give your team smaller wins
to celebrate along the way, but they also serve as moments to pivot
or course correct if needed.
THE INTERNET OF LEGACY THINGS
In the industrial world, assets are in the field for 20 to 50 years.
Connecting these assets isn’t as easy as installing sensors or replacing
them with new machines — especially with price tags of $200,000 to
upwards of $1 million.
Therefore, it’s important to solve for the legacy and the existing
install base through retrofitting. You need to make sure your tech-
nology solution and go-to-market strategy consider older gears you
may have.
THERE ARE NO COOKIE-CUTTER CASE
STUDIES OUT THERE
You could look at other industries for success stories, but digital busi-
ness transformations are still relatively new in the manufacturing
world. If you want to disrupt, you must get comfortable with being
the first mover in your market.
If you’re a service provider or manufacturer of equipment and
there is nothing for you to look to and copy, you have to start from
scratch and develop it. As a first mover, you’ll probably come up
against the classic inventor’s dilemma, but don’t worry: some stuff
you’ll do wrong, yet others you’ll do right and improve.
This is an area where an expert partner can help guide you
through the process, ensuring you have a sound strategy, the right
resources in place, and are prepared for the cultural evolution needed
for success.
DISCOUNTING THE CULTURAL MIND SHIFT
Many businesses get so wrapped up in the business transformation,
and they forget to support internal changes. Worse yet, they underes-
timate how much focus and energy it takes to keep the momentum
going.
Ask yourself: Do you have the right team in place who can make
sense of the data you’re harvesting? How can you ensure others
throughout the organization, especially those who aren’t used to
the new processes or metrics, understand and are aligned? How do
you set up an organization that embraces failure?
Changing the underlying mindset of your culture and the incen-
tives that follow is a major factor in how well your business can adapt
to new ways of working.
WHAT’S IN IT FOR YOUR BUSINESS
As long as gear and rotating equipment manufacturers have been
around, they’ve been differentiated by their products. Whoever had
the best, longest-lasting asset for a competitive price would win the
business. All of this is changing with technology.
About 200 CXOs at industrial companies were surveyed by relayr,
and this year’s results showed that nearly half of U.S. businesses want
to change the way they take products to customers. Even geographies
are blurring. Where once German or U.S. companies would serve
their respective markets, for example, now your reach can extend
well beyond borders.
Today’s manufacturers need to start differentiating by exploring
aftermarket services.
In the industrial sector, the interest of operators and their end cus-
tomers isn’t aligned with manufacturers’ interests. This is because
the manufacturer usually sells gears as a capital expense (CAPEX)
and then goes away for 15 to 20 years and loses touch. They’re incen-
tivized to build high-quality machines that don’t fail.
But, if the machines don’t fail, the manufacturers aren’t making
any aftermarket revenue — and of course, the end customer doesn’t
want the machine to go down. So, when we talk about monetizing
your value, we’re really talking about aligning these interests.
Vertical integration is one area seen more and more in the indus-
trial ecosystem as businesses look to remove barriers and create more
value.
For original equipment manufacturers (OEMs), they’re forward
integrating by trying to get into the aftermarket space to continue
customer relationships, which will compete with the service provid-
ers. At the same time, service providers are backward integrating by
being OEM-agnostic. They know how your equipment works, and it
doesn’t matter who made it.
manufacturers and customers. According to Bain & Company, not
only does the customer experience a 15-percent reduction in operat-
ing costs, but the manufacturer or gear provider can make 50 per-
cent more revenue throughout the lifetime of the asset. Additionally,
aftermarket, uptime guarantees, and consumables all come with
much more customer intimacy than traditional models.
While subscription models might not make sense for every busi-
ness, it becomes more appealing when looking at your utilization.
For example, suppose the utilization is high with rotating equip-
ment, around 90 percent, or low at less than 15 percent. In that case,
an EaaS model with uptime and availability guarantees starts to
make a lot of sense.
FOCUSING ON VALUE OVER PRODUCTS
Often, we can’t predict issues, natural disasters, and other macro
unknowns that may affect your business. What we can do, though,
is identify those areas that are key for resiliency and how advanced
technology, such as IIoT, AI, and machine learning, can help bring
them to life. Whether it’s vertical integration, a pay-per-use subscrip-
tion model, or machine uptime guarantees, it’s all about how you
leverage the data and the value it can bring. 
ABOUT THE AUTHOR
Guneet Bedi is the senior vice president of global sales, business
development at relayr, overseeing the company’s sales, business
development, and revenue generation efforts; relayr supplies enterprise
middleware and IoT solutions for industrial organizations. Contact Bedi
at Guneet@relayr.io.

NEW FINANCIAL MODELS

A digital business transformation can enable numerous efficiencies
and outcomes that can all make operations more resilient. One of the
more popular strategies for manufacturers is switching to a pay-per-
use model. You’ll also see this referred to as equipment-as-a-service Performance
(EaaS) or servitization.
Instead of purchasing an asset outright with pay-per-use pricing Dependability
models, the OEM retains ownership and charges the customer on
a subscription basis. Customers benefit by switching from CAPEX
to operating expenses (OPEX), while manufacturers get more pre-
Value
dictable and recurring revenue streams, additional customer touch-
points, and the flexibility to enter new customer markets.
EaaS is not a new concept but is a model seen more in software and
consumer-focused industries. An example in the industrial world is
“Power by the Hour,” coined by Rolls Royce, which was packaged as
“Total Care” in the early ’90s.
Instead of selling jet engines outright, the company bundles them
with a variety of services. Rolls Royce then leverages the data from
the equipment to provide more guaranteed outcomes and perfor-
mance of those assets. It’s committing to asset performance and
charging for utilization, then bundling all the services and perfor-
mance guarantees as well.
This is possible because Rolls Royce is closing the loop (see Figure
1). And by closing the loop to your customer, you can leverage the
data from those machines to your benefit and the benefit of your
customers.
1.866.HOB.TOOL
w w w . h o b s o u r c e . c o m
As a closed-loop system, EaaS helps align the interests between
July 2021     45
COMPANY SINTO AMERICA, INC.
PROFILE

GIVING FORM
AND LIFE TO
PROCESS
MATERIALS

Peening, particularly for

gears, is a critical process.
(Courtesy: Sinto America)

46     gearsolutions.com
Sinto America, Inc. and its group of operating
companies provides high quality, cost-effective,
and innovative equipment and solutions to a
variety of industries throughout North America.
By KENNETH CARTER, Gear Solutions editor

E
very Sinto America employee takes pride in ensur- concerning non-destructive testing and quality assur-
ing the best possible outcome for any challenge ance. Using Sinto’s Sightia product line, manufactur-
that comes its way. As a matter of fact, the compa- ers may perform 100 percent in-line, product quality
ny’s very name boasts a clue to that philosophy. checks. The process is very rapid, as little as 10 sec-
In Japanese, Sinto is written as two characters: onds, depending on the surface treatment performed
“new” and “east.” Within those two simple words are on the gear.
the key to how Sinto America approaches its custom- “With any type of development, we’re always try-
ers: by taking on new challenges while always mov- ing to look ahead in the industry that we’re partici-
ing forward with hope — essentially combining its pating in and see what challenges our customers are
strengths with its passion.
“I would say our overriding philoso-
phy is to help our customers succeed
with cost-effective products and services
we can provide; we aim for satisfaction
across the board with our customers,
starting from the first phone call, all
the way to supporting them after their
equipment has been installed,” said
Charlie Gorman, vice president of Sinto
Surface Treatment. “But specific to gear
manufacturing, we want to develop and
provide the latest technologies to our
customers in order to participate in
the advancement of the transportation
industries that use these products that
depend on the applications.”

ENHANCING THE VALUE

OF GEARS
Particularly for the gear industry, Sinto
America provides services that can
enhance the value of gears, according
to Mike Fredbloom, director of Sales for A Sightia XRD histogram showing a residual stress curve. (Courtesy: Sinto
Sys-T-Mation and new products. America)
“Sinto provides foundry equipment
and services; one of the product lines we provide is
blasting equipment for a foundry’s cleaning room to
de-sand castings,” he said. “From that, Sintokogio (the
parent company of Sinto America) adapted their prod-
ucts for other applications; peening gears for the auto-
motive industry is an example. Sinto has developed
several different models of shot peening machines for
different applications, including the gear industry.
Peening is one of the ways we are becoming involved
in the gear manufacturing industry.”
Sinto has a product line called Sightia for nonde-
structive testing and quality assurance, according to
Fredbloom. Sinto will be submitting a technical paper
to GEAR Magazine for their fall technical conference
facing,” Fredbloom said. “We want to provide a better
way to achieve a goal that improves quality, reduces
process variation, and ideally lowers costs.”
MAXIMUM CUSTOMER SATISFACTION
With an international engineering support team,
Sinto America can tackle a customer’s challenge from
both a high level, as well as a lower level of detail,
according to Gorman.
“From a high level in order to stay within the scope
and budget of the project and then we tackle the details
so we can ensure that the product is going to correctly
function, be dependable, and be repeatable over the life-
time of the product or service,” Gorman said.
July 2021     47
X-ray diffraction. (Courtesy: Sinto America)

A robotic load/unload of individual gears. (Courtesy: Sinto America)

48     gearsolutions.com
 Also, looking for partnerships with other companies is becoming
the norm for Sinto America to give its customers more value-added
product. Gorman emphasized such arrangements will ultimately
strengthen Sinto America’s reputation, as well as its products and
services.
“I think in today’s business environment, it’s going to require
multiple types of solutions, whether it’s our equipment or not,” he
said. ”We want to participate primarily with the technology. Sinto
has worked very hard to develop non-destructive, quality control
products. Sinto’s Sightia product line is designed to perform 100-per-
cent part-quality assurance checks within the production process ‘in
line.’ Our PSMX-II, an X-ray diffraction device, measures the residual
stress to confirm surface treatment is performed to customers’ speci-
fications, while our ECNI eddy current device determines if the treat-
ment covered the entire part.”
INNOVATION GOALS
With a history that covers decades of providing products and ser-
vices to a variety of industries, Sinto has carved an impressive swath
of innovation, particularly when it comes to peening, according to
Fredbloom. For example, Dr. Yuji Kobayashi, a development manager
at SintoKogio, was named “shot peener of the year” in 2018 and holds
several patents on Sinto technology.
“Many of the technologies and processes that Dr. Yuji Kobayashi
has developed are now the products that we are trying to promote
in the North American gear market,” Fredbloom said. “His develop-
ment in the area of peening and non-destructive testing have led to
multiple products now being sold.”
That approach to peening will be necessary as electric vehicles
become more of the norm, according to Gorman.
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“With electric vehicles, weight is a huge concern,” he said.
“Providing compressive stress adds strength and fatigue resistance
to components that allow designers to reduce the weight of those
components. We see that as a big driver going forward. The use of
more automated processes and controls — non-destructive testing
being one of them —reduces costs associated with surface enhance-
ment processes. Sinto is striving to lead the way in the development
of several of these different technologies.”
REMOTE MONITORING
As Sinto America continues to evolve and move into the future, the
company is developing new Industry 4.0 technologies. Among these
technologies are remote monitoring capabilities that are able to
monitor processes and provide immediate feedback to the customer,
according to Fredbloom.
“We have seen this technology demonstrated,” Fredbloom said.
“Sintokogio has an internal video of this process of remote gear sur-
face treatment evaluation, where a customer is at their manufactur-
ing location, peening their gear, and Sinto technicians are located
remotely at Sinto’s Surface Technology Center, reading the informa-
tion on those gears. Then, the Sinto technicians advise the customer
on how to calibrate the process to effectively peen the gears better.”
Peening, particularly for gears, is a critical process. Gorman point-
ed out that process control also remains critically important in the
gear industry. Sinto is working to advance peening technologies and
developments for future industry requirements. 
MORE INFO sintoamerica.com
M&M 3025
July 2021     49
 PRODUCT
SHOWCASE
The Mitsubishi GE15HS, one of two models with enhanced precision and efficiency added to the GE Series. High-
speed, high-torque main spindles provide optimal machine structure for high-efficiency processing of mass
production gears. (Courtesy: Mitsubishi Heavy Industries Machine Tool Co., Ltd.)
MHI Machine Tool
launches two new
hobbing machines
Mitsubishi Heav y Industries Machine
Tool Co., Ltd., a part of Mitsubishi Heavy
Industries (MHI) Group, recently launched
the GE15HS and GE25HS models of hobbing
machines. Emphasizing high speed, preci-
sion, and efficiency, the new machines pro-
duce gears for electric and hybrid cars amid
the global trend toward reducing the carbon
footprint.
The GE15HS model is for gears with a
maximum diameter of 150mm, widely
used in automobiles and motorcycles. The
50     gearsolutions.com
NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS
high-speed, high-torque direct-drive motor
for the main cutting spindle provides a
maximum spindle speed of 6,000 rpm —
three times faster than previous models.
The high efficiency spindle holding the
work piece uses a special table that provides
high rigidity and high-speed rotation to
handle the necessary thrust load for high
efficiency machining. Cutting gears with
Mitsubishi’s super-hard cutting tools yields a
surface roughness of less than Ra0.4; on par
with gear grinding. The GE15HS provides
process efficiency, eliminating the finishing
process of shaving prior to heat treatment,
improving productivity, and reducing
processing cost.
The GE25HS is for larger gears up to
250mm in diameter, such as automobile dif-
ferential gears. With its high-efficiency pro-
cessing, this model uses a high-speed, high-
power spindle, eliminating the effects of
temperature variations during production.
The high rigidity table has the backlash elim-
inator incorporated as standard equipment.
In addition, the motor torque and maximum
spindle rotation speed of the main spindle
have been increased 1.5 times from previous
models, providing a 42 percent reduction in
processing time.
Used in combination with MHI Machine
Tool’s new materials and coatings for cut-
ting tools, the GE25HS model provides sta-
ble mass production with a cutting speed of
more than 400m/min.
MHI has delivered and installed more
than 2,800 GE Series hobbing machines
since the product launch in 2004.
Demand for mass production of high-pre-
cision gears is continuing to rise with the
shift to electrification of vehicles. With the
need for improvements in NVH and fuel effi-
ciency, and the move toward low-cost man-
ufacturing, MHI Machine Tool, with exper-
tise in both gear machine tools and cutting
tools, offers a full lineup of gear production
machines, including these two new models.
By delivering precision cutting tools and pro-
cessing solutions to achieve high-precision,
high-efficiency processing, MHI provides
comprehensive support for manufacturing
in a wide variety of industries.
MORE INFO www.mhi.com
Helios offers abrasives
for gear manufacturers
to increase productivity
Demand for ground gears continues to grow,
especially in the automotive and truck power
transmission industries. Consequently,
manufacturers need improved solutions
for abrasive tools. Helios Gear Products has
launched the latest line of abrasives backed
with dedicated application engineers spe-
cifically for gear manufacturers. These tools
cover all applications for gearing, including
form grinding wheels, continuous generat-
ing grinding wheels, diamond dressing tools,

Helios two-zone continuous generating grinding and
superfinishing wheel. (Courtesy: Helios)
honing rings, bevel grinding cups, and tradi-
tional solutions for OD and ID grinding.
Gear grinding means qualit y, so
manufacturers require state-of-the-art
abrasive tools. The Helios abrasives line
includes such tools that use the latest
technology for ceramic and aluminum oxide
grains and bonds. For example, the Tyrolit
Burka-Kosmos Mira Ice series of form (single-
profile) grinding wheels uses the latest
grains combined with an innovative, high-
strength bond system and increased porosity
to achieve industry-leading “cool” grinding.
Mira Ice enables gear manufacturers to push
the envelope on speeds and feeds.
“It is not uncommon for gear manufac-
turers to decrease cycle times 20–30 per-
cent by switching to an optimized grinding
wheel technology, such as Helios’s Mira line.
Additionally, manufacturers can extend
tool life dramatically by optimizing their
processes (engineering their applications)
with the Helios team,” said Tim Lee, Helios
technical sales manager – hard finishing.
Several solutions comprise the rest of
the Helios abrasives line for gear manufac-
turers. These tools for generating grinding,
tool dressing, honing (with the industry’s
shortest lead times), and bevel gear grind-
ing meet the Helios standard of globally
competitive manufacturing solutions. Many
of these tools are manufactured in techni-
cally cutting-edge European and U.S. facto-
ries, and they equip manufacturers to serve
global markets.
By leaning on the Helios team of appli-
cation engineers, gear manufacturers can
reap the benefits offered by contemporary
wheel specs.
“Successful manufacturers know that what
comes in the box is not just a grinding tool
but also the team of engineers to support it.
By literally using the Helios team, manufac-
turers can stay at the top of their game,” said
David Harroun, Helios vice president.
MORE INFO www.heliosgearproducts.com
Heller’s new generation sizes H 2000, H 4000, H 5000, and H 6000,
of proven horizontal covering a stroke range from 630 mm to
1,000 mm: the first two models for tools
technology cuts costs with HSK-A 63, the larger ones with HSK-A
100. With a construction in modular design
Heller launched the fourth generation of the and many standard components, users have
H series in early 2021. The 4-axis horizontal a wide range of options to adapt the machine
machining centers offer numerous benefits to their individual requirements. In terms
over the previous generation and stand out of drive technology, there are essentially
from other machines with shorter idle times, two equipment packages to choose from:
increased milling performance, reduced ser- Power and Speed. The Power package has
vice times, and more flexible customization been designed for medium batch sizes and
to customers’ requirements. for the machining of steel and difficult-to-
Heller has been known as a specialist machine materials. The Speed package is
for 4-axis machining centers since the suited for high-volume machining of cast
1960s. With the H series (H for horizontal) iron, aluminum, and other light metals.
presented in 2007, the company then “With the Speed equipment package for
launched a machine tool that is considered the Gen4 we have succeeded in reducing
the benchmark by users from many chip-to-chip times by an average of 10
industries. percent,” Gerst said. “One of the crucial
In spring 2020, the first machines of the factors are the short positioning times. In
fourth generation were put into field test field tests, we were also able to demonstrate
operation at selected customers. “Our goal cycle time improvements of approximately
was to put the H series through rigorous seven percent.”
testing under real-life conditions in order What has also proved helpful is the new
to launch a mature machine to the market AutoSet technology cycle for weight-depen-
at the beginning of 2021,” said Dr. Manuel dent dynamics adjustment of the Z-axis and
Gerst, Heller head of development. B-axis included in the Speed equipment
Since February, Heller has been offering package. The cycle helps to achieve the opti-
the horizontal machining centers in the mum axis dynamics in direct correlation to
PRECISION MECHANICAL
COMPONENTS & ASSEMBLIES
Standard industrial components • Made to print parts
GEARS, PULLEYS, SHAFTS, BEARINGS, COUPLINGS,
FASTENERS, CUSTOM GEAR BOXES
Value added features and services
• Engineering, Refurbishing OTHER SERVICES ADD
& Design • Press bearings into pulleys • Grooves • Flats • Keyways
• Custom Made to Print Parts • Assemble bearings to shafts • Pins • Threads • Staking
• Modified Standard Parts • Set backlash on gears • Pressing • Testing
• Assemblies and Sub- • Assemble drive boxes
Assemblies • Straightening
• Custom Mounts for Shafts • Welding
• Build Sub-Assemblies and • Kitting
Complete Assemblies • Plating / custom coating
• Prototype Work • Heat treat
Nordex.com I Sales@nordex.com I Eng@nordex.com
800-243-0986 I 203-775-4877
July 2021     51
PRODUCT
SHOWCASE
the load capacity. Moreover, the developers
have optimized the tool change process in
order to enable time savings for medium
tool weights and have reduced the spindle
run-up times. Depending on spindle size,
these vary between approximately 1.4 and
2.6 seconds.
The in-house developed spindle for the
Gen4 machines is available in three differ-
ent versions: Power (PC), Speed (SC) and a new
Dynamic Cutting (DC) version. All spindles
are available with HSK-A 63 or HSK-A 100
tool holder. The DC units in particular offer
a perfect combination of high torques and
high speeds — with the DC 63 i version provid-
ing 16,000 rpm and 180 Nm and the DC 100
i option delivering 12,000 rpm and 400 Nm.
However, the high spindle power and the
extreme axis dynamics alone are not suffi-
cient to increase the machine’s productivity
in practical application. To achieve this, the
machine also has to provide the necessary
stability and a suitable damping behavior.
Therefore, the classic machine design with
a twin-drive in the Z-axis has been main-
tained and improved with regard to numer-
ous details.
The machines from the H series already
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• NADCAP ACCREDITED • CERTIFIED WOMAN-OWNED BUSINESS
• ISO 9001:2015 • AS9100D • IATF 16949:2016
www.sst.net • 586.293.5355 • info@sst.net
52     gearsolutions.com
With its new Gen4 H series 4-axis machines
Heller reduces idle times while increasing milling
performance – for the machining of aluminum (B06a)
as well as steel (B06b).
provide high basic accuracy and surface
finishes. In combination with the optional
High-Accuracy package, a further improve-
ment in these two regards can be achieved.
The integral U-axis of the Heller out-fac-
ing head allows users to perform contour
turning operations on their components
using motion tools. Moreover, maintenance
and service work can now be performed even
faster. The key to this is good accessibility
to all units.
“Our zero spindles can be exchanged with-
in about an hour as only the mechanical
parts have to be replaced. The motor remains
SPECIALISTS
IN PRECISION
CONTROLLED
HEAT TREATING
• GAS CARBURIZE
• PRESS/PLUG/ROLL QUENCH
• NEUTRAL HARDEN
• VACUUM CARBURIZE
• VACUUM HEAT TREAT
• GAS NITRIDE
• PRECIPITATION HARDEN
• SUPPLY CHAIN MANAGEMENT
inside. As a result, our customers are able to
save approximately 30 percent of running
costs throughout the life cycle of a spindle
compared to classic motor spindles. With
the reduced downtimes not even counted
in,” said Heller head of sales Fabian Mattes.
Not new, but significantly enhanced, and
opted for by more than 80 percent of H series
buyers, is the wide range of Industry 4.0
features available from HELLER under the
product name HELLER4Industry. All these
HELLER4Industry features can be visualized
directly at the machine, in the company net-
work or online.
MORE INFO www.heller-us.com
New grinding wheel
blends rapid stock
removal, operator control
Sigma Z, a high-performance grinding wheel
for stainless steel, carbon steel, mild steel,
galvanized steel, and alloys, is now available
from Rex-Cut Abrasives.
Sigma Z grinds stainless steel welds up to
15 percent faster than other leading wheels.
In addition to a high
material removal
rate, this new wheel
features cool grind-
ing, extended wheel
life, and a chatter
free operation.
“Sigma Z is the
hard working and
reliable wheel you’d
expect from the Sigma Z is available now
from Rex-Cut Abrasives.
Sigma Line. Grain
(Courtesy: Rex-Cut
and bond advance-
Abrasives)
ments allow this
wheel to knock down welds in record time,”
said Bob Costa, Rex-Cut Abrasive president.
Sigma Z is available now in 4.5-inch,
5-inch, and 7-inch diameters.
Rex-Cut Abrasives provides the metalwork-
ing industry with high performance, non-
woven cotton fiber and other premium abra-
sive products, improving the daily grind for
a worldwide customer network. Rex-Cut prod-
ucts are specialized for use on stainless steel,
aluminum, mild steel, and exotic metals. A
100 percent employee-owned organization,
Rex-Cut offers many other specialty products
for use on a variety of grinding, deburring,
blending, and finishing applications. 
MORE INFO www.rexcut.com
 BONUS SECTION

TOOLING &
WORKHOLDING

JULY 2021 • gearsolutions.com

July  2020     53
TOOLING & WORKHOLDING
SOFTWARE
THOUGHT
BACKWARDS
When using the proper design software, manufacturers are able
to go from the desired gear to the perfect skiving tool.
By ZITA BADER
T
here are already an infinite number of different
gear geometries. Nevertheless, engineers are con-
stantly coming up with new variants. For example,
gears are becoming smaller, more complex, and
lighter. At the same time, the demand for performance
— quiet, smooth operation, even under highest load — is
always higher. The variety of gears knows no limits, but
high-precision manufacturing does.
Today, the desired geometry of a gear is often achieved
by skiving. This means the precision of the gear is limited
by the precision of the tool. The principle of skiving has
been known for more than a hundred years, but the tech-
nology in mechanical engineering has only been able to
perform skiving reliably for a few years. That is, the previ-
ously desired precision of the tools and thus of the skiving
The manufacturing process was achieved in elaborate development steps.
of complex gear
profiles requires
“Just a few years ago, the quality of gears in class
highly sophisticated 4 to 6 was the measure of all things,” said Haas
calculations. (Courtesy: Schleifmaschinen software manager Wolfram Hermle.
Haas Schleifmaschinen) “Today, tolerances of 2µ are not uncommon.”
54     gearsolutions.com
Hermle said the time was ripe to take a fundamental
look at this issue in order to search for a groundbreak-
ing solution.
EXACT TIMING
In a high-precision gearbox, exact timing is everything.
The cylindrical gears must mesh 100 percent. Flank
shape and helix angle do not allow any tolerances, and
this applies to both internal and external geometries.
The manufacturing of such complex profiles requires
highly sophisticated calculations. In the profile accuracy
or the pitch accuracy of the gears, the smallest error con-
tinues and leads to inaccuracies in the entire gear unit.
Often, when the gearbox is prototyped, it is not even
apparent where exactly the error is hiding. Therefore, it
was time for the engineers at Haas Schleifmaschinen to
come up with a solution.
“On the market, there has been no satisfactory calcula-
tion model for ever increasing precision requirements.”
Hermle said, describing the situation two years ago
when he initiated the project in the development of the
Multigrind® software.
The goal was to create a calculation basis that is able
to cope with the unbelievable variety of gears. And this
with a precision that opened up new horizons for gear
manufacturers. Derived from the perfect geometry of a
cylindrical gear, the calculation is based on the geometry
of the skiving tool. The motion sequences in production
and the relative speed of the flanks define the future
geometry of the respective generating skiving tool.
“We calculate with the exact path resulting from the
movement of the gear,” Hermle said; however, he does
not want to be more specific about this because, after all,
this calculation model is a new development from Haas
Schleifmaschinen that is causing a lot of excitement in
the market with its unique position.
The desired grinding paths are created on the calcu-
lated surfaces in longitudinal, transverse, and trochoi-
dal paths. The contact point between tool and workpiece
can thereby move on the grinding wheel profile. This
Above: The image of a
skiving tool does not
capture how complex
the calculation of its
geometry actually
is. (Courtesy: Haas
Schleifmaschinen)

Left: The GearScan

500. (Courtesy: Haas
Schleifmaschinen)

July 2021     55
 The picture shows the shortens the grinding paths and, thus, the grinding time.
white contact point Standard grinding wheels are used for this application.
between the tool and the This eliminates the need to purchase expensive form
workpiece. (Courtesy:
grinding wheels.
Haas Schleifmaschinen)
However, the new calculation model is only one side
of the coin. The other is implementation. Because pre-
cise software requires equally precise coordination with
precise hardware, the exact transfer of the Multigrind®
Horizon software to the machine movement does not
allow any deviations. To generate this precision, the
alignment of the grinding wheel must be accurate to
1/10,000ths of a degree.
MEASURING, DRESSING, GRINDING,
MEASURING, DRESSING, GRINDING
The desired grinding performance cannot be achieved
without sophisticated measurement technology and fre-
quent dressing of the grinding tools. The desired accu-
racy of the skiving tool and subsequently of the gear can
only be achieved if all production steps are coordinated
with each other in a collaborative process. The results of
the permanent re-measurement with subsequent com-
pensation of errors are the basis for the fine correction
of the grinding path. This automatic process takes place
entirely in the sense of a closed loop. In this way, the
quality remains constant and error-free — workpiece for
workpiece. The Multigrind® Horizon software handles
this production sequence reliably and quickly, even in
ABOUT THE AUTHOR Zita Bader works in the marketing and communication department of Haas Schleifmaschinen
GmbH.
56     gearsolutions.com
an unmanned operation.
“As far as I know, this level of precision can only be
achieved within the Haas Schleifmaschinen Cosmos,”
Hermle said. “Only when software and hardware are
perfectly matched to each other can the perfect tool be
created for manufacturing a perfect gear. At Haas, we
specialize in developing from the desired end product.
The question ‘What properties should the gear have?’
becomes the starting point of our manufacturing strat-
egy for the perfect skiving tool.”
HAAS SCHLEIFMASCHINEN: TURNKEY
SOLUTIONS SINCE 1934
Haas Schleifmaschinen opened its doors in the
southwest of Germany in 1934. In the beginning, the
multi-axis high precision grinding machines served for
automotive and watch-manufacturing industries. The
third-generation, family-owned company offers in the
Multigrind® series several models of 5-axis CNC grinding
centers that can grind parts from 3 millimeters up to 3
meters; however, the highly flexible grinding machines
of the Multigrind® series become high-tech tools thanks
to the smart software solutions. The unique combination
of perfectly matched hardware and software offers the
customers of Haas Schleifmaschinen maximum added
value. Last year, the daughter company Haas Multigrind®
LLC moved to Charlotte, North Carolina. For more
information, go to multigrind.com. 
 www.toolink-eng.com
4665 Nautilus Ct. South 502A
Boulder, Colorado 80301
303-776-6212 July 2021     57
TOOLING & WORKHOLDING
PATENTED
CONSIDERATIONS
IN HIGH TORQUE
TOOLING
The only retention knob designed to run the gamut on eliminating
V-Flange CNC milling problems.
By CRAIG A. FISCHER
I
t is common knowledge in the CNC manufacturing
community that if you use V-Flange tooling, you use
retention knobs, which are the critical interface
between the spindle and the toolholder and tool.
Often considered nothing more than a bolt, the knob is
actually a precision tool made to strict specifications and
tolerances. While some machine-tool manufacturers
have standardized their requirements, others have
defined several different knobs as options. The fact is,
V-Flange tooling is flawed, and machinists, operators,
and owners must be educated about the importance
of the retention knob, and the right retention knob, to
correct the flaws.
JM Performance Products, Inc., a leading
manufacturing innovator of CNC mill spindle
optimization products since 2009, recognizes it is of
Figure 1: Key to the paramount importance to illustrate that retention
design is a relief knobs not uniquely manufactured to JMPP’s patented
beneath the pilot, that High Torque © design standards are just standard
forces the threads of
the knob deeper into
retention knobs that don’t fully address the gamut of
the threaded bore of the vital and costly V-Flange production issues.
toolholder. (Courtesy: JM Extensive testing has proven that toolholder
Performance Products) expansion is an inherent design flaw of V-Flange tooling.
58     gearsolutions.com
The following is a deep-dive examination into patented
High Torque© retention knob essentials for CNC milling,
which correct this flaw:
THE V-FLANGE TOOLING DESIGN DILEMMA
V-Flange tooling should be the most productive and prof-
itable tooling system available. Its precursor, using NMTB
holders, employed a 7/24 taper with an extended, internally
threaded neck, which accepted the threaded draw bar. This
manual change system was replaced by V-Flange to imple-
ment automatic tool changes. In order to facilitate this
change, the draw bar was modified to include a collet closer
(or fingers), and the extended neck was removed from the
holder and replaced by the retention knob, which threads
directly into the taper.
While these modifications made tool changes occur
quickly and automatically, they introduced a variety of
issues that were not present with the NMTB system, such as
excessive chatter and run-out, resulting in poor finishes and
expensive secondary processes. Holding tolerances can be
problematic, requiring skilled machinists tweaking speeds
and feeds, affecting production in an effort to reduce scrap.
Still a good option for heavy milling processes, V-Flange
forced the industry to look to HSK, CAPTO, and other pre-
cision tooling systems, all significantly more expensive to
adopt in a shop.
The modifications caused these problems essentially
because steel maintains its elastic properties, even after
hardening, and threads create torsional stress. This
stress, exerted by the engagement of the threads of the
retention knob with the threads of the V-Flange holder at
the small end of the holder, often creates a distortion of
the holder. Once expanded or distorted, the holder will
no longer pull all the way into the spindle, stopping short
of full engagement. The small end of the taper makes
contact before the large end at the gage line, leaving
the holder to move randomly within the spindle, much
like a bell-clapper.
This random movement translates to vibration and
chatter (and the above resultant issues), and negatively
affects tool life, especially expensive carbide that is frag-
ile and susceptible to microfracturing (which yield poor
surface finishes). If a microfracture occurs, the whole
tip may disappear, and the inserts can be rendered use-
less. Toolholder expansion caused by standard retention
knob installation can reduce the toolholder to spindle
contact by 70 percent or more. Carbide tool life is dimin-
ished by 50 percent for every 0.0005” distance short of
full engagement.
THE HIGH TORQUE DESIGN INCEPTION
JMPP became aware of this tooling system design flaw,
and designed a gage to measure and study the expansion.
Using this gage, JMPP redesigned the standard reten-
tion knob into its patented High Torque retention knob,
which uses the lowest available threads in the toolholder.
Key to the design is a relief beneath the pilot that forces
the threads of the knob deeper into the threaded bore of
the toolholder, where a thicker cross-section of material
resists the expansion and deformation.
Notably, the design can be used in any toolholder as
long as it is made to industry specifications. Additionally, JMPP’s patented
we found that most holders, unless improperly hardened, High Torque© design
will return to their original form, so even those holders standards address the
gamut of vital and costly
that were expanded by a standard knob could be kept
V-Flange production
in service. issues. (Courtesy: JM
Figure 1 compares a standard knob without a pilot Performance Products)
to a standard knob with a pilot, and finally to the High
Torque design knob. Note that, from the top of the knob
head to the flange that rests on the holder face, the
knobs are dimensionally alike. The additional length of
the High Torque design is beneath the flange, inside the
toolholder bore.
DIFFERENTIAL DESIGN FEATURES
OF HIGH TORQUE RETENTION KNOBS
PRECISION PILOT
The pilot is that portion beneath the knob flange above
the threads that stabilizes the knob in the toolholder. The
High Torque design includes a precision ground pilot that
ensures the perfect alignment of the knob in the holder
during installation. It is important to note that some tool-
holder manufacturers do not adhere to strict tolerancing
of the counter bore at the small end of the holder. In cases
where this counter bore is uncontrolled — while the pilot
July 2021     59

Any non-mechanically does add some strength and rigidity to the knob and there-
necessary threads fore, the tool — it may not facilitate alignment.
are removed, so the
mass of the knob is MATERIAL
dynamically balanced
by design. (Courtesy: JM
Today’s CNC mills are designed to operate with greater
Performance Products) draw bar pressure, faster tool changes, higher feed rates,
and greater depths of cuts, which place more demand
on retention knobs in V-Flange tooling than ever before.
In response to meeting machine manufacturers’ future
requirements and ever-increasing demands, JMPP has
decided to manufacture all 30 and 40 taper retention
knobs, including the patented High Torque knobs, from
AISI 9310H material, offering 40 percent more tensile
strength, instead of the traditional 8620H material.
40 percent added tensile strength is the minimum
benefit derived by combination of the steel composition
and the effects of heat treating (carburization). JMPP
60     gearsolutions.com
The taper gage measured toolholder expansion, leading to the
patented High Torque retention knob design, which uses the lowest
available threads in the toolholder. (Courtesy: JM Performance
Products)
worked closely with metallurgical specialists to define
the proper temperatures, processes, depths, and case
hardening values to ensure the standards for retention
knobs are exceeded. Additionally, proper quenching
and cryogenic freezing greatly reduces the possibility of
cracks. The processing of JMPP’s knobs is done by highly
skilled and certified heat-treat partners.
PRODUCTION PROCESSES
JMPP reviewed the standards and identified a design
flaw in regards to the expected cross-sectional strength
of the knob. To correct this, the size of the coolant holes
in many of the company’s 30 and 40 taper knobs was
modified. The knobs will continue to supply more cool-
ant than demanded, but will be sized to increase the
cross-sectional strength of the knob.
Of note, JMPP uses a black oxide, non-acid process with
strict temperature control to safeguard against hydrogen
embrittlement of the AISI 9310H material. This process
ensures proper adhesion of the blackening process to the
dense chromium molecules present in this material.
The engineering catch phrase for “approximate radi-
us or a series of radii next to each other” is called Blend
Radii. This relates to common machining/engineering
knowledge that a sharp edge, including those on reten-
tion knobs, creates stress points that are easily subject to
failure. Therefore, JMPP eliminates the sharp edges and
corners using radii in transitional surfaces during the
machining or finishing processes.
Finally, a hard-turning machining operation is applied
to each lot of knobs manufactured from 9310H material.
In this process, all critical and control surfaces are con-
trolled to 50 percent of allowable tolerances. Tolerances
under 0.0008 are 100 percent inspected to ensure confor-
mity. All surface to surface runouts are 0.0004 TIR or less,
which ensures better uniformity of gripper to retention
knob contact in machine tool spindles.
THREADS
JMPP precision cuts its threads, with each thread start-
ing and finishing at 180 degrees to the next thread.
Each part is held on the major diameter of the threads
to ensure precision runout between threads, and all
surfaces being hard-turned are held to 0.001 TIR. Keep
in mind that most standards require 0.002 maximum
TIR to threads. This thread-making process is designed
to provide a precision mating between the toolholder
threads and the retention knobs threads.
Notably, the High Torque design takes into account
the mechanical functionality of each thread, and the
fact the load on each thread diminishes with each
step down from the first thread. To that end, JMPP has
removed any non-mechanically necessary threads, so
the mass of the knob is dynamically balanced by design.
Simply adding an additional thread or two will not yield
a better installation result and do nothing to resolve
toolholder expansion. A review of the load percentage
on each thread of a retention knob reveals the maxi-
mum number of functional threads is six; any additional
threads are unnecessary. Also, the process of forming the
threads, whether cutting or roll forming, does not affect
the distribution of the thread load.
MAGNETIC PARTICLE TESTING
Magnetic particle testing is a non-destructive test that
will reveal faults and cracks in the material. Using
only high-quality U.S. made steel that has eddy current
testing (ECT) certification, ensures the part’s material is
defect-free from surface and sub-surface flaws.
JMPP will conduct magnetic particle inspection
tests on purchased knobs, which is useful for detecting
minute surface and near-surface cracks down to a
depth of about 0.100”. Essentially, a magnetic field is
induced in the test specimen, which is then “dusted”
with iron particles, either dry or in a liquid suspension.
The particles will collect along the edges of any micro
cracks or other discontinuities in the structure of the
material to provide a readily visible indication of the
flaw. Notably, JMPP’s testing typically proves out at a 100
percent flawless rate.
INSTALLATION TORQUE SPECIFICATIONS
JMPP provides an axial force calculation, based on draw-
bar force and taper size, to define the installation torque
that should be used on each knob during installation.
This value ensures against over-torqueing the knob
(resulting in premature fatigue and failure of the knob),
eliminates expansion in toolholders made to spec, and
ensures the knob is installed with sufficienttorque
ABOUT THE AUTHOR
Craig Fischer is the JMPP plant manager. Established in 1966, JM Performance Products, Inc. (JMPP) has established
itself as a leading manufacturer of CNC mill spindle optimization products. Across a myriad of markets, JMPP is
dedicated to reshoring with over 500 styles of patented retention knobs for BT, DIN, ISO, and CAT toolholders from 30
taper to 60 taper − all manufactured and material sourced in the United States. All products in the integrated suite are
engineered to optimize milling machine performance including: improving finishes, eliminating run-out, reducing chatter
and harmonics, decreasing set-up times, extending tool life, and increasing spindle performance. For more detailed
information contact: www.jmperformanceproducts.com.
so it does not back out of the holder during cutting
operations.
Many competitors will specify torque values well in
excess of JMPP’s top-range values, for instance: 76 ft. lbs.
for a 40 taper knob. Inasmuch as testing has proven that
as little as 13 ft. lbs. of torque can cause toolholder expan-
sion and excessive knob stress, JMPP specifies values less
than 40 ft. lbs. for most 40 taper knobs. It is important to
recognize that any installation torque values that have
been published earlier were based on bolted threads. It
is also vital to recognize the V-Flange tooling design flaw
and the negative effects of over and under torqueing the
retention knobs during installation.
REPLACEMENT SPECIFICATIONS
As they are subjected to more stress than any other tool
used in CNC milling, retention knobs are not intended
to last forever; therefore, any knobs showing wear should
be replaced. It is always better to replace knobs before a
catastrophic failure occurs, so if the knobs are exposed
to multiple shifts, heavy cuts, or excessive side-pressure,
they should be replaced more frequently.
Typically, knobs should be replaced based on their
time in service. JMPP recommends replacement after
three years if you’re running a single shift, after two
years if you’re running two shifts, and after a year if
you’re running “lights out” or three shifts. Also, reten-
tion knobs should not be removed from a toolholder that
has been in service and re-installed in another holder.
This process will flatten and distort the threads, allow-
ing for unintentional over-torqueing of the knobs.
PATENTED HIGH TORQUE
CONSIDERATIONS/CONCLUSION
While many competitive retention knobs on the mar-
ket recognize toolholder expansion (or swelling), they
have not taken any significant measures to eliminate
the inherent V-Flange tooling condition. This continues
to cost shops significantly as less than 75 percent taper
contact with the spindle results in poor T.I.R. (runout),
poor tool life, poor tolerances, vibration and chatter,
poor finishes, and excessive spindle wear and tear.
JMPP’s patented High Torque design was intended
to eliminate (or vastly reduce) toolholder expansion
caused by the torsional stress exerted on the thinner
wall of the small end of the holder by the knob threads.
Uniquely, it provides for a relief beneath the precision
pilot, which forces the threads to engage deeper in the
toolholder bore, where a greater material cross-section
resists deformation. The difference is crucial in terms of
today’s time, tooling, and production results. 
July 2021     61
PRODUCTS
& NEWS
Helios carbide gear cutting tools: hobs, shaper cutters, broaches, and milling cutters. (Courtesy: Helios Gear
Products)
Helios’ Motion + Power
Technology
Expo 2021 preview
After more than a year of COVID-19 pandemic
challenges, gear manufacturers are ready to
get back to work. This includes learning about
the latest technology available to the indus-
try, so Helios Gear Products will be exhibiting
at the 2021 Motion + Power Technology Expo
(MPT Expo) September 14–16, 2021. Gear man-
ufacturers of all types can attend the show to
see the latest on processes such as hobbing,
shaping, thread milling, deburring, grinding,
inspection, and more.
“The expo is a critical research tool for
manufacturers to stay up-to-date on indus-
try trends and manufacturing disrupters,”
said Adam Gimpert, Helios president.
In the Helios show booth, manufactur-
ers will see a Hera 90 CNC gear hobbing and
thread (worm) milling machine with unified
gantry automation. This machine offers a
62     gearsolutions.com
NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS
single platform for automatically hobbing
and milling parts up to approximately 3.5”
outside diameter. With its 6,000 rpm cutter
spindle, the machine productively handles
small parts with small hobs by maximizing
surface speeds. This high-speed spindle also
enables productive milling of worms.
Also in the Hera series of hobbing
machines, show attendees will learn about
the uncompromising model 350, which
empowers manufacturers as a robust verti-
cal hobbing platform for parts up to approx-
imately 15” outside diameter. As with other
Hera hobbers, the 350 is surprisingly afford-
able and offers several options for an opti-
mized solution, such as 2- or 4-station ring
loaders, re-hobbing abilities, automation
systems, and more. Similarly, Helios offers
the Hera models 500 and 750 for parts up
to approximately 30” outside diameter.
Additionally, manufacturers of fine- and
ultra-fine-pitch gears can learn about the
Hera 30, which features dual direct-drive
work spindles, and a 10,000 rpm hob spin-
dle for productive hobbing of parts up to
approximately 1.6” outside diameter.
For productive manufacturing of inter-
nal gears, Helios will feature the Neo
Power Skiving (“NEOPS”) line. This series of
machines, which includes the models 100,
200, and 400, produces internal or external
gears for parts up to approximately 16.5” out-
side diameter. Compared to traditional shap-
ing, a NEOPS can produce precision gears
in a fraction of the time, making it a go-to
choice for manufacturers of internal gears.
“Show attendees will really want to stop
by and learn about the Neo power skiving
machine, which offers this cutting-edge
technology at a fraction of the price com-
pared to competitors in the market,” said
David Harroun, Helios vice-president.
At the MPT Expo, Helios will also fea-
ture the 2021 CNC upgrades to its line of
Tecnomacchine (“TM”) gear deburring
machines. The TM series now offers manu-
facturers complete CNC programming of the
chamfer-deburring process. This includes
tool position (radial, axial, tangential, and
inclination), tool pressure, tool rotation
speed, tool rotation direction, workpiece
rotation direction, and workpiece rotation
speed. This allows manufacturers to store
a complete application to later be recalled
by the CNC with just a few software steps.
Consequently, changeover time reduces to
a few minutes rather than the traditional
30-45 minutes. Moreover, it significantly
lowers the bar for personnel training, alto-
gether making the machine investment
more flexible and productive for high-mix
gear manufacturing.
Helios also offers manufacturers cut-
ting and abrasive tools, including hobs,
milling cutters, shaper cutters, continuous
generating grinding wheels, form (single-
profile) grinding wheels, bevel gear grind-
ing cups, diamond dressing gears, and more.
Manufacturers can establish their commu-
nication channel with Helios engineers at
the show to empower their manufacturing
teams with guidance on tool specifications
and machining parameters. Show attend-
ees can ask questions and learn from Helios
experts on the spot while viewing machines
and tools that enable globally competitive
production of gears.
MORE INFO www.heliosgearproducts.com

Serrations on the gripping surfaces make Dillon hard jaws ideal for cast parts, scaly parts, or parts with
imperfections. (Courtesy: Dillon)
Dillon diamond-shaped
serrations increase pull-
down effect for hard jaws
Aggressive diamond-shaped serrations
on hard jaws from Dillon Manufacturing
increase the pull-down effect that reduces
part slippage and push back from using a
bar feeder.
Serrations on the gripping surfaces are
ideal for cast parts, scaly parts, or parts with
imperfections. They are manufactured of
8620 steel and case hardened with precision
ground locating surfaces, then black oxide
coated for corrosion resistance. The hard
jaws are available in one-step or two-step sets
and are reversible for OD or ID chucking. One
set covers a wide clamping range.
Dillon hard jaws are available in standard
sizes from stock and in different mounting
configurations including serrated, T&G,
Acme, and square serrated key types to fit all
brands of chucks. Dillon chuck jaws are ver-
satile, with multiple radiuses for both inside
and outside clamping to make them ideal
for any size run. Dillon also offers special or
modified hard jaws with industry-best turn-
around time, which saves time and money by
reducing down time.
MORE INFO www.dillonmfg.com
Suhner adds machining
block spindle for
high-speed operations
Suhner Industrial Products Corp., automa-
tion division introduces the BEX8, a high-
speed machining block spindle capable of
Suhner PowerMaster® provides reliable performance
at extremely high-speed operations. (Courtesy:
Suhner)
maintaining rigidity, precision, and reliable
performance at extremely high-speed opera-
tions — up to 25,000 rpm.
The BEX8 is a smaller version of the
popular Suhner BEX15, but weighs only 33
pounds and features the ability to mount
directly onto robotic arms for fully auto-
mated machining operations in high-speed,
high-production departments in automotive,
appliance, off-highway, and other industries.
The standard motor supplied is either
0.37kW or 0.75kW and the standard tool-
holder supplied is ER20.
This new machining spindle from Suhner
adapts to the UA15 slide unit via the integral
mounting supports. Spindle concentricity is
better than 0.01mm.
MORE INFO www.suhner.com
Big Kaiser expands
hydraulic chuck offering
for Swiss lathes
Big Kaiser has expanded its program for
hydraulic chucks for Swiss lathes to include
inch-size Standard Type chucks, as well as
new F Type and R Type chucks.
Standard Type hydraulic chucks with
tool-side clamping are now available in inch
sizes with the clamping range of ø1/8”, 3/16”,
and 1/4”.
The new F Type’s single wrench enables
easy cutting tool changes on the tool post.
The easy-access rear clamping design is ideal
for front tool post. Clamping from the oppo-
site side of the cutting tool and optimum-
length design improves overall ease of use.
The F Type is available in a clamping range
of ø3-10mm and coolant delivery is possible
with an Rc(PT)1/8’’ screw.
The new R Type eliminates interference
at both the upper or lower tool post positions
with a unique block design and tightening
at an offset position in the tool side. The
R Type is available in a clamping range of
ø3-10mm and its oil hole drills can be used
for coolant delivery when mounted on the
upper section.
To minimize machine downtime and pro-
vide operator safety, these hydraulic chucks
use a simple hex wrench that requires only
two to three turns for both clamping and
unclamping. Tightening is complete when
the clamping screw hits the bottom; con-
trolling tightening torque is not needed.
Once a hydraulic chuck is centered, the
runout will not vary, even if a cutting tool
is changed repeatedly. Runout of fewer than
three microns at four times diameter can be
July 2021     63
PRODUCTS
& NEWS
achieved. Hydraulic chucks have a standard
pipe thread for coolant-through connection
and are available for most Citizen and Star
machines with 3/4’’ or 22mm straight shank.
Big Kaiser, a global leader in premium
high-precision tooling systems and solutions
for the metalworking industries, introduced
hydraulic chucks for Swiss lathes in 2018, the
first improvement to the technology in more
than 30 years.
MORE INFO www.us.bigkaiser.com
Schunk gripper has
bionically inspired
adhesion technology
Imagine gripping smooth surfaces with ease,
leaving no trace of residue or imprint. With
the ADHESO gripper from Schunk, it’s pos-
sible.
The bionically inspired gripper technol-
ogy ADHESO, based on the principle of adhe-
sion, uses the intermolecularly acting Van
der Waals forces for handling components.
Made of special polymers, the patented sur-
face architecture is optimized by numerical
simulation, creating a structure of extreme-
ly finely structured legs that adhere to dif-
ferent materials and objects.
Glass fibers as light as feathers; the small-
est SMD components or micro-mechanical
parts; sensitive battery components; plastic
64     gearsolutions.com
This year, Big Kaiser’s program has expanded
to include inch-size Standard Type chucks,
as well as new F Type and R Type chucks.
(Courtesy: Big Kaiser)
films; paper and glass — all can be handled
by the ADHESO gripper. Gripping of automo-
tive or mechanical engineering components
of a weight of 33 pounds and more is also
possible. Automated separation of breath-
able components is also feasible. With the
ADHESO gripper, solutions can be tailored
to each customer’s individual needs, creat-
ing opportunities that are as diverse as the
applications themselves.
Using Van der Waals forces, the face of the
gripper is gently pressed onto the workpiece
during the gripping process, increasing the
contact surface and locking the grip into
place. This effect can be reversed by applying
a slight pressure/rotary movement so that
the gripper can be loosened from the object
without leaving a residue or any marking.
The alternative use of a wiper ensures that
the object is gently put down.
The respective adhesive forces and
removal of ADHESO depend on the type of
material, surface roughness or flatness, and
miniaturization, and can be customized to
the different requirements of the relevant
environment. Therefore, the adhesive struc-
tures can be adapted to the required size and
the loading condition (horizontal/vertical) of
the application, and can be designed trans-
parent, translucent, or opaque. This high
degree of individualization ensures that
components with dimensions of a few hun-
dred micrometers can be handled as reliably
as those measuring several meters.
Installation costs and commissioning
efforts are minimal. The adhesive technol-
ogy is gentle on components, low-noise, and
doesn’t require compressed air, vacuum, or
current. An external energy supply is not
necessary for gripping or for maintaining
the gripping force. In case of a power failure
in the handling system, the holding forces of
the gripper are reliably maintained. Schunk
ADHESO allows gripping times of < 100 ms:
It can be used in conventional industrial
environments, but also in cleanrooms and
vacuum environments. In the field of micro
handling, repetitive positioning accuracies
of < 0.01 mm can be achieved with this tech-
nology and it can be also used in collabora-
tive applications. The ADHESO gripper has a
bayonet lock and therefore the grippers can
be exchanged in just a few simple steps.
Schunk is a leader for gripping systems
and clamping technology. With more than
11,000 standard components, Schunk offers
the world’s largest assortment of gripping
systems and clamping technology from one
source. 
MORE INFO www.schunk.com
Adhesive Schunk
gripper with ADHESO
gripper technology
is customized to the
individual application.
This way wafers and
smallest electronic
components can be
handled, but also foils
or workpieces from the
field of metalworking
and automotive
assembly. (Courtesy:
Schunk)
 TOOLING &
WORKHOLDING
LISTINGS
BROACHES
Accu-Cut Diamond
Tool Co., Inc.
4238-40 North Sayre
Norridge, IL 60706
708-457-8800
www.accucutdiamond.com
Advent Tool &
Manufacturing, Inc.
25005 Joe Meier Pkwy Ste 100
Trevor, WI 53170
800-847-3234
www.advent-threadmill.com
Alliance Broach & Tool
5664 North River Rd.
East China, MI 48054
810-765-8121
www.mastertechdiamond.com
American Broach &
Machine Co.
575 South Mansfield St.
Ypsilanti, MI 48197
734-961-0300
www.americanbroach.com
Apollo Broach
39001 Webb St.
Westland, MI 48185
734-467-5750
www.apollobroach.com
Ash Gear & Supply Corp.
42650 Nine Mile Rd.
Novi, MI 48375
248-374-6155
www.ashgear.com
Avon Broach
& Production Co.
Colonial Tool
Group, Inc.
Horn USA
320 Premier Court
Pioneer Broach Co., Inc.
6434 Telegraph Rd.
1089 John R. Rd. 12344 Delta Drive Suite 205 Los Angeles, CA 90040
323-728-1263
Rochester Hills, MI 48307 Taylor, MI 48180 Franklin, TN 37067
248-650-8080 866-611-5119 615-771-4100 www.pioneerbroach.com
www.avonbroach.com www.colonialtool.com www.hornusa.com
Polygon Solutions, Inc.
DTR Corporation 16770 Link Court, Siute 106
Best Eng. LLC Ingersoll
Fort Myers, FL 33912
2200 South Calhoun Rd. 1865 Hicks Road Cutting Tools
New Berlin, WI 53151 Suite A  845 S. Lyford Rd. 239-628-4800
www.polygonsolutions.com
262-784-2200 Rolling Meadows, IL  60008 Rockford, IL 61108
www.bestengLLC.com 847-375-8892 815-387-6600
www.dtrtool.com www.ingersollcuttingtools.com
Seco Tools, Inc.
2805 Bellingham Dr.
Broach Masters/
Universal Gear Co. Federal Broach Kingsford Broach Troy, MI 48083
248-528-5200
1605 Industrial Drive & Machine Company & Tool, Inc.
Auburn, CA 95603 1961 Sullivan Dr. P.O. Box 2277 www.secotools.com
530-885-1939 Harrison, MI 48625 Kingsford, MI 49802
Slater Tools, Inc.
www.broachmasters.com 989-539-7420 (906) 774-4917
44725 Trinity Dr.
www.federalbroach.com www.kingsfordbroach.com Clinton Township, MI 48038
Broaching Machine
586-465-5000
Specialties Hassay Savage Milwaukee
Company www.slatertools.com
25180 Seeley Road Broach Co., Inc.
Novi, MI 48375 10 Industrial Blvd. N51 W13821 Northpark Dr. Slone Gear International
248-471-4500 Turners Falls, MA 01376 Menomonee Falls, WI 53051 2154 Liberty Rd.
www.broachingmachine.com 413-863-9371 262-781-7644 New Carlisle, OH 45344
www.hassay-savage.com www.milwaukeebroach.com 937-478-1595
Broaching www.slonegear.com
Technologies LLC Helro Corporation Nachi America, Inc.
N63 W22621 Main St. 326 Albertson 715 Pushville Rd. Somma Tool Company, Inc.
Sussex, WI 53089 PO Box 80732 Greenwood, IN 46143 109 Scott Road
262-820-1200 Rochester, MI 48307 317-530-1040 Waterbury, CT 06705
www.keyway-spline-broaching.com 248-650-8500 www.nachiamerica.com (203) 753-2114
www.helro.com www.sommatool.com
Carbide Tool Ohio Broach
Services, Inc. HobSource, Inc. & Machine Company Tazz Broach & Machine
1020 Lund Blvd 384 E. Rand Rd. #2 35264 Topps Industrial Pkwy. 34026 James J. Pompo Dr.
Anoka, MN 55303 Mount Prospect, IL 60056 Willoughby, OH 44094 Fraser, MI 48026
763-421-2210 847-398-8320 440-946-1040 586-296-7755
www.carbidetool.com www.hobsource.com www.ohiobroach.com www.tazzbroach.com
July 2021     65
LISTINGS

Toolmex Corporation
1075 Worcester St.
Natick, MA 01760
508-653-8897
www.toolmex.com
TSA America, LLC
30311 Clemens Rd., Suite 2
Westlake, OH 44145
440-614-0170
www.tsageartools.com
Ty Miles, Inc.
9855 Derby Lane
Westchester, IL 60154
708-344-5480
www.tymiles.com
VW Broaching Service
3250 W. Lake Streat
Chicago, IL 60624
773-533-9000
www.vwbroaching.com
Wolverine
Broach Co., Inc.
41200 Executive Dr.
Harrison Twp., MI 48045
586-468-4445
www.wolverinebroach.com
CUTTING
COOLANTS
Kluber Lubrication Cogsdill Tool
32 Industrial Dr. Products, Inc.
Londonberry, NH 03053 PO Box 7007
603-647-4104 Camden, SC 29021
www.kluber.com 803-438-4000
www.cogsdill.com
Micro Surface Corporation
270 Hillsdale Ave. E-Z Burr Tool Co., Inc.
San Jose, CA 95136 41180 Joy Rd.
Plymouth, MI 48170
408-723-0700
www.ws2coating.com 734-459-5310
www.ezburr.com
Milacron LLC
Engis Corporation
3000 Disney St.
105 West Hintz Rd.
Cincinnati, OH 45209
Wheeling, IL 60090
888-246-2665
www.milacron.com 847-808-9400
www.engis.com
Mullen Circle Brand, Inc.
3514 West Touhy Ave. Gleason
Lincolnwood, IL 60712 Corporation
847-676-1880 1000 University Ave.
www.mullenoil.com PO Box 22970
Rochester, NY 14692
Nye Lubricants 585-473-1000
12 Howland Rd. www.gleason.com
Fairhaven, MA 02719
Heule Tool Corp.
(508) 996-6721
4722 A Interstate Dr.
www.nyelubricants.com
Cincinnati, OH 45246
Oelheld US 513-860-9900
1760 Britannia Drive # 1 www.heuletool.com
Elgin, IL  60124
Joma Diamond
TSA America LLC Engis Corporation
30311 Clemens Rd., Suite 2 105 West Hintz Rd.
Westlake, OH 44145 Wheeling, IL 60090
440-614-0170 847-808-9400
www.tsageartools.com www.engis.com
Gleason Corporation
GRINDING 1000 University Ave.
WHEELS
Rochester, NY 14692
585-473-1000
3M www.gleason.com
3M Center Bldg 223-6S-03 
St. Paul, MN  55144 Joma Diamond Tool LLC
651-733-5399 46A Baldwin St. East
www.3m.com/abrasives Longmeadow, MA 01028
413-525-0760
Advanced
Superabrasives, Inc. www.jomadiamondtool.com
200 Sunpac Ave.
JRM International, Inc.
Henderson, NV 89009
5701 Industrial Ave.
702-564-7735
www.advanced-sa.com Rockford, IL 61111
815-282-9330
Advent Tool &
www.jrminternational.com
Manufacturing, Inc.
25005 Joe Meier Pkwy
KAPP Technologies
Suite 100
2870 Wilderness Place
Trevor, WI 53170
Boulder, CO 80301
800-847-3234
303-447-1130
www.advent-threadmill.com
www.kapp-usa.com
Banyan Global
Technologies Koepfer America, L.L.C.

& OILS
Amsoil
925 Tower Ave.,
Superior, WI 54880
800-956-5695
www.amsoil.com
Bel-Ray Lubricants
P.O. Box 526
Farmingdale, NJ 07727
732-938-2421
www.belray.com
Blaser Swisslube, Inc.
31 Hatfield Lane
Goshen, NY 10924
845-294-3200
www.blaser.com
Chemtool, Inc.
801 West Rockton Rd.
Rockton, IL 61072
815-957-4140
www.chemtool.com
Engineered Lubricants Co.
11525 Rock Island Ct.
Maryland Heights, MO 63043
314-872-9540
www.englube.com
Evonik Corporation
299 Jefferson Road
Parsippany, NJ 07054
973 929-8000
www.evonik.com/us
Houghton
International, Inc.
Madison & Van Buren Avenues
PO Box 930
Valley Forge, PA 19482
610-666-4000
www.houghtonintl.com
847-531-8501 20836 Hall Rd., Suite 156 635 Schneider Drive
www.oelheld.com Tool LLC Clinton Township, MI 48038 South Elgin, IL  60177-1162
46A Baldwin St.
815-786-5986 847-931-4121
Power Coolant East Longmeadow, MA 01028 www.banyangt.com www.koepferamerica.com
& Chemical 413-525-0760
15619 Frohock Place www.jomadiamondtool.com Bates Technologies, Inc. Liebherr Gear
Charlotte, NC 28277 9059 Technology Lane Technology, Inc.
www.pcchemical.com Michigan Deburring Tool Fishers, IN 46038
5684 E. Highland, Suite 2 1465 Woodland Dr.
317-841-2400 Saline, MI 48176
Royal Purple Howell, MI 48843 www.batestech.com
One Royal Purple Lane 517-545-3008 734-429-7225
Porter, TX 77365 www.mideburring.com Best Eng. LLC www.liebherr.us
281-354-8600 2200 South Calhoun Rd.
www.royalpurple.com Mitsubishi Gear New Berlin, WI 53151 Meister Abrasives USA
Technology Center 262-784-2200 201 Circuit Dr. North
UNIST, Inc. 46992 Liberty Dr. www.bestengLLC.com Kingstown, RI 02852
4134 36th St., SE Wixom, MI 48393 401-294-2530
Grand Rapids, MI 49512 248-669-6136 Cinetic Landis Corp. – www.meister-abrasives.com
616-949-0853 www.mitsubishigearcenter.com CITCO & Gardner
www.unist.com Abrasives Mitsubishi Gear
Monster Tool Co. 7605 Discovery Lane Technology Center
2470 Ash St., Unit 1 Concord, OH 44077 46992 Liberty Dr.
DEBURRING
Vista, CA 92081 440-709-0700
760-477-1000 Wixom, MI 48393
TOOLS
www.cinetic-landis.co.uk
www.monstertool.com 248-669-6136
Dianamic Abrasive www.mitsubishigearcenter.com
Abtex Corp. Osborn Products, Inc.
89 Main St. • PO Box 188 1100 Resource Dr. 2566 Industrial Row Dr. Norton/Saint-Gobain
Dresden, NY 14441 Brooklyn Heights, OH 44131 Troy, MI 48084 4611 Elk Ridge Court Suite B 
315-536-7403 216-361-1900 248-280-1185 Flowery Branch, GA  30542
www.abtex.com www.osborn.com www.dianamic.com 770-967-3954
www.nortonindustrial.com
Brush Research Redin Production Dr. Kaiser/S.L. Munson
Manufacturing Co., Inc. Machine & Company Osborn
(BRM) 2433 20th St. 1404 Old Dairy 1100 Resource Dr.
4642 Floral Dr. Rockford, IL 61104 Columbia, SC 29201 Brooklyn Heights, OH 44131
Los Angeles, CA 90022 815-398-1010 803-252-3211
216-361-1900
323-261-2193 www.redinmachine.com www.slmunson.com
www.brushresearch.com www.osborn.com
Star SU LLC DVS Technology
Chamfermatic, Inc. 5200 Prairie Stone Pkwy. 44099 Plymouth Oaks Blvd. QC American, LLC
7842 Burden Rd. Suite 100 Suite 102 575 S. Mansfield St
Machesney Park, IL 61115 Hoffman Estates, IL 60192 Plymouth, MI  48170 Ypsilanti, MI  48197-5157
815-636-5082 847-649-1450 734-666-8951 734-961-0300
www.chamfermatic.com www.star-su.com www.dvs-technology.com www.qcamerican.com

66     gearsolutions.com
Reishauer Corporation
1525 Holmes Rd.
Elgin, IL 60123
847-888-3828
www.reishauer.com
J. Schneeberger Corp.
1380 Gateway Dr.
Suite 8
Elgin, IL 60124
847-888-3498
www.schneeberger.ch
Winterthur Wendt USA
546 Enterprise Dr.
Royersford, PA 19468
508-949-1061
www.winterthurtechnology.com
Wolfco, Inc.
22 Woodstock Ave.
Route 171
Thompson, CT 06277
860-928-1383
www.wolfcoincorporated.com
HOBS
Advent Tool &
Manufacturing, Inc.
25005 Joe Meier Pkwy Ste 100
Trevor, WI 53170
800-847-3234
www.advent-threadmill.com
Ash Gear & Supply Corp. Engineered Tools Hanik Corporation Koepfer America, L.L.C.
42650 Nine Mile Rd. Corporation (ETC) 201 E. Ogden Ave., Suite 34 635 Schneider Drive
Novi, MI 48375 2710 West Caro Rd. Hinsdale, IL 60521 South Elgin, IL 60177-1162
248-374-6155 Caro, MI 48723 847-364-4800 847-931-4121
www.ashgear.com 989-673-8733 www.hanikcorp.com www.koepferamerica.com
www.engineeredtools.com
Banyan Global HobSource, Inc. LMT-Fette, Inc.
Technologies Erasteel 384 E. Rand Rd. #2 1081 S. Northport Blvd.
20836 Hall Rd., Suite 156 Mount Prospect, IL 60056 Waukegan, IL 60085
95 Fulton Street
Clinton Township, MI 48038 847-398-8320 800-757-0346
Boonton, NJ  07005-1909
815-786-5986 www.hobsource.com www.lmtfettetools.com
331-453-8636
www.banyangt.com
www.erasteel.com Luren Precision Chicago
Best Eng. LLC INDEX Corporation Co., Ltd.
2200 South Calhoun Rd. Federal Broach 14700 North Pointe Boulevard 707 Remington Rd., Suite 1
New Berlin, WI 53151 & Machine Noblesville, IN  46060 Schaumburg, IL 60173
262-784-2200 Company 317-770-6392 847-882 1388
www.bestengLLC.com 1961 Sullivan Dr. www.index-usa.com www.luren.com.tw
Harrison, MI 48625
Bitner Tooling Ingersoll Cutting Tools Mitsubishi Gear Technology
989-539-7420
Technologies, Inc. 845 S. Lyford Rd. Center
www.federalbroach.com
6650 Burroughs Ave. Rockford, IL 61108 46992 Liberty Dr.
Sterling Heights, MI 48314 Gleason Corporation 815-387-6600 Wixom, MI 48393
586-803-1100 www.ingersollcuttingtools.com 248-669-6136
1000 University Ave.
www.bitnertooling.com PO Box 22970 www.mitsubishigearcenter.com
Interstate Tool Corporation
Ceramtec NA Rochester, NY 14692 4538 West 130th Street Mitsubishi Materials USA
One Technology Place 585-473-1000 Cleveland, OH  44135-3566 11250 Slater Ave.
www.gleason.com
Laurens, SC 29360 216-671-1077 Fountain Valley, CA 92708
864-682-1846 www.itctoolcorp.com 714-352-6154
www.spk-tools.com Greg Allen Company www.mmus.com
& Index King Precision
DTR Corporation Technologies, Inc. Technologies, Inc. Modern Gearing, Inc.
1865 Hicks Road, Suite A  21135 Lorain Rd. 2827 A Gray Fox Rd. 2277 Leger
Rolling Meadows, IL  60008 Fairview Park, OH 44126 Monroe, NC 28110 LaSalle, QC H8N 2V7
847-375-8892 440-331-0038 704-296-9100 514-595-9897
www.dtrtool.com www.gallenco.com www.kpt-inc.com www.moderngearing.com
July 2021     67
LISTINGS

Nachi America, Inc. www.bitnertooling.com www.klingelnberg.com

715 Pushville Rd.
Greenwood, IN 46143 Carbide Tool Services, Inc. Knight Carbide
1020 Lund Blvd. 48665 Structural Dr.
317-530-1040
Anoka, MN 55303 Chesterfield Township,
www.nachiamerica.com
763-421-2210 MI 48051
Russell Holbrook & www.carbidetool.com 586-598-4888
Henderson www.knightcarbide.com
Cinetic Landis Corp. –
25 East Spring Valley Ave. CITCO & Gardner Abrasives Luren Precision
Maywood, NJ 07607 7605 Discovery Lane Chicago Co., Ltd.
201-226-9000 Concord, OH 44077 707 Remington Rd., Suite 1
www.tru-volute.com 440-709-0700 Schaumburg, IL 60173
www.cinetic-landis.co.uk 847-882 1388
Schnyder SA www.luren.com.tw
Jakobstrasse 52 CH-2500 Cole Carbide
Biel 8 Industries, Inc. Mastertech Diamond
41 32 344 0400 24703 Ryan Rd. Products Co.
www.schnyder.com Warren, MI 48091 9465 Hamilton Dr.
Dr. Kaiser/S.L. Munson & Nagel Precision 586-757-8700 Mentor, OH 44060
Seco Tools, Inc. Company 288 Dino Dr. www.colecarbide.com 440-352-1112
1404 Old Dairy Ann Arbor, MI 48103 www.mastertechdiamond.com
2805 Bellingham Dr.
Columbia, SC 29201 734-426-5650 Duramill Industrial
Troy, MI 48083
248-528-5200
803-252-3211 www.nagelusa.com Supplies, Inc. Melin Tool Co.
www.slmunson.com 21 Bradwick Dr., Unit 2 5565 Venture Dr., Unit C
www.secotools.com Sunnen Products Company Concord, Ontario L4K 1K6 Cleveland, OH 44130
DVS Technology 7910 Manchester Rd. 905-738-8665 216-362-4200
Star SU LLC 44099 Plymouth Oaks Blvd. St. Louis, MO 63143 www.duramill.ca www.endmill.com
5200 Prairie Stone Pkwy., 314-781-2100
Suite 102
Suite 100 Plymouth, MI  48170 www.sunnen.com Emuge Corp Mitsubishi
Hoffman Estates, IL 60192 734-666-8951 1800 Century Dr. Materials USA
MILLING
847-649-1450 www.dvs-technology.com West Boylston, MA 01583 11250 Slater Ave.
www.star-su.com
CUTTERS
800-323-3013 Fountain Valley, CA 92708
German Machine Tools of www.emuge.co 714-352-6154
TSA America, LLC America (GMTA) www.mmus.com
30311 Clemens Rd., Suite 2 Advanced Tool, Inc. Engineered Tools
4630 Freedom Dr.
9169 River Rd. Corporation (ETC)
Westlake, OH 44145 Ann Arbor, MI 48108 Modern Gearing, Inc.
Marcy, NY 13403 2710 West Caro Rd. 2277 Leger
440-614-0170 734-973-7800
315-768-8502 Caro, MI 48723 LaSalle, QC H8N 2V7
www.tsageartools.com www.gmtamerica.com
www.endmillsolutions.com 989-673-8733 514-595-9897

HONING TOOLS Gleason Corporation www.engineeredtools.com www.moderngearing.com

1000 University Ave.
Accu-Cut Diamond PO Box 22970
Tool Co., Inc. Rochester, NY 14692
585-473-1000
4238-40 North Sayre
Norridge, IL 60706 www.gleason.com
708-457-8800
www.accucutdiamond.com Helro Corporation
326 Albertson
Bates Technologies, Inc. PO Box 80732
9059 Technology Lane Rochester, MI 48307
Fishers, IN 46038 248-650-8500
317-841-2400 www.helro.com
www.batestech.com
Involute Gear
Brush Research & Machine Company
46449 Continental Drive
Manufacturing Co., Inc.
(BRM) Chesterfield, MI  48047
586-329-3755
4642 Floral Dr.
www.involutegearmachine.com
Los Angeles, CA 90022
323-261-2193
Joma Diamond Tool LLC
www.brushresearch.com 46A Baldwin St. East
Longmeadow, MA 01028
Diamond Abrasive 413-525-0760
Products
www.jomadiamondtool.com
8605 Santa Monica Blvd.,
#28769 KAPP Technologies
Los Angeles, CA 90069 2870 Wilderness Place
323-284-4938 Boulder, CO 80301
www.diamondabrasiveproducts.com 303-447-1130
www.kapp-usa.com
Dianamic Abrasive
Products, Inc. Meister Abrasives USA
2566 Industrial Row Dr. 201 Circuit Dr. North
Troy, MI 48084 Kingstown, RI 02852
248-280-1185 401-294-2530
www.dianamic.com www.meister-abrasives.com
Advent Tool &
Manufacturing, Inc.
25005 Joe Meier Pkwy Ste 100
Trevor, WI 53170
800-847-3234
www.advent-threadmill.com
Ash Gear & Supply Corp.
42650 Nine Mile Rd.
Novi, MI 48375
248-374-6155
www.ashgear.com
Banyan Global
Technologies
20836 Hall Rd., Suite 156
Clinton Township, MI 48038
815-786-5986
www.banyangt.com
Best Eng. LLC
2200 South Calhoun Rd.
New Berlin, WI 53151
262-784-2200
www.bestengLLC.com
BIG Kaiser Precision
Tooling, Inc.
2600 Huntington Blvd.
Hoffman Estates, IL 60192
847-228-7660
www.bigkaiser.com
Bitner Tooling Technologies,
Inc.
6650 Burroughs Ave.
Sterling Heights, MI 48314
586-803-1100
Federal Broach
& Machine Company
1961 Sullivan Dr.
Harrison, MI 48625
989-539-7420
www.federalbroach.com
Gleason Corporation
1000 University Ave.
PO Box 22970
Rochester, NY 14692
585-473-1000
www.gleason.com
HobSource, Inc.
384 E. Rand Rd. #2
Mount Prospect, IL 60056
847-398-8320
www.hobsource.com
Ingersoll Cutting Tools
845 S. Lyford Rd.
Rockford, IL 61108
815-387-6600
www.ingersollcuttingtools.com
KEO Cutters, Inc.
25040 Easy St.
Warren, MI 48089
586-771-2050
www.keocutters.com
Klingelnberg America, Inc.
118 East Michigan Ave.
Suite 200
Saline, Michigan 48176
734-470-6278
Monster Tool Co.
2470 Ash St., Unit 1
Vista, CA 92081
760-477-1000
www.monstertool.com
Russell Holbrook &
Henderson
25 East Spring Valley Ave.
Maywood, NJ 07607
201-226-9000
www.tru-volute.com
Sandvik Coromant
1702 Nevins Rd.
Fair Lawn, NJ 07410
201-794-5000
www.sandvik.coromant.com
Seco Tools, Inc.
2805 Bellingham Dr.
Troy, MI 48083
248-528-5200
www.secotools.com
Severance
Tool Ind., Inc.
3790 Orange St.
Saginaw, MI 48605
989-777-5500
www.severancetool.com
Tools For Industry, Inc.
3015 Production Ct.
Dayton, OH 45414
937-890-5550
www.toolsforindustryinc.com

68     gearsolutions.com
Ultra-Dex Tooling Systems Broach Masters/
7162 Sheridan Rd. Universal Gear Co.
Flushing, MI 48433 1605 Industrial Dr.
810-638-5388 Auburn, CA 95603
www.ultradexusa.com 530-885-1939
www.broachmasters.com
Walter USA, LLC
N22 W23855 RidgeView Carbide Tool
Pkwy. West Services, Inc.
Waukesha, WI 53188 1020 Lund Blvd.
262-347-2400 Anoka, MN 55303
763-421-2210
www.walter-tools.com
www.carbidetool.com
RACK CUTTERS
Cinetic Landis Corp. –
CITCO & Gardner
Ash Gear & Supply Corp.
Abrasives
42650 Nine Mile Rd.
7605 Discovery Lane
Novi, MI 48375
Concord, OH 44077
248-374-6155 440-709-0700
ashgear.com www.cinetic-landis.co.uk
Banyan Global Deltec, Inc.
Technologies 4230 Grissom Dr.
20836 Hall Rd., Suite 156 Batavia, OH 45103
Clinton Township, MI 48038 513-732-0800
815-786-5986 www.deltec-inc.com
www.banyangt.com
DTR Corporation
Engineered Tools 1865 Hicks Road Suite A  200
Corporation (ETC) Rolling Meadows, IL  60008
2710 West Caro Rd. 847-375-8892
Caro, MI 48723 www.dtrtool.com
989-673-8733
www.engineeredtools.com Engineered Tools
Corporation (ETC)
Gleason Corporation 2710 West Caro Rd.
1000 University Ave Caro, MI 48723
PO Box 22970 989-673-8733
Rochester, NY 14692 www.engineeredtools.com
585-473-1000
Federal Broach
www.gleason.com
& Machine Company
1961 Sullivan Dr.
HobSource, Inc.
Harrison, MI 48625
384 E. Rand Rd. #2
989-539-7420
Mount Prospect, IL 60056
www.federalbroach.com
847-398-8320
www.hobsource.com Gleason Corporation
1000 University Ave.
Modern Gearing, Inc. PO Box 22970
2277 Leger Rochester, NY 14692
LaSalle, QC H8N 2V7 585-473-1000
514-595-9897 www.gleason.com
www.moderngearing.com
HobSource, Inc.
Russell Holbrook & 384 E. Rand Rd. #2
Henderson Mount Prospect, IL 60056
25 East Spring Valley Ave. 847-398-8320
Maywood, NJ 07607 www.hobsource.com
201-226-9000
www.tru-volute.com Ingersoll Cutting Tools
845 S. Lyford Rd.
SHAPER Rockford, IL 61108
CUTTERS
815-387-6600
www.ingersollcuttingtools.com
Ash Gear &
Interstate Tool Corporation
Supply Corp.
4538 West 130th Street
42650 Nine Mile Rd.
Cleveland, OH  44135-3566
Novi, MI 48375 216-671-1077
248-374-6155
www.ashgear.com
www.itctoolcorp.com
King Precision
Best Eng. LLC Technologies, Inc.
2200 South Calhoun Rd. 2827 A Gray Fox Rd.
New Berlin, WI 53151 Monroe, NC 28110
262-784-2200 704-296-9100
www.bestengLLC.com www.kpt-inc.com
Klingelnberg
America, Inc.
118 East Michigan Ave.
Suite 200
Saline, Michigan 48176
734-470-6278
www.klingelnberg.com
Koepfer America, L.L.C.
635 Schneider Drive
South Elgin, IL  60177-1162
847-931-4121
www.koepferamerica.com
Liebherr Gear
Technology, Inc.
1465 Woodland Dr.
Saline, MI 48176
734-429-7225
www.liebherr.us
Luren Precision
Chicago Co., Ltd.
707 Remington Rd.
Suite 1
Schaumburg, IL 60173
847-882 1388
www.luren.com.tw
Mitsubishi Gear
Technology Center
46992 Liberty Dr.
Wixom, MI 48393
248-669-6136
mitsubishigearcenter.com
Mitsubishi Materials USA
11250 Slater Ave.
Fountain Valley, CA 92708
714-352-6154
www.mmus.com
Modern Gearing, Inc.
2277 Leger
LaSalle, QC H8N 2V7
514-595-9897
www.moderngearing.com
Russell Holbrook &
Henderson
25 East Spring Valley Ave.
Maywood, NJ 07607
201-226-9000
www.tru-volute.com
Star SU LLC
5200 Prairie Stone Pkwy.
Suite 100
Hoffman Estates, IL 60192
847-649-1450
www.star-su.com
TSA America LLC
30311 Clemens Rd. • Suite 2
Westlake, OH 44145
440-614-0170
www.tsageartools.com
SHAVERS
Ash Gear &
Supply Corp.
42650 Nine Mile Rd
Novi, MI 48375
248-374-6155
www.ashgear.com
Engineered Tools
Corporation (ETC)
2710 West Caro Rd.
Caro, MI 48723
989-673-8733
www.engineeredtools.com
Federal Broach
& Machine Company
1961 Sullivan Dr.
Harrison, MI 48625
989-539-7420
www.federalbroach.com
Gleason Corporation
1000 University Ave.
PO Box 22970
Rochester, NY 14692
585-473-1000
www.gleason.com
HobSource, Inc.
384 E. Rand Rd. #2
Mount Prospect, IL 60056
847-398-8320
www.hobsource.com
Klingelnberg America, Inc.
118 East Michigan Ave., Suite
Saline, Michigan 48176
734-470-6278
www.klingelnberg.com
Knight Carbide
48665 Structural Dr.
Chesterfield Township,
MI 48051
586-598-4888
www.knightcarbide.com
Liebherr Gear
Technology, Inc.
1465 Woodland Dr.
Saline, MI 48176
734-429-7225
www.liebherr.us
Luren Precision
Chicago Co., Ltd.
707 Remington Rd., Suite 1
Schaumburg, IL 60173
847-882 1388
www.luren.com.tw
Mitsubishi Gear
Technology Center
46992 Liberty Dr.
Wixom, MI 48393
248-669-6136
www.mitsubishigearcenter.com
Mitsubishi Materials USA
11250 Slater Ave.
Fountain Valley, CA 92708
714-352-6154
www.mmus.com
Modern Gearing, Inc.
2277 Leger
LaSalle, QC H8N 2V7
514-595-9897
www.moderngearing.com
Nachi America, Inc.
715 Pushville Rd.
Greenwood, IN 46143
317-530-1040
www.nachiamerica.com
Star SU LLC
5200 Prairie Stone Pkwy.,
Suite 100
Hoffman Estates, IL 60192
847-649-1450
www.star-su.com
TSA America LLC
30311 Clemens Rd., Suite 2
Westlake, OH 44145
440-614-0170
www.tsageartools.com
U.S. Gear Tools, Inc.
20580 Hoover Rd.
Detroit, MI 48205
828-686-5486
www.usgeartools.com
THREAD
CUTTING
Advanced Tool, Inc.
9169 River Rd.
Marcy, NY 13403
315-768-8502
www.endmillsolutions.com
Advent Tool &
Manufacturing, Inc.
25005 Joe Meier Pkwy
Suite 100
Trevor, WI 53170
800-847-3234
www.advent-threadmill.com
Allied Machine &
Engineering Corp.
120 Deeds Dr.
PO Box 36
Dover, OH 44622
330-343-4283
www.alliedmachine.com
Best Eng. LLC
2200 South Calhoun Rd.
New Berlin, WI 53151
262-784-2200
www.bestengLLC.com
Bitner Tooling
Technologies, Inc.
6650 Burroughs Ave.
Sterling Heights, MI 48314
586-803-1100
www.bitnertooling.com
Carbide Tool Services, Inc.
1020 Lund Blvd.
Anoka, MN 55303
763-421-2210
www.carbidetool.com
Cold Forming
Technology, Inc
44476 Phoenix Dr.
Sterling Heights, MI  48314
313-550-9630
www.coldformingtechnology.com
Cole Carbide
Industries, Inc.
24703 Ryan Rd.
Warren, MI 48091
586-757-8700
www.colecarbide.com
July 2021     69
LISTINGS

Duramill Industrial U.S. Gear Tools, Inc. Emuge Corp KAPP Technologies SMW Autoblok Corporation
Supplies, Inc. 20580 Hoover Rd. 1800 Century Dr. 2870 Wilderness Place 285 Egidi Drive
21 Bradwick Dr., Unit 2 Detroit, MI 48205 West Boylston, MA 01583 Boulder, CO 80301 Wheeling, IL 60090
Concord, Ontario L4K 1K6 828-686-5486 800-323-3013 303-447-1130 (847) 215-0591
905-738-8665 www.usgeartools.com www.emuge.co www.kapp-usa.com www.SMWautoblok.com
www.duramill.ca
Walter USA, LLC EuroTech King Precision Somma Tool Company, Inc.
Emuge Corp N22 W23855 RidgeView Corporation Technologies, Inc. 109 Scott Road
1800 Century Dr. West Pkwy. N48 W14170 Hampton Ave. 2827 A Gray Fox Rd. Waterbury, CT 06705
Boylston, MA 01583 West Waukesha, WI 53188 Menomonee Falls, WI 53051 Monroe, NC 28110 (203) 753-2114
800-323-3013 262-347-2400 262-781-6777 704-296-9100 www.sommatool.com
www.emuge.co www.walter-tools.com www.eurotechcorp.com www.kpt-inc.com
Speedgrip Chuck, Inc.
Engineered Tools Forkardt Inc. Kitagawa-North Tech, Inc.
WORKHOLDING
2000 E. Industrial Pkwy.
Corporation (ETC) 2155 Traversefield Drive 301 E. Commerce Dr. Elkhart, IN 46515
2710 West Caro Rd. Traverse City, MI 49686 Schaumburg, IL 60173 574-294-1506
Caro, MI 48723 A.G. Davis - AA Gage (800) 544-3823 847-310-8787 www.speedgrip.com
989-673-8733 6533 Sims Dr. www.forkardt.us www.kitagawa.com
www.engineeredtools.com Sterling Heights, MI 48313 Star SU LLC
Gear Resource Klingelnberg America, Inc. 5200 Prairie Stone Pkwy.
(586) 977-9000 118 East Michigan Ave.,
Gleason www.agdavis.com Technologies, Inc. Suite 100
Corporation 49 Shire Oaks Dr. Suite 200 Hoffman Estates, IL 60192
1000 University Ave. Pittsford, NY 14534 Saline, Michigan 48176
Acme Wire Products 847-649-1450
PO Box 22970 585-383-9160 734-470-6278
P.O. Box 218, 7 Broadway Ave www.star-su.com
Rochester, NY 14692 www.gear-resource.com www.klingelnberg.com
Extension Mystic, Connecticut
585-473-1000 06355 Taylor-Winfield
www.gleason.com Gleason Corporation Kromhard Twist Drill Co. Technologies, Inc.
860-572-0511 1097 Sweitzer Ave.
www.acmewire.com 1000 University Ave. 3200 Innovation Place
Ingersoll PO Box 22970 Akron, OH 44301
PO Box 779
Cutting Tools Rochester, NY 14692 330-535-7129
Alpha Workholding Youngstown, OH 44509
845 S. Lyford Rd. www.kromhard.com
Solutions 585-473-1000 330-259-8500
Rockford, IL 61108 820 Cochran St. www.gleason.com www.taylor-winfield.com
815-387-6600
Lyndex-Nikken
Statesville, NC 28677 1468 Armour Blvd.
www.ingersollcuttingtools.com 704-872-8888 Hainbuch America Corp. TE-CO
W129 N10980 Washington Dr. Mundelein, IL 60060
www.alphaworkholding.com 109 Quinter Farm Rd.
Knight Carbide 847-367-4800
Germantown, WI 53022 Union, OH 45322
48665 Structural Dr. www.lyndexnikken.com
ATS Workholding 414-358-9550 937-836-0961
Chesterfield Township, MI 30222 Esperanza www.hainbuchamerica.com www.te-co.com
Northfield Precision
48051 RSM, CA 92688 Instrument Corp.
586-598-4888 949-888-1744 Hardinge Grinding Toolink Engineering
4400 Austin Blvd.
www.knightcarbide.com www.ats-s.com Group 1921 Miller Dr.
Island Park, NY 11558
One Hardinge Dr. Longmont, CO 80501
516-431-1112
Mitsubishi Best Eng. LLC Elmira, NY  14902 303-776-6212
Materials USA www.northfield.com
2200 South Calhoun Rd. 800-843-8801 www.toolink-eng.com
11250 Slater Ave. New Berlin, WI 53151 www.hardinge.com Positrol Workholding
Fountain Valley, CA 92708 262-784-2200 3890 Virginia Ave. Toolmex Corporation
714-352-6154 www.bestengLLC.com Hydra-Lock Cincinnati, OH 45227 1075 Worcester St.
www.mmus.com Corporation 513-272-0500 Natick, MA 01760
BIG Kaiser Precision 25000 Joy Blvd.
www.positrol.com 508-653-8897
North American Tool Corp. Tooling, Inc. Mt. Clemens, MI 48043 www.toolmex.com
215 Elmwood Ave. 2600 Huntington Boulevard 586-783-5007 Prime Tool Supply
South Beloit, IL 61080 Hoffman Estates, IL 60192 www.hydralock.com 301 Cardinal Dr. Tools For Industry, Inc.
800-872-8277 847-228-7660 Bloomingdale, IL 60108 3015 Production Ct.
www.natool.com www.bigkaiser.com FORKARDT Inc. USA 630-894-8065 Dayton, OH 45414
2155 Traversefield Drive 937-890-5550
Reiff & Nestor Co. Coast Tool Co. Traverse City, 49686 RB Machine & Design, Inc. www.toolsforindustryinc.com
50 Reiff St. 2099 Edison Ave. 231-995-8300 4727 Singing Trees Dr.
Lykens, PA 17048 San Leandro, CA 94577 www.forkardt.com Racine, WI 53406 Western Pegasus
717-453-7113 510-569-1945 262-619-1233 728 East 8th St.
www.rntap.com www.coasttool.com Jenkins Machine www.rbmachineanddesign.com Holland, MI 49423
and Tool Co. 616-393-9580
Sandvik Coromant DA Swiss 16W588 Crest Ave. Riten Industries, Inc. www.westpeg.com
1702 Nevins Rd. 324 Second St. Pike, Unit B Bensenville, IL 60106 1100 Lakeview Ave.
Fair Lawn, NJ 07410 Southampton, PA 18966 630-766-7262 Washington Court House,
201-794-5000 215-364-3835 www.jmtsales.com OH 43160
www.sandvik.coromant.com www.daswiss.com 740-335-5353 • www.riten.com
Jergens, Inc. – Workholding
J. Schneeberger Corp. Drewco Corporation Solutions Group Schunk, Inc.
1380 Gateway Dr., Suite 8 3745 Nicholson Rd. 15700 S. Waterloo Rd. 211 Kitty Hawk Dr.
Elgin, IL 60124 Franksville, WI 53126 Cleveland, OH 44110 Morrisville, NC 27560
847-888-3498 262-886-5050 800-537-4367 919-572-2705
www.schneeberger.ch www.drewco.com www.jergensinc.com www.us.schunk.com

Seco Tools, Inc.
2805 Bellingham Dr.
Troy, MI 48083
248-528-5200
www.secotools.com
DT Technologies CZ s.r.o.
V. Nového 973/II
337 01 Rokycany
+420 378 608 604
www.dttechnologies.com
JRM International, Inc.
5701 Industrial Ave.
Rockford, IL 61111
815-282-9330
www.jrminternational.com
Slone Gear International
2154 Liberty Rd
New Carlisle, OH 45344
937-478-1595
www.slonegear.com

70     gearsolutions.com
 BONUS SECTION

INSPECTION
& METROLOGY

JULY 2021 • gearsolutions.com

July 2020     71
INSPECTION & METROLOGY
THE GROWING ROLE
OF METROLOGY IN
EV PRODUCTION
Advanced finishing and grinding technologies will be needed to produce
extremely complex and precise surface features in gear teeth to enhance
efficiency and reduce noise, thereby improving customer satisfaction.
By MICHAEL SCHMIDT
I
t has become abundantly clear that not only are elec-
tric vehicles (EVs) becoming more prevalent on the
roads but that almost all automotive companies are
announcing plans where EVs will eventually domi-
nate their product portfolio. As the shift from internal
combustion (IC) to electric continues, the number of
drivetrain components will dramatically lessen. And
the remaining components found in cars of all types
will be more critical to the vehicle’s operation and lon-
gevity. One such area is the gear components necessary
to convert the high-force torque from electric motors to
the RPMs at the wheel.
Two factors of the vehicle’s operation are related to
these new gear packs for electric cars —efficiency, or
“rangeability,” and gear noise. To appeal to consumers,
electric vehicles will need to reach similar mileage as
Example of non-
their internal combustion counterparts. Accomplishing
planar stitching over this will require gears with lower surface texture, where
a hypoid gear flank, surface friction is reduced, thereby increasing the vehi-
from root to tip. cle’s overall range. Second, the sound from the IC engine
72     gearsolutions.com
typically masked the noise from the drivetrain. Efforts
to dampen sound in the passenger cabin were designed
into the vehicle frame and the passenger compartment.
Yet, with the shift to electric engines, gear noise could
again become prominent if it were not for a change to
new manufacturing methods and processes.
With recent processing developments and tighter
specifications on EV gears, precision metrology can play
a fundamental role. ZYGO’s work with industry partners,
such as the Ford Motor Company, has helped advance
these processes by establishing a reliable method to
measure and monitor these surfaces, allowing for even
tighter specifications and stringent quality control.
MAKING PRECISION GEARS
The design and manufacture of gears can take many
paths, leading product design engineers to evaluate
different methods to achieve stringent surface texture
and waviness specifications and high-production volume
demands. Contingent on the production method, fabri-
cating accurate gear tooth form and flank texture can be
a balancing act. But when achieved, specific techniques
can produce gears in high quantities while attaining the
required form and surface texture demands. One such
method is continuous generating grinding. This method
uses threaded wheels, which remain in constant contact
with the developing gear-tooth structure (see Figure 1).
This method, among others, has been proven to produce
the essential gear texture and waviness specifications
to improve gear tooth interaction while reducing con-
tingent noise.
THE ROLE OF PRECISION METROLOGY
To ensure the surfaces on the gears are optimized, it is
essential to use metrology tools to analyze, understand,
and characterize. Because these gears are high value
means it is highly preferable that non-contact metrol-
ogy solutions are used, which will not compromise
or damage the post-processed gears. As gear surfaces
become smoother, tactile and other analysis methods
will become more challenging to use. They may result
in surface scoring or simply not reach the critical inspec-
tion areas. This is why industry partners, such as Ford,
look to ZYGO’s suite of 3D non-contact optical profilers.
At the heart of ZYGO’s optical metrology solutions
is its coherence scanning interferometry (CSI), which
uses specialized optical microscope objectives that pro-
vide the imaging and magnification of a surface and
measure the 3D topography of the surface. CSI profil-
ing is entirely non-contact, and, in contrast with other
microscope-based 3D topography techniques, CSI has
the distinct advantage that the height resolution of the
measurement is consistent across all magnifications,
whether the magnification is 1x or 100x. This presents
a unique opportunity for CSI-based systems as the shape
and size of the gear may limit the types of objectives able
to gain access to the area of interest.
With other technologies, the use of a long working-
distance objective may limit the vertical resolution of the
measurement. ZYGO’s internally developed objectives
lose neither vertical resolution nor measurement preci-
sion. This was one of many determining factors for Ford
in selecting the ZYGO Nexview™ product for its EV gear Figure 1: Example
line. Other considerations included the extreme stabil- of hypoid planetary
ity of the measurement, ease of gaining access to the gear grinding,
becoming typical in EV
measurement area, as well as the assortment of objec-
transmissions.
tives to meet the company’s demanding requirements
for on-the-floor production metrology.
STITCHING
Another key driver built into ZYGO’s solutions is field
stitching. With some similarities to panoramic photog-
raphy, a user can set up a measurement to capture more
area than the installed objective. This creates a matrix
of overlapping measurements that, when done acquiring,
are “stitched” together to form a larger measurement
than a single objective can accomplish. Where this is
advantageous in gear metrology is the acquisition of
surface texture along a gear flank, from edge to edge,
or stitching from the gear root to the tip, traversing over
the involute shape. What should be emphasized is the
ability to perform these stitched measurements over
non-planar surfaces, such as hypoid-shaped surfaces. By
programming the start and end positions of the mea-
surement sequence, a user can re-measure a hypoid gear
July 2021     73
Processing of data for waviness allows engineers to visualize small fluctuations that may occur in part processing.

Gear flank roughness with continuous high precision because of ZYGO’s pro-
plays a key role in prietary stitching algorithms.
lubricant film retention Combining the stitching and measurement meth-
as well as making
ods with ZYGO’s in-house long- and super-long working
surfaces more durable.
distance objectives, software ease-of-use, and internal
Python scripting provides customers with a complete
solution for measuring many different gear types.
It also explains why ZYGO works alongside an array of
global EV manufacturers, allowing for the fast, efficient,
accurate, and repeatable measurement of the newer gen-
eration of highly polished gears.
SUMMARY
The growth of the EV market is inevitable. It places sig-
nificant challenges in front of manufacturers as they
wrestle with the need for technological advancements
in the real nuts and bolts of vehicle engineering. Top of
the list at the moment is the requirement for advanced
finishing and grinding technologies that are used to pro-
duce extremely complex and precise surface features in
gear teeth to enhance efficiency and reduce noise, there-
by improving customer satisfaction.
As is so often the case in advanced design and manu-
facturing, metrology’s role moves from a necessary evil
to enabling technology when pursuing innovative tech-
nological advancements. In the area of gear manufactur-
ing for EVs, it is vital to be able to accurately, quickly, and
easily characterize the precision surface features. ZYGO’s
suite of non-contact optical solutions easily meets these
challenges.
Optical metrology is an extremely versatile inspec-
tion method and has an essential role in verifying gear
quality and design intent achievement. Today, it has
become the “go-to” metrology solution, benefiting
from the fact that it is non-contact, non-destructive,
fast, highly sensitive, and has exceptional resolution
and accuracy. 

ABOUT THE AUTHOR

Mike Schmidt, market development manager for the Zygo Corporation, has served the precision machining and industrial
markets for nearly two decades and has extensive knowledge of non-contact optical metrology technology and application
solutions development. Schmidt has helped numerous market-leading and global precision manufacturing companies
transition and deploy optical technology and process control solutions to the factory floor. Schmidt also has authored and
co-authored several industry articles, white papers, and conference papers and remains active in supporting 3D standards
and the advancement and adoption of non-contact optical metrology methods. For more information, go to www.zygo.com.

74     gearsolutions.com
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July 2021     75
INSPECTION & METROLOGY
OVERCOMING
METROLOGY
BOTTLENECKS
IN ADDITIVE MANUFACTURING
The focus in the area of metrology for AM is to reduce the time
and cost inefficiencies inherent today of relying on a vast range
of duplicate and often inadequate metrology steps to validate
that an end-use part is fit for purpose.
By ERIC FELKEL
U
ndoubtedly there are many benefits associated
with the use of additive manufacturing (AM) as a
production technology. Across industries, manu-
facturers exploit the fact that, through the use
of AM, they can not only build complex parts — in one
piece — which were previously impossible, but they can
also build stronger, lighter-weight parts, reduce mate-
rial consumption, and benefit from assembly component
consolidation across a range of applications.
These advantages have been well documented dur-
ing the last 10 to 20 years as AM has emerged as a truly
YGO Nexview™ CSI
microscope: true color disruptive technology for not just prototyping but also
3D image of the AM production, and are invariably seen as being enabled by
Ti6Al4V cube. the additive hardware that builds the parts. In reality,
76     gearsolutions.com
this is a partial picture, particularly for serial production
applications of AM. AM hardware systems are just one
part — albeit a vital one — of an extensive ecosystem of
technologies that enable AM, both pre- and post-build.
Of unique importance today is the role of post-process
metrology to validate the integrity of AM builds. One spe-
cific reason for this importance is that many parts pro-
duced by AM end up in safety critical applications where
end-use functionality is of vital importance. The nature
and relative roughness of AM surfaces, whether analyz-
ing individual layers within a build, or the surface of a
finished part render conventional metrology solutions
somewhat impotent. In this article, we review develop-
ments from ZYGO including work alongside Richard
Leach that allow for hitherto unattainable metrology
results, which are being used to enhance the use of AM
as a production technology by making validation proto-
cols more efficient.
METROLOGY AND ADDITIVE
MANUFACTURING
ZYGO is delighted to be working with Richard Leach,
professor in Metrology at the University of Nottingham,
Nottingham, U.K., on various projects related to the use
of metrology in AM. It is Leach’s view that the issue of
metrology is crucial to the success of AM as it begins to
establish itself as a true production technology.
“There is absolutely no doubt that inadequate metrol-
ogy solutions able to cope with the specific characteristic
of an AM-produced part are a huge obstacle to overcome
if AM is to be used as a viable production technology
across industry,” Leach said. “Basically, as we stand today,
there is a lack of clarity as to the precise nature of defects
that you get when undertaking an AM build, and you
also have little idea how they may cause problems in
terms of part functionality. We don’t have a detailed
enough map of how the topography of the defects and
the anomalies that you get during the AM process propa-
gate through to the part in an end-use scenario.”
“Imagine you are making a turbine blade in an AM
layering process, and you see that there was a blip in
the topography in layer four,” he said. “This layer will, in
time, be covered up, so its characteristics will be funda-
mentally different by the time the finished part is com-
plete, and it is at this moment impossible to know — with-
out the clarity that good metrology provides — whether
the blip is in fact still there when the build is complete,
and if so, if it was actually significant in the first place.
Essentially, we are working on — but still haven’t com-
pletely solved — the problem of understanding what
issues you get on the surface and under the surface when
using AM, and how these relate to product functionality.
Therefore, it is difficult to predict the mechanical prop-
erties, the thermal processes, the fatigue properties, etc.,
from the types of structures we are seeing post-process.
Defect-function analysis may allow us to move toward Nottingham University
controlled AM by just stopping the process when things Ti6Al4V selective laser
go wrong, as right now, we spend hours building a part melting sample part
that may in fact have a problem in layer one.” measured by a Zygo
Nexview™ interference
Despite these challenges, many companies are microscope.
already using advanced AM successfully for the pro-
duction of critical parts and components, often in
aerospace applications where part failure is not an
option. To ensure these AM-produced parts conform
fully with design intent, part suppliers undertake far
more mechanical testing and metrology verification
than they would normally employ for conventional
manufacturing processes.
Necessarily, manufacturers are forced to focus on
process development and throw all the validation
resources they can to “prove” the integrity of the fin-
ished AM part. This latter is effectively a belt-and-braces
approach, relying on Gage R&R reproducibility and
repeatability as a stand-in for a more rigorous measure-
ment uncertainty approach when evaluating the integ-
July 2021     77
 Surface structure of
an Aluminum AlSi10Mg
rity and functional characteristics of AM parts. The cur-
rent solution is what could be termed “extreme-testing.”
sample fabricated
at the University of
“Everyone blames the confusion on a lack of stan-
dards for measuring AM parts, but this is not where
Nottingham using
laser powder bed attention should be focused,” Leach said. “You cannot
develop standards if you don’t have the correct measure-
fusion and measured
by a Zygo NewView™ ment technology in place to start with. Standards being
CSI microscope. 3a) developed without the technology solution ready to use
surface topography are actually worse than no standards at all. That is why
color map, and 3b) the emphasis with ZYGO and other metrology instru-
surface structure –
ment suppliers is on adapting metrology solutions to
true color 3D.
make them better aligned with the unique character-
istics of the AM process and AM end-use parts. In the
respect of standards, our focus today is on producing a
good practice guide along with ASTAM, showing OEMs
what metrology solutions are in place today, and how
to get the best results from these when applied to AM
surfaces, and setting the instrument up in the best way
to understand the data.”
ZYGO CSI FOR AM METROLOGY
So, the focus in the area of metrology for AM is to reduce
the time and cost inefficiencies inherent today of rely-
ing on a vast range of duplicate and often inadequate
metrology steps to validate that an end-use part is fit
for purpose.
As Leach works on this vital area, he is involved with
a number of metrology instrument suppliers, using a
variety of measurement technologies, but among them,
ZYGO is perceived to be the most trusted supplier,
thanks to its pedigree and near 50-year history in the
ultra-precise metrology regime.
“For post-process metrology, a number of alternatives
exist including confocal and focus variation, and ZYGO’s
coherence scanning interferometry (CSI),” Leach said.
“Initially, it was thought that CSI was not suitable to the
vagaries of post-process AM parts (with their unusual
78     gearsolutions.com
“You cannot develop standards
if you don’t have the correct
measurement technology in
place to start with.”
surface roughness), but ZYGO enhanced its CSI instru-
ments by introducing new ways of playing with the opti-
cal light source, illumination conditions, and also the
company played with the detection conditions that led
to the attainment of high-quality results with extremely
rough and complex AM surfaces. I have to admit that
before looking in depth at the ZYGO CSI solutions, even I
thought that they probably wouldn’t be able to be applied
to AM parts, but it actually works extremely well.”
Leach’s initial work with CSI that informed his early
view of the inappropriateness of the technology for AM
super-rough surface metrology was based on CSI from
an alternative supplier other than ZYGO. The CSI instru-
ment his work was initially focused on was a CSI instru-
ment in terms of its basic measurement principle, but
it differed from the ZYGO system in terms of hardware,
firmware, and data analysis.
Using data from the alternative CSI solution provid-
er, Leach and his team at Nottingham concluded that
interferometry was fundamentally not suitable for AM
metrology, because the example instrument failed to
capture most of the highly irregular topographic fea-
tures. However, ZYGO had already solved this problem
with the introduction of its Nexview™ instrument in
2014. It is the Nexview™ technology that Leach and ZYGO
work on together now, and which is now accepted to be
a strong and viable AM metrology tool.
The Nexview™ instrument and its sister product, the
NewView™, included innovative hardware and software
upgrades, the package of improvements being referred
to internally at ZYGO as “More DataTechnology,” and this
made the instrument much better suited to AM parts.
“We installed a NewView™ 8300 instrument at
Nottingham in October, 2016,” Leach said. “Measure-
ments made at Nottingham as well as at ZYGO’s head-
quarters in Middlefield, Connecticut, USA, on AM sur-
faces conclusively demonstrated that ZYGO’s CSI imple-
mentation was well suited to the task. The ZYGO system
is arguably a reference standard today for AM metrology,
and other research groups have confirmed its superior
capabilities. Today, we work with ZYGO’s Nexview™ opti-
cal surface profiler.”
The “More Data” capability has been part of ZYGO’s
complete product line (ZeGage™ and NewView™ optical
profilers, and Nexview™ system) for several years now
and has been shown to be one of the most successful
technology developments for the product line.
“More Data” significantly improves the baseline sen-
sitivity of CSI and enables high-dynamic range (HDR)
operation making it valuable for a wide range of parts,
from steeply-sloped smooth parts to exceptionally rough
textures with poor reflectivity. Additionally, HDR is able
to measure parts with a wide range of reflectance, often
a struggle for other CSI instruments. HDR is unique to
ZYGO, meaning an alternative implementation of CSI
may not be able to achieve the performance on AM parts
that ZYGO can provide.
Today, the focus is on using the ZYGO HDR CSI tech-
nology to undertake surface texture analysis and to
attempt to better understand its links with the AM pro-
duction process.
“My work with ZYGO is centered around understand-
ing precisely how the CSI instrument works, and accu-
rately modeling it for AM applications,” Leach said. “At
the moment, the issue is that AM surfaces are so differ-
ent from what we are used to in terms of the raw surface
and the post-processed surface that there is no standard-
ized way of measuring and characterizing these surfaces.
We are working with ZYGO to ensure that we continue to
optimize metrology solutions for the increasingly impor-
tant area of AM for production scenarios.” 

ABOUT THE AUTHOR

Eric Felkel is the product manager for 3D optical profilers at Zygo Corporation in Middlefield, Connecticut. He can be
contacted at eric.felkel@ametek.com. ZYGO is a worldwide supplier of optical metrology instruments, high-precision
optical components, and complex electro-optical systems, and its products employ various optical phase and analysis
techniques for measuring displacement, surface shape and texture, and film thickness. For more information, go to www.
zygo.com.

WE’RE CERTIFIABLE
Our ISO 17025 A2KA Laboratory is
available to certify or recertify your
Master Gears and Spline Gauges or
Contract Inspection of your gears.
Our rapid turnaround service
minimizes the “out of service” time.

6161 Webster Street, Dayton, Ohio 45414

937-660-8182 sales@pentagear.com www.gearinspection.com

July 2021     79
PRODUCTS
& NEWS
Exact Metrology adds
AI-powered, HD mode
for 3D scanners
Exact Metrology, a comprehensive 3D
metrology service provider and hardware
sales company, has increased the capability
of its Artec 3D handheld scanners with the
new HD mode. This Artificial Intelligence-
powered scanning technology provides ultra-
sharp, clean, and detail-rich scans for Artec
Leo and Artec Eva.
Powered by Artec 3D‘s AI neural engine,
users can obtain sharp 3D scans with a
resolution of up to 0.2 mm. Trained on
hundreds of thousands of carefully selected
samples, the engine’s neural network detects
familiar patterns, surface details, and shapes.
This allows the 3D scanner to reconstruct
a higher number of polygons per frame,
resulting in 3D data that’s both denser and
higher quality. Now, the desired HD density
can be selected from a standard 1X density
80     gearsolutions.com
NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS
Scanned Honda engine
with Artec Leo. (Courtesy:
Exact Metrology)
up to 36X for Eva (~3 mln polygons per
frame) and 64X for Leo (~5 mln polygons
per frame). HD mode makes it possible to
capture smaller, thinner elements with the
3D scanner while also considerably reducing
noise. With these Artec scanners, fine
edges can be captured in high definition,
faithful to their original shape. It’s easy to
capture hard-to-reach areas as the scans are
reconstructed with every detail, giving users
complete surface geometry.
Handheld Eva and Leo scanners can
easily scan dark or shiny surfaces in high
resolution and capture the full range of their
geometries, without additional steps. Using
the Artec AI engine, little to no noise in the
raw scan data results in cleaner processed
data and also saves time when producing
the final 3D model. Once difficult to capture,
now short hair, even separate strands, is fully
within reach when scanning with HD mode.
Furthermore, these scanners can capture a
broad range of objects flawlessly and in high
detail: from smaller, intricate parts such as
thin pipes or valve handles, to larger objects
with multiple high-detail sections, including
car engines and skeletons. A perfect fit for
reverse engineering and quality control due
to clean, comprehensive data, scans can be
easily fitted with primitive shapes and
exported to the most popular CAD solutions
for development.
Exact Metrology is ISO, AS9100 Certified
as well as FFL and ITAR Registered. Exact
Metrology, with facilities in Cincinnati, Ohio;
Moline, Illinois; and Milwaukee, Wisconsin,
plus affiliated offices throughout the coun-
try, is a comprehensive metrology services
provider, offering customers 3D and CT scan-
ning, reverse engineering, quality inspection,
product development, and 2D drawings. The
company also provides turnkey metrology
solutions, including equipment sales.
MORE INFO www.exactmetrology.com
Collect residual stress
data with Sightia
in 10 seconds
Sinto America launched Sightia™, a new
surface evaluation technology that provides
real time, non-destructive quality assurance
checks for pre and post blasting or peening
processes.
Sightia is a class of technology encompass-
ing a group of non-destructive testing equip-
ment and services suitable for harsh industri-
al environment developed by Sinto America
to evaluate surface properties of parts under-
going surface treatment processes delivering
accurate and repeatable results.
Sinto, a global turnkey industrial solu-
tions provider, wants customers who are cur-
rently facing surface defects in their parts
at different stages of manufacturing, such
as casting, machining, heat treatment, and
surface treatment processes to overcome the
challenges with the help of Sightia devices.
Sightia is applicable for evaluating gears,
springs, pins, fasteners, and other cylindri-
cal parts used within the automotive, aero-
space, railway, infrastructure, construction,
and die-casting industries.
“This technology makes accurate, fast,
and consistent x-ray diffraction measure-
ment possible. Sightia products are now
proven in both the laboratory and in the
 Machinists Inc.
From single
parts to complete
manufacturing
systems
MI cuts gears
to 250 inches
in diameter and
grinds gears to
102 inches in
diameter.

Offering in-line use or embed into an existing conveyor line, Sightia provides a highly accurate, easy-to-use,
and reliable surface evaluation process. (Courtesy: Sinto America)
field. Sightia allows for 100 percent qual-
ity check on every part produced affordably
and implementation is simple with Sinto’s
PSMX-II,” said Charlie Gorman, VP Sinto
surface treatment.
Sightia’s ECNI-I non-destructive peening
inspection instrument is used for detecting
variation in machining, peening coverage,
and heat treatment. ECNI can detect defects
on the surface of parts in just three seconds
ensuring 100 percent inspection without
slowing down the production flow at all.
Sightia’s PSMX-II x-ray residual stress
measurement device measures each
product’s surface residual stress without
destroying it. With the PSMX-II, users can
collect residual stress data after they have
been peened in 10 seconds. It is possible to
inspect in-line by integration the technology
into existing processes, making in-process
quality control possible and minimizes
distribution of defective products.
MI provides full
service gearbox
repair & testing
and applications. Our goal with this book is for dependable
to help technicians and engineers quickly overhaul and
address their questions, regardless of their enhancement of
level of experience with surface analysis. But gear drives.
more than that, we want this book to be a
learning resource that will benefit readers
far beyond their immediate need.”
“Every day in my work I answer questions
like, ‘What is filtering?’ and ‘What is wavi-
ness?’” said Dr. Mark Malburg, co-author
and president of Digital Metrology Solutions.
“These are important questions about measur-
ing and specifying surfaces, most of which
are not taught in schools. We found there was
a real need for a resource to directly address
these kinds of questions in a user-friendly,
non-academic way. This book includes hun-

MORE INFO www.sintoamerica.com

Q&A-style ‘The Surface

Texture Answer Book’
now available
A new resource makes it easier to find
answers to surface texture related concepts Call us about
and applications. The Surface Texture Answer
Book answers more than 100 commonly- your project
asked questions regarding surface texture
measurement, analysis, interpretation, 800 / 244.4130
specification, and application. www.machinistsinc.com
“Surface texture is more than just a num- The Surface Texture Answer Book answers commonly-
ber from a measurement device,” said Carl ISO 9001 certified
asked questions regarding surface texture
Musolff, co-author. “It’s a microscopic world measurement, analysis, interpretation, specification,
with huge implications for many industries and application. (Courtesy: Digital Metrology)

July 2021     81
PRODUCTS
& NEWS
To showcase Exact
Metrology’s CT scanning
services, powered by the
Metrotom 6 scout, a scan
was done on a medical
stent. This medical stent,
with a diameter of only 1
millimeter, was measured
within a 5-micron
resolution. (Courtesy:
Exact Metrology)
dreds of figures to help make texture visual,
which we’ve found is the best way to help
readers grasp and retain these concepts.”
The Surface Texture Answer Book draws on
information from numerous resources, as
well as the authors’ combined 70 years of
industry experience. Topics focus primar-
ily on two-dimensional measurement tech-
niques, which represent the vast majority
of surface texture measurements in indus-
try today. The book also touches on some
important aspects of 3-dimensional (areal)
measurement, which is becoming more
prevalent in development and industrial
applications.
“We believe that this book clarifies a lot of
the concepts, and misconceptions, relating
to surface texture,” said Musolff. “We hope
readers will be able to come to the book for a
particular answer, then encounter other top-
ics along the way that expand their knowl-
edge as well.”
The 400-page paperback book is available
through amazon.com and through the digi-
talmetrology.com website.
Musolff is an industry veteran with more
than forty years of experience in product
development, wear analysis, failure analysis,
materials, metallurgical engineering, and
surface texture analysis and specification.
He has worked on thousands of projects to
improve performance and longevity across
a variety of components and applications.
Musolff is deeply immersed in understanding
surfaces from a functional perspective, and
he has drawn on his passion for teaching to
mentor dozens of engineers and technicians.
Malburg is the president of Digital
82     gearsolutions.com
Metrology Solutions. With more than 30
years in applied surface metrology, he is the
chief architect of a range of standard and
custom software for surface texture and
shape analysis. Malburg has consulted in
numerous industries ranging from optics
to aerospace. He is a regular participant
in national and international standards
committees and has helped shape many
of the standards that govern surface
specification and control.
MORE INFO www.digitalmetrology.com
Zeiss Metrotom 6 scout
digitizes complex
parts in finest detail
Exact Metrology, a comprehensive 3D
metrology service provider and hardware
sales company, installed a Zeiss Metrotom 6
scout, formally known as a GOM CT, scanner
at its facility in Brookfield, Wisconsin.
Considered the powerhouse of resolu-
tion for CT inspection and metrology, the
Metrotom 6 scout digitizes complex parts
including the internal geometries at the fin-
est level of detail. Users obtain a complete 3D
image for GD&T analysis or nominal-actual
comparisons. The metrology CT excels in
digitizing small plastic parts.
The combination of a 3k detector and 225
kV X-ray enables Zeiss Metrotom 6 scout to
provide high contrast, high-resolution mea-
surement results and exceptional sharp-
ness of detail. As a result, even the smallest
defects in the part become visible and can
be analyzed to the last detail.
To showcase the abilit y of Exact
Metrology’s CT scanning services, powered
by the Metrotom 6 scout, a scan was done on
a medical stent. This medical stent, with a
diameter of only 1 millimeter, was measured
within a 5-micron resolution. Thus, Exact
Metrology inspectors were able to evaluate
critical features with amazing precision.
CT scanning provides several benefits
including being the only way to get 3D
views inside a part and the only way to
obtain accurate dimensional data without
cutting up and destroying an object. In
addition, CT scanning requires very little
time to capture data and troubleshoot
parts and also offers multiple uses with
one scan (void analysis, inspection, volume,
porosity, reverse engineering, etc.). In
contrast to conventional tactile coordinate
measurement techniques, a CT acquires all
surface points simultaneously — on even
the most complex objects. This includes
all hidden features such as undercuts,
which are not accessible using other non-
destructive measurement methods.
Due to its ability to see data layer by layer,
CT scanning permitted Exact Metrology
inspectors the ability to see any possible
defects/details on the stent. This is crucial
for any medical device, especially something
as small and essential as a stent that goes
into the human body.
Exact Metrology is ISO, AS9100 certified
as well as FFL and ITAR registered. 
MORE INFO www.exactmetrology.com
 INSPECTION
& METROLOGY
LISTINGS

BALANCING Precision Spindle and Cole Manufacturing

Systems
Geartrology Kurt Manufacturing,
Ind. Division
MACHINES
Accessories, Inc. 3101 111th Street SW,
PO Box 269 750 Loggers Circle Suite A 9445 East River Road NW
Otterville ON N0J 1R0 Rochester, MI 48307 Everett, WA  98204 Minneapolis, MN 55433
American 734-516-1365 425-418-6165 877-226-7823
519-671-3911
Hofman Corp. www.colemfgsystems.com www.geartrology.com www.kurtworkholding.com
www.precisionspindleinc.com
3700 Cohen Place
Lynchburg, VA 24501
Mahr Federal, Inc.
SCHENCK Corporation Colonial Tool Group, Inc. Gleason Corporation 1144 Eddy Street
434-522-0300 12344 Delta Dr. 1000 University Ave
535 Acorn Street Providence, RI 02905
www.hofmann-balancing.com Taylor, MI 48180 PO Box 22970
Deer Park, NY 11729 401-784-3100
866-611-5119 Rochester, NY 14692 www.mahrfederal.com
Balance Systems 631-242-4010
www.colonialtool.com 585-473-1000
Corporation www.schenck-usa.com Marposs Corporation
www.gleason.com
5884 Sterling Dr. 3300 Cross Creek Parkway
Comtorgage Corporation
Howell, MI 48843 Universal Balancing Ltd. Auburn Hills, MI 48326
517-586-6008
58 N.S. Industrial Dr. Greg Allen Company &
20750 Civic Center Dr., PO Box 1217 Index Technologies, Inc. 248-370-0404
www.balancesystems.com Suite 418 www.marposs.com
Slatersville, RI 02876 21135 Lorain Road
Coetz Technologies USA Southfield, MI 48076 401-765-0900 Fairview Park, OH 44126 Mitutoyo USA
11228 Lemen Road, Unit D 734-212-1200 www.comtorgage.com 440-331-0038 965 Corporate Blvd.
Whitmore Lake, MI 48189 www.universal-balancing.com www.gallenco.com Aurora, IL 60502
734-449-9340 EuroTech Corporation 888-648-8869
N48 W14170 Hampton Ave.
Hanik Corporation www.mitutoyo.com
www.coetzbalancing.com
201 E. Ogden Ave., Suite 34
HAND/TOOL
Menomonee Falls, WI 53051
Commtest, Inc. 262-781-6777
Hinsdale, IL 60521 Modern Gearing, Inc.

GAUGES
6700 Baum Dr., Suite 12 847-364-4800 2277 Leger
www.eurotechcorp.com
Knoxville, TN 37919 www.hanikcorp.com LaSalle, QC H8N 2V7
514-595-9897
865-588-2946 A.G. Davis – AA Gage Foerster Instruments Inc.
6533 Sims Dr.
Kapp Niles www.moderngearing.com
Hines Industries Inc 140 Industry Drive Metrology
Sterling Heights, MI 48313 Pittsburgh, PA 15275 2870 Wilderness Place
Parker Industries, Inc.
793 Airport Blvd
586-977-9000 412-788-8976 1650 Sycamore Ave.
Ann Arbor, MI 48108 Boulder, CO 80301
www.agdavis.com www.foerstergroup.com Bohemia, NY 11716
734-769-6622 303-447-1130
631-567-1000
www.hinesindustries.com www.kapp-niles.com
Broach Masters/Universal www.parkerind.com
Gage Crib
Kokusai USA Gear Co. Worldwide, Inc. Koepfer America, L.L.C. Penta Gear Metrology
5333 W. 79th Street 1605 Industrial Dr. 6701 Old 28th St. SE, Suite B 635 Schneider Drive 6161 Webster St.
Indianapolis, IN 46268 Auburn, CA 95603 Grand Rapids, MI 49546 South Elgin, IL 60177-1162 Dayton, OH 45414
317-704-9922 530-885-1939 616-954-6581 847-931-4121 937-660-8182
www.kokusaiusa.com www.broachmasters.com www.ring-plug-thread-gages.com www.koepferamerica.com www.gearinspection.com

July 2021     83
 LISTINGS
Polygon Solutions, Inc.
16770 Link Court, Suite 106
Fort Myers, FL 33912
239-628-4800
www.polygonsolutions.com
Precision Gage Company
100 Shore Drive
Burr Ridge, IL 60527
630-655-2121
www.precisiongageco.com
R&P Metrology USA
2870 Wilderness Place
Boulder, CO 80301
(303) 447-1130
www.kapp-usa.com
Slone Gear International
2154 Liberty Road
New Carlisle, OH 45344
937-478-1595
www.sloangear.com
Spline Gauges UK
Piccadilly Tamworth
Staffordshire B78 2ER
011-44-1827-87-2771
www.splinegauges.co.uk
Star SU LLC
5200 Prairie Stone Parkway
Suite 100
Hoffman Estates, IL 60192
847-649-1450
www.star-su.com
GEAR SOLUTIONS
MEDIA PORTAL
Gear Solutions’ online portal is your gateway to
social media news and information resources
from manufacturers and service providers in the
gear industry. You’ll find links to social media as
well as webinars, blogs and videos.
This quick-and-easy resource is just a click away
at gearsolutions.com.
84     gearsolutions.com
VGage LLC
21101 Fern Ave.
Oak Park, MI 48237
248-589-7510
www.vgage.com
TSA America LLC
30311 Clemens Road
Suite 2
Westlake, OH 44145
440-614-0170
United Tool Supply
851 Ohio Pike
Cincinnati, OH 45245
513-752-6000
www.united-tool.com
Western Gage
Corporation
3316 A Maya Linda
Camarillo, CA 93012
805-445-1410
www.westerngage.com
Western Pegasus
728 E. 8th Street
Holland, MI 49423
616-393-9580
www.westpeg.com
WS GearDynamics GmbH
Grossklamm 10
Rheinstetten, 76287 Germany
+49 721 53077 10
www.ws-geardynamics.com
INSPECTION Criterion NDT Gleason Corporation
EQUIPMENT
3702 West Valley Highway N., 1000 University Avenue
Suite 202 PO Box 22970
Auburn, WA 98001 Rochester, NY 14692
American Stress 253-929-8800 585-473-1000
Technologies, Inc. www.crterionndt.com
540 Alpha Dr.
www.gleason.com
Pittsburgh PA 15238 Dontyne
Hans Precision Tool &
412-784-8400 Systems, Ltd.
www.astress.com Engr. Co
3786 Hopper Hill Road
Cincinnati, OH 45255 1251 Rand Road
Balance Systems Corp.
216-255-0227 Des Planes, IL  60016
5884 Sterling Drive
www.dontynesystems.com 847-644-6488
Howell, MI 48843
517-586-6008
Fischer
www.balancesystems.com Hexagon Metrology, Inc.
Technology, Inc.
250 Circuit Dr. N.
Carl Zeiss Industrial 750 Marshall Phelps Road
Kingstown, RI 02852
Metrology LLC Windsor, CT 06095
6250 Sycamore Lane North 860-683-0781 800-274-9433
Maple Grove, MN 55369 www.fisher-technology.com www.hexagonmetrology.us
800-327-9735
www.zeiss.com Gage Crib Involute Gear & Machine
Worldwide, Inc. Company
Cole Manufacturing 6701 Old 28th St. SE, Suite B
46449 Continental Drive
Systems Grand Rapids, MI 49546
750 Loggers Circle Chesterfield, MI 48047
616-954-6581 586-329-3755
Rochester, MI 48307
www.ring-plug-thread-gages.com
734-516-1365 www.involutegearmachine.com
www.colemfgsystems.com
Gear Resource
Technologies, Inc. Kapp Niles Metrology
Comtorgage Corporation
49 Shire Oaks Drive 2870 Wilderness Place
58 N.S. Industrial Drive
Slatersville, RI 02876 Pittsford, NY 14534-1523 Boulder, CO 80301
401-765-0900 585-383-9160 303-447-1130
www.comtorgage.com www.gear-resource.com www.kapp-niles.com
Keyence Corporation
of America
1100 N Arlington Heights Rd.,
Suite 210
Itasca, IL 60143
888-539-3623
www.keyence.com
King Precision
Technologies, Inc.
2827 A Gray Fox Road
Monroe, NC 28110
704-296-9100
www.kpt-inc.com
Klingelenberg
America, Inc.
118 East Michigan Ave.,
Suite 200
Saline, MI 48176
734-470-6278
www.klingelnberg.com
Koepfer
America, L.L.C.
635 Schneider Drive
South Elgin, IL 60177-1162
847-931-4121
www.koepferamerica.com
Kurt Manufacturing, I
nd. Division
9445 East River Road NW
Minneapolis, MN 55433
877-226-7823
www.kurtworkholding.com
Mahr Federal, Inc.
1144 Eddy Street
Providence, RI 02905
401-784-3100
www.mahrfederal.com
Marposs Corporation
3300 Cross Creek Parkway
Auburn Hills, MI 48326
248-370-0404
www.marposs.com
Napoleon Engineering
Services
1601 Johnson Street
Olean, NY 14760
877-870-3200
www.nesbearings.com
Newage Testing
Instruments
820 Pennsylvania Blvd
Feasterville, PA 19053
215-355-6900
www.hardnesstesters.com
Nikon Metrology, Inc.
12701 Grand River Ave.
Brighton, MI 48116
810-220-4360
www.nikonmetrology.com
Cole Manufacturing Marposs Corporation
Systems 3300 Cross Creek Parkway
750 Loggers Circle Auburn Hills, MI 48326
Rochester, MI 48307 248-370-0404
734-516-1365 www.marposs.com
www.colemfgsystems.com
Mitutoyo USA
FARO 965 Corporate Blvd
250 Technology Park Aurora, IL 60502
888-648-8869
Lake Mary, FL 32746
www.mitutoyo.com
407-333-9911
www.faro.com Penta Gear Metrology
6161 Webster St.
Geartrology Dayton, OH 45414
3101 111th Street SW, STE A 937-660-8182
Everett, WA  98204 www.gearinspection.com
425-418-6165
www.geartrology.com Precision Gage Company
100 Shore Dr.
Gleason Corporation Burr Ridge, IL 60527
1000 University Ave. 630-655-2121
Rochester, NY 14692 www.precisiongageco.com
585-473-1000
www.gleason.com R&P Metrology USA
2870 Wilderness Place
Penta Gear Star SU LLC
Metrology 5200 Prairie Stone Parkway, Hans Precision Tool Boulder, CO 80301
303 447-1130
6161 Webster St. Suite 100 & Engineering Co
Dayton, OH 45414 Hoffman Estates, IL 60192 1251 Rand Road www.kapp-usa.com
937-660-8182 847-649-1450 Des Planes, IL  60016
www.star-su.com Slone Gear International
www.gearinspection.com 847-644-6488 2154 Liberty Road
Precision Gage Tokyo Technical New Carlisle, OH 45344
Hexagon Metrology, Inc.
Company Instruments USA Inc 937-478-1595
250 Circuit Dr. N. www.slonegear.com
297 Kinderkamack Road #133
100 Shore Dr. Kingstown, RI 02852
Oradell, NJ 07649
Burr Ridge, IL 60527 800-274-9433 Star SU LLC
201-634-1700
630-655-2121 www.hexagonmetrology.us 5200 Prairie Stone Parkway,
www.tti-geartec.jp
www.precisiongageco.com Suite 100
United Tool Supply Involute Gear & Machine Hoffman Estates, IL 60192
Promess, Inc. 851 Ohio Pike 46449 Continental Dr. 847-649-1450
11429 Grand River Rd Cincinnati, OH 45245 Chesterfield, MI 48047 www.star-su.com
Brighton, MI 48116 513-752-6000 586-329-3755
810-229-9334 www.united-tool.com www.involutegearmachine.com Tokyo Technical
www.promessinc.com Instruments USA, Inc
Wenzel America Kapp Niles Metrology 297 Kinderkamack Road #133
Proto Manufacturing, Inc. 28700 Beck Road
2870 Wilderness Place Oradell, NJ 07649
12350 Universal Dr. Wixom, MI 48393 201-634-1700
Boulder, CO 80301
Taylor, MI 48180 248-295-4300 www.tti-geartec.jp
303-447-1130
313-965-2900 www.wenzelamerica.com
www.kapp-niles.com
www.protoxrd.com Trilion Quality Systems
WS GearDynamics GmbH 500 Davis Dr. Suite 200
Klingelnberg
Grossklamm 10
Rigaku Americas Plymouth Meeting, PA 19462
Rheinstetten, 76287 Germany America, Inc.
Corporation 215-710-3000
+49 721 53077 10 118 East Michigan Ave.,
9009 New Trails Drive www.trilion.com
www.ws-geardynamics.com Suite 200
The Woodlands, TX 77381
Saline, MI 48176 United Tool Supply
281-362-2300 Zygo Corporation
734-470-6278 851 Ohio Pike
www.rigaku.com Laurel Brook Rd.
Middlefield, CT 06455
www.klingelnberg.com Cincinnati, OH 45245
SICK, Inc. 860-347-8506 513-752-6000
6900 West 110th Street Koepfer America LLC www.united-tool.com
www.zygo.com
Bloomington, MN 55438 635 Schneider Dr.
Wenzel America
MEASURING
952-829-4730 South Elgin, IL 60177
847-931-4121 28700 Beck Road
MACHINES
www.sickusa.com
www.koepferamerica.com Wixom, MI 48393
Slone Gear 248-295-4300
International American Stress Kurt Manufacturing, www.wenzelamerica.com
Technologies, Inc. Industrial Division
2154 Liberty Road WS GearDynamics GmbH
540 Alpha Dr. 9445 East River Road NW
New Carlisle, OH 45344 Grossklamm 10
Pittsburgh PA 15238
937-478-1595 Minneapolis, MN 55433
412-784-8400 Rheinstetten, 76287 Germany
www.slonegear.com 877-226-7823 +49 721 53077 10
www.astress.com
www.kurtworkholding.com www.ws-geardynamics.com
Spline Gauges UK Carl Zeiss Industrial
Piccadilly Tamworth Staf- 6250 Sycamore Lane Mahr Federal, Inc. Zoller USA
1144 Eddy Street
fordshire North Maple Grove, 3753 Plaza Dr., Suite 1
B78 2ER MN 55369 Providence, RI 02905 Ann Arbor, MI 48108
011-44-1827-87-2771 763-744-2400 401-784-3100 734-332-4851
www.splinegauges.co.uk www.zeiss.com/industrial-metrology www.mahrfederal.com www.zoller-usa.com
July 2021     85
 MARKET Manufacturing excellence through quality, integration,

PLACE materials, maintenance, education, and speed.

Contact Gear Solutions at 800-366-2185 to feature your business in the Marketplace!

WE’RE
NEW ONLINE ORDERING AVAILABLE
NEW KEYSEATER TOOLING
CERTIFIABLE Mitts & Merrill, Morrison and Fromag style tooling available!

Our ISO 17025 A2LA Laboratory is available

to certify or recertify your Master Gears and
SERVICING
SERVICINGFELLOWS
FELLOWSGEAR SHAPERS Spline Gauges or Contract
OnGEAR SHAPERS
Site Service: Emergency & Scheduled Inspection of your gears. INSERT CUTTERS BAR-TYPE CUTTER
Technical Support:Emergency
On Site Service: & Scheduled
Via Telephone, Fax or E-mail
Training:
TechnicalOperator,
Support:Set-up & Maintenance
Via Telephone (Electrical
or E-mail Our rapid turnaround
CALL US TODAY FOR A COMPLETE LINE OF KEYSEATER TOOLING
& Training:
Mechanical)Operator, Set-up & Maintenance (Electrical service minimizes the • Tool Post • Feed Wedge • Insert Cutters • Expansion Bushings
Preventive Maintence Plan: Customized to Your Needs
& Mechanical) “out of service” time. • Top Clamp
• Post Adapter
• Bar-Type Cutter
• Tool Bar
• Step Bushings
• Taper Wedges
• Super Tool Bar with
Bolt-in Cutter
Parts: New and/or
Preventive Used Plan: Customized to Your
Maintenance • Super Tool Bar

Retrofi
Needsts - Counters, Servo Controllers, or Single and
Multiple
Parts: Axis
New CNC
and/or Used
Hydrostatic Guides: Repair Service or Purchase New
Retrofits: Counters, Servo Controllers, or Single and
Multiple
Allen Axis CNC
Adams
Hydrostatic
SHAPER Guides: Repair
SERVICES, Inc.Service or Purchase New
174 InnovationADAMS
ALLEN Drive N. SHAPER SERVICES, INC. FEED WEDGES MITTS & MERRILL STYLE
Clarendon, VT 05759
174 Innovation Drive • North Clarendon, VT 05759 6161 Webster Street, Dayton, Ohio 45414
Telephone:
Telephone:802-226-7891
802-226-7891
E-mail: shaperservices@sharperservices.com
E-mail: shaperservices@shaperservices.com
937-660-8182 sales@pentagear.com MACHINE TOOLING TECHNOLOGY
Website: www.sharperservices.com
Website: www.shaperservices.com www.gearinspection.com 847-541-1800 • www.mttkey.com

MicroGear
GET CUSTOM-MANUFACTURED

GEAR RACKS MicroCheck

& GEARS An uncompromisingly versatile
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American and Metric Standards

Straight and Helical
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Prototype and Production Quantities
Unique Tooth Configurations
Turn your existing manual gear tester of any make
or model into a computerized gear analyzing system.
Call 630-766-2652 for a free quote! Evaluate the result to AGMA or DIN specs. Print
charts of the gear results and save the data.
INNOVATIVE RACK & GEAR Very affordable. Highly advanced.
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3999 25TH AVE. • SCHILLER PARK, IL 60176 • 630-766-2652 Phone: +1 909 590 4327 • Fax: +1 909 590 8784
www.gearracks.com www.MicroGear.us • info@MicroGear.us

86     gearsolutions.com
ADVERTISER Koro Sharpening Service

INDEX
For Quality Hob Sharpening

• Quick Turnaround
• HSS & Carbide Hobs
CONTENTS PAGE NO. • Bore & Shank Hobs with
Center Hole and Straight
AFC Holcroft.........................................................................................31
Flutes
ALD Thermal Treatment Inc...................................................................11
• Length up to 7 inches
All Metals & Forge Group.........................................................................9
• Diameter up to 5 inches
Allen Adams Shaper Services Inc...........................................................86
• Thin Film Coatings
Amorphology........................................................................................IFC
• Precise Rake and Spacing
ASM International.................................................................................35 Guaranteed
Avers Machine and Gear........................................................................86

Circle Gear & Machine Co Inc................................................................14

Colonial Tool Group.................................................................................4

Drewco.................................................................................................16 RUSH Service Available

Gleason Corporation................................................................................2 CALL: 763-425-5247
Hobsource Inc......................................................................................45
FAX: 763-425-5261
E-mail: info@koroind.com
KAPP Technologies................................................................................25

KISSsoft USA LLC................................................................................25

Koro Sharpening Service
9530 85th Avenue North
Koro Sharpening Service........................................................................87
Maple Grove, MN 55369
Machine Tooling Technology...................................................................86

McInnes Rolled Rings............................................................................13

MicroGear.............................................................................................86

Mitsubishi Heavy Industries America Inc................................................ BC

New England Gear...................................................................................7

Nordex.................................................................................................51

Careers that fit

Northrop Grumman...............................................................................87

Penta Gear Metrology..................................................................... 49, 86

Piselli Enterprises Inc.......................................................................... IBC your life.

RHH Inc...............................................................................................11

Sinto America.......................................................................................15

Solar Atmospheres................................................................................21 At Northrop Grumman we don’t just develop the answers – we invent the
Solar Manufacturing..............................................................................41 question. Our Mission Systems team is hiring in support of our customers.
Are you ready to define possible?
Specialty Steel Treating.........................................................................52

STD Precision Gear & Instrument Inc.....................................................12 Job ID Job Title Location Clearance Level

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

21009874 Gear Front Line Sunnyvale, CA None
Manager 2
TOOLING & WORKHOLDING
Advent Tool...........................................................................................67 Questions about this opening?
Contact Anne-Marie.Moschera@ngc.com or
Toolink Engineering Inc.........................................................................57 Autumn Halstead Autumn.Halstead@ngc.com

The search for your new career starts here. Join us.
INSPECTION & METROLOGY
Machinist Inc........................................................................................81 ngc.com/careers

Penta Gear Metrology............................................................................79 © 2020 Northrop Grumman is committed to hiring and retaining a diverse workforce. We are proud to be an Equal Opportunity/Affirmative Action Employer, making decisions without regard
to race, color, religion, creed, sex, sexual orientation, gender identity, marital status, national origin, age, veteran status, disability, or any other protected class. U.S. Citizenship is required for
most positions. For our complete EEO/AA and Pay Transparency statement, please visit www.northropgrumman.com/EEO.

United Tool Supply................................................................................75

July 2021     87
 Q& A STEVE YOUNG
INTERVIEW WITH AN CO-PRESIDENT    EX AC T METROLOGY
INDUSTRY INSIDER
“The Metrotom 6 was designed and built from Day 1
from the ground up to work like a CMM.”
What makes CT inspection and metrology important, particularly
for the gear industry?
The key to CT scanning is the ability to see 100 percent of the part.
A typical inspection device is a single-point tactile system. With
structured light scanning, it’s all line of sight. CT scanning allows
us to see 100 percent of the parts, inside and out. When looking at
plastic gears, you might have what we call voids or little air bubbles
inside the gear. The capabilities of CT scanning allow the user to see
all these variables without destructing the part. It’s non-destructive.
You can quantify the size and the location of those just like you
would measure a feature on the part. And if it’s close to another air
bubble, another surface, or close to any other feature, it will warn
me. So, I have a lot of analytical capability
knowing that I have 100 percent of the part
information.
Having 100 percent of the information
gives you many other advantages. You may
be looking at the root, crest diameter, or
radius today, but tomorrow, there might
be an issue with something else that you
never noticed in the previous scan. There is
an incredible advantage in this because you
don’t need to rescan the part. The data from
the previous scan is still saved.
Exact Metrology recently installed the
Zeiss Metrotom 6 Scout scanner in its
Brookfield, Wisconsin facility. What makes
the Metrotom 6 scanner superior to previous equipment?
Most CT scanners were kind of carry-overs from the medical industry,
where accuracy was not a big deal. If they’re within a millimeter,
that’s good enough, and you’re usually not measuring something
from a medical CT. You’re just trying to see: Is it there? Is it not there?
When you bring CT into the metrology world, obviously we want
certifications. We want accuracy statements, uncertainty statements.
We want all that information, and CT scanners never had it. They
were trying to take the medical CT scanners and qualify them so
there would be an accuracy or uncertainty statement. The Metrotom
6 was designed and built from Day 1 from the ground up to work
like a CMM and be a metrology tool. It is calibrated, and you do get a
factor of uncertainty. And the accuracy on the machine is 3 microns
+L/100, which is very impressive for a CT scanner.
And the second advantage is it has a 3K detector in it, and that
gives us down to a 2-micron resolution.
Why was it important to add the scanner to the facility?
It provides a capability that very few people have. It’s not a low-cost
investment. The scanners are somewhat expensive, so not everyone
has them. Not only can we provide that as a service to people, but we
can also educate people on the capabilities of CT scanning.
88     gearsolutions.com
How does the Metrotom 6 scanner offer an advantage over
conventional tactile techniques?
The advantage is seeing 100 percent of the part. Assuming, of course,
we can get through the part. Density can be an issue. You need
enough power to get through the material, but assuming you are
through the material, you are seeing 100 percent of the part, and
that’s the key.
The Metrotom 6 does have greater accuracy than traditional CT
scanning, but it does not typically have greater accuracy than your
conventional tactile measurements.
But I’m not controlling the temperature and humidity like you
do on those machines. They have to be in very special environments.
You’re also measuring one point at a time,
so if you didn’t touch the area that had the
defect, you wouldn’t know there was a defect
there.
How were similar inspections handled
before this new technology was available?
This is so new that what we consider the
conventional way is still being done by the
mass majority, and that’s putting the part on
a conventional CMM, and a CMM would tac-
tilely go around and inspect it. If you needed
to see something that was not visible, you
would have to destroy the part. You would
have to cut it, and you’d have to look at it in
a 2D sense on a vision machine. Now, you
destroyed the part; you had to pod it and polish it and then put it
on a vision machine. After that, you had to put it on the CMM to get
the three-dimensional information. It’s quite possible that it could
take you an hour, hour and a half, to check one part, where on a CT
scanner, I can put it in there, scan it for 10 minutes, and I’m done.
Can you give me an example of how the scanner will help with
the inspection of gears?
Obviously, there’s a gear, and then there’s another gear that it’s
mating to. We can scan those two gears independently, even if they
were made at separate manufacturing locations. I can scan those
two, and I can virtually put them together, seeing if there’s any
interference, if there’s any rubbing, any tight spots where, maybe
it passed the inspection, but both parts were a little plus, it causes a
situation when you put the two together. We call it virtual assembly.
I can start doing that virtual assembly on those parts and understand
that interference or potential wear points before I ever find it as a
warranty claim from a customer. 
MORE INFO www.exactmetrology.com
 2007 Kapp Model KX-300P CNC Generating-Style Gear Grinder with Loading

Fellows Model 10-4 CNC 3-axis Gear Shaper

with Fanuc Controls, Motors & Drives

2009 Liebherr LFS 600 2000 Gleason Pfauter P400G

CNC Gear Shaper Gear Grinder

Gleason Phoenix Model 275HC II CNC

Gleason Model 350 GMM CNC Gear testers , 2004 Gleason Model 600 HTL CNC
Bevel Gear Cutting Machine updated software in 2016 & renishaw probes Turbo Lapper Fanuc 160i-M Controller

1
left

2007 Liebherr Model Lfs 220 CNC Gear 2013 Gleason Model 210H 6-Axis 2006 Mitsubishi Model SE25A CNC
Shaping Machine, Siemens 840D Control
2007 Liebherr Model LC-180 CNC Hobber, Siemens 840D Control Gear Shaper with Autoloading

820 Cochran Street Statesville, NC 28677

704.609.0766 • rich@pisellient.com
THE #1 SOURCE FOR YOUR USED MEMBER

www.pisellient.com
GEAR MACHINERY — AND MORE! MEMBER
Contact us to add your surplus machinery
GE15HS High Speed-High Power
Hobbing With Precision

NEW!
The Mitsubishi GE15HS
Running Past
The Competition
Maximum spindle speed
6,000 min -1
Eliminate
Gear Shaving

Up to 3x More
Production
Surface Finish
Less than Ra 0.4

NEW! GE25HS also available for parts up to 250mm OD

Higher Technology - High Speed With Precision

The all new GE15HS from Mitsubishi, with high speed and high
torque, delivers process efficiency and can eliminate shaving in
many cases. With surface finishes rivaling gear grinding, the
newest member of the Mitsubishi hobbing team provides
LEGENDARY RELIABILITY at high speed.

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