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Presented by: AGMA, AGMA Foundation, Raymond Drago, P.E. & Joseph W. Lenski, Jr.

, Drive Systems Technology, Inc. November 7-9, 2007 Clearwater, Florida

Gearbox CSI: Forensic Analysis of Gear & Bearing Failures Useful Tools For Optimizing Gearbox Design

earbox failures are not always related to predicted B-10 bearing life and gear service factor calculations. Forensic analyses of gear and bearing failures show that only a few of these failures are the result of true fatigue (B-10 or basic gear rating). Many failures, although fatigue in basic origin, are the result of other contributing factors, often of such magnitude that they overshadow the basic gear and bearing rating considerations. Therefore, careful evaluation of the results of forensic analysis must be given in the design of gearboxes to achieve the best gear and bearing performance possible. Forensic analysis has become an important gearbox designers tool. The objective of this seminar is to provide a better understanding of various types of gears and bearings and educate the designer with the limitation and capabilities of rolling element bearings and the gears that they support, so that the designer can properly apply the best gear - bearing combination to any gearbox, whether simple or complex. Bearings come in various types, sizes and configurations. Selecting the best bearing to optimize the overall gearbox design may not be possible unless we know how to take advantage of each configuration and apply the results of forensic analysis of past failures. Understanding gearbox bearing failures is critical in eliminating them in future designs. Forensic analysis will determine the root cause and then the designer must determine what has to be done to eliminate this root cause in future designs. Some of the cures are very basic, while others require extensive efforts to incorporate the corrective measures into gearbox design. This approach is very important in optimizing the gearbox to achieve the best performance of both gear and bearings. Actual data based upon the presenters own gear design for the application and rolling element bearing experience will be presented. The presentation is illustrated with numerous photographs and many case study synopses are discussed to provide real world examples of both failures and preventative measures based on an understanding of the failures.

In addition to being colleagues for more than 40 years, the seminar leaders have had the great privilege of working directly together as an integrated bearing/gear team. This experience ranges from aircraft and space vehicles (including a wide variety of helicopters, fixed wing aircraft and space vehicles including the Space Shuttle and Atlas Rocket) to automotive and consumer products (such as mixers, electric tooth brushes, etc.), through heavy industrial equipment (steel and aluminum mill drive systems, mining applications, printing presses, etc.). Learn from this experience to minimize your problems and maximize your successes in future gearbox bearing designs. It is our belief that a good gearbox designer is only as good as his or her bag of tricks! Join us and fill your personal bag of tricks. See the seminar outline on the back of this page ...

Where:
Sheraton Sand Key Resort 1160 Gulf Blvd. Clearwater, Florida 33767 USA Phone: 727-595-1611 Room Rate: $160 single/double Hotel Cut-Off Date: October 5, 2007

Cost:
AGMA members: Nonmembers: $1,895 1st Registrant $1,695 Additional Registrant $2,395 1st Registrant $2,195 Additional Registrant

Included in the fees for this seminar: Fees include all educational materials, scheduled meal functions and an opening evening networking reception. A certificate will be awarded upon completion of the seminar.

SEMINAR OUTLINE Gearbox CSI: Forensic Analysis of Gear & Bearing Failures Useful Tools For Optimizing Gearbox Design

Presented by: AGMA, AGMA Foundation, Raymond Drago, P.E. & Joseph W. Lenski, Jr., Drive Systems Technology, Inc.
I. Introduction

t Recognize, analyze and correct failures; correlate problems and solutions t Study failures; We learn more from failures than successes t More than one thing can go wrong t Beware of laboratory analysis

t Understand applications; realizing gears, bearings, housing and lubrication interact t Diagnosis; recognize the thing that broke may not be thing that caused the failure

II. Gear design and failure analysis

t Appropriate application of technology t Lubrication failure t Resonance

t Failure types; wear, scoring, interference, surface durability and fracture

t Processes and related damage; handling, marking, electric arc, magnetic particle inspection, etc. t Compound effects; misalignment with spacing errors, poor lubrication distribution III. Material and manufacturing related effects t Inclusions t Hydrogen embrittlement t Residual tensile stresses t Voids and porosity t Forging problems

t Heat treatment and processing controls t Grinding burns and cracks IV. Preventive measures

t Detailed gear design, manufacture and quality control specifications t Advanced technology application

V. Bearing design and failure analysis loading

t Proper understanding and selection of bearing types and configurations bearing selection as influenced by gear type and t Design and fabrication controls; how to select a bearing supplier t Methods to reduce manufacturing defects

t Basic bearing B-10 life calculations; standard catalog rating methods and modified load factors t Understanding operating conditions as influenced by deflection and load t Conducting a bearing forensic failure investigation t Definition of true bearing fatigue failures t Assembly induced failures

t Operational induced failures; loads, misalignment, lubrication, improper settings and clearance, contamination, dynamics

Gearbox CSI: Forensic Analysis of Gear & Bearing Failures Useful Tools for Optimizing Gearbox Design
Presented by: Raymond Drago, P.E. & Joseph W. Lenski, Jr., Drive Systems Technology, Inc.

Program Schedule Gearbox CSI: Forensic Analysis of Gear & Bearing Failures Useful Tools for Optimizing Gearbox Design
When: Wednesday, Nov. 7 Thursday, Nov. 8 Friday, Nov. 9 8 a.m. 4:30 p.m. 8 a.m. 4:30 p.m. 8 a.m. 4:30 p.m.

TO REGISTER: Please fill out the information below and fax this form to
AGMA, or register online at www.agma.org. Name: _____________________________________________________________ First Name for Badge:_________________________________________________ Title: ______________________________________________________________ Company: __________________________________________________________ Division/Dept.: ______________________________________________________ Address: ___________________________________________________________ City: ______________________________________________________________ State: __________ ZIP: ______________ Country: _______________________ Phone: ____________________________________________________________ Fax: _______________________________________________________________ E-mail: ____________________________________________________________ r want to join AGMA by October 5, 2007 to attend at the member discount. I *Offer is available to new corporate members only. r Registrant AGMA member 1st r Additional Member Registrant from Same Company r Registrant Non-Member 1st r Additional Registrant from Same Company Total $1,895 $1,695 $2,395 $2,195 $__________

Cost: AGMA members: $1,895 1st Registrant $1,695 Additional Registrant Nonmembers: $2,395 1st Registrant $2,195 Additional Registrant
Included in the fees for this seminar: Fees include all educational materials, scheduled meal functions and an opening evening networking reception. A certificate will be awarded upon completion of the seminar.

Where: Sheraton Sand Key Resort 1160 Gulf Blvd. Clearwater, Florida 33767 USA Phone: 727-595-1611 Room Rate: $160 single/double Hotel Cut-Off Date: October 5, 2007
To obtain the preferred rate, be sure to mention AGMA when making your reservations. The hotel will sell out so book early, directly with the hotel by October 5.

Payment Method:
r Check r American Express r Visa r Discover r Mastercard

4 Ways to Register
Online: www.agma.org Phone: (703) 684-0211 Fax: (703) 684-0242 Mail: 500 Montgomery Street, Suite 350 Alexandria, VA 22314-1581
Guarantee your place by registering online or faxing this form today!

*For bank transfer information, contact AGMA. Remit in U.S. Funds Only. Card Number: _______________________________________________________ Expiration Date: _____________________________________________________ Name on Card: ______________________________________________________ Signature: __________________________________________________________ Space is limited. Registration for this seminar is on a first come, first served basis.
Conditions of sale: Payment must accompany this form by pre-registration date. All cancellations must be in writing and received by AGMA prior to Friday, October 5, 2007. A $50 U.S. processing fee will be assessed for each cancelled registration that results in a refund. Refunds will not be issued if cancellation occurs on or after Friday, October 5, 2007.