0614_GearSolutions

gearsolutions.comJUNE 2014

GEAR SOLUTIONS MAGAZIN

EUN

COVER HIDDEN POTEN

TIALS IN H

OBBING

JUNE 2014

A New Standard Under Development:

Specifying Powder Metallurgy Gears

Uncover Hidden Potentials in

Hobbing

Purchasing Gear Lubricants: Playing the Numbers Game

COMPANY PROFILE:

Involute Gear and Machine

kapp-usa.com 2870 Wilderness Place | Boulder, CO 80301 p: 303.447.1130 | f: 303.447.1131 | [email protected]

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Invest in your future. Kapp Niles machines provide increased productivity to grow your business. Our machines are built for the long haul, so you can pass them down from generation to generation with 97% of our

finishing machines still in operation since 1984. Plus, our quality service and retrofitting capabilities allow you to

stay current with changing technologies. Invest in Kapp-Niles and invest in the future of your business.

ZPI/E: Profile grinding of internal gears with large modules. Switches from internal to exter-nal grinding by swiveling the grinding arm 1800. Wheels are dressed while in grinding position. Precise, efficient, flexible.

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Indiana Technology & Manufacturing Companies, Inc. (ITAMCO), left to right: Nobel Neidig - President Joel D. Neidig - Technology Manager Gary Neidig - Vice President

03/18/14 Invelo Ad CMYK Gear Solution Alt 2 8.375 x 10.875

JUNE 2014 3

Features44Company Profile: Involute Gear and MachineBy Tim Byrd

Involute Gear and Machine uses

over 75 years of experience to

manufacture gear honing tools

and perform gear inspection.

26

Uncover Hidden Potentials in Hobbing

By Dr. Friedrich Momper

Successful applications for the G90 in hobbing are combined with the

calculation of total lifetime costs of the hobs.

A New Standard Under Development: Specifying Powder Metallurgy Gears By Fred Eberle

The best PM manufacturing

suppliers that specialize in making

gears have a gear engineer on staff

who works with the customer to

make them successful.

30

Purchasing Gear Lubricants: Be Careful When Playing the Numbers GameBy John Sander

This 10-step process for lubricant

selection makes the process

easier and more systematic,

resulting in improved equipment

reliability.

34

JUNE 2014 5

Departments

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 repro-duced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without per-mission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All "Industry News" material has either been submitted by the subject company or pulled directly from their corporate web site, which is assumed to be cleared for release. Comments and submis-sions are welcome, and can be submitted to [email protected].

8Reports, data, and developments to keep you aware of whats happening with your colleagues in the gear-manufacturing industry around the country and world.Industry News

52News of products, equipment, and resources from across the manufacturing spectrum that will help propel your company toward success. Product Showcase

24Over the years, FNC and gas nitriding have been used in applications where reduced surface friction is a requirement, such as gears and brake rotors.

Hot SeatJack Titus

25For an industry as quality-obsessed as gear manufacturing, the importance of industry standards is self-evident.

Trend TalksTim Byrd

Noise is affected by the accuracy of the profile, lead, and spacing.Ron Green 23Tooth Tips

22Materials MatterHaving covered the advantages of the forging process in gear production, Meehanite Metal Corp. begins a series on the casting process.

Meehanite Metal Corp.

50MACHINERY

54MARKETPLACE

55ADVERTISER

INDEX

Resources

JUNE 2014 | VOLUME 12 / NO. 06

Dr. Michael MassarskyPresident, Turbo-Finish Corporation 56Q&A

American Gear ManufacturersAssociation

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

17

Gears are, in many ways, the tie that binds.Recently, I had the pleasure of attending AWEA Windpower 2014 in Las Vegas. Our sister pub-

lication Wind Systems was showcasing its new boothone of almost 400. My editor and I took turns greeting people at our booth, attending meetings, visiting other booths, and losing money at the roulette table. We met people from every corner of the industryconstruction, maintenance, man-ufacturing, safety equipment, etc. We even met a politician or two. And as we discussed everything from policy to products, safety standards to coating a turbine blade, I was consistently reminded of the gears elemental role in all things. All of these concepts apply to gear productionefficiency, quality, the right materials, and an accurate design.

Gearboxes, certainly, are the clearest connection between the two. Gear Solutions has published multiple articles on gearbox maintenance, performance, lubrication, and testing. But, as AGMA president Joe Franklin describes in this months Trend Talk, the gear and wind industries support each other in other waysparticularly through industry standards. One industry holding the other accountable is a check-and-balance system that has worked for years, and the bonds are only get-ting stronger.

I want to extend thanks to the authors of this particular issue of Gear Solutions, one of which we are particularly proud. The articles cover a broad range of product, process, and policy. Gleason Corporation leads a discussion on a new tool material, G90, that is closing the performance gap between HSS materials and tungsten carbide. In Uncover Hidden Potentials in Hobbing, Dr. Friedrich Momper uses Gleasons field data to reveal how you can take full advantage of this recent development in gear production.

Fred Eberle, a technical specialist in the development of powder metal gearing, gives us an update on AGMAs powder metal standard, AGMA 6008-A98, as well as a brief history of its inception in his article, A New Standard Under Development: Specifying Powder Metal Gears. Eberle traces the standard back to the late 1980s, and his article is a prime example of how indus-try standards reflect evolving technology.

Finally, the experts at Lubrication Engineers have outlined a ten-step process for lubricant selec-tion, making the traditionally complex process much simpler. John Sander argues that theres more to consider when choosing the right lubricant than temperature, speed, and load. Factors such as the operating environment, viscosity, price, and gearbox capacity have a significant impact on the performance of your gear lubricant. The bullet-points in this article explain the importance of set-ting goals and seeking advice to ensure you make the right choice on your gear lubricant.

Were switching things up a little with our columns. For the past six months, weve had the plea-sure of learning about the forging process in gear production from Scot Forge. The characteristics of forgingstrength, reliability, response to heat treatmentare what make it an indispensable process for many.

But theres another side to the coincasting. Meehanite Metal Corp. will spend the next season of raw materials discussion on the versatility, affordability, and variety of metals avaliable in the casting process. As each step in the casting process depends on the one preceding it as well as on the one succeeding it, Meehanite will discuss each step in depth, and the importance of making the right process choice.

An integral part of gear manufacturing is timingnot just with metal, but with the business in general. Involute Gear and Machinethis months company profilehas built a powerful orga-nization by knowing not only how, but when to act. In late 2009, Nachi Machining Technology Company (formerly known as National Broach & Machine) announced that it was ceasing the manufacturer of all gear hone tools. Involute Gear and Machine Company purchased all equip-ment, machines, supplies, materials, gages, and engineering drawings for the manufacturing of all types of Red Ring Hone Tools and Honing Compounds. Company president Rodney Soenen tells Gear Solutions how 75 years of combined industry experience from his staff allowed him to strike while the iron was hot.

Its easy to get caught up in the echo chamber of your own industry. Our own little bubble is how Ive heard the gear industry described on plenty of occasions. But were not an island. Our industry is interwoven with every variety of manufacturing, everywhere, and it is our responsibility to keep that tie strong.

Tim Byrdmanaging editor

Gear Solutions [email protected]

(800) 366-2185 x205

6 gearsolutions.com

EDITORLETTERFROM THE

PUBLISHED BY MEDIA SOLUTIONS, INC.P. O. BOX 1987 PELHAM, AL 35124

(800) 366-2185 (205) 380-1580 FAX

David C. CooperPUBLISHER

Chad MorrisonASSOCIATE PUBLISHER

Dav id C . C o operPRESIDENT

C had Mor r i s on VICE PRESIDENT

Ter e sa C o operOPERATIONS

CONTRIBUTING WRITERSFRED EBERLERON GREEN

FRIEDRICH MOMPERJOHN SANDER

JACK TITUS

EDITORIALStephen Sisk

EDITOR

Tim ByrdMANAGING EDITOR

SALESChad Morrison

ASSOCIATE PUBLISHER

CIRCULATIONTeresa Cooper

MANAGER

Kassie BogganCOORDINATOR

Jamie WillettASSISTANT

ARTJeremy Allen

CREATIVE DIRECTOR

Rebecca AllenGRAPHIC DESIGNER

Michele HallGRAPHIC DESIGNER

Coop wants to use this one for the website

Vertical Logo Horizontal Logo

New England Gear 343 John Downey Dr.

New Britain, CT 06051 p. 860-223-7778 f. 860-223-7776 www.newenglandgear.com

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8 gearsolutions.com

INDUSTRYNEWS

Companies wishing to submit materials for inclusion in Industry News should contact the Managing Editor Tim Byrd at [email protected] accompanied by color images will be given first consideration.

New Products, Trends, Services, and Developments

The Gear Works Honored as Midsize Manufacturer of the Year by Seattle Business MagazineSeattle Business magazine honored 19 top manufacturers in Washington State at its Washington Manufacturing Awards at the Seattle Design Center. The event was attended by 280 members of the regions manufacturing community. The Gear Works was awarded Manufacturer of the Year in the Midsize Firms category.

In presenting the award, Seattle Business recognized the company for its develop-ment of new markets, specifically wind tur-bines, and its investment in new technolo-gies and equipment. In 2013, The Gear Works made a significant investment at its gearbox repair and test center in Seattle,

which increased its gearbox testing capacity fourfold, making it one of the few places to do the sophisticated testing needed for the production of high-speed, high-horsepower gearing. The half million-dollar investment in the facility put The Gear Works into the high horsepower repair market, capable by only a few companies worldwide.

Other achievements The Gear Works was recognized for include an assembly department repairing wind turbine gear-boxes, marine propulsion drives, extruder drives, and many other industrial gearboxes used in demanding applications.

In accepting the award on behalf of The Gear Works, Sterling Ramberg, president, acknowledged The Gear Works employees, many of whom have been at the company for decades, thanking them for their part in

helping the company flourish and earn its place at the global table. He also acknowl-edged his brother Roland as his mentor and his late father and company founder, Ingwald Ramberg, saying, Our father would be so proud and thrilled to see us honored by the Seattle business community for our work. Starting in a tiny garage with local customers, he never would have imag-ined that wed have 150,000 square feet of manufacturing, and more than 100 employ-ees and customers around the world.

For more information on The Gear Works, visit www.thegearworks.com.

GMTA News of Note Effective immediately for North America,

GMTA (German Machine Tools of America) now represents two addition-

JUNE 2014 9

al lines of quality German machines. Agreements have been finalized for GMTA to handle the Rosink line of parts washers plus the Arnold line of laser welding machines. According to Scott Knoy, VP at GMTA, These are natural complements to our existing lines and will strengthen our value proposition in current and also new market segments, going forward. A Rosink parts washer will be on display in the GMTA booth during the upcoming IMTS in Chicago.

GMTA proudly announces the sale of multiple Profilator Scudding machines to General Motors for gear production. It is estimated this purchase saved GM over $4 million in capital expenditures, compared with acquiring the multiple machines that would have been neces-sary to achieve the same production levels.

GMTA also announces the sale of Profilator Scudding and gear point-ing machines to Magna Mexico, plus machines to Magna Canada for polygon generation.

GMTA has sold nine Praewema honing machines to Ford.

Last but not least, GMTA proudly announces that Claudia Hambleton, cor-porate treasurer and administrative man-ager, received her MBA from Eastern Michigan University (EMU) on April 27, 2014. Claudia has been a GMTA associ-ate since the company opened its doors in January, 1991. As Claudia notes, I am very grateful to GMTA for support-ing my efforts to acquire an MBA. I look forward to using my new skills to further enhance the business at our company. It

was also very rewarding to network with the business school students and staff at EMU, where GMTA now has a working relationship with their German business development track. GMTA routinely hosts a program in German for students in the EMU business school who plan to work for or with German companies as a career path.

GMTA represents various top-quality German metalworking machine builders, including Profilator, Pittler, Praewema, and WMZ. These machines are sold to the North American market by GMTA primarily for gear and spline production, as well as other power transmission appli-cations. The companys target markets include automotive, off-highway, OCTG

10 gearsolutions.com

and other heavy equipment manufactur-ing. Machines are provided for gear hon-ing, gear grinding, the patented Scudding process for gearmaking, polygon milling, turning, gear tooth pointing, and multi-task machining operations.

To learn more about GMTAs products and services, visit www.gmtamerica.com.

U.S. Patent Office Publishes Solar Manufacturing Patent ApplicationThe management of Solar Manufacturing Inc. and affiliate company Solar Atmospheres Inc. has announced that Solar Manufacturing inventors Robert J. Wilson and Robert F. Daley were noti-fied by the U.S. Patent and Trademark Office that their Patent Application, Publication No. US2014/0042678 A1, for a new 20 Bar Super Quench Vacuum Furnace was published on February 13, 2014 and is now available to the public on the USPTO.gov website.

The published patent application, a first step in the patent process, contains 19 claims that detail the unique design of a horizontal, single chamber front loading vacuum heat treating furnace capable of in-situ gas quenching at pres-sures up to 20 bar and with cooling gas speeds reaching up to 200 mph.

One major advantage of the new design is the use of movable radiation baffle doors that prevent heat loss dur-ing heat cycles and open wide to avoid pressure drops during cooling cycles. The application of the open doors in combination with the use of a plenum fan arrangement, generous annular space for uniform gas flow, and a low static pres-

sure loss nozzle design provide inert gas quenching capabilities typically achieved only with oil quenching by concentrat-ing the available system horsepower on the task of producing a high nozzle exit velocity. The system also permits excel-lent cooling at lower pressures. Low pressure cooling is typically sacrificed by undersized fans normally selected for high pressure quench systems. The new system operates in a constant horsepower mode over a large range of quenching pressures.

Commercially, Solar Manufacturings first 20 bar high pressure quench vacuum heat treating furnace is currently in pro-duction at Solar Atmospheres of Western PA. The cooling rates are reported to be significantly better than any other high pressure gas quench furnace currently in production.

According to Solar Atmospheres of Western PA president, Bob Hill, the new 20 Bar Super Quench furnace is the fastest cooling furnace in the Solar fleet and one of only a few of its kind in the U.S. By adding the unique capabilities of the 20 bar quenching to our repertoire, we can now effectively process a wider range of materials and assist more cus-tomers than we could with our 10 bar furnaces.

Solar Manufacturing has also announced the installation of a new and compact vacuum furnace design located at its Solar Atmospheres of Western Pennsylvania heat treating affiliate com-pany facility in Hermitage, Penn. This production scale furnace was designed and developed to accommodate the heat treating and brazing of smaller to mid-size furnace loads in an efficient and economical manner.

In related news, the name Mentor has been chosen to highlight Solars lead in advancing the heat treating industry. The furnace is a Solar Manufacturing Model HFL-2018-2IQ with an effective work-zone that measures 12 wide x 12 high x 18 deep and is capable of processing loads up to 250 pounds. The hot zone design utilizes a .060 thick graphite foil hot face backed by four lay-

JUNE 2014 11

ers of half-inch rayon graphite felt. This design allows for operation up to 2500F with temperature uniformity of +/- 10F from 1000F to 2400F. The vacuum system consists of an Alcatel Model 2033, 33 CFM mechanical pump backed by a Varian Model VHS-6 water-cooled dif-fusion pump allowing for vacuum levels down to the 10-6 torr range. An internal 2 bar gas cooling system is incorporated using a 7.5 HP motor and heat exchanger for rapid quenching.

Michael Johnson, sales manag-er for Solar Atmospheres of Western Pennsylvania, said This furnace will give us the ability to process a variety of loads that we were not able to quote prior using our larger furnaces.

For more information, contact Pete Reh, vice president of sales, at 267-384-5040, or email [email protected].

Seco to Spotlight Solutions for Composite Machining at THE BIG M At THE BIG M manufacturing convergence event, taking place June 912 in Detroit, Mich., Seco Tools, LLC will showcase inno-vative milling and drilling tools and tech-niques that bring increased cutting perfor-mance to the machining of composite-based components in booth 330.

Among the solutions Seco will have on dis-play include the Jabro JC800 series of CVD-diamond-coated cutters, Seco Feedmax solid carbide drills and Niagara DiamondPlus productsall of which prevent uncut fibers and delamination in demanding composite applications for various industry segments, including aerospace, automotive, construc-tion, and wind power.

With low surface roughness and very high substrate adhesion, the Jabro JC800 series of diamond-coated solid carbide and PCD end mills efficiently and accurately machine work-pieces from modern carbon fiber reinforced polymers. Consisting of the JC840 and JC845 helix cutters, JC850 ball nose cutter, JC860 honeycomb sandwich router cutter, JC870 and JC871 multi-flute routers, and JC880 and JC885 low-helix four-flute end mills, the series has a high degree of specialization so it can meet the specific requirements of diverse

and highly challenging composite materials. With its Seco Feedmax family of solid car-

bide drills, Seco has optimized these tools for tackling a wide variety of holemaking opera-tions in composite materials. This expansive range of tools with various geometries consists of the C1 and C2 diamond-coated drills with diameters ranging from 0.12600.5 as well as the three-flute CX1 and flat geometry

CX2 PCD-tipped drills with a mix of dimen-sions for holes between 0.125 and 0.375. While each of these drills serve a unique pur-pose, each one works to achieve the highest possible productivity and hole quality

Designed for fast, precise machining in advanced abrasive materials, Niagara DiamondPlus products feature a 100 per-cent real diamond crystal coating that makes

Pusher

Vacuum

Batch

Heat Treat Knowledge

Choose versatility

Atmosphere and vacuum solutions to fit your every need:

Medium-to-high production throughputs, or flexible production for specialized parts

Lowest cost per part

Highest energy-efficient equipment

Most comprehensive, global service and support network to keep your equipment running at peak performance

Heat Treating ChallengesWhen it comes to the mass production of components necessary for executing critical functions in large, heavy-duty machines, these components need to meet strict industry specifications. Being able to carburize, nitride and harden parts with different materials, case depths, hardenability and geometries also requires flexibility.

At Ipsen, we know the challenges you face and design equipment that allows you to achieve low cost per part, all while maintaining the quality and flexibility you need and your customers demand.

Pusher FurnacesWhen your output is measured by the hundreds of thousands or even millions of parts and when those parts need to meet precise carburizing or nitriding depths and hardness specifications choose Ipsens controlled-atmosphere Pusher or Rotary furnaces.

Batch FurnacesWhen your heat treating production mix has several recipes, Ipsens atmosphere batch furnaces deliver flexibility with production lines that run different processes simultaneously and can expand as production demands increase.

Vacuum FurnacesIpsen delivers proven vacuum technology that allows you to achieve maximum flexibility by executing various processes, including brazing of heat transfer devices, sintering of components and hardening or annealing of parts and tools, depending on your specific needs.

Visit www.IpsenUSA.com/atmosphere or scan the QR code for more information.

JUNE 2014 13

them extremely hard, approaching 10,000 Vickers. The coatings matrix of micro and nano crystalline diamond provides a smooth, tough surface that is highly resistant to chip-ping and cracking, allowing for long tool life. This comprehensive tool series encompasses more 200 different products, including 2- and 4-flute square and ball end mills in different geometries and lengths, compression cutters in fine and course pitches, drills, reamers and fiber router burrs.

For more information, visit Seco online at www.secotools.com.

EMAG Showcases Complete Portfolio of Technologies at IMTS 2014At IMTS 2014, EMAG will feature Manufacturing Systems for Precision Metal Components. Multiple machines from its new modular standard VL and VT product families will be on display. These Modular Standard Machines offer a system approach that is advantageous to establishing a highly efficient manufac-turing process, with different operations offered on the same platform allowing for easy interlinking and eliminating any great outlay for automation. The VL vertical pick-up lathe series opens up new opportunities for the machining of a wide range of chucked components, small gearwheels, planetary gears, sun gears, sliding sleeves synchro-nizer rings or flange components, for example, can be machined with great efficiency. The smallest lathe of the VL product family, the VL 2, machines work-pieces with a maximum diameter of four inches and a length of up to six inches. Increasing in size, the VL 4, VL 6 and VL 8 offer a number of different turning and milling operations within the framework of a single closed-loop production pro-cess. Specially designed for the handling of large components the largest vertical turning machine of the series, the VL 8, Ideal for commercial vehicle production, handles workpieces up to 16 inches in diameter and 12 inches in length. Built within the same modular concept is the VT-Series for machining large quantities of shaft components. With four

axes, a self-loading turret and integrated automation, the VT 2-4 machines shafts with a max diameter of 2.5 inches and 16 inches in length. Spindle speeds of up to 6,000 rpm achieve extremely short cycle times as the shaft is clamped vertically between work-spindle and tailstock and machined from two sides. The vertical alignment of the workpiece ensures process integrity, where the unhin-

dered chip flow prevents the build-up of chip nests in the machining area.All machines of the VL and VT product families offer the same advantages for every size workpiece: A pick-up spindle/turret loads the machine

itself, picking up the raw parts from the integrated conveyor and returning the finish machined component.

14 gearsolutions.com

A 12-station tool turret known for very short indexing times. For drilling and milling operations it can also be equipped with driven tools in all 12 stations.

Service units that are quickly and freely accessible, making for short set-up and change-over times.

A machine base out of MINERALIT polymer concrete to ensure stability through outstanding damping qualities, resulting in excep-tional surface finishes.

Optional Y axis Integrating the technologies of the EMAG Group into these new modular standards, the VLC 200 H will make its North American debut at the McCormick Center. The VLC 200 H hobbing machine integrates EMAG-KOEPFER technology into the EMAG verti-cal platform, including the pick-up design where the main spindle removes the raw part from the conveyor belt, transfers it to the tailstock flange and removes it from the machining area after the completion of the hobbing cycle. Gears with a maximum diameter of 8 inches and module 4 can be dry-milled at greatly shortened cycle times.

EMAG will also present its entire portfolio of production tech-nologies, from turning, hobbing and grinding to those that comple-ment traditional metalworking processes, such as its production Laser Welding, Heat Shrink Technology and Electro-Chemical Machining (ECM) capabilities. ECM processes offer, non-contact machining with no heat affected zone or mechanical stress to com-

ponents with no tool wear. An ECM machined blisk will also be on display.

EMAG invites manufacturers to visit them at booth N-6846 to meet with technology experts to discuss production solutions for the automotive and commercial vehicle, aerospace, and oilfield industries.

For more information on the EMAG Group portfolio, visit them online at www.emag.com.

Parker Industries and Star-SU, LLCEffective June 2, 2014, product inquiries, quotes, and resulting orders formerly handled by Parker Industries will be directed and managed by Star SU, LLC. Additionally, Bruce Cowley will join Star SU as regional sales manager covering Southern Ohio, Eastern Kentucky, and all of West Virginia, and Bruce will work with the Star-SU, LLC sales network to support and further develop existing spline gage and master gear product programs.

We are most excited with this agreement as this provides market growth opportunities while sustaining project inquiry, quoting, and order fulfillments for cutting and forming tools and related gaging and work-holding requirements for our valued customers, said Cowley.

During the next 90 days, Parker Industries will contact and schedule visits with their customers to answer questions and communicate the scope and benefits of our products and services.

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After June 1st, Star-SU, LLC and its repre-sentatives will receive all Parkers website and product and service inquiries, RFQs, review each project for feasibility, issue quotations, and process and fulfill purchase orders for former Parker Industries customers.

Parker Industries has assigned Cheri Colangelo as the primary Account Rep for inside sales functions. Cheri will work with Melanie Renner who has decided to retire after 34 years of service. We all will miss Melanie and wish her well in her retire-ment years, said Cowley. Parker Industries encourages you to continue to direct your product and service inquiries to the following contacts:

Bruce Cowley: [email protected] Tel: 513-235-8589

Cheri Colangelo: ccolangelo@star-su. com. Tel: 937-405-1547

For more information on products and services, visit www.star-su.com.

MSI Sells Machinery and Tooling Supply to DXPMachinery Systems Inc. (MSI) has announced the sale of its Machinery Tooling & Supply company to DXP Enterprises, Inc. (NASDAQ: DXPE). Headquartered in Houston, Texas, DXP Enterprises is a publicly traded industrial distributor of technical products and services for MRO (maintenance, repair, operating), OEM and capital equipment customers. DXP has over 178 locations throughout the United States, Canada, Sonora, Mexico and Dubai includ-ing 7 regional distribution centers, 58 Supply Chain Service locations, eight fabrication centers, and over 3,300 employees.

Machinery Tooling & Supply will continue to operate under the leadership of Robert (Bob) Cuthbertson, President, and under its own distinct brand identity. It will main-tain its facilities in Schaumburg, Illinois and Brookfield, Wisconsin; however, will likely relocate to larger facilities in the future based on anticipated growth. The company has 55 employees. The company offers a full line of cutting tools and industrial supplies, including MRO, health and safety products, and inven-tory management systems designed to help tooling customers cut costs by 25% or more. Were thrilled with what this expansion will

mean to our customers, explains Ron Mager, president & CEO, Machinery Systems Inc. Overall, the transition will be seamless from their perspective, with the exception of increased services and products.

The joining of Machinery Tooling & Supply and DXP was a natural fit, adds Mager. DXPs mission, culture and growth

plans mirror Machinery Tooling & Supplys, which in the past few years has more than doubled in size.

Machinery Tooling & Supplys and Machinery Systems Inc.s customers will continue to enjoy access to both companys services and products lines through their strategic allegiance.

To find out more, call (847) 310-8665.

Getting the reliable gears youneed requires a surprisingly simple plan.

At Gear Motions, weve been designing and manufacturing precision gears for more than a century. And in that time, weve built something else a reputation for quality and proven performance in almost any application. Were a full-service company that uses the latest in gear-grinding technology to help you create a reliable solution to meet your exact requirements. Thats what we call Precision in Motion.

T 315-488-0100 | F 315-488-0196 | 1750 Milton Avenue, Syracuse, NY 13209 | www.gearmotions.com

Make one call to Gear Motions, and well work with you from start to finish to deliver the custom solutions you need.

The Gear Motions Network: Nixon Gear | Oliver Gear | Pro-Gear | Niagara Gear

Madelaine MorganDirectorwww.agma.org

American Gear ManufacturersAssociation

JUNE 2014 17

Networking at All Levels of the IndustryNetworking is a fundamental part of doing business, especially in the gear industry. Our mission as the Association for the gear in-dustry is to foster networking by connecting employees of AGMA member companies at every level, not just our executives. Some-times this can be easy, but sometimes it is challenging. Companies are different; they have different structures and consequently have

employees with varied job descriptions. At AGMA we have created technical seminars for researchers

and engineers that cover a variety of advanced topics. We also of-fer courses for sales teams and those new to the industry who ben-efit from immediate take-home knowledge. We recognized that

our education covered a wide swath of member-employees, but what was missing were opportunities for younger middle manag-ers to gather, network, and foster professional growth among the new leaders in the industry.

To meet this need, a grass-roots effort was formed at AGMA

that focused on the younger executives. Initially called The Fu-ture Leaders Conference, it was renamed the Strategic Resources Network (SRN). This group brings a commitment to leadership development and a strong belief in unity that has fostered their growth over the past several years.

As with a lot of great things, the SRN started as one thing but has slowly morphed into something more powerful. The initial mission was to provide leadership training to new committee members, arming them with incentive and skills that would en-courage their appointments to more advanced volunteer roles at AGMA. Ultimately, they would grow to the point of serving on the board of directors. While many of the current board mem-bers can trace their history to the SRN, over the last few years this group has grown and now provides one of the most dynamic net-working opportunities for those in and around the gear industry.

The SRN Steering Committee has been instrumental in gather-ing middle managers to regional meetings where the emphasis is threefold: relevant presentations with take-home benefits; plant

tours; and great stand-alone networking opportunities. The group

continues to be dedicated to these objectives. When combined the objectives are powerful enough to provide exciting experiences rather than just your typical meeting.

Over the last four years, SRN attendees have travelled to the Carolinas; Washington, DC; Erie, PA; and Ontario, bringing to-gether its core group and a nice mix of local manufacturers. Plant tours have included trips to General Electric, BMW, Ajax Rolled Ring & Machine, Ontario Drive and Gear, Linamar, and Meritor. In 2011, the SRN made a special visit to Capitol Hill to meet with members of Congress, sharing the challenges they face as small businesses. While attendees will remember being in the historic GE Thomas Edison building watching the assembly of locomotives in Erie, or attending Oktoberfest in Canada, it is the business connections that have become their most valued asset.

These more intimate meetings provide invaluable networking opportunities. It is quite possible that an attendee could meet a sales rep from a forging company; a technical engineer; an advanced gear manufacturing technology manager from a huge corporation; and/or the head of a small job shop. The benefits are enormous. Not only do the SRN attendees leave with in-creased knowledge and great memories, they also a leave with a pocket full of business cards to use as new resources when problems arise.

The next SRN regional event is scheduled for September 23-25, 2014 in the Chicago area. The event includes plant tours at Scot Forge and Overton Chicago Gear Corporation. Presenta-tions are on the topics of heat treat and metallurgy, steel market update, stellar customer service, and coatings. And not to disap-point, we are providing an interesting Welcome Reception, and a rooftop networking event overlooking the last regular-season Cubs game at Wrigley Field. We invite the middle managers from the all AGMA members to join us. Get engaged in the dy-namic educational opportunities. Your personal and professional growth will be exponential.

18 gearsolutions.com

NEW INFORMATION SHEET ON FINE-PITCH GEAR SPECIFICATION DATA

AGMA 910 consists of a series of print-ed forms for gear drawings that contain the appropriate data to be tabulated by the gear designer for the gear manufac-turer. It also includes a series of defi-nitions of the various tabulated items. This information supersedes AGMA 910-C90.

AGMA 910-C90 was a revision of AGMA 114.02, which updates the style and formats for spur gears, helical gears, bevel gears, wormgearing, face gears and racks.

The new AGMA 910-D12 updates the information relative to the ANSI Y14.5 definitions for toleranced, basic and reference dimensions and clari-fies previously ambiguous terminology. The new information sheet is available for purchase, in electronic format, on AGMA website at www.agma.org, click on the STORE button.

The AGMA Fine Pitch Gearing Com-mittee dedicates the new document to Irving Laskin. His inspiration and dedi-cation to the Fine-Pitch Committees

work over many years lead to the devel-opment of this information sheet. In ad-dition, the committee wishes to thank all participants for their valuable contribu-tions during the development of this new information sheet.

To find out how you can get involved

with any of the AGMA committees which actively serve the industry, contact Head-quarters at [email protected] for details.

NEW INFORMATION SHEET ON AERO-

SPACE BEVEL GEARS

The AGMA Aerospace Gearing Com-mittee recently completed the devel-opment of the new information sheet AGMA 937-A12 Aerospace Bevel Gears.

This information sheet covers aero-space bevel gears for power, accessory, and actuation applications. It provides additional information on the design, manufacturing, and quality control unique to the aerospace environment.

AGMA 937-A12 was developed to fill the void following the withdrawal

of AGMA 431.01. It expands the scope to include all applications of aerospace bevel gearing. The information sheet was created by reviewing existing prac-tices specific to aerospace bevel gear-ing. In general, this information sheet is a consolidation of the most common practices and standards currently in ex-istence.

The new information sheet is avail-able for purchase, in electronic format, on AGMA website at www.agma.org.

AGMA ANNOUNCES STAFF CHANGES

Jenny Blackford has been promoted to vice president of marketing. She has a proven leadership track in her organi-zation of the marketing and communi-cations of the association and her di-rection of Gear Expo 2011, 2013, and 2015. She will be the staff lead in the 100th AGMA Anniversary Centennial Celebration.

Amir Aboutelab has been promoted to vice president of the technical divi-sion. Amir has led more than 500 tech-nical committee meetings in his years of service for AGMA. He looks forward to this new leadership role and the inter-national work with ISO standards for our industry.

Justin Sikorski is the new staff engi-neer for AGMA. Justin graduated with a degree in Mechanical Engineering Technology from the University of Dayton (Ohio). He spent three years working for Honda Engineering North America in Marysville, Ohio before moving to the Washington, DC area. His most recent work has been for the U.S. Patent and Trademark Office in Alexandria, VA. Justin joins the AGMA Technical team to work with standards and software development within the technical committees.

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

**Event open to AGMA members only. Not a member? Send e-mail to [email protected].

Gear Accuracy Committee Meeting July 8-9 Chicago, IL

Plastics Gearing Committee Meeting July 10-11 Chicago, IL

Metallurgy & Materials Committee Meeting July 16 WebEx

Helical Gear Rating Committee Meeting July 23 WebEx

Cutting Tools Committee Meeting July 24-25 Cleveland, OH

Powder Metallurgy Committee Meeting July 29-30 Buffalo, NY

Bevel Gearing Committee Meeting July 30 WebEx

Mill Gearing Committee Meeting July 31 WebEx

Lubrication Committee Meeting August 5 WebEx

Helical Gear Rating Committee Meeting August 13 WebEx

Metallurgy & Materials Committee Meeting August 13 WebEx

Wind Turbine Committee Meeting August 19 WebEx

Cutting Tools Committee Meeting September 17 WebEx

Epicyclic Enclosed Drives Committee Meeting September 25 WebEx

Vehicle Gearing Committee Meeting June 2 WebEx

Enclosed Drives for Industrial Applications Committee Meeting June 3 WebEx

Fine Pitch Committee Meeting June 3-4 Cheektowaga, NY

Bevel Gearing Committee Meeting June 4 WebEx

Metallurgy & Materials Committee Meeting June 5 WebEx

Gear Failure Analysis Seminar June 9-11 Big Sky, MT

Helical Gear Rating Committee Meeting June 12 WebEx

Helical Enclosed Drives High Speed Units Committee Meeting June 17 WebEx

Gear Manufacturing & Inspection June 17-19 Rosemont, IL

Computer Programming Committee Meeting June 18 WebEx

JULY

JUNE 2014 19

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20 gearsolutions.com

John Cross: President, ASI Technologies

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

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

John E. Grazia: President, GearTec Inc.

Sulaiman Jamal: Managing Director, Bevel Gears India

Steve Janke: President, Brelie Gear Company, Inc.

Jan Klingelnberg: CEO/CFO, Klingelnberg

Justin McCarthy: Vice President , Sales, Scot Forge Company

Mark Michaud: President, REM Surface Engineering

Brian L. Schultz: President, Great Lakes Industry, Inc.

Dylan Smith: President, VanGear

Wendy Young: President, Forest City Gear Company

AGMA LEADERSHIP

BO

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D O

F D

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S

Lou Ertel: ChairmanPresident & CEO, Overton Chicago Gear Corporation

Matt Mondek: Chairman EmeritusPresident/CEO, Reliance Gear Corporation

Dean Burrows: TreasurerPresident,Nixon Gear

John Strickland, Jr.: Chairman, BMECFairfield Manufacturing Co.

Buzz Maiuri: Chairman, TDECSenior Product Manager, The Gleason WorksE

XEC

UTI

VE C

OM

MIT

TEE

Joe T. Franklin, Jr.: President

Amir Aboutaleb: Vice President , Technical Division

Jill Johnson: Director, Member Services

STA

FF

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

(703) 684-0211 | www.agma.org

General requests: [email protected] | Membership questions: [email protected] | Gear Expo information: [email protected] Technical/Standards information: [email protected] | AGMA Foundation: [email protected]

American Gear ManufacturersAssociation

IS YOUR COMPANY LISTED?The new AGMA Marketplace provides a great resource for those looking for products and services in the gear industry.

Find gear manufacturers that can produce products you need for your current project, or find services to assist with your gear manufacturing plant.

The Marketplace replaces the product directory that was previously available through the AGMA website. All those with listings must create a new account to be listed again.

AGMA members are afforded a free listing in this Market-place. For complete information send an email to AGMAs Web Communications Manager: [email protected].

SOLUTIONS FOR CYLINDRICAL AND BEVEL GEARS OF ALL TYPES, SIzES AND PROCESSES

For worldwide sales locations and additional information, visit:

www.gleason.com [email protected]

Gleason hobs featuring our new G90 substrate

deliver long-sought productivity gains and longer

tool life as compared to traditional PM-HSS. With

the addition of our newest operation, Gleason

Cutting Tools GmbH, were also giving customers

access to the widest array of high-performance

solid carbide hobs and application expertise.

Just some of the many solutions youll find at:

www.gleason.com/cuttingtools.

OUTPERFORM YOUR COMPETITION WITH NEW G90 AND SOLID CARBIDE HOBS

Returning your hobs to the same high quality and performance standards as new tools is faster and more efficient with Gleasons comprehensive reconditioning/resharpening services.See us at Booth #N-7000

22 gearsolutions.com

THE ADVANTAGES OF USING CASTINGS FOR ENGINEERING components such as gears are well appreciated by design engineers. Of major importance is the fact that shapes of any degree of complexity and of virtually any size can be produced. Modern metallurgy has also provided a great variety of cast metals, presenting a choice of many physical and mechanical properties that enable the design of components to meet service conditions, conditions imposed by economy, and conditions imposed by design factors.

Of all the materials available in the cast form, cast iron offers the greatest versatility, the greatest range of physical and mechanical characteristics, and the lowest cost.

The art of casting metals into those shapes, called castings, is dependent on many basic laws of physical chemistry, and the design engineer can achieve maximum success only when he designs with these in mind.

This series of the Materials Matter column has the express purpose in mind of providing the design engineer with a working knowledge of foundry practice, particularly as related to cast iron, to which general classification the family of Meehanite Metal belongs. In compiling this column, we have also clearly designated those important characteristics of the Meehanite process that have made Meehanite Metal castings the prime material for quality engineering components. The dependability of Meehanite castings is no accident. It is the result of an intimate knowledge of all phases of metallurgy and foundry practice and the ingenious application of this knowledge to provide the design engineer with the component he had in mind, when he applied his own creative effort.

It is sincerely hoped that this information will give the design engineer greater insight into foundry technology than he has, perhaps had in the past, and that this in turn, will enable him to make better castings in his engineering creations.

It might be thought that the design engineer had too many problems of his own to give much thought to foundry practice; nothing could be further from the truth, because it is only knowing what the foundryman can and cannot do, that the design engineer can evolve a truly efficient engineering component that will do justice to his creative ability.

THE MAKING OF A CASTINGIn its simplest form, the making of a casting involves starting with a pattern of a given engineering component (such as a gear), preparing a refractory mold containing this pattern, removing the pattern from the mold, and filling the resultant cavity with molten metal, and allowing it to solidify into the shape of the engineering component.

As each step depends on the one preceding it, as well as on the one succeeding it, this column will discuss each of them; particularly from the standpoint of the design engineer, showing where he plays an important role in determining the ultimate success of the casting. The element of casting design, as related to foundry practice, will also be discussed in some detail.

SOLIDIFICATION OF METAL IN A MOLDWhile this is not the first step in the sequence of events, it is of such fundamental importance and is governed by such adamant laws of physical chemistry that it forms the most logical point of beginning in understanding the making of a casting.

Consider a few simple shapes transformed into mold cavities and filled with molten metal:

In a sphere, heat dissipates from the surface through the mold, and solidification commences from the outside and proceeds progressively inwards in a series of layers. As the liquid metal solidifies, it contracts in volume and, unless feed metal is supplied, a shrinkage cavity will be formed in the center. In cast iron, feed metal requirements vary according to the type of metal, viz., its carbon equivalent, and may be gauged, very generally, by its tensile strength. This is because graphite in the structure controls strength and graphite is lower in density, thus a cast iron, high in graphitic carbon content, shows less solidification shrinkage, than one which is lower in carbon content. Feed metal is supplied by risers.

White irons containing carbides, instead of graphite, exhibit 6% shrinkage. Of special interest are the nodular, ductile, or S types of Meehanite Metal, which, by virtue of their composition, exhibit from 0 to 1.0% of solidification shrinkage. Extremely soft cast irons exhibit an expansion on solidification and cannot be fed solid by risering. They present special problems, where density is important. The controlled graphitic carbon content, which is inherent to the Meehanite Process, makes it behave predictably and exhibit less solidification shrinkage than any other material of equivalent mechanical properties.

The design engineer must realize that a shrinkage problem exists and that the foundryman will have to attach risers to the casting, or resort to other means to overcome it. Designing for use of lower mechanical properties, where this is practicable, decreases the foundrymans problem.

When the simple sphere described on the previous page has solidified further, it continues to contract in volume, so that the final casting is smaller than the mold cavity. This causes the need for correction allowance, in order to hold dimensional tolerances. This contraction also relates roughly to tensile strength and is at its highest in white cast irons.

MATERIALSMATTER

Having covered the advantages of the forging process in gear production, Gear Solutions turns to the experts at Meehanite Metal Corp. for a look at casting.

COMPANY INFORMATION: Meehanite Metal Corp. is a family of 24 different types of superior engineered

cast irons, including nodular iron, flake graphite, and white cast irons. For more information, visit www.meehanitemetal.com or call (262) 240-0210.

Meehanite Metal Corp

JUNE 2014 23

THIS COLUMN MARKS THE END OF A THREE-PART DISCUSSION on control of the three basic elements: profile, lead, and spacing. Figure 1 depicts three hobbed profile traces. The middle trace shows an undercut that is quite common and is manufactured by the addition of protuberance on the tip of the cutter. This provides clearance for the shaving cutter tip and reduces the amount of work done by the tip of the cutter. The bottom trace shows both an undercut and a tip relief. The undercut in this case would be unacceptable because there would still be non-cleanup above the SAP. The tip relief is also used more in fine pitch gears to reduce the deflection of the tip during the gear tooth manufacturing processes.

Figure 2 identifies five different profile shapes on a finished gear, the first one being unmodified. The second and third are deliberate modifications induced to provide better running conditions. The fourth and fifth traces, while not normal modifications, are nevertheless very common, especially in form ground gears. The minus involute occurs when the part is finished undersize and the positive involute occurs when the part is ground oversize.

Figure 3 shows different types of involute forms from shaved gears. The top involute indicates that the shaving cutter does not have the correct form or requires sharpening. This phenomenon also occurs if the tooth is worn in operation.

The second trace shows a common occurrence in the inspection area. Gears are normally cleaned with a brush a hair, which can stick to the profile. Because of the high resolution of the probe, a thin hairin this case approximately .0005"can result in what you see.

The third and fourth traces are a result of the shaving cutter being out of balance. That is the pressure on the shaved tooth is not the same as it rolls through mesh.

Figure 4 shows the lead surface after a precision hobbing operation. The depth of the scallop is important as it affects the subsequent shaving process or grinding process. All gear flanks should be cleaned up, including removal of all previous operation tool marks.

The second trace shows a crown hobbed gear. Crown hobbing is done to provide constant material removal in both shaving and post heat treat grinding. In shaving, it prolongs the life of the cutter. In post heat treat grinding, it provides a constant case depth across the tooth. This is done more in fine pitch gearing where the case depth is small.

TOOTHTIPS

Noise is affected by the accuracy of the profile, lead, and spacing.

ronGREENChief Engineer, Eaton Corporation

Ron Green is retired from Eaton Corporation as a chief engineer. He has over 60 years of experience in the gear industry. Eaton is a power man-agement company providing energy-efficient solutions that help custom-

ers effectively manage electrical, hydraulic, and mechanical power.

ABOUT THE AUTHOR:

Figure 4: Lead surface after precision hobbing.

Figure 1: Three hobbed profile traces.

Figure 2: Five profile shapes on a finished gear.

Figure 3: Involute forms from shaved gears.

24 gearsolutions.com

ping force, unless the pressure of the hydraulic system is elevated.

From my experience in commuting 156 miles a day round-trip, rotor wear wasnt the problem. But warp-ing from heat was especially problematic in stop & go traffic. Everyone has experienced pulsating (unrelated to anti-lock braking) from the break pedal. Prior to anti-lock brakes, a driver would lock the wheels in a panic, thereby eliminating a lot of pad/rotor wear. As the brake system alternately applies pressure to the rotor keeping the wheels from skidding, the pads and rotor will likely experience more heat from a high-speed stop than without anti-lock brakes. Thus, increasing rotor wear necessitates the FNC process.

Applying FNC to rotors may also require changes to the brake pad composition, to improve the pads performance with increasing heat. In racecars, reduc-ing heat buildup during braking is a primary design function of the rotor. This necessitates the grooving and holes found in high-performance rotors. Heat is dissipated into the rotor mass itself via convection to the air flowing around the rotor. If the rotor is too thin, heat will build up, rapidly increasing brake fade, increasing weight, and reducing mileage.

As for the FNC process itself there are two compet-ing directions. For decades, 50% endo gas plus 50% ammonia has been used in refractory-lined batch furnaces and retort lined pit or horizontal systems designed for traditional nitriding. Rather than using endo gas as the carbon source, retort furnaces rely on the more complex mixtures of ammonia/CO2/DA (dissociated ammonia)/nitrogen and the associated Kn process controller. Since epsilon is composed of >7.5% atomic nitrogen (N) at 995F the Kn control point must exceed 7.5%. or >1% Kn. Cast irons are ideal candi-dates for FNC since their higher percent carbon 2% + will readily form epsilon. The additional carbon source of CO2 (in retort furnaces) and CO in endo gas will ensure that the entire surface matrix can for epsilon [in the lower carbon regions of the material surface] cre-ates as much as possible a continuous white layer.

Due to the large number of rotors producedsince they are a consumable itemits not unusual to require loads of thousands in one processing lot weighing 30,000 to 50,000 pounds. For such massive loads very large batch furnaces are used from the tra-ditional integral batch furnace with top (gas) cooling capability to large car-bottom or tip-up systems. No quenching is required although it has its place is some applications, these very massive loads are slow cooled in nitrogen gas.

HOTSEAT

Over the years, FNC and gas nitriding have been used in applications where reduced surface friction is a requirement, such as gears and brake rotors.

jackTITUSDirector of Process and Developmental Engineering, AFC-Holcroft

GEARS ARE NOT THE ONLY COMMODITY to receive the benefit from FNC (Ferritic-Nitro carburizing). Brake rotors have also become a popular recipient of the process for automobile manufacturers in the last few years, for a couple of reasons: improved wear and reduced corrosion. FNC, an abbreviated form of gas nitriding, adds a thin epsilon white, or compound, layer to the cast iron rotors generally between 15 to 25 microns- (0.0006 to 0.001 in.-) thick. Corrosion is reduced because of the high concentration of nitrogen on the rotor surface. This reduces the exposed ironthus, less oxidation.

Like many commodities produced today, pre-purchase processing is required to maintain cosmetic and functional value during storage or transportation before the consumer is ever involved. FNC eliminates the potential rust that forms on rotors, as the cars endure cross-country travel and possibly months of outside storage in all kind of weather. An example highlighted to me recently is: brake rotors visible through aluminum wheelsunsightly rust can be a turn-off to a prospective car buyer.

FNC differs from nitriding in that nitriding is intended to add a diffusion zone that may or may not include a (gamma prime) white layer. Many times, a white layer is unwanted because the composition can be more difficult to control, pro-ducing a brittle surface. Since brake rotors are not exposed to impact loading, their working application requires only a hard surface to withstand the squeezing load of the brake caliper/pad to the rotor.

FNC requires no supporting diffusion zone. Therefore, the time to achieve the compound layer is very short compared to gas nitridingusually two to five hours at or above 1075F. Gas nitriding can take 12 to well over 24 hours at a lower temperature to create the diffusion zone, depending on the required case depth.

Over the years, FNC and gas nitriding have been used in applications where reduced surface friction is a requirement, such as gears. Crankshaft Babbitt bear-ing journals is a classic application for the improved wear and reduced friction from FNC. And therein resides a sort of application oxymorondisk brakes creating friction between the pad and the rotor to improve the lubricity of the rotor seems counter intuitive for stopping power. Increasing the surface hardness of the rotor would improve wear, but it does so at the expense of reduced stop-

Jack Titus can be reached at (248) 668-4040 or [email protected]. Go online to www.afc-holcroft.com or www.ald-holcroft.com.

ABOUT THE AUTHOR:

JUNE 2014 25

Standard: a level of quality, achievement, etc. that is considered acceptable or desirable.

In theory, standards arent necessary. In fact, in prac-tice, standards arent necessary. The American National Standards Institute and the International Organization for Standards have criteria for creating, modifying, and imple-menting standards, but they have no requirement that a manufacturer adhere to them. In other words, conforming to industry standards in the gear industry is optional.

Optional, that is, unless the manufacturer is inter-ested in attracting new customers. In that case, the seal of ISO, ANSI, AGMA, or API certification is indispensible. Certification in the gear industry is more than belonging to an exclusive club, or sporting a fancy seal on your web-site. It means youre evolvingjust like the standard itself. AGMA president Joe Franklin explained the rigorous process each standard must face every five yearsat least.

If substantial change occurs within the five-year periodnew findings come out, technology changes dramaticallya new standard will be created.

ANSI and ISO rules state that every document must be reviewed at least once every five years, with several criteria in mind:

1. Is the content still relevant? If not, the commit-

tee may withdraw that standard from active sales, encouraging people not to use it anymore. Either its been superseded by a new document, or the technol-ogy doesnt exist anymore.

2. If it is deemed relevant, the committee reviews and revises the standard, taking into account technologi-cal change, new research, errors discovered within the standard, etc. Over the five-year period, the committee leaders keep track of the information to be incorporated.

3. A standard can also reaffirmed, meaning there is no reason to make any changes. It complies, still representing state-of-the art technology.

Clearly, industry standards are effective in keeping product quality high. But in looking at one particular standardANSI/AGMA/AWEA 6006-A03whats good for one industry is good for another. This standard effectively saved the wind industry in the late 1990s.

At the time, insurance companies were unhappy with the frequency of gearbox failures within the turbines, threatening to require replacement of gearboxes every six or seven years. It was an issue that threatened the survival of the wind industry.

You cant have a viable industry with that kind of requirement, said Franklin. The industries came togeth-er with great force and momentum and created new standards. AGMA, along with AWEA, created a technical standard for gearbox design in wind turbine applications. This was a significant undertaking that was very strongly supported by the wind industry. All of the parts and play-

TRENDTALKS

For an industry as quality-obsessed as gear manufacturing, the importance of industry

standards is self-evident.

timBYRDGear Solutions

ers that were needed were at the tablesometimes as many as 90 people participated in the discussions.

Another example of a pioneering standards committee came with the advent of powder metal technology in the late 1980s. Fred Eberle, a member of the original PM standards committee, recalls some growing pains in the early days.

There was a lot of stuff to work out, said Eberle. At the time, PM manufacturers werent interested in sharing information with each other. Everything was proprietary. When people are new to a committee, they can be reticent. But I had learned from being on the plastic gearing committeea very technical committeethat sharing information has a significant, tremendous benefit.

That was over 20 years ago, and Eberle says its been an incredible ride. Today, the powder metal committee is very mature. Theres a tremendous amount of knowledge that sits on that committee today, and we want to get that knowledge out there, he said.

Standards arent just pulled from thin air. Field research is required to develop a stan-dardactual application data instead of blue sky research. A comprehensive represen-tation of industry experts validates the process and the document. With 205 companies supplying 410 individuals on AGMAs technical committees, we can honestly say were representing the marketplacecompanies large and small, said Joe Franklin. And if we have a committee that has spotty representation, we assess that, asking the question, Who needs to be here?

This kind of well-rounded group is ideal for creating an industry standard: Cross-examining the other guys data is an invaluable exercise in accountability. These are techni-cal documents for commercial purposes, written so that people can manufacture the best products to support their business.

Cui Bono?In talking to Franklin and Eberle, I had one lingering question: Who benefits the most

from a new standard? If an updated standard requires manufacturers to purchase new equipment, doesnt that compromise the integrity of the committee? Franklin clarifies this doubt with a familiar example.

A standard may be centered on new methods for processing and heat treating tech-niques that would increase the power density of a gear, said Franklin. Manufacturers might not need new equipment to do thatthey can simply apply the old equipment in a slightly different way, modifying a tooth profile, heat treating it differently, use a different alloy, etc. Thats what a standard iscommon procedure, commonly done, and recog-nized across the sector as the right way to do this.

For an industry as quality-obsessed as gear manufacturing, the importance of industry standards is self-evident.

Contact Tim Byrd, managing editor, Gear Solutions(205) 380-1573 ext. 205.

FOR MORE INFORMATION:

26 gearsolutions.com

By Tim Byrd

COMPANYPROFILE

This Michigan company helps gear companies of all sizes navigate the industry, optimize their tool life, and improve production schedules.

Involute Gear and Machine

JUNE 2014 27

F

Nachi had decided to close their Michigan headquarters and relocate to their Indiana office and manufacturing facilities. Sev-eral employees decided they didnt want to relocate, and an op-portunity to purchase the gear honing line presented itself.

So we did just that, said current company president Rodney Soenen. All of us have more than 25 years experience in the gear industry, representing a wide range of experience including in-spection, hobbing, shaving, broaching, grinding, and gear manu-facturing.

Soenen purchased all the equipment, machines, supplies, ma-terials, gages, and engineering drawings for the manufacturing of all types of Red Ring Hone Tools and Honing Compounds. Then he and the rest moved down the street about a quarter mile into a small building. That held them over until November of last year, when they purchased a 14,400-sq. ft. building about nine miles away (still in southeastern Michigan, Rodney assures me).

My responsibility at Nachi was sales of Kashifuji Gear Hob-bing Machines and Osaka Seimitsu Gear Inspection Machines, said Soenen. I had about a 30-year relationship with these two machine builders. They agreed to follow us, and when combined with Hone Manufacturing, we could justify our own company. Today, Involute Gear and Machine has over 75 years of com-bined experience to manufacture gear honing tools and sell Ka-shifuji gear hobbers and Osaka Seimitsu Gear CNC gear and inspection machines.

Kashifuji Works recently celebrated their 100th anniversary and Osaka Seimitsu Kikai (OSK) has been in business for about 60 years. Both are the largest suppliers of their type of equipment in Japan, especially to the automotive market. We have both Kashifuji & OSK demo machines on our floor, advised Soenen.

There arent too many people making the gear hone style that we manufacture, which are designed for the National Broach/Red Ring gear honing machine, but can also be used on shaving machines, said Soenen. There are still plenty of them in the world, and we still supply all those customers. The only time we lose a customer is when they change the processif, for example, they go from shave heat treat to heat treat grinding. We have aero-space customers that, even after grinding the workpieces, require honing to obtain a surface finish above what is attainable through grinding.

Soenen says Involute Gears contract gear inspection service is picking up as of late. Currently, the company has two OSK CLP 35s for parallel access gear inspection with a maximum of 350 mm with 800 mm tailstocks for the longer shaft parts. They perform internal/external gear inspection as well as hobs, worm shafts, and worm wheel inspection. And they do it fast.

We can usually turn around a gear inspection the same day parts are received, said Soenen. If not, certainly by the next af-ternoon were scanning and emailing inspection charts. Our cus-tomers enjoy that kind of service. We can inspect a gear in about

four minutes and we serve a variety of industries. We just picked up a customer that makes printing presses. They bring in all their gears from overseas, and theyve been having some quality issues, so we were able to identify profile/lead issues that were causing noise. The problem? A poor grind job, something the printing press maker suspected all along, but never had the documentation to prove.

The company also deals with a large range of clients. Some of our best customers are the small shops, who require a lot more hands on training and support, said Soenen. Many are pur-chasing their first CNC hobber and/or CNC gear tester. Con-sequently, they required a lot of help. Many times they werent aware of what CNC hobbers and gear inspection machines were capable of, and how these machines would benefit their business.

If these customers didnt know what CNC gear machines could do, they at least knew they had to have them. We helped them get into the business and optimize their tool life and current pro-duction schedules, said Soenen. Often, we get people calling us asking, Do you know someone who can do this kind of work and to this quality level? Yeah, call these guysthey have some great inspection equipment and they can give you accuracy documen-tation.

Involute Gear deals with the big boys, too. The company recently received an order for two Kashifuji hobbers from an automotive supplier, for a high volume drive train part. Bosch, Whirlpool, Visteonthe list of big names goes on.

We enjoy selling to guys making loose gears, said Soenen. Theyre easier to sell to and its more our line of business. I like to say we look for the ones that fall through the cracks, the ones that our main competitors have missed, the guys who want to sell 10 and 20 machines at a time.

Involute Gear and Machine imports and installs Ka-shifuji and OSK machines and supplies training, service, and spare parts. Soenen said its not unusual to get a call from guys with machines installed 10 years ago with ques-tions about programming or software, maybe a minor ma-chine problem.

Soenen explained, Well get phone calls asking, Can our machine do this? Its a special cutting cycle, and we want to start quoting this. Its either yes, or, if not, we sup-ply additional software. This is especially true in the gear inspection market, where the standards change so often and the software has to get updatedwhether its an ISO, DIN, JIS or AGMA type inspection.

FOUR YEARS AGO, EVERYONE PRESENTLY AT MACOMB, MICH.S INVOLUTE GEAR AND

MACHINE WAS WORKING FOR NACHI MACHINING TECHNOLOGYFORMERLY NATIONAL

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A New Standard Under Development: Specifying Powder Metallurgy GearsThe best PM manufacturing suppliers that specialize in making gears have a gear engineer on staff who works with the customer to make them successful.

By Fred Eberle

IIN THE EARLY NINETIES, I WAS WORKING AT A TRANSMISSION MANUFACTURING FACILITY

IN INDIANA THAT MADE LAWN AND GARDEN TRANSMISSIONS. THEIR PRODUCTS USED

LARGE NUMBERS OF POWDER METAL AND CUT GEARS. ON A TYPICAL DAY, 15,000 PM

GEARS WOULD BE ASSEMBLED INTO PRODUCT. THIS COMPANY MADE TRANSMISSIONS

FULL OF PM GEARS FOR 30 YEARS OR MOREMILLIONS OF GEARS EVERY YEAR.

They were having all kinds of problems, so they recruited me to work for them as a gear engineer and power transmission designer. Having written extensive gear and bearing calculation programs in college, I had an intimate knowledge and love for the work, but I had never designed gears out of powder metal. I was familiar with standards for commercial and industrial gears, having worked for several years designing mill gear reducers, so I knew what to do. I immediately began searching for some industry standards on PM gearing. I was shocked to f ind out that there werent any.

BACKGROUNDBack in the late 1980s, there was a stark discon-nect between the PM manufacturers and those who purchase PM gear components. At that time, there were no standards relating to durability or strength of PM gearing. Knowledge of bending or pitting was simply not available outside of select companies that had rigorously tested and painstakingly developed their products. The only data available for mechani-cal properties was MPIF Standard 35 put out by the Metal Powder Industries Federation. It is an excellent standard, but one must never confuse PM mechanical properties with gear durability. Like plasticsto some extentthere are variables involved that are not found in wrought steel.

In 1993, under the leadership of our good friend Irving Laskin, the American Gear Manufacturing Association formed a committee for developing and writing powder metallurgy gear standards. The com-mittee started out with several companies who were making PM gears and a few gear engineers who were designing the PM products into lawn and garden, various consumer goods, and automotive applications. Irving was a highly respected gearing consultant and mentor of mine for decades who often shared with me that several OEMs manufacturing a plethora of geared devices were desperate for knowledge of medi-um-strength power gearing. These companies simply needed to leverage the incredible economy of volume that PM offers.

The f irst and most pressing issue the PM Gear com-mittee took up in 1993 was to create a document that outlined the vital issues the buyer (customer) needed to know about purchasing PM gearing. At the time of the

f irst document release, there were 25 active participat-ing members on the PM committee and many more associate members. Five years later, and after much discussion and work, AGMA 6008-A98 was formally released. This document was deemed so imperative for the industry that it superseded any attempt by the committee to develop a specif ic gear ratings standard. It would be nearly another eight years before the spur gear standard was published. At this time in powder metal gearing history, there were still misunderstand-ings between PM manufacturers and customers regard-ing the differences between wrought steel gearing and PM products in design, materials, and process. Some of this is still true today, but to a much lesser extent. The best PM manufacturing suppliers that specialize in making gears have a gear engineer on staff who works with the customer to make them successful. These engineers also tend to be active participants on the PM committee.

The document Specif ications for Powder Metallurgy Gears, released in 1998, is the only one of its kind, specif ically devoted to gearing. It remains a signif icant source of published information on this subject.

Today, the AGMA PM Gearing Committee is mak-ing large efforts to signif icantly expand 6008-A98. When it is ready to go to the membership for ballot, it will be the most comprehensive authority on specifying PM gears that we know of. Here are some of the new expansion items the committee is considering:

Similarities of some PM alloys to specific wrought materials

In some cases, there are PM alloys that exhibit very similar performance to steel gears.

Avoiding dangers of grease lubrication with PM materials and how to manage and avoid loss of lubrication

PM materials can be oil impregnable. This is a great property, but it can be a double-edged sword. Specif ic knowledge is required to leverage the obtainable lubri-cation advantages in PM materials.

Possibilities and limitations of multi-cavity tools

It is possible to make multiple parts from a single press. However, only specif ic geometry makes this practical.

JUNE 2014 31

PM alloys and their specific appli-cations and advantages in PM gear performance

PM materials cover a wide range of special alloys with unique performance with materi-als not available any other way.

Process and treatmentsAnswering the question: Why would we consider one process or treatment over the other? Some treatments are unique to PM components. Since mold is not generating, specific optimization in root strength can be realized.

Specific heat treatments/processes and their relationship in gear perfor-mance

Some PM treatments will give equal perfor-mance to wrought steel alloys.

Sinter bonding: how, why, and the major advantagesSinter bonding basically takes to net shape PM parts before sintering and assembles them while in their green un-sintered

state. After sintering they become one ridged assembly. Multi-level net shape sub-assemblies or assemblies are possible. Green machining There are applications where a signif icant advantage can be obtained by machining geometry that cannot be pressed in a non-sintered part.

Green inspection with a signifi-cant emphasis on green roll testing (double f lank inspection) and how it relates to the sintered part quality

This is a technique specif ic to gearing to evaluate tooling set up and general quality and correlate it back to a f inished, hard-ened part.

Tolerance: An index of typical length/diameter/geometry tolerances by process and treatment for guidance in the design process.

Tooling: Understanding the tools that make PM gears (a most misunderstood area) for buyers.

Tooling: Specif ic knowledge for specify-ing multi-level parts.

Crush ribs and special tooth densif iers for strengthening critical areas.

Understanding and predicting section-al density variations with multi-level parts.

Molding integral one piece, multi-level net shape gear & shaft/gear and hub geometries.

Special tooling and characteristics of PM helical gears

Helical gears are more diff icult and require experience and understanding of design, tooling and process. Helical gears can be made very successfully and with excellent accuracy.

Secondary operations Shot peening, peening in general (vari-

ous types and how it works with PM) Steam treat: how, why and unique

benefits

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Resin impregnation Roll densifying: surface strengthening

increasing gear accuracy methods Understanding Oil impregnations (typical /

special) lubricants Rust preventativesrecommendations, uses PM related honing, grinding and secondary

machining of sintered gears

Methods for increasing gear accuracy of pressed & molded gears

New technologies and techniques that enhance performance in PM gears

Statistical Process controls and Process Capability for high volume PM

Chamfers, radii: things that should not be done in the part design.

AGMA PUBLISHED DOCUMENTS(ANSI/AGMA 6008-A98) Specifications for Powder Metallurgy Gears

(AGMA 942-A12) Metallurgical Specifications for Powder Metallurgy, PM, Steel Gearing

(AGMA 930-A05) Calculated Bending Load Capacity of Powder Metallurgy (P/M) External Spur Gears

DOCUMENTS CURRENTLY UNDER DEVELOPMENT(AGMA 936-AXX) Calculated Bending Load Capacity of Powder Metallurgy (P/M) External Helical Gears

(A N S I /AG M A 6 0 0 8 - A X X ) Specif ications for Powder Metallurgy Gears Revised & Updated:

(AGMA 944-AXX) Mechanisms of Powder Metal, PM, Gear Failures

If you or your company designs with uses or manufactures PM gearing, the AGMA PM committee invites you to join the discussions and development of these key technical documents. Active AGMA members enjoy the wealth of knowledge, intelligence, expertise, and industry con-tacts that comes with participation in this outstanding process. For more infor-mation, please feel free to contact Amy Lane: [email protected].

ABOUT THE AUTHOR:Fred Eberle is a technical specialist in the development of gearing, drive motors, and power closure devices in the automotive industry. Over the last 25 years he has worked as a gear development engineer in the mill gearing, lawn & garden, and commercial industrial gear manufacturers. He has a bachelors degree in mechanical engineering from the Rochester Institute of Technology, teaches GD&T and is a certified Six Sigma Master black belt. Eberles participation in various AGMA technical committees spans 24 years, having served as past chairman of the Powder Metallurgy Committee, and currently on the Plastic and PM Gearing Committees. Eberle has authored several papers on gearing, measurement system analysis and process statistics. He can be reached at [email protected].

JUNE 2014 33

Purchasing Gear Lubricants: Be Careful When Playing the Numbers GameThis 10-step process for lubricant selection makes the process easier and more systematic, resulting in improved equipment reliability.

By John Sander

AAN ASSUMPTION HAS BEEN MADE THAT ANYONE READING THIS HAS A BASIC KNOWLEDGE

OF MOST GEAR TYPES AND THEIR GEOMETRIC MAKEUP. GEARS ARE A UNIQUE

APPLICATION FOR LUBRICATION IN THAT THEY PROVIDE A DIFFERENT CHALLENGE THAN

OTHER LUBRICANT APPLICATIONS.

In non-gear applications, the moving surfaces are in sliding motion or rolling motion. Gear teeth, however, experience both rolling and sliding motion at the same time. With these interesting conditions in mind, the formulator has numerous ingredients available to build a gear lubricant that provides proper protection. See Table 1 for a list of common ingredients used in various combinations for gear oil formulas. A formula does not have to contain every one of these additives, and there are multiple additives available to provide specific functions. It is the job of the lubricant formulator to choose the proper ingredients to provide synergistic performance in a given application.

So, how does a formulator choose the proper ingredients for gear oil for a specific application? To answer this question, it might help to define how gear oils are categorized. As you can see in Figure 1, gear oils are categorized first based upon the application as either an open gear lubricant or an enclosed gear lubricant. As these names would suggest, an open gear lubricant is not enclosed in a gearbox or oil sump. As such, open gear lubricants are generally formulated as either high viscosity fluids or greases. This paper will focus on enclosed gears only.

10-STEP GEAR OIL SELECTION PROCESSFor years, many have stated that when selecting a gear lubricant, or any lubricant for that matter, one must consider only temperature, speed and load. More recently, this advice has been expanded to include environment. An easy way to remember this is LETS: load, environment, temperature and speed. While this advice is simple and memorable, it still doesnt provide sufficient direction to make an educated deci-sion. Instead, the following 10-step process is recommended

to anyone who is responsible for purchasing enclosed gear lubricants.

1. Set Lubrication Goals2. Seek Professional Advice and Consultation3. Review OEM Recommendations, Including Compatibility4. Determine Type of Load5. Know Gearbox Construction and Capacity6. Minimize Effects of Operating Environment7. Identify Viscosity Recommendation8. Consider Gear Speed9. Ensure Fluid Durability for Extended Drains10. Evaluate Price

SET LUBRICATION GOALSAs with most things in life, it is very important to have a goal. This is even important when it comes to selecting a gear lubricant for use in a specific piece of equipment. Most maintenance groups have a broad goal of increasing the reli-ability of the equipment for which they are responsible. In trying to improve reliability, one thing that is often reviewed is uptime. The higher the percentage of uptime, the more reliable it is considered. Lubrication has often been traced to reliability. Also, many maintenance individuals would like to reduce the amount of time they have to spend performing lu