Finite Element Analysis - Gear Solutions

gearsolutions.com AUGUST 2014

GEAR SOLUTIONS MAGAZIN

EFINITE ELEM

ENT AN

ALYSIS OF A FLOATING PLAN

ETARY RING GEAR W

ITH EXTERN

AL SPLINES

AUGUST 2014

Design Parameters of Gearing

with Non-parallel Axes of Rotation

Finite Element Analysisof a Floating Planetary Ring Gear with External Splines

Grinding Alternatives

Case Study: RUF Briquetting Systems

Gear Failure Analysis

and Lessons Learned

COMPANY PROFILE:

Motion Industries

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

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Features32Company Profile: Motion IndustriesBy Tim Byrd

Three things separate Motion

Industries from the rest: people,

products, and process.

30

Grinding AlternativesBy Walter Graf

A series of Fine-ground and Polish-

ground gears are currently being

tested by various gear manufacturing

companies and transmission

developers around the world.

56

Principal Design Parameters of Gearing with Non-Parallel Axes of RotationsBy Stephen P. Radzevich

Examples of gearing with non-

parallel axes can easily be found.

Case Study: RUF Briquetting SystemsBy Greg Tucholski

Two companies make the most of

their swarf with RUF Briquetting.

Gear Failure Analysis Aircraft High-Lift ActuationBy Anngwo Wang, Seth Gitnes, Lotfi

El-Bayoumy and Jonathan Davies

Several gear failure cases

yielded important lessons for the

development phase of aircraft high

lift actuation systems.

44

64

60

Finite Element Analysis of a Floating Planetary Ring Gear

with External SplinesBy Vanyo Kirov and Yun Wang

An investigation of the stresses and deflections of a floating

ring gear with external splines working in za large planetary

wheel motor of a mining truck..

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AUGUST 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 what’s happening with your colleagues in the gear-manufacturing industry around the country and world.

Industry News

An armchair guide for predicting results for LPC and atmosphere carburizing.

26Hot SeatJack Titus

Love it or hate it, subcontracting is an integral part of an industry dealing with an aging workforce and a growing market.

28Trend TalksTim Byrd

In the manufacture of complex shapes such as gear tools, a great deal of machining is required on the pressed blank.

Ron Green 24Tooth Tips

Materials Matter 22There is no substitute for net shape gears when you must leverage the economy of volume to be successful.

Fred Eberle

80MACHINERY

82MARKETPLACE

83ADVERTISER

INDEX

Resources

AUGUST 2014 | VOLUME 12 / NO. 08

Brett FroatsColonial Tool Group 84Q&A

American Gear ManufacturersAssociation

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

17

As an editor, I’m on the receiving end of quite a few product releases. “___ Gear Introduces the New Gear-Zoom 2000!” or “Revolutionize Your Hobbing Process with _____’s New Hobb-erizer!” are headlines I see almost every morning when I check my inbox. It’s a great reminder of an energized industry (keep ‘em coming, marketing!), but it makes me wonder: Are these people really that excited about their products? Absolutely. And with an 800-pound gorilla like IMTS just around the corner, you better believe any market-ing team worth its weight is working overtime to get you excited, too. Gear Solutions is no different. This, our pre-IMTS issue, and next month’s IMTS issue, are road maps to a myriad of gear gadgets and expertise coming to Chicago in just a few weeks. First, we’re thrilled to say that Fred Eberle, a technical specialist in the development of gearing, drive motors, and power closure devices in the automotive industry, is our new Materials Matter columnist. For the past few months, both Scot Forge and Meehanite Metals Corporation have outlined the forging and casting processes, respectively. Now we turn to Mr. Eberle for his expertise on net shape gears. Mr. Eberle is a founding member of the AGMA powder metal standards committee, in addition to being an excellent writer. Jack Titus and Ron Green, our Hot Seat and Tooth Tips columnists, each continue their discussions of the heat treat process and machining pressed blanks. If you haven’t tapped in to the resource that is our columns, you’re missing out on three incredible field experts who continue to dazzle me with how brilliant they are in their respective fields. All glowing praise aside, the rest of this issue is fantastic. Our company profile this month is located just down the street from us. Birmingham, Ala.’s Motion Industries is a leading distributor of quality products and services to 150,000 government and industrial customers in North America. I spoke to Motion’s senior VP of marketing & strategic planning, Randy Breaux, about the three things that separate the company from the rest: people, products, and process. And our company Q&A is Colonial Tool Group’s Brett Froats, who brings us up to speed on the company’s steady growth in the U.S. and abroad. This month’s Gear Solutions includes five articles — and they’re all great. The 2013 AGMA fall technical meeting featured experts MOOG Industrial Group and Caterpillar, and we’re pleased to publish both articles in their entirety. Several gear failure cases in the development phase of aircraft high lift actuation systems are reviewed in MOOG’s article “Gear Failure Analysis and Lessons Learned in Aircraft High-Lift Actuation.” Meanwhile, Caterpillar conducted an investigation of a ring gear working within a large wheel motor of a mining truck. The result is “Finite Element Analysis of a Floating Planetary Ring Gear with External Splines.” Reishauer’s Walter Graf tells us about a series of fine-ground and Polish-ground gears currently being tested by various gear manufacturers and transmission developers around the world in “Grinding Alternatives.” Dr. Stephen P. Radzevich has provided us with his extremely technical “Principal Design Parameters of Gearing with Non-Parallel Axes off Rotations.” Finally, we have an interesting case study by RUF Briquetting on their innovative re-use of grinding sludge for two different companies. Corrugated Replacements and Horburgh-Scott are just two companies who have benefited from this “green” process, and their reviews of the process are glowing. As we prepare for the maze of booths in Chicago, I found this month’s Trend Talk — on subcontracting — to be particularly relevant. Gear Solutions spoke with three industry veterans about their experiences in performing outsourced work, and whether the term “subcontracted” still makes industry folks squirm. Ready or not, Chicago is coming. And the best way (in this editor’s humble opinion) to get ready? Take full advantage of everything that Gear Solutions has to offer: a free mobile app, a comprehensive search engine on gearsolutions.com, and, of course, the magazine itself. Thanks for reading!

Sincerely,

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

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Dav id C . C o operPRESIDENT

C had Mor r i s on VICE PRESIDENT

Ter e sa C o operOPERATIONS

CONTRIBUTING WRITERSJONATHAN DAVIES

FRED EBERLELOFTI EL-BAYOUMY

SETH GITNESWALTER GRAFRON GREEN

VANYO KIROVSTEPHEN P. RADZEVICH

JACK TITUSGREG TUCHOLSKIANNGWO WANG

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EDITORIALStephen Sisk

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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

Polygon Solutions Expands Tooling Product LinePolygon Solution Inc.’s new ‘Made in USA’ broach is a rotary broach with multiple text letters allowing machinists to stamp or mark their part in a lathe or milling machine without removing the part from the machine. The rota-ry broaching system is usually used for making hexagon, square or gear shape holes in preci-sion machined products. It will have its offi-cial debut at the International Manufacturing Technology Show (IMTS), September 8-13, 2014 in Chicago, Ill.

Polygon Solutions first introduced an innova-tive and award winning adjustment free Rotary Broach Tool Holder in 2010, ideal for CNC machines because of maintenance-free sealed bearings and a new pressure relief system. The company later announced a series of letter broaches in 2012. The broaches have letters or numbers and are inserted into Polygon’s broach holder to mark parts. The different identifying

marks improve quality to distinguish between mixed lots of parts made in the same machines.

The ‘Made in USA’ broach was first tested during Polygon’s annual National Association of Manufacturers (NAM) Manufacturing Day tour in 2013. Lee Virtual School students in Fort Myers, Fla. were taught about product development and how the new rotary broach ‘wobbles’ or displaces material to create the text. Polygon showcases new products to students in hopes of promoting the desire for STEM education in a new generation of engineers and machinists.

“‘Made in America’ is one of the strongest selling points we have, even for our U.S. custom-ers,” says Matt Chambers of Marine Concepts in Cape Coral, Fla. “The quality of the overseas product has been, from the start an inferior product, and as the cost of quality is more than ever being taken into account, not only are we sought after for quality but our total cost for our customer is less.” Marine Concepts and

Polygon Solutions Inc. actively work together as members of Florida’s Southwest Regional Manufacturing Association (SRMA).

Polygon’s new broach is not limited to the ‘Made in USA’ mark. The company sells its tools worldwide and is also developing the system to mark logos, slogans, and symbols. “We’ve had a few challenges to get it to work perfectly,” says Peter Bagwell, product engi-neer at Polygon. “But we keep working with our customers and our partners to get it right. Customers re-shoring their parts want to show they are now made in the United States.”

Bagwell adds “We’ve learned from our cus-tomers that our rotary broach holder is very easy to set up in the machine and very easy to use for making small hexagon and square holes. We hope the new ‘Made in USA’ broach helps them achieve an even higher level of satisfaction in both their parts and ours.”

Partners include the Precision Machined Product Association and National Tooling & Machining Association.

For more information on Polygon Solutions, visit www.polygonsolutions.com.

Machine Tool Giant Fadal Engineering Under New OwnershipFadal Engineering and Merrill Technologies Group (MTG) have joined forces to launch a new Fadal CNC full-range product line.

“Fadal will manufacture in Michigan and California, and sell globally through a distribu-tor network,” said Tansel Avci, chairman. Fadal was a global leader in the production of Vertical Machining Centers (VMC) before closing its manufacturing facility in Chatsworth, CA in 2008.

Fadal will launch its new Classic Series VMC at this year’s International Manufacturing

AUGUST 2014 9

Technology Show (IMTS), September 8-13, 2014, in association with Ingersoll Cutting Tools of Rockford, Illinois. The Classic Series — VMC2516, VMC3016, VMC4020, VMC6030, and VMC8030 — mirror the legacy box-way machine models that made Fadal one of the most prominently known CNC machine tools for nearly 30 years. Fadal is also proud to announce the following CNC horizontal turning centers: FG5, FL6, FL8, FL8L, FL10 and FL12. Fadal has updated the legacy American-made VMCs with the latest in engineering enhancements.

“Fadal consistently ranked best-in-class with a Cat-40 spindle torque rate of 220 ft/lb, nearly double that of its competition,” said Michael Naert, vice president of operations. “MTG updated not only the mechanicals — for instance, a new spindle design to incor-porate Big Plus technology — but the new Fadal CNC-64MP control functions with the same language and compatibility of the legacy Fadal CNC-88, CNC-88HS, and CNC-32MP control, all with greater processing power and speed. This provides accuracy, simplicity and a price point our customers deserve.”

“The new Fadal is all about bringing back to market an easy to use, CNC machine tool of sound design and state-of-the-art technology,” said Tim Consalvi, director of sales.

Later in 2014, Fadal will release its VMC Performance Series, offering larger trav-els, greater weight capacity, higher traverse rates, and greater CAT-50 spindle speeds. In 2015, Fadal will offer customers even bigger machines; The Heavy Series will be Fadal’s third entry into the market. This series will have extremely large machining and turning ranges and capacity, making it desirable for the energy, off-road, aerospace and defense markets.

For more information, visit www.fadal.com.

SW North America, Inc. Opens Canton Technical Center SW North America, Inc., a leading manu-facturer of precision metalworking produc-tion machines, has opened its new North American sales and technical center to better serve and support its customers. The new Canton Technical Center is located at 40615 Koppernick Road, Canton, Mich. 48187-4280.

Located in the Detroit metropolitan area, the new office allows SW North America, Inc. to

expand its foothold in the growing automotive market while increasing its customer base in the industrial, aerospace and defense, alternative energy, transportation, consumer products, and medical sectors.

The office is being led by Mark Reichenbacher, president & CEO, a 20-year industry veteran with management positions at various manufacturing companies. Prior to

joining SW North America, Inc., he held posi-tions at Grede Holdings LLC, ThyssenKrupp Waupaca, and Metaldyne.

“We will provide our U.S. and Canadian cus-tomers with the same level of service and sup-port that our European customers have enjoyed from our home office,” said Reichenbacher. “The Canton Technical Center provides a total solutions approach to the North American mar-

10 gearsolutions.com

ket. That includes turnkey sales, service, spare parts, and project engineering.”

In conjunction with the new office, the com-pany hired James Campbell as vice president of sales. Campbell has more than 30 years of sales and management experience, including senior leadership positions at The Cross Company, Giddings & Lewis, Future Tool & Machine Company, and Tri-Way Manufacturing Technologies Corp.

“We plan to aggressively build up our sales and marketing presence in North America,” said Campbell. “In fact, we have already estab-lished contracts with both American, Canadian, and other multinational companies.”

For more information on the Technical Center, visit www.sw-machines.com.

New Standards For Industrial Maintenance and Mechatronics Technicians: Call for InputThe National Institute for Metalworking Skills (NIMS), the precision manufacturing industry’s premier standards and workforce certification body, is pleased to present the first draft of

National Skill Standards to support the devel-opment of a world-class industrial maintenance and mechatronics workforce. The standards are the foundation of quality training and indus-try credentials that give individuals industry-certified in-demand skills and help employers identify qualified talent.

NIMS requests international review of the standards before formal publication in order to continue to ensure that NIMS standards and certifications meet the needs of industry.

“There are nearly 100,000 open jobs in the machining industry and over 115,000 open jobs in the industrial maintenance sector,” said Jim Wall, executive director, NIMS. “As the manufacturing industry evolves, NIMS com-mits to help companies, workers, and students keep up by providing the most current and complete information about advancing industry standards and job requirements.”

NIMS worked with Ivy Tech Community College, employers, and educators to develop the skills standards, which include the primary knowledge, skills, and abilities in which indi-viduals must be proficient to meet performance

requirements and expectations in the work-place. The 12-month development process included a series of national review sessions and interviews with employers and employees across industry sectors. This documented and validated the basic requirements for the major-ity of skilled positions within the industrial main-tenance and mechatronics industries.

“Companies in multiple industries and sec-tors internationally need certified industrial maintenance and mechatronics technicians,” said Wall. “We are calling on all employers, associations, and educators to provide feedback on these standards to help us build a world-class workforce.”

For more information regarding the stan-dards and the survey, contact NIMS at [email protected] or call (703) 352-4971.

Röhm Opens Subsidiary in Mexico to Support Growing MarketRöhm GMBH recently opened a new sub-sidiary in Mexico to quickly and effectively meet the sales, service, and support needs of its growing customer base in Mexico and Central America. The new Röhm Products Mexico S. de R.L. de C.V. is managed by Rodolfo Espeleta, who has 15 years of industry-related experience, with a strong background in engi-neering, sales, and the manufacturing sector in Mexico. The location also has the full sup-port of Röhm GMBH and Röhm Products of America.

In his position, Espeleta oversees the sales and service operations of Röhm’s comprehensive offering of chucks, centers, vices, tool clamping, and automation systems as well as custom-ized solutions for turning, milling, drilling, and grinding.

“With Mexico’s machine tool consumption expected to grow by 15 percent this year, we see a lot of business potential with manufac-turing customers in diverse industries such as aerospace, automotive, energy, and oil and gas,” said Espeleta. “These are all industries in which Röhm’s more than 10,000 products can greatly contribute to increased productivity, and the new subsidiary will focus on helping local customers get the maximum return on their Röhm purchases.”

A native of Monterrey, Mexico, Espeleta earned a mechanical electrical engineer-ing degree from the Monterrey Institute of

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Technology and then served as a CAD instructor and designer in the foundry industry in Mexico and the United States. He later worked at a precision aluminum foundry for automotive components as well as in sales and customer service for machine tools and perish-able tooling.

Röhm Products of America CEO Matthew Mayer said, “Rodolfo has worked in a variety of metalworking design, production, and sales areas in Mexico. As a result, he is intimately familiar with that market and the needs of its customers, and is the ideal choice to lead Röhm’s new subsidiary.”

For more information on Röhm’s prod-ucts and services visit them online at www.rohm-products.com.

TDM Systems Realigns Strategy Towards Tool Lifecycle ManagementTDM Systems will exhibit at IMTS 14 Booth No. E-3264, showing how the TDM 4.7 soft-ware package for tool lifecycle management makes life easier for machining companies. The package will also be presented in the Walter (W-1700) and Parlec (W-2300) booths.

Managing director Peter Schneck said, “We want to make sure that not only we, but espe-cially our existing and future customers, have a clear idea of the distinct advantages of TLM for the entire production process — from defining the tools, to using them in planning, to ensuring a seamless transfer to and use in pro-duction. In particular, a new feature is that the information from the individual process steps is fed back directly from production, ensuring continuous improvement of the data.”

For more information on TDM Systems, visit www.tdmsystems.com.

United Grinding North America, Inc. Names Finance ArmUnited Grinding North America, Inc. recent-ly named National Machine Tool Financial Corporation (NMTFC) a financial service provider. Through this partnership, United Grinding customers in North America now have quick, easy access to a variety of highly competitive loan and lease options for acquiring new grinding equipment.

United Grinding opted to partner with NMTFC as a way to leverage the indepen-

dent financing company’s vast product platform and credit expertise while maintaining a stellar United Grinding-based customer experience.

“We take a customer-centric approach to everything we do, which includes making the purchase of our products a world-class experi-ence,” said Terry Derrico, president and CEO of United Grinding North America, Inc. “By establishing a finance arm for our customers,

we make it easier for them to obtain the latest grinding technology for gaining the competitive advantage in today’s challenging manufacturing marketplace.”

Established in 1986, NMTFC has its roots firmly planted in the machine tool industry. In fact, the company has a certified machine tool sales engineer (CMTSE) on staff to assist United Grinding customers.

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The NMTFC team understands that machine tool purchases are not one-size-fits-all situations and, thereby, follows a custom-ized and flexible funding model, with a variety of lease and loan options for equipment that costs anywhere from $10,000 to $10,000,000. There are also “application only” programs that do not require a company’s financials or tax returns for equipment up to $350,000.

Having provided close to $1 billion in financing to more than 10,000 businesses and a credit team with more than 50 years of com-bined financial experience, NMTFC has what it takes to provide United Grinding customers with a highly productive financing experience.

For more information about United Grinding products and NMTFC financial services, visit grinding.com and netlease.com, respectively.

Abtex Corp. Acquires Nihmble TechnologiesAbtex Corp. has announced the acquisition of Nihmble Technologies, a Bloomfield, NY company specializing in the design and cre-ation of robotic systems for manufacturing, systems integration, and process control. The acquisition means manufacturers will now be able to use robotics technology to smoothly integrate Abtex’s deburring equipment into existing operations for unexpected efficiency. According to Abtex owner and president Mark Fultz, “Well-designed robotics systems provide manufacturers a wide range of ben-efits, from enhancing the flow of a single operation to efficiently connecting multiple operations to deburring multiple surfaces of a part in a single step.

“For many manufacturers, deburring is an essential element of quality control because burrs left on the edges of freshly cut metal parts create both safety and operational haz-ards,” Fultz said. “Adding a well-designed, automated method of smoothly integrating deburring equipment into an existing opera-tion increases both the quality and safety of the product and the efficiency of the opera-tion. That’s what the Nihmble acquisition promises our current and future customers.”

Started in 2002, Nihmble Technologies provided systems integration, automa-tion support, design, and consultation to companies such as Corning Inc., Thermo

Fisher Scientific, General Electric, Motion Industries, TRW, CooperVision, and Alstom Signaling. The company has been develop-ing customized solutions for Abtex customers since 2008. Nihmble co-founder Damian Clemons has joined Abtex as automation specialist.

For more information, visit them online at www.abtex.com.

Klüber Lubrication Obtains ISO 21469 Certification For Manufacturing FacilitiesKlϋber Lubrication has received the National Sanitation Foundation (NSF) ISO 21469 cer-tification at its Londonderry, New Hampshire facility. The certification from the NSF ensures food-grade lubricants from Klüber Lubrication are manufactured in a hygienic environment,

14 gearsolutions.com

using both best practices and the safest ingredi-ents. Klüber Lubrication leads the industry with five global locations that are NSF ISO 21469 certified.

ISO 21469 specifies hygiene requirements for the formulation, manufacture, use, and handling of lubricants which, during manufac-ture and processing, can come into incidental contact with products and packaging used in the

food, food processing, cosmetics, pharmaceuti-cal, and tobacco industries.

The certification specifies requirements to ensure ingredients used in lubricant products are safe and product labels are true and accu-rate. In addition, it ensures the manufacturer has identified and evaluated relevant hazards associated with the use of the certified lubricant. Furthermore, it confirms quality procedures

and good manufacturing practices are followed through production facility audits and analytical testing has verified the integrity of the product composition.

With the certification, Klüber Lubrication is in an ideal position to provide better recommenda-tions to customers on best practices within their own facilities.

“It goes beyond the lubricant formulations being recommended,” says Toby Porter, mar-ket manager for the food industry at Klüber Lubrication North America L.P. “With the NSF ISO 21469 certification, these products are being manufactured through a hygienic process that works to avoid risks for contamination. We then offer support on best practices to the end user that include the proper storage, handling and use of these lubricants to further mitigate these types of risks and deliver more than food safety.”

For more information, please visit them online, www.klueber.com.

Elmo’s Motion Control Experience Offers Free Online Remote Practice System (RPS) Elmo’s Motion Control is now offering a free remote login access via the Internet for its unique EASII Experience - Remote Practice System (EASII-RPS), enabling anyone from anywhere around the globe to experience first-hand the advanced motion tools provided by Elmo’s EASII software environment. The EASII Experience RPS is an exclusive, advanced, simple-to-use Motion Control system.

“We are launching a free online motion con-trol experience tool that allows learning and exercising advanced motion control, high per-formance servo technology and EtherCAT net-working,” said Haim Monhait, CEO of Elmo Motion Control.

“The RPS is a true educational system for any engineer that is involved in automation and motion,” said Monhait. “For beginners, it is a very efficient and comprehensive introduction to advance motion control. For skilled engineers, it demonstrates the most updated and state-of-the-art servo tuning, complex multi-axis capabilities and real time EtherCAT networking. It is Elmo’s modest contribution to improve the awareness to today’s very advance level of automation and motion control.”

Elmo is offering login access to its unique EASII Experience RPS for anyone to explore

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the motor and the drives in action, configure the EtherCAT network, perform complex multi-axis synchronized motions, develop IEC-61131-3 programs, motor automatic simplified and advanced tuning, advanced system analysis in the frequency and time domains, filter schedul-ing, motion sequencing, drive programing and data recording and much more. Setting up a machine has never before been so simple.

Elmo designs and manufactures cutting-edge servo drives and network motion controllers that are one-stop solutions for any motion control technology. As a leading global company with over 25 years of experience and millions of servos at work worldwide, we bring our clients profit-ability and success. With a focus on performance, reliability, safety and standards compliance, our solutions are integrated in a wide variety of appli-cations from industrial to extreme environment automation.

For more information on Elmo Motion Control products, visit www.elmomc.com.

Oerlikon Metco Well Positioned to Meet Global Market Demand for Advanced CeramicsOerlikon Metco announced increased manu-facturing capacity for its advanced ceramics products to meet growing demand from the aerospace, power generation and other per-tinent industries. The company of the newly formed Oerlikon Surface Solutions Segment as announced on June 3 now provides more flexible and shorter delivery times, design and produc-tion of novel customer-specific products, as well as new product innovations.

Key advanced ceramic materials produced by Oerlikon Metco are more readily available as a result of the implementation of excellence initiatives and new developments in manufactur-ing techniques, such as lean manufacturing and advanced automation of production lines. These improvements generated tighter production con-trols and a capacity boost of about one hun-dred tons per year that can be viably delivered to the market.

The improved capacity enables a broader product mix to more customers. Products posi-tively affected include Oerlikon Metco’s yttria-stabilized zirconia (YSZ) powders produced by the HOSP™ (agglomerated, plasma-densified) manufacturing process, and agglomerated and sintered YSZ materials. These advanced ceram-

ics produce high-performance thermal barrier coatings required for power generation and aero turbine engine components. It’s a complete portfolio of standard chemistries, as well as high purity YSZs for higher temperature condi-tions, all desired for extended coating life.

The HOSP YSZ portfolio is the largest seg-ment of TBC materials available from Oerlikon Metco, which also includes agglomerated and

sintered YSZ ceramics. In addition, the com-pa-ny offers a growing number of advanced thermally-protective ceramic compositions for spe-cialized applications; including compositions for Low-K, higher strain tolerance and envi-ron-mental barrier coatings (EBCs) used to protect ceramic matrix composites (CMCs).

For more information on Oerlikon Metco, visit www.oerlikon.com.

SOLUTIONS FOR CYLINDRICAL AND BEVEL GEARS OF ALL TYPES AND SIzES

For worldwide sales locations and additional information, visit:

www.gleason.com • [email protected]

on display...150 years oF innovation

Visit Gleason at IMTS, and find the latest in 150 years of innovation:

3 300PS Power Skiving Machine: much faster than shaping; more flexible than broaching.

3 PHOENIX® 280G Bevel Gear Grinding Machine: new design for greater accuracy, reduced non-productive time.

3 GENESIS® 200GX Threaded Wheel Grinding Machine: maximum productivity, minimal setup time.

3 300GMS: the complete gear inspection system for automotive, aerospace and similar sized gears.

3 Tooling solutions for every gear production challenge.3 Gleason 4.0: our new ‘smart factory’ initiative.

See what the future holds at: www.gleason.com/IMTS.

see us at Booth #n-7000

Amir AboutalebVP, Technical Divisionwww.agma.org

American Gear ManufacturersAssociation

AUGUST 2014 17

The Fall Technical Meeting Comes to the Nation’s CapitalOnce again, the heat of summer will break and the beautiful fall season will transform nature with stunning and splendid colors. As if all the beauty were not enough, the season brings with it yet another excitement for us “gear folks” in the form of the AGMA Annual Fall Technical Meeting.

For decades, around the same time when we are blessed with nature’s colorful displays, AGMA displays the latest gear research and innovations at its Fall Technical Meeting. This year the FTM once again brings the best experts in gearing from around the world to present their latest findings to the industry. The 2014 FTM will be held October 12-14 at the Westin Crystal City in Arlington, VA only a stone’s throw away from the “Seat of Power,” our Nation’s capital.

In preparation for this FTM, we have received a good number of abstracts, and the Technical Division Executive Committee and others have worked assiduously with the authors to select the 25 best papers for presentation at the 2014 FTM. In only two and half days, you will learn, share ideas, and network with others on design, analysis, manufacturing, and application of gears, gear drives, and related products, as well as associated processes and procedures.

This year’s FTM will have five sessions, each different in subject matter. The sessions are:

• manufacturing and inspection• gear drive design and application• design calculations• gear drive components• gear design

A complete list of the papers that will be presented on each topic can be found on AGMA’s website, www.agma.org.

In addition to the regular sessions outlined above, attendees will also benefit from two special presentations on topics affecting your operations:

• “An Analytical Model for Real-Time Design Evaluations of Spline Couplings,” by Yi Guo and Jonathan Keller, National Renewable Energy Laboratory; Robert Errichello, GEARTECH; and Chris Halse, Romax Technology

• “ISO 1328-1:2013: The New World Standard for Spur and Helical Gear Tooth Accuracy — What is New, and How it Differs from Previous Standards,” by John Rinaldo, Atlas Copco Comptec

Attending the FTM affords you an intimate setting for learning and networking. The conference is designed for attendees to take in all the presentations and take home practical information that may ultimately affect your company’s bottom line. Additionally, AGMA prides itself on the ample time allowing participants to question the authors on the technical aspects of their papers and research, which often leads to interesting and thought-provoking discussions. But the meeting is also designed to afford invaluable networking time between sessions and in the evenings to interact with colleagues and meet new experts in the industry.

While I would encourage you to take advantage of all the great papers during the Fall Technical Meeting, we understand that you may not have two and a half days to attend the event. Each session is designed to cover a particular subject area, so if you only have a few hours, you can still make it for a few papers that you are particularly interested in by registering a la carte for the sessions. For more information on all of your registration options, visit www.agma.org. To get the most value, make sure you register before the “early bird” deadline of September 12th. Plan early and save hundreds of dollars!

The Fall Technical Meeting is your best opportunity to learn the latest gear research from the best experts in the industry. I look forward to seeing you there.

18 gearsolutions.com

STRATEGIC RESOURCES NETWORK TO HOLD REGIONAL EVENT IN CHICAGOAGMA’s Strategic Resources Network gives gear professionals the opportunity and knowledge to become proficient leaders within the industry and provides “take-away” practical tools from meetings that can be shared within the attendee’s companies. This fall, September 23-25, the SRN will hold a regional event open to all gear industry professionals that is packed with information and two plant tours of Scot Forge and Overton Chicago Gear.

In addition to the plant tours and networking events, there will be seven speakers covering heat treating, apprenticeship programs, getting involved with AGMA, customer relations and more. The speakers include:

“SUCCESSFUL GEAR HEAT TREATMENT APPROACH”Bill Andreski, President MetConsult, LLCJoin Bill as he explains how the proper planning for heat treat-ment can improve the gear manufacturing process. Topics will include when to initiate the planning process, what factors need to be considered, and what timeline is appropriate. Bill will help you understand the importance of heat treatment in the overall process and how to improve the probability of meeting the job’s metallurgical requirements.

“PLANNING FOR AND EXECUTING A SUCCESSFUL APPRENTICESHIP PROGRAM”Don Williams, Apprentice Administrator, Rock River Valley Tooling and Machining Association (RRVTMA)As a leader in a gear manufacturing company, no doubt you have been involved in several discussions regarding workforce develop-ment. The apprenticeship model is one form of workforce de-velopment that seems overlooked and misunderstood these days. With Don’s guidance you will learn about the apprenticeship models and how to assess the benefits of this opportunity. He will also provide an example of how apprentices are being integrated at Forest City Gear. Finally, you will leave with information on how Don connected the NTMA, local community colleges, and a company’s training needs to the benefit of all three.

“STEEL MARKET UPDATE”Robert Weidner, President and CEO, Metals Service Center InstituteThe global steel industry has twice the excess capacity of 2001, and the surge in steel imports to North America are approaching record levels and sparking trade complaints citing the need for im-port tariffs. Bob Weidner, president & CEO of the Metals Service Center Institute, will discuss the current state of the steel industry in North America, including the economic outlook for major end-use markets. Bob will also comment on other factors which impact the supply and demand for steel in North America, including the impact of China’s steel exports which are surpassing their highest levels since 2008.

“AGMA FOR YOU, YOUR COMPANY, YOUR PROFESSION, AND YOUR EMPLOYEES”Joe Franklin, President, AGMA, and Thomas “Buzz” Maiuri, Chair Technical Division Executive Committee (TDEC) and Senior Project Manager, The Gleason WorksThe American Gear Manufacturers Association (AGMA) is quickly approaching our milestone centennial celebration in 2016. Over the past 100 years, AGMA has seen dramatic changes in member-ship, technology, and our overall business model.

The speakers will provide an in depth look at the current infra-structure of AGMA, including how you and your company should be utilizing this member-driven organization. Find out what com-mittees will be beneficial and how to become instrumental within them. You will return to work armed with this knowledge and ready to share and stimulate both your business and technical employees.

“COATINGS 101”Bernie Janoss, Global Segment Manager Foaming & Molding, IHI Ionbond, Inc.Several coating processes will be reviewed that will increase your awareness of the overall coating procedures and offer case stud-ies that apply directly to the gear manufacturing business. Bernie will highlight the PVD process, its applications and strengths with a look towards the future of this type of coating. The case studies will cover hobs, shapers and stick blades as they relate to the gear manufacturing applications.

“DELIVERING CUSTOMER DELIGHT”Steven Zipkoff, President and CEO, Zipkoff SolutionsSteve will delight you with his “laugh, learn and listen” approach as he guides you toward understanding the importance of delivering internal and external customer delight, identifying customer needs and give you the working tools of customer delight to build sales, profits and employee retention. A delightful company will lead to profitability.

For more information about this event, and to register, visit AGMA online at www.agma.org.

WHY EXHIBIT AT GEAR EXPO 2015?For three days at Gear Expo, gear buyers and manufacturers network and build relationships that benefit their respec-tive companies. Gear Expo was recognized by Trade Show Executive magazine as one the 50 fastest growing shows in 2013, and space is already running out for 2015. The 2015 Gear Expo will be in Detroit, October 20-22, and more than 130 companies have already committed to exhibiting.

For more than two decades, gear professionals — includ-ing CEOs, owners, presidents, engineers, marketing and sales managers, consultants, and other executives — come to Gear Expo to learn the latest industry information and see firsthand technology, products, and services that help them expand and streamline their business.

Attendees represent a variety of industries including de-fense, automotive, aerospace, agriculture, and construction. They come from around the United States, international man-ufacturing hubs, and emerging markets to conduct profitable business transactions and collaborate on the innovations that make their operations more streamlined. And the co-location of the Heat Treating Society’s Conference & Exposition and expansive marketing to end users offers an ever-expanding audience of potential new customers. The success of this co-location brings an additional 1,700 buyers to the show floor.

Exhibitors have the opportunity to meet face-to-face with attendees and other exhibitors, and will display more than 750,000 pounds of machinery on the show floor!

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

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

Lubrication Committee Meeting – August 5 WebEx

Metallurgy & Materials Committee Meeting – August 13 WebEx

Computer Programming Committee Meeting – August 14 WebEx

Spline Committee Meeting – August 19 WebEx

Wind Turbine Committee Meeting – August 19 WebEx

Technical Division Executive Committee Meeting – August 20 WebEx

Bevel Gearing Committee Meeting – August 21 WebEx

Gear Failure Analysis Seminar (SOLD OUT) – September 8-10 Big Sky, MT

Fine Pitch Gearing Committee Meeting – September 10 WebEx

Helical Gear Rating Committee Meeting – September 16-17 Chicago, IL

Cutting Tools Committee Meeting – September 17 WebEx

Industrial Enclosed Drives Committee Meeting – September 18 WebEx

Basic Training for Gear Manufacturing – September 22-26 Chicago, IL

SRN Regional Event: Chicago Area – September 23-25 Chicago, IL

Epicyclic Enclosed Drives Committee Meeting – September 25 WebEx

Plastics Gearing Committee Meeting – October 9-10 WebEx

Fall Technical Meeting – October 12-14 Arlington, VA

Wind Turbine Committee Meeting – October 15-16 Arlington, VA

Flexible Couplings Committee Meeting – October 15-16 Arlington, VAOC

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AUGUST 2014 19

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The conference programming, sponsored by AGMA, ASM, and other allied associations, also adds to the attendee base. We will also continue to offer high-impact networking and programming to the core audience of gear buyers and manu-facturers, including the end user segments.

Gear Expo has what you need to develop profitable partner-ships:

• The only trade show dedicated to the complete gear manu-facturing process.

• One of the world’s most affordable machinery shows for ex-hibitors.

• Face-to-face meetings with a concentration of quality pros-pects.

• A opportunity to demonstrate products and services and get immediate feedback.

• Customers who are excited to see the latest advances in gear technology.

• An energetic atmosphere that helps strengthen relation-ships with customers and colleagues.

WHY DETROIT?Detroit, the location for Gear Expo 2015 is located in the heart of the gear and heat treat industries. Historically, the ASM Heat Treat Exposition and Gear Expo see their largest attendance when the shows are in Detroit. The city was also the birthplace of the Heat Treat Society and will be the kick-off location for AGMA’s 100th anniversary

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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

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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

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Joe T. Franklin, Jr.: President

Amir Aboutaleb: Vice President , Technical Division

Jill Johnson: Director, Member Services

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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

in 2015. Both shows were last held in Detroit in 2007, and with so many positive changes occurring at Cobo Center, 2015 is a great opportunity to return.

Metro Detroit is undergoing a complete transformation, with billions of dollars being invested in new industries, attractions, and meeting facilities. A renovated Cobo Cen-ter, new and renovated hotels, and new restaurant and entertainment options all make 2015 the ideal time to re-turn to Detroit. The area is growing with 21st Century in-dustries that include defense, green technologies, medical research, transportation logistics, and a revitalized auto industry.

Detroit’s Cobo Center is investing $300 million in reno-vations, giving the building a face lift with a glass exte-rior, expanded exhibit space, new parking options, and upgraded loading docks. Most of the construction is un-derway or completed, and all of the construction will be complete in January 2015 — in plenty of time for our events in October. New features include new labor rules allowing exhibitors more leeway in setup, a three-story atrium overlooking the Detroit River, a new food court, and concession options.

Plan today to be in Detroit with your prospects, custom-ers, colleagues, and competitors next October and secure

your exhibit space now. Visit www.gearexpo.com for more information.

AGMA ANNOUNCES NEW ADVANCED BEVEL GEAR DESIGN COURSEThis fall, AGMA will debut a new course as part of its Advanced Gear Engineering Academy. The course, “Bevel Gear System Design, Manufacture, Heat Treatment, In-spection & Application: A Practical Approach for the De-sign Engineer,” will be taught by gear expert Raymond Drago in Arlington, Virg. immediately following this year’s Fall Technical Meeting, October 15-17th.

This seminar addresses every aspect of the design and application of bevel gear systems including: a brief re-view of bevel gear history; the types of bevel gears and selection criteria for particular applications (straight, ze-rol or spiral); design optimization of the gear set includ-ing root tilting, cutter size considerations, integral blank configuration, etc.; manufacturing methodology and the relation of these processes to gear set application; quality control, inspection, and interpretation; lubrication and maintenance; system design, application mounting, and bearing support; and installation — pattern setting, back-lash determination, adjustment, and control.

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22 gearsolutions.com

IN THIS COLUMN, EVERY MONTH WE ARE GOING TO EXPLORE some very interesting aspects of net shape gears. But first, what are net shape gears? Generally these are the molded types usually made in either plastics or by pow-der metallurgy. According to some data I have seen, it may be that 80 percent of all gearing produced worldwide annually is molded. This seems reason-able. For most consumer products (i.e. appliances, lawn & garden, recreational vehicles, toys, and other commercial items), high volume manufacturing makes precipitous use of plastic and PM gearing. If that is the case, then why do we hear so little about it? Where are the books written on the subject? Where is the multitude of papers and published R&D gear research? How can it be that 20 percent of one gearing type contains nearly all of the known published information and international standards on the subject?

The truth is that molded gearing is completely outnumbered by the devel-opment, analysis, and publications of wrought steel gearing. And this is understandable if you consider historical automotive, military, and aerospace applications. It is clear with high performance mechanical power transmission applications — historically, the trend in gearing is to continuously transmit more power with less noise, less vibration, more efficiency, and with less mass. These are the main drivers that get funded by governments and industry for optimization of geometry and high strength materials. Hence, much research and development has been written about and published for wrought industrial and precision power gearing.

In the early years of plastics and PM, many gear engineers would cut plastic and PM materials by conventional processes and test the components in appli-cation to see what happened. Don’t laugh — that is literally how it was done most of the time. However, the prize would be a significant component cost reduction if the material worked.

I’ll give one example. I designed a pinion for an automotive application. It had an external 10-tooth spline and a 17-tooth external gear of 1.0 module. The requirement was for 100,000 pieces the first year and 250,000 annual thereafter. Imagine my shock when a number of traditional steel gear manu-facturing companies surveyed did not want to quote the job. Of the few that did quote, the best commitment I could get was 100K annual quantity and no guarantee for more, with selling prices ranging from $11.00 to $26.00 a piece.

The decision to go with a net shape PM design was an easy one. However, the problem, at the time, was the realization that there was some risk involved. Would the part be strong enough? Would it be of high enough quality? Would materials and density cause unforeseen problems? What unknowns were lurking, only be discovered after initial production? Can you imagine the pain resulting from unforeseen production or quality issues in the application and with this kind of vol-ume? Unless you have been through one of these, you cannot imagine the total loss of revenue and confidence that would result. And as usual - there was virtually no time left in the project to do the kind of validation that would mitigate the risks!

The design engineer and the PM manufacturer vetted the project very carefully. There were many

unnecessary problems, especially on the produc-tion side, but over time the project was very suc-cessful. Unnecessary problems imply that there were many lessons learned. By the way, the final cost for the part? Total cost: less than one dollar apiece, as the years went by the cost went up but not a lot. During the third production year, quanti-ties rose to 280K pieces annual. The benefit of net shape production was enormous.

If you have made it this far, you now know that there is no substitute for net shape gears when you must leverage the economy of volume to be successful.

The singular goal of future net shape gear col-umns is to share the knowledge and experience you need to be successful in the design and appli-cation of molded power transmission components. We will cover some very diverse and technical topics along the way revealing many of the lessons learned and case studies. But let’s hear from you. Do you have a net shape issue you are dealing with or a molding question or problem? We will ask the experts and see where it goes.

MATERIALSMATTER

There is no substitute for net shape gears when you must leverage the economy of volume to be successful.

ABOUT THE AUTHOR: Fred Eberle is a technical specialist in the development of gearing, drive motors, and power closure devices in the automotive industry. He cur-

rently serves on the AGMA Plastic and PM Gearing Committees. Eberle has authored several papers on gearing, measurement system analysis and pro-

cess statistics. He can be reached at [email protected].

Fred EberleHi-Lex Automotive Center

“Molded gearing is

completely outnumbered

by the development,

analysis, and publications

of wrought steel gearing.”

24 gearsolutions.com

particles together but will not affect the properties of the tungsten. At that point the material is fully hardened and may only be machined with diamond tools. Most production machining is today per-formed using a form of this material. It can be used dry and has the highest cutting speed capability of any of these materials.

The latest development in these materials com-prises much smaller particles than previously used and these are called “microfine” carbides.

In the manufacture of complex shapes such as gear tools, a great deal of machining is required on the pressed blank. This can be done with standard machines and tools, and since the blank material is very weak, it can easily be broken (by hand, in fact). Heat treatment makes the blank extremely hard and can only be machined with diamond tools.

The great advantages of this material, which is entirely non-ferrous, is its initial hardness, allowing for cutting speed increases in the order of 300% when compared to common high speed steels, and its hardness at elevated temperatures allowing for the elimination of coolant from the cutting process. The disadvantages are in the high cost and vulner-ability to breakage.

BRIDGE MATERIALS These are very highly alloyed high speed steels and are also known as “Super HSS”. They are made by the PM method. The composition includes very high percentages of cobalt and vanadium for very high red hardness. (Hardness at high temperature at the point of the tool). These tools can be used to cut steel in “normal” hardness ranges without cool-ant and as such they “bridge” the gap between HSS and carbide. To be effective they must be used in conjunction with specially developed coatings. They are more brittle than other high speed steels but not nearly so as carbides. Examples of these steels are ASP 2080 and CPM Rex 121. The coatings are generally proprietary to the coating manufacturer.

The coatings fall into two categories — layered and lattice. These are combinations of different materials applied as a combination or in layers.

APPLICATION OF HSS AND PM HSS MATERIALSThe most common High Speed Steels used in gear tools today are:

• M4• M4+5• Rex 45 (Rex is a trademark of Crucible Steel)

ASP2030• Rex 76 ASP 2060• T15

TOOTHTIPS

In the manufacture of complex shapes such as gear tools, a great deal of machining is required on the pressed blank.

ronGREEN Eaton Corporation

Ron Green is retired from Eaton Corporation as a chief engineer. He has over 60 years of experience in the gear industry.

For more information, call (904) 392-0907.

ABOUT THE AUTHOR:

CARBIDECarbide is the basis for most cutting tools used today in non-gear cut-ting applications. It has been in use approximately 50 years. It cannot be machined by normal methods, preventing it from becoming readily available for tools of complex shapes such as hobs and shaper cutters. Any machining of these tools performed in the hard state, including service re-sharpening, must be done with diamond wheels. Initial machining is performed with standard cutting tools but when the carbide is in its pre-sintered state. At this stage the material has the strength of chalk and must be handled with extreme care. This is a non-ferrous material, more accurately called by its full name of cemented tungsten carbide. This is a tungsten alloy made into powder form and pressed into the rough shape of the finished product along with a cementing binder material, such as cobalt, with a lower melting point than the tungsten carbide.

After pressing into shape, the material is then sintered (baked) at a tem-perature to melt the binding material and cement the tungsten carbide

Figure 1: Comparison of various PM materials.

AUGUST 2014 25

These materials are most often of the PM type, with the wrought HSS materials used only in non-critical applications, such as very low production. All of these materials need to be used with a coolant when cutting steel and without coolant when cutting cast iron.

The most common all-round high per-formance HSS for this application is M45. This has good strength, wear resistance, and red hardness. It readily out-performs the earlier common materials of M2 and M3 and can be used with confidence in most situations.

In the search for higher performance it is necessary to consider the conditions under which the tool is expected to per-form. There is a difference in requirement for a tool to perform at higher speed in materials of high machinability and those of a tool to cut materials that are harder and tougher than the norm.

For readily machinable steels, the next higher grade to consider would be M45. This could be expected to allow an increase in cutting speed approximately 15 to 20 percent above that of M4. For the same materials, the application of Rex 76 would give even higher cutting speed.

Figure 1 gives a rough comparison of the materials and is based on Crucible Steel’s designations. At the end of this module is a chart that compares the steels of various suppliers.

For every increase in performance there is generally an additional cost and a low-ering of strength. The tools may be too brittle to support the cutting load, espe-

cially toward the end of cutter life when the tooth becomes thin.

For tougher part materials the need is generally to increase the wear resistance of the tool and that calls for a different approach. In this case the next higher grade material would be M4+5, and then T15. The same considerations of cost and strength apply.

“For every increase in performance,

there is generally an additional cost and a lowering of strength. The tools may be too

brittle to support the cutting load,

especially toward the end of the cutter

life when the tool becomes thin.”

We only use Rotek® rings to manufacture our industry-leading bearings.

From rolled rings to fully customized machined rings, we offer a wide range of sizes that give you the design flexibility you need. In fact, whatever your production demands,

Rotek is behind you every step of the way. For a quote, visit www.rotek-inc.com or call us at (800) 221-8043.

© 2014, Rotek Incorporated. All rights reserved.

RotekExceptional Rings Lead to Exceptional Bearings

26 gearsolutions.com

lene flow will provide too much carbon resulting in excessive carbide (Fe3C).

To produce the LPC carbon gradient and limit excessive carbide formation, the surface carbon must be controlled without the benefit of an oxygen probe. This is where the rubber meets the road. The only parameters available are acetylene flow, pressure, and time. Pressure is fixed.

LPC’s marketing pitch in addition to no IGO is carburiz-ing speed, up to 0.070” (1.75 mm) total cased depth; deeper than 0.070” starts to negate the higher carbon flux’s effect on the diffusion rate.

To reduce the cementite forming potential of LPC, puls-ing functionality must be employed and simulation programs can provide the recipe sequence when the acetylene flow, surface area, and temperature are provided. When the LPC carbon flux is considered (using flow, area, and temperature) within the algorithm, two case depth points are required — the user-supplied ECD (effective case depth) and final surface carbon.

To develop the estimated case carbon profile the simula-tion program considers the ECD plus a depth (specific to the software manufacturing) approximately 0.001” to 0.004” (0.025 to 0.01 mm) below the surface of a specified steel alloy. With the assumed carbon flux, the weight percent carbon is calculated at the 0.001” to 0.004” depth and this value is used throughout the case carbon profile calculation. Simulated time at temperature with the acetylene pulse flows will calculate the gradient until the ECD is reached. After the appropriate quantity (mass) of carbon is added to the steel the surface carbon will generally still be too high, therefore a final diffuse segment must be included to diffuse the surface carbon down to the target level.

Acetylene pulses can be of two types — pressure or flow. Pressure pulses will admit acetylene in successively lower flow quantities and greater times between pulses with evacuation between each pulse. Acetylene flow pulses will have nitrogen flow between each pulse to purge the used acetylene from the vessel. In either case, the carbon concen-tration just below — but as close to the surface as possible — is computed and used as the finite carbon flux. When the percent carbon just below the surface moves to the right of the Acm line for the temperature on the iron-carbon phase diagram corrected to the steel in process, the acetylene flow stops and waits for the carbon to diffuse left of the Acm line where another pulse starts. As the carbon concentra-tion continues to enrich the case carbon profile more time is required to allow carbon to diffuse into the steel thus the need for more and longer diffusion pulses.

With experience the heat treat supervisor can become very good at estimating the time required to reach a spe-cific case depth for endo carburizing especially with the published data. What’s not so easy for LPC users is deter-mining the proper acetylene flow and number of pulses vs. surface area when higher alloy (more carbide prone) steels are processed.

HOTSEAT

An armchair guide for predicting results for LPC and atmosphere carburizing.

jackTITUSDirector of Process and Developmental Engineering, AFC-Holcroft

OVER THE LAST FEW YEARS I’VE CONTRIBUTED to discussion and dissection, and have generally peeled away the layers to discover how the LPC and atmosphere carburiz-ing processes work and which is right for a particular type of product. But I don’t believe many of those interested in the topics understand how the simulation software relates to the individual process.

Endo gas carburizing is managed by controlling the carbon potential of atmosphere — in essence, we control the carbon content of the atmosphere and allow that fixed percent carbon to diffuse into the steel up to the potential’s limit. If we want a 0.85 percent surface carbon we set up the atmosphere via an oxygen probe, shim test, CO2, or dew point with the probe being the most preferred.

FICK’S 1ST AND 2ND LAWSCarburizing simulation programs employ Fick’s 1st and 2nd laws to calculate carbon dif-fusion based on the carbon potential and the base carbon content of the steel. Fick’s 1st law says a molecular substance will migrate or diffuse through a media (gas, liquid, or solid) from the higher concentration to the lower. Fick’s 2nd law dictates the rate of change of that diffusion over time. In addition, according to the chemical makeup of an individual steel grade, the case depth is calculated based on the temperature. Menu input options in simulation applications besides the steel grade will consist of base carbon — for endo carburizing boost carbon potential/time — and diffuse CP (carbon potential)/time. A gradient curve is produced based on the supplied information. Some programs will allow part shape as in diameter or ID as a parameter. In most cases the CO is assumed to be 20%, 40% H2, and 40% nitrogen. Carburizing/diffusion time can be manually input or automatically calculated based on the target effective or total case depth when the CP is provided.

An advantage of endo case/carbon profile modeling is the integrated (boost + diffuse) automatic calculated influence of lower CP levels vs. time at varying temperatures. Boost/diffuse recipes can be manually computed (estimated) using the published Harris case carburizing curves.

Modeling programs for LPC (low pressure carburizing) do not consider the CP of the partial pressure atmosphere since there is no managed carbon potential set point. These programs assume an estimated carbon flux again based on Fick’s laws of diffusion. Case carbon gradients are solely based on the soak time given and an assumed carbon flux. Carbon flux is the quantity and rate at which carbon enters the steel surface. In endo car-burizing it’s a given, in LPC however, it’s based on empirically estimated criteria embedded in the model’s algorithm. This is why surface area is a requirement for LPC modeling. As the surface area increases for a fixed acetylene flow, fewer carbon atoms will be available to uniformly carburize the load. The opposite is also true — less area with the same acety-

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

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TRENDTALKS

As IMTS approaches, Gear Solutions spoke to three companies about the concept of “other people’s work.”

timBYRDGear Solutions

STAYING IN CONTROL OF A GEAR BUSINESS — its products, workforce, and repu-tation — is a process as meticulous as cutting a gear. For a business that can produce a gear, from start to finish, without any outside help, staying in control is all in a day’s work. But for the rest of the industry, subcontracting can prove to be a sticky situation. “Will I lose control of my product?”

As you might have guessed, the answer isn’t so simple. In fact, relinquishing control of part of the gear production process — heat treat, cutting, finishing — is surprisingly commonplace. For a word that’s generally considered profane in the manufacturing industry, “subcontracting” is actually an important part of the gear industry, especially in light of everyone’s favorite gripe: the declining workforce.

“It’s hard to find the right people nowadays, even for people like us.” That’s Zen Cichon, president, Innovative Rack and Gear. Gear racks are something of a specialty item, so naturally Innovative does quite a bit of work for companies who outsource their work. Specialists like those at Innovative are virtually an endangered species, and as the demand for their work grows, so does the acceptance that, well, they are the ones that do the work.

“All our business is because of subcontracting,” says Cichon. “When it comes to gear racks, most people don’t want to invest in rack milling machines. It’s hard to justify buy-ing a new million-dollar machine just to do the rack work they need. And it’s no secret that the workforce is aging. They’d rather just leave it to a company like us to do it.”

A CERTAIN SKILL SETA few steps earlier in the gear-making process, Forest City Gear’s new Special Ops program is designed to get gear cutting work only—outsourced work from OEM’s and other companies looking exclusively for gear cutting. Rustin Mikel, the company’s direc-tor of corporate marketing, said, “We make a good margin doing gear cutting only, and we’ve recently divided some of our machines and production into doing gear cutting only—specific gear cutting machines that do gear cutting only.”

Presently, Forest City Gear is generating the Special Ops campaign to start increasing this kind of business. With Forest City’s reputation as a capable company in terms of equipment and capability in the industry — doing work for over 75 gear companies — Mikel isn’t shy about his feelings on outsourced work. “We’re huge fans of it,” he said, “because we’re on the receiving end!”

On the other side of the coin, Mikel says that some of Forest City Gear’s customers want to be “hush-hush” about outsourcing their work. “It’s touchy, but we’re in position to take advantage of it,” said Mikel. “When they send us a print and we’re only making

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

FOR MORE INFORMATION:

a spline and they’re making the rest of the gear, they have to block out the customer name on the print because they don’t want us going after that particular business. Shops that do precision machining, but they don’t have gear cut-ting abilities. They might need an intricate gear or spline feature on a difficult part, so they have to outsource the gear cutting.

“People are finicky about it because everybody wants to be known as a one-stop shop,” says Mikel. “But if you don’t have control over certain aspects of a part, you want to make sure you have good qualified people that are capable and have the right type of equipment to do that.”

THE HEAT TREAT GAMEOf course, you can’t really talk about outsourcing work in the gear industry without mentioning heat treating. The Heat Treat Doctor Dan Herring knows a thing or two about subcontracted work. “You have certain companies that look at outsourcing because they don’t want the hassle of bringing heat treating in house,” said Herring. “If I’m suddenly going to bring an atmosphere heat treat operation in house, I have to support it three shifts a day, I have to deal with combustible atmospheres and complex equipment — and I’m a machine shop! What I do best is machining. It’s not that I’m not capable of doing this. It’s just best left to others, as long as they provide quality coming back to me.”

Manufacturers are implementing lean manufacturing strategies these days — a “lean, green, and agile” philoso-phy. In trying to get continuous, single-piece flow of their product, they’re asking the question: Is heat treating really our core competency? Or does our it lie somewhere else? If it lies elsewhere, then it makes sense to look at outsourc-ing the heat treat process, rather than keeping in house.

“What drives a number of people to do in-house heat treating,” said Herring, “is that they can control the delivery of the product. I’ve got a client, for example, that prides himself on being able to say, ‘If you give me an order by 3 pm, I’ll ship it today.’ That quick turn around means he has to do his own heat treating. He can’t wait two or three days to send a part out. Sometimes the reason is quality. I hear captive heat treaters telling me, ‘We just can’t get the same quality as if we do it ourselves.” Captive shops are looking at it and saying, ‘Ok, what’s our principal driver?’ At one time, many manufacturers had these large pusher furnaces, for example, capable of thousands of pounds per hour. Now they have shorter production runs, so as a result, they revamped their heat treat or sent the business outside.”

IN CONTROLOn the whole, gear manufacturers are too concerned about making an excellent product to let any part of the process get out of control. And that’s not an indictment — it’s a compliment. Whether you’re a one-stop-shop, or you outsource part of the process, if the work is done right, it’s never really out of your control.

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By Tim Byrd

COMPANYPROFILE

Three things separate Motion Industries from the rest: people, products, and process.

Motion Industries

AUGUST 2014 31

A

PEOPLE Breaux said, “We have a solid base of technically compe-tent personnel in the f ield to make sure our customers are getting the right replacement parts for their applications.” Motion Industries employs about 6,500 people in approxi-mately 550 branch locations, 42 service shops, and 15 dis-tribution centers throughout North America. The shops provide gearbox repair, gearing change-out in gearboxes, install seals, and perform hydraulic shaft repair and hy-draulic pump services.

“I don’t think there’s a customer we can’t reach within two days,” said Breaux. “Our distribution centers operate with a “hub-and-spoke” distribution model. Each center will service about 150 branch locations, which is how we get products to our customers so fast. We either ship it out of the branch warehouse, from one of our distribution cen-ters or have the manufacturers drop ship directly to our customers for timely service.”

PRODUCTSMI represents the top brands in the mechanical power transmission industry that have large installed bases in North America. Those are the brands that the custom-ers in the industry prefer to use, and for good reason. They’re top quality, the best in their class, they provide the best service, and they do all of these things the right way. “These are our largest suppliers because that’s who we build our business around to support our customers with,” said Breaux.

He tells a story to illustrate his point. “We were in Houston recently. We assembled our oil f ield team, and there are many mechanical products used in the oil f ields — gears, bearings, motors, etc. I overheard the com-ment, ‘If we don’t have this brand available, we will lose 50 percent of the replacement business that we currently sell.’ Both the brand and the product were that strong in the market. There are at least two others who supply a drop-in replacement product. But, if product A fails, he gets to replace it with the same brand and keep his job. If a drop-in replacement product B fails, he may lose his job for using a perceived inferior brand, because it doesn’t carry the same weight as brand A does in the market. Motion Industries carries the brands that our customers perceive as best in class. It’s invaluable to have the right product.”

PROCESSMore than 50 percent of the time MI receives an order, it is for something that’s broken that very moment. Breaux said, “Most of the time, customers don’t have time to plan for their replacement. It’s broken, it needs to be f ixed,

and they come to us. We either have the product in stock, or we reach into the manufacturer’s inventory, or we can f ind alternatives solutions from the original part that was in the equipment.”

These processes are in place for MI to respond to the end-customer’s needs, understanding that they aren’t go-ing to have the product in their inventory — nor will they even know that they needed it more than half the time.

Breaux said, “We’ve learned to become very responsive in our processes, providing the parts and service custom-ers need on a timely basis. In a given year, some customers will only need a product one time. So the breadth of our inventory and the suppliers we work with must be very wide.”

SERVICE FOR CUSTOMERS LARGE AND SMALL It’s important to know that about a half of MI’s business is servicing large, multi-location customers. With these cus-tomers, Motion has an agreement in place to service that contract from Motion’s branches, wherever the customers’ plants are located. Motion’s local customer service rep will have a relationship with the local purchasing and mainte-nance manager at that plant. Breaux said, “If this relation-ship doesn’t exist, it’s very difficult to service the customer.”

Motion’s other customers are single-location. “For these customers,” said Breaux, “we have a local office and cus-tomer service rep that services them in no different fashion that we service the large ones. This is critical. It’s all about establishing a relationship. There’s a trust factor involved — do what you say you’re going to do, when you say you are going to do it.”

In the mid 1970s, MI was acquired by Genuine Parts, headquartered outside of Atlanta. Today, MI represents one third of Genuine Parts’ business. Genuine Parts’ other busi-nesses include NAPA, SP Richards and EIS, all located in Atlanta

Like the rest of the industry, Motion is learning to deal with a maturing workforce. “Every day,” said Breaux, “our customers rely more and more on us to provide them techni-cal assistance — for productivity gains and improvements, cost savings, reducing the material content, reducing the amount of labor — as their seasoned employees are retiring. Looking at MI in the future, I can see our service business and technical business growing.” Motion Industries sets the standard in the industry for industrial distribution as their tag line says “Keeping Industry in Motion”!

ACCORDING TO RANDY BREAUX, SENIOR VP OF MARKETING FOR BIRMINGHAM, ALA.’S

MOTION INDUSTRIES, THERE ARE THREE THINGS THAT SEPARATE HIS COMPANY FROM THE

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Finite Element Analysis of a Floating Planetary Ring Gear with External SplinesAn investigation of the stresses and deflections of a floating ring gear with external splines working ina large planetary wheel motor of a mining truck.

By Dr. Vanyo Kirov and Dr. Yun Wang, Caterpillar Global Mining, LLC

TTHE DESIGN OF A PLANETARY RING GEAR IS ALWAYS A CHALLENGE DUE TO THE

CONTRADICTIVE REQUIREMENTS IT MUST COMPLY WITH. ON ONE HAND, THE RING GEAR

SHOULD BE STRONG AND STIFF ENOUGH TO SUCCESSFULLY CARRY THE APPLIED LOAD.

ON THE OTHER HAND, IT SHOULD HAVE AS SMALL VOLUME AS POSSIBLE TO ACCOUNT

FOR THE RADIAL RESTRAINTS OF A PLANETARY GEARBOX IMPOSED BY THE TRUCK TIRES.

ADDITIONALLY, THE RING GEARS ARE FLOATING IN MANY CASES. ALTOGETHER, THE

DESIGNER JOB BECOMES VERY COMPLICATED.

One of the design issues of the strength calcula-tions of the ring gear is that none of the American Gear Manufacturers Association (AGMA) standards, including ANSI/AGMA 2001-D04 [1], rate internal gears. No acceptable methodology is def ined to cal-culate geometry factor for internal gears, following the method for external gears in ANSI/AGMA 908-B89 [2]. ANSI/AGMA 2001-D04 provides guidelines for the calculations of the ring gear rim thickness by introducing the rim thickness factor.

Very often the ring gears have external spline teeth, which transmit the torque to the f inal driven member of the gearbox. ANSI/AGMA6123-B06 [3] gives a methodology for calculating splines, which include shear capacity, fretting, and wear as well as ring burst-ing. The standard assumes that 50% of the splines are carrying the torque. Other approaches suggest differ-ent ways to calculate splines [7].

The stresses in the gear and the spline teeth are inf luenced by the def lections of the gear itself and also by the def lections of the entire gearbox. AGMA does not have published codes for calculating these def lec-tions. It stresses in different standards like ANSI/AGMA 2001-D04 the importance of determining the def lections, and provides examples of using Finite Element Analysis (FEA) methods.

Because of these diff iculties in the engineering design of ring gears, more and more researchers are using modern calculation methods like FEA. One researcher showed that when properly used, FEA and AGMA methods give closer results [6]. In this study a ring gear assembly is evaluated using FEA software in order to determine the stresses and def lections in the system.

DESIGN MODELThe assembly consists of a carburized ring gear and a through hardened torque tube (Figure 1) used in the wheel motor of large electrically driven mining truck. The torque path comes from three planet gears (not shown and used in the study), whose teeth are meshed with the internal teeth of the ring gear. The ring gear transmits the torque to the torque tube through its external splines. The torque tube transmits the torque from its internal splines to the hub through a bolted joint and from there to the truck tires.

The meshing areas between each planet and inter-nal gear teeth are marked as zones 1, 2, and 3 (Figure 2). Each one is modeled with different root radii and crowning of the external splines. The gear and spline teeth are ground to quality 6 per ANSI/AGMA 2015-

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

Figure 1: Ring gear and torque tube assembly view. Figure 2: Ring gear splines root radii and crowning.

AUGUST 2014 33

1-A01 [4] and ANSI/AGMA 20015- 2- A06 [5].

LOADING AND CONSTRAINTSThe applied torque is assumed to be equally divided among the three plan-ets per ANSI/AGMA6123-B06 (Figure 3), which recommends a mesh load factor of

“unity” for high speed and high qual-ity gears for the presented case. For the purpose of this study the force acting on each tooth is applied at the highest point of single tooth contact for each location (Figure 4) and equally distributed along the line of contact, which means using load distribution factor of “unity.”

The application of the force transmitted through the splines is determined by the FEA software. The ring gear is floating in all directions. The radial and circular movement of the gear is limited by the backlash in the assembly and the axial movement is restricted by axial stoppers, which are not shown.

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Figure 3: Force location on the internal gear teeth of the ring gear. Figure 4: Force application on the internal gear teeth: Ft – tangential component of the gear tooth force; Fc – gear tooth force.

34 gearsolutions.com

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FEA MODELINGA nonlinear static analysis of the ring gear and torque tube was conducted in ABAQUS. The ring gear teeth and the splines of the ring gear and torque tube were modeled with a f ine mesh of 8-node brick elements. The model transitioned to a coarser mesh of linear tetrahedral elements away from the splines (Figure 5).

Using a cylindrical coordinate system, the loads were applied on three internal teeth of the ring gear. Contact pairs were used to capture the interaction between ring gear and torque tube splines. These contact pairs were def ined between the mating surfaces of the ring gear’s external splines and the torque tube’s internal splines. The model had about 3.5 million nodes and the analysis was run on a supercomputer in order to obtain results in a reasonable time frame.

RESULTSFEA snapshots of only the overall displacement magnitude of the ring gear and the splines stresses are shown on Figure 6 and Figure 7. Von Mises, maximum and minimum principle root stresses in locations I, II, and III of only one tooth flank (Figure 8) of the ring gear teeth and external splines, and torque tube internal splines, are shown on the graphs of Figures 9 through 17.

CONCLUSIONS• The analysis shows heavy triangulation of the ring gear

(Figure 6).• Only about 10% of the splines teeth carry most of the load at

the same time.• Close analysis of these stressed teeth (not shown) points out that

Figure 5: Image on the right shows a zoom in view of the mesh around the ring gear’s external splines.

Figure 7: Von Mises stresses of the ring gear external splines in zone 1.

Figure 8: Location of the root stresses presented in the table.

Figure 9: Von Mises root stresses of the ring gear external splines.

Figure 6: Overall displacement in inches of the ring gear.

Figure 10: Von Mises root stresses of the ring gear internal teeth

Figure 11: Von Mises root stresses of the torque tube internal splines.

36 gearsolutions.com

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the stresses are not evenly distributed and only few teeth at a time take the highest load. This leads to the conclusion that the fatigue calculations of splines with similar behavior are as important as the shearing and wearing calculations.

• In many instances the principle stresses are higher than the allowable fatigue stress numbers per ANSI/AGMA 2001-D04.

• The higher crowning increases the stresses and that is why the stresses in zone 2 are generally smaller than the other zones.

Figure 12: Max. principle root stresses of the ring gear external splines.

Figure 13: Max. principle root stresses of the ring gear internal teeth.

Figure 14: Max. principle root stresses of the torque tube internal splines.

Figure 15: Min. principle root stresses of the ring gear external splines.

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• The smaller root radius increases the stress and this is clearly seen in the highest stresses in zone 3.

• The results from the FEA study conf irm the f ield feedback.

• The FEA is an effective method of ana-lyzing and predicting the complicated def lections of f loating planetary ring gears.

LIMITATIONS OF THE STUDY• Only two parts of the entire wheel

motor are used in this study — the ring gear and the torque tube. If other parts like the hub, the wheel bearings, the planets, etc. and stress-inf luencing fac-tors like the truck load were added, the stif fness of the investigated mechanical system would change and the results would be different.

• The force transmitted from the planets to the internal teeth of the ring gear was applied at the highest point of single tooth contact and uniformly distributed along the tooth surface. In reality the force may not be at that point for flexible systems and certainly would not be distributed evenly.

• Only three zones of the ring gear were modeled with different crowning and root radii, which limit the understanding of their influence on the stresses.

ACKNOWLEDGEMENTSThe authors would like to thank to Srinivas Rallabandi and Deepak Rotti who worked

Figure 16: Min. principle root stresses of the ring gear internal teeth.

“The application of the force transmitted through the

splines is determined by the

FEA software.”

42 gearsolutions.com

on the FEA modeling and analysis, as well as Nick Dame who worked on the solid models.

REFERENCES1. ANSI/AGMA 2001-D04, "Fundamental

Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth"

2. AGMA 908 - B89, "Geometry Factors for Determining the Pitting Resistance and Bending Strength of Spur, Helical and Herringbone Gear Teeth"

3. ANSI/AGMA 6123-B06, "Design Manual for Enclosed Epicyclic Gear Drives"

4. ANSI/AGMA 2015-1-A01, "Accuracy Classif ication System - Tangential Measurements for Cylindrical Gears

5. ANSI/AGMA 2015-2-A06, Accuracy Classi f icat ion System - Radial Measurements for Cylindrical Gears"

6. Kirov, V., "Comparison of the AGMA and FEA Calculat ions of Gears and Gearbox Components Applied in the Environment of Small Gear Company," 10FTM05

7. Silvers, J., Sorensen, C.D., and Chase, K.W., "New Statist ical Model for Predicting Tooth Engagement and Load Sharing in Involute Splines," 10FTM07.

ABOUT THE AUTHORS

Dr. Vanyo Kirov has MENg degree from the East Ukrainian National University, PhD in gearing from the University of Ruse, Bulgaria and MBA from the University of Wisconsin - Whitewater. He has more than 25 years of experience in different fields of gearing - manufacturing, design, assembly, tooling, manage-ment. Currently Dr. Kirov is Senior Engineering Specialist in Design at Caterpillar Global Mining LLC, South Milwaukee.

Dr. Yun Y. Wang has a Ph.D. in Mechanical Engineering from North Carolina State University. She has over 13 years of industrial experi-ence, with a focus on structur-al analysis. Currently Dr. Wang is enngineering manager at Caterpillar Global Mining LLC, South Milwaukee.

Figure 17: Min. principle root stresses of the torque tube internal splines.

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AUGUST 2014 43

Gear Failure Analysis and Lessons Learned in Aircraft High-Lift ActuationSeveral gear failure cases yielded important lessons for the development phase of aircraft high lift actuation systems.

By Anngwo Wang, Seth Gitnes, Lotfi El-Bayoumy and Jonathan Davies, MOOG Inc. Aircraft Group

TTHE HIGH LIFT SYSTEM OF AN AIRCRAFT, INCLUDING TRAILING AND/OR LEADING EDGE

SLATS/FLAPS, INCREASES LIFT FOR TAKEOFF, CONTROLS FLIGHT DURING CRUISE, AND

REDUCES LANDING DISTANCE FOR TOUCH-DOWN.

This flight control system is usually composed of power drive units (PDUs), torque tubes, bevel gear boxes, offset gearboxes, leading edge (LE) geared rotary actuators (GRAs), trailing edge (TE) GRAs, and leading edge sector gears and pinions (Figure 1). The sys-tem also includes other components, such as torque limiters, slip clutches, no-back drive devices, and wing tip brakes to provide system protection from over-loading. Many of these components contain different types of gears that are usually highly loaded to increase the power to weight ratio. Because of the requirements on weight or envelope and consideration of cost, the gears in a high lift system are always designed with minimal margins.

The structure that supports the gear is limited in size or simplified, and the gear material and heat treatment are selected for easy manufacturing. De-flections and misalignments between meshing gears cause edge loading which generates noise and high bend-ing and contact stresses. The deflection emanates from the high loading and the misalignment comes from wing bending or the deflection of gear\shafts and housings. Irrespective of the load, once the misalignment and/or deflec-tion cause the contact area to shift and diminish, the stress becomes large enough to cause problems.

AGMA publishes an atlas of failure modes [1] that identify some common types of wear. Bajpai et. al. [2] com-bines a contact analysis model and a wear prediction model to describe the evaluation of tooth surface wear of spur and helical gear pairs. In these previous papers, the focus is on the outcome of failures, and not the reasons and sourc-es of gear wear. Drago [3] discussed spalling caused by tip interference and showed that a contact failure can lead to a more severe tooth fracture. Drago

et. al. [4] also discussed the relation between micropitting to specific lubri-cation additive package combinations, gear quality and surface finish, which can be resolved by profile modifica-tions. Errichello et. al. [5] investigated that the root cause of macropitting

is the geometric stress concentration caused by tip-to-root interference. All these previous three papers deal with failures caused by tooth geometries and quality of gears. Errichello [6] investi-gated a gear set which failed due to lu-brication breakdown.

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

Figure 1: Schematic of the high lift system of an aircraft (left LE shown, TE similar).

Figure 2: Typical leading edge GRA.

Figure 3: Typical trailing edge GRA.

Figure 4: Schematic of the output stage of a typical trailing edge GRA.

AUGUST 2014 45

The main objective of this presentation is to find out how to solve these problems if the cause is due to edge loading from the misalignment of gear mounting and/or deflection of support-ing structure. In this article, several different gear failure cases in the development phase of high lift systems are presented, including lead-ing edge geared rotary actuators, and trail-ing edge geared rotary actuators, sector gears and pinions, and offset gearboxes. The failure modes can be classified as spalling or pitting at the location of concentrated loads. Most of the problems can be resolved by providing correct lead modifications to alleviate the concentrated

loading, while some can only be corrected by increasing the gear diameters, design modifica-tions, or introduction of materials with higher allowable. Detailed analyses to predict deflec-tions and misalignments on system and com-ponent levels is the key to the amount of lead modification, from which increased local con-tact stresses can be calculated.

The cases presented in this paper are from the pre-production risk mitigation units (RMUs). Normally the RMUs were designed with little margin to achieve minimum weight. Most system or component deflections can be predicted by analyses during the design phase.

If there are any unanticipated misalignments or deflections, then failures will show up and the situation can be improved with corrections in the production units. In this way designs are optimized for minimum weight.

LEADING EDGE ROTARY GEARED ACTUATORSThe cross section of a typical leading edge geared rotary actuator is shown in Figure 2. There are three gear meshes on each one of the planet gears. The output is on the left side of the actuator. The output planet gears are overhung and balanced by the planet gears on the right. The center planet gears act as a pivot point. Be-cause the output planet gears are overhung, it is called a cantilever GRA.

TRAILING EDGE GEARED ROTARY ACTUATORSThe cross section of a typical trailing edge geared rotary actuator is shown in Figure 3, and the gear schematic is shown in Figure 4. The output consists of two load paths from two end ring gears. The sun gear drives the right end planet gears. The stiffness difference be-

Figure 5: Typical leading edge sector gear and pinion set.

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tween the right and left load paths causes the compound planet gear to tilt. Thus, not only the planet gear loads due to meshing with the ring gears have to be considered, but also the misalignment from the two load paths needs to be included for selecting the optimum crown-ing which also reduces load mal-distribution across the gear tooth faces and increases local contact stresses. Therefore, excessive crowning must be avoided.

LEADING EDGE SECTOR GEARS AND PINIONSA typical leading edge sector gear and pinion set is shown in Figure 5. The pinion has to be crowned to allow for wing bending if a spheri-cal bearing mount is not possible. This gear set is exposed to outside environment and grease or dry film lubrication may be depleted be-tween service intervals. Crowning radii have to be optimized so that contact stresses can be minimized and the risk of running dry can be mitigated.

From all the above applications in a high lift system, we can understand the importance of a good face load distribution between mating gear teeth. If misalignments become excessive, gears will suffer edge loading. Five different failure examples from pre-production risk miti-gation units are the subject of the next section.

FAILURE EXAMPLESExample 1: Offset Idler Gear SetAn offset gear set with one bearing very close to one end of the gearbox and another support far at the other end is shown in Figure 6. This is a very special layout, and is not the normal offset gearbox straddle mounted between two bear-ings. One can calculate the face load distribu-tion according to AGMA [9]. Because of the deflection, gears are edge loaded and pitted as

shown in the figure. To solve the problem, the gears need to be crowned to accommodate this misalignment. The face width is 0.80 inch. The total slope including the deflection and manu-facturing errors is 0.0048 in/in. After solving the equations as discussed in [7], the crowning radius is 91 inch, and the crowning center is at the end of the tooth. A contact stress of 266 ksi is calculated under the max tangential load of 1000 lbf. From Figure 7, we can see that the crowning has eliminated the pitting problem, so that the full tooth is now sharing the load.

Lessons LearnedThe lesson learned in this case is that the loca-tion of bearing supports has significant impact on the load distribution of gears. Of course, it is better to have gears straddle mounted and sit just in the middle of two rigid supporting bear-ings. But sometimes, because of the restriction from the structure of gearboxes, it is unavoid-able to have lead modifications to relieve the situation.

Another lesson learned is that if there is a large chamfer (Figure 8) on any member of the gears in mesh, the net face width at the lowest point of single tooth contact (LPSTC) should be used to calculate the contact stress, not the face width at the root. Using this net face for contact stresses is very easy to overlook at the early stage of design process. When the design is so critical, a small percentage can make a significant difference on life calculations. The increased contact stress should be recalculated considering the localized load distribution from the crowned teeth.

Example 2: Sector and Pinion Gear SetA sector and pinion gear set in Figure 5 must accommodate wing deflections. Because of be-ing exposed to outside environment, the con-

Figure 6: Damaged gear without crowning. [7]

Figure 8: Large chamfer on gears affects the net face width.

Figure 9: Contact pattern on a sector gear.

Figure 10: Contact pattern of a crowned sector pinion. [7]

Figure 7: Good gear contact with crowning. [7]

Figure 11: Reacting forces on cluster pinions.

Figure 12: Pitted input sun pinion.

AUGUST 2014 47

tact stress must be low enough so that running the gears without grease is possible.

The baseline design is regularly lubricated, and maximum allowable misalignment is 0.0015 in/in. The calculated contact stress is 312 ksi with crowning under maximum oper-ating loads. However, the test was done with no re-grease between service intervals. It is clear from the gear and pinion shown in Figure 9 and Figure 10 that although the contact pat-tern is localized, yet because of the higher con-tact stress due to crowning, initial lubrication is gone after a while and soon after micro-pitting and rusting will result. Therefore, the goal is to make it lube-free. For a given misalignment, a new crowning radius and face width are pro-posed so that the stress is low enough to elimi-nate the need for re-lubrication in service. The increased face width comes with a weight pen-alty, though. Another solution is to change to a material that has a higher contact allowable.

Lessons LearnedA common engineering practice for calculat-ing fatigue life is to use the mean load of a load spectrum. The mean load is the time averaged load of a spectrum which contains multiple load sets (load vs. time) and is given by equa-tion 1. The exponent m establishes the relation-ship between load (i.e., stress) vs. cycles to fail. Various exponents may be used to determine the mean load, but the most common are the followings: m = 3 for bearing wear analysis [8] and m = 9 for gear contact fatigue [9].

Equation 1 is known as the Lundberg-Palmgren equation used in the mean load cal-culation [8] for rolling bearings. This method can be extended to gear contact life analyses, where m = 9 is derived from the slope of pitting S-N logarithmic curves [9], and the square re-lation between loads and contact stresses. How-ever, this mean load method may not be cor-rect for the sector and pinion gear set, because

Figure 15: Wear pattern of the internal gears of the housing, which exhibits slight spalling near bottom of the tooth profile, towards one end.

Figure 13: Spalled cluster pinion where a portion of the teeth broke away.

Figure 14: Typical simplified compound planetary gears.

48 gearsolutions.com

the high load at one tooth cannot be shared by other teeth due to the limited stroke range. The lesson learned in this failure study is that un-like other types of gears the teeth get multiple hits from mating members, the sector gear gets certain loading with specific load conditions. A cumulative damage analysis, Equation 2 [9] recommended by AGMA, is more suitable.

Example 3: Cluster Pinions in TE GRAsThe cluster pinions in the input stage of a trail-ing edge GRA (Figure 3) failed at the pinion gear which mated with the ring (Z) gear. A free body diagram showing the force (red dashed line with arrows) acting on the gears is shown in Figure 11. Due to the deflection and internal clearances between bearings and the mounting housing, the cluster pinions tilt downwards and inwards on the pinions at the left. Therefore, the forces between the gear mesh of cluster pin-ions and ring (Z) gears are concentrated at the end of the cluster pinions. The evidence of tilt-ing gears is also shown on the input sun pinion (Figure 12).

Shown in Figure 13 is the spalling failure caused by edge loading on the end of the cluster pinions. Portions of the teeth then broke away from the origin of the spalling in a way very similar to what was described in [3]. It starts from the inner bottom end of the teeth, then pitting/spalling propagates up along the profile in the direction of sliding. The crack then turns in the direction of the line of action into the ma-terial, resulting in a chunk of metal separating from the teeth. Because the damage is only at

one end of the teeth, the cause of failure is edge loading, instead of tip interference.

The solution to this problem is to provide lead modifications on the cluster pinions simi-lar to Example one, so that the load concentra-tion can be alleviated. Another option is to use carburized materials, so that even with unde-sired load distribution the design can still hold the load. Other possible options are to preload the bearings to reduce the clearance or to in-crease the span of bearing supports to reduce the effect of the clearance. However, the latter modification will increase the length of the ac-tuators.

Lessons Learned1. The effect of bearings internal clearances on

overhung gears cannot be neglected, especial-ly when the bearing span is relatively small;

2. The deflection from the supporting carrier needs to be considered in the misalignment;

3. Do not underestimate the loading in the in-put stage. Although the load is relatively low

Figure 16: Close-up view of spalling on lower gear tooth profile of the housing, towards one end.

Figure 19: Cracks around all output ring gear teeth.

Figure 20: Cracks around some housing ring gear teeth.

Figure 17: View of chipped and damaged housing gear teeth.

Figure 18: View of sun gear teeth, which exhibited some pitting, spalling, and chipping near one end of gear teeth.

AUGUST 2014 49

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compared to the output stage, once the gears are tilted and the contact shifts to the edge, then the stress becomes very large.

4. There are more teeth hits on the input stage than on the output, so the de-rating factors need to be adjusted accordingly.

Example 4: Simplified Compound GRAs in LEThe triple planet gears shown in Figure 2 can be simplified to simple planet gears but still mesh with two ring gears. A degenerate version of the cantilever GRAs is shown in Figure 14 which is called simplified compound GRAs. When diametral envelope is available on the leading edge of an airplane, the cost saving on

using simplified compound planetary gears could be beneficial. It has the same advantage and disadvantage of the cantilever actuator with a larger diameter but shorter length.

Risk Mitigation Testing:1. At 50% of life teardowns, signs of spalling

are shown in the root area of the housing ring gear at the interface between two ring gears (Figure 15 and Figure 16).

2. The failed unit exhibited chipped housing ring gear teeth, initiating from the root of the edge facing the output ring gear (at the inter-face between the two ring gears) (Figure 17).

3. The end of the sun gear also shows sign of interference near the start of active profile

(Figure 18). This confirmed that the planet gears are tilted under equal and opposite loads from both ring gears.

4. Upon magnetic particle inspection, both the fixed ring gear and the output shaft ring gear exhibited fatigue cracks in the tooth root area (Figure 19 and 20).

5. The failure of the fixed ring gear (Figure 20) indicates an edge loading condition in excess of what was used in the gear calculation on face load distribution.

Proposed Improvements Based on Risk Mitigation Testing Results:1. Shot peening the ring gear teeth on the pro-

duction unit provides improved bending fa-tigue performance over the risk mitigation unit, which was not shot peened.

2. Tapered ring gear teeth (via tilting the part in the shaper cutter) or plunge hobbing the planets can improve the face load distribu-tion and prevent hard edge loading (Figure 21 and Figure 22). Another option is to increase the diameter so that the gears can take the extra load mal-distribution.

3. Improvement can be made without increas-

Figure 21: Edge loading of simplified compound planetary gears (normal section view).

Figure 22: Improvement on load distribution (normal section view).

50 gearsolutions.com

ing the diameter by built-in slope on the ring gears. The load mal-dis-tribution of the gears before the proper lead modification is shown in Figure 21 in which the planet gears are tilted. When the lead modifica-tion is implemented as shown in Figure 22 on both housing ring gears and output ring gears, the face load distribution becomes uniform.

Lessons Learned1. The tilting from bearings internal clearances and carrier deflections

cannot be reduced enough to solve the load mal-distribution.2. There is more weight benefit by increasing the diameter and reducing

the face width, if the envelope allows.

Example 5: Cantilever Compound GRAs in LEA prototype cantilever (unbalanced) compound geared rotary actu-ator similar to the one in Figure 2 is shown in Figure 23. The major

Figure 24: Free body diagram of cantilever compound planetary gears (normal section view; Wt : tangential force).

Figure 25: Free body diagram of cantilever compound planetary gears with separator ring Wr_L at the end (cross section view, Wr : radial force).For more information and to see demonstration

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Figure 23: Prototype cantilever compound GRA.

Figure 26: Free body diagram of cantilever compound planetary gears with separator ring Wr_L in the middle (cross section view, Wr : radial force).

52 gearsolutions.com

difference between these two is the location of the supporting rings.

Figure 24 shows a free body diagram in the normal section through the gear pitch in the XZ plane. For a correct design where the left separator ring is at the end shown in Figure 2 and Figure 25, the tangential force bends the planet gears in the way that the radial load and bell mouth effect on out-put ring gears compensate the def lection. Therefore, the left end planets have a bet-ter face load distribution (combining the Y-def lection from Figure 24 and Figure 25). The center planet gears have minimum de-f lections and the right end planet gear is far from the center with a shorter face width. Therefore, there is no need to crown even with both def lections in the same direction caused by tangential and radial loads.

On the other hand, Figure 26 shows a free body diagram in the cross section in the XY plane of a poor design where the def lec-tion caused by radial load acting on the end planet gears is in the same direction as the tangential load does shown in Figure 24.

Lessons LearnedThis unit failed because there is too much def lection and tilting due to wrong sepa-rator ring locations and chattering due to synchronous and low efficient designs. The output planet gear NBP should be as close to the center planet gear as possible and the left supporting ring should be at the end of whole planet gears. By doing this, the def lection and tilting will be smaller to mitigate the edge loading. The right planet gears need to be extended far enough to re-duce the tilting and the loads. By control-ling the diametral tolerance of the separa-tor rings, the backlash can be minimized as well as the tilting.

Other Differences and Lessons Learned1. The geared rotary actuators should be

non-synchronous [10];2. Sun gears need to be crowned to accom-

modate the tilting of planet gears;3. It should have higher efficiency so that it

will not chatter under aiding loads [10].

Because of the gear ratio requirement, the average forward efficiency becomes very close to 50%. The risk mitigation unit was a

synchronous gear set, and the instantaneous efficiency varies plus/minus 20%. Therefore, at the aiding load condition, the unit chat-ters because it is not back drivable when the instantaneous forward efficiency falls below 50% (Figure 27 and Figure 28).

The methods to resolve this failure include:

1. Lower the gear ratio by adding an input stage;

2. Move the separator rings to the end of the planet gear, NBP;

3. Change from synchronous to non-syn-chronous designs;

4. Reduce the number of planets gears so that each planet is larger and def lection is smaller;

5. Improve the quality of the gears so that the backlash and tilting can be mini-mized.

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CONCLUSIONSDeflections and misalignments in a gear set can be detrimental when the gears are edge loaded, generating noise and high bending and contact stresses. Tooth deflections usually result from highly loaded gears and mis-alignments come from wing bending or deflections of the gear housings.

In this paper, several gear failure cases in the development phase of high lift systems were presented, including leading edge geared rotary actuators, trailing edge geared rotary actuators, sector gears and pinions, and offset gearboxes. The failure modes can be classified as spalling or pitting at the location of concentrated loads. Most of the problems can be mitigated by providing correct lead modifications to alleviate the concentrated loadings, while some need increase of the gear diameters, design modifications, or introduction of materials with higher allowable.

ACKNOWLEDGEMENTSThe authors would like to thank MOOG management for the approval of publication of this paper.

REFERENCES1. ANSI/AGMA 1010-E95, Appearance of Gear Teeth - Termi-

nology of Wear and Failure2. Bajpai, P., Kahraman, A., and Anderson, N.E., A Surface

Wear Prediction Methodology for Parallel-Axis Gear Pairs, Journal of Tribology, ASME, July 2004, Vol. 126, PP 597-605.

3. Drago, R.J., The Effect of Start-Up Load Conditions on Gear-

box Performance and Life Failure Analysis, with Supporting Case Study, 07FTM12.

4. Drago, R.J., Cunningham R.J., and Cymbala, S., The Anatomy of a Micropitting Induced Tooth Fracture Failure, Its Causation, Initia-tion, Progression and Prevention, 09FTM12.

5. Errichello R., Hewette C., and Eckert R., Point Surface Origin (PSO) Macropitting Caused by Geometric Stress Concentration (GSC), 10FTM11.

6. Errichello R., Friction, Lubrication, and Wear of Gears, Friction, Lu-brication, and Wear Technology, Vol. 18, ASM Handbook, ASM In-ternational, 1992, p. 535-545.

7. Wang, A., and El-Bayoumy, L., Crowning Techniques in Aerospace Actuation Gearing, Proceedings of the ASME 2009 International Design Engineering Technical Conferences & Computers and Infor-mation in Engineering Conference, DETC2009-86358, September 2009.

8. Harris, Tedric A., Rolling Bearing Analysis, 3rd edition. John Wiley and Sons, New York, 1991.

9. ANSI/AGMA 2001-D04, Fundamental Rating Factors and Calcula-tion Methods for Involute Spur and Helical Gear Teeth.

10. Wang, A., Gitnes, S., and El-Bayoumy, L., The Instantaneous Ef-ficiency of Epicyclic Gears in Flight Control Systems, ASME Journal of Mechanical Design, Vol. 133, 051008, May 2011.

ABOUT THE AUTHORS Anngwo Wang is an engineering specialist at MOOG Inc. Aircraft Group. He received his Ph.D. from Professor Litvin at University of Illinois at Chicago in 1997. He is responsible for gear design and analysis of the transmission in the aircraft flight control system. Recent major projects he has worked on included F35 Leading Edge Flap Actuation System and Wingfold System, Boeing 787 Leading Edge Slat Actuation, Airbus A350XWB Trailing Edge Flap Actuation System, and KC46 Tanker Boom and Hoist Actuators.

Seth E. Gitnes is a mechanical design engineer at Moog Aircraft Group. He has been with Moog for 14 years, working Flap/Slat and other mechanical systems for many commercial aircraft including B787, A350, G450, G650 and G280. Prior to Moog, he worked for Boeing Commercial Aircraft Group for nine years, working on the Flap and Slat systems on the B777, B737, B767 and B757 aircraft. He graduated from the University of Washington with a Bachelor of Science in Mechanical Engineering in 1991. He also holds patents for various mechanical devices used on many current aircraft.

Dr. Lotfi El-Bayoumy is head of the Analysis Group at Moog with over 30 years experience in structural integrity, gear technology, turbo machinery, and vibration control. He has participated in the design and development of many commercial and military aircraft, including 747, 757, 767, 777, 787, A320, A330, A340, A350, F-16, F-18, F-22, F-35, CH47, and V-22. Dr. El-Bayoumy holds a B.Sc. and M.Sc. in Aeronautical Engineering from Cairo university and a Ph.D. in Aeronautics & Astronautics from New York University.

Jonathan P. Davies is platform lead – Mechanical Actuation at Moog Aircraft Group Wolverhampton, UK. He has over 22 years experience in the conceptual design, detail design and analysis. He holds a BSc (Hons) in Applied Science from Wolverhampton University focusing on maths, physics, and electronics. After spending several years as a self-employed engineer working in both the industrial and aerospace sectors he joined Dowty Boulton Paul Ltd as a Design engineer. The company changed owners several times and in 2009 became part of Moog. During his time with the company he has worked on many mechanical, electro-mechanical and hydraulic units and systems on both civil and military aircraft and research and technology programs, including: B767-400, B777, B787, A380, F-35, JAS39, Aermacchi M346, ELGEAR, NGCW, BAe Mantis, Comac C919. He has successfully patented various mechanical devices and systems for aerospace applications.

Figure 27: Forward efficiency plots of prototype cantilever compound GRA.

Figure 28: Backdrive efficiency plots of prototype cantilever compound GRA.

54 gearsolutions.com

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A series of Fine-ground and Polish-ground gears are currently being tested by various gear manufacturing companies and transmission developers around the world.

By Walter Graf

AAS THE ORIGINAL INVENTOR OF CONTINUOUS GENERATING GEAR GRINDING TECHNOLOGY,

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Among the best-known company's developments, are: continuous-shift generating grinding, high-performance generating grinding, low-noise shifting and twist-control grinding. The newly developed Fine and Polish grinding technology extends the range of process options.

Reducing energy consumption and automotive CO2 emissions require further engine developments, but more importantly, today these reductions demand substantial increases in transmission power density. This requires greater gear tooth load-carrying capacity and reduced transmission power loss. Improvements to both material properties in the surface zone of gear teeth and complex modifications of the gear f lank geometry help to opti-mize tooth meshing under load. In addition, numerous research projects have shown that reducing gear f lank sur-face roughness increases the load-carrying capacity and reduces transmission power loss. The effects of improved surface roughness which result in the proof of strength required by DIN 3990 that act on the specific factors have been investigated in a series of FVA projects at the FZG Gear Research Centre at the Technical University of Munich. The experimental investigation verified that reducing the surface roughness of the gear f lanks from a conventional Ra ≈ O.4mm to Ra ≤ O.1 mm produced an increased load-carrying capacity of approximately 14%. This improvement was seen as the direct result of a substantially reduced amount of micro-pitting. As with the majority of previous scientific tests, the experiments were carried out with gears that had been machined using vibratory super finishing.

IMPROVED SURFACE QUALITYAs a consequence of these promising results, automo-tive transmission manufacturers have begun looking for a more suitable method other than vibratory finish-ing to reduce surface roughness on ground gear f lanks. Continuous generating gear grinding is widely seen as the most productive hard finishing machining method for the manufacture of automotive transmission gears. For this reason, automotive transmission manufacturers are now focused on a suitable extension to this process so that surface quality targets can be met based on this alterna-tive machining technology. Reishauer’s proven Low Noise shifting technology produces specifically modified ground surface structures which reduce overall noise emissions caused by gear meshing. Furthermore, now the com-

pany’s Finegrinding and Polish-grinding method results in considerable improvements to the load-carrying capac-ity and working efficiency of gear teeth. These improve-ments are due to the superior surface quality achieved with the modified continuous generating gear grinding process. Reishauer's Fine-grinding and Polish-grinding were specifically developed to create a surface finish level comparable to that of vibratory finishing to reduce the initial surface roughness of gear teeth machined using the continuous generating gear grinding process. Contrary to vibration finishing, the f lank design and surface zone characteristics of the active tooth f lanks are not adversely affected by this new method.

THE PROCESSWithout interrupting the overall machining process, Reishauer's Fine-grinding and or Polish-grinding are performed as a final machining pass immediately after conventional grinding. This final pass could consist of Fine-grinding with a vitrified bonded grinding wheel set or, alternatively, after conventional finishing, of a Polish-grinding pass with a vitrified or resin bonded grinding wheel set. During Fine-grinding and Polish-grinding, the roughness peaks are removed. This reduces the rough-ness profile height and, therefore, increases the contact area of the gear f lanks. In comparison to the quality achieved with the previous finishing method, the geomet-ric accuracy of the gear f lanks in the active range is also improved. During the Polish-grinding machining step, an additional machining pass is usually sufficient to achieve the required surface finish. To apply this new process, the customer will require a special Reishauer grinding worm set which consists of a conventional ceramic grinding worm combined with a fine grit vitrified bonded grinding worm, or combined with resin bonded Polish-grinding worm. This innovative grinding worm set is manufactured in-house by Reishauer's tooling division. Depending on the chosen grinding wheel specifications and the corre-sponding machining technology, the process delivers sur-face qualities with mean roughness values of Ra ≈ O.211 μm in the case of Fine-grinding, and Ra < O.1 μm in the case of polish-grinding. Regarding the grinding kinemat-ics, Reishauer's Fine-grinding and Polish-grinding differs greatly from the various vibration finishing methods used in previous scientific studies and R&D projects. For this reason, Reishauer commissioned an independent assess-

(Left) Grinding wheel set developed for Reishauer Fine-grinding and Polish-grinding.

AUGUST 2014 57

ment by the FZG institute at the Technical University of Munich to investigate the effects of various finishing options during continuous generating gear grinding on the efficacy of gear teeth in transmis-sions. The tests were carried out and evaluated based on the test method defined by the FZG in the FVA-Drive Technology Research Association research project FVA 345 Efficiency Test. This assess-ment confirmed an approximate 15% reduction in total power losses for the Polish-ground samples, and therefore, considerably reduced friction values for operation under load compared with a convention-

ally ground reference sample. This result was further confirmed on a test bench running at a lower lubricating oil steady state temperature.

CONVINCING RESULTSA series of Fine-ground and Polish-ground gears are currently being tested by various gear manufacturing companies and transmission developers around the world. As well as testing load carrying capacity and effectiveness, these tests investigate the inf luence of f ine-ground gears on changes to f lank clearance in

Figure 1: Gear ground by conventional gear grinding (left) compared with a Polish-ground gear (right).

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precision transmissions on the overall ser-vice life of coated gear f lanks, and on noise generation in transmissions. The initial test bench results also confirmed the posi-tive results shown in the initial research project regarding increased load-carrying capacity. In addition to this, tests are planned to investigate potential additional power loss reduction by using lower viscos-ity grades of transmission lubricating oils. The direct integration of Fine-grinding and Polish-grinding as a subsequent step in the conventional continuous generating grinding process translates into compara-tively low additional investment costs. For this reason, these methods are an interest-ing alternative to the vibratory process in the f inishing of gears with improved surface quality.

Figure 2: After the conventional roughing and finishing pass of generating gear grinding, thePolishing pass reduces the peaks of the roughness profile without changing the flank design.

ABOUT THE AUTHOR Walter Graf completed his tool making apprenticeship in 1974. He worked for 10 years in tool and mold making workshops. Following this, he continued his studies in Australia and the UK and was awarded a Bachelor of Science Degree (Honors). Some 21 years ago, he began as a product manager for superabrasives at Winterthur Schleiftechnik AG, Switzerland. Three years later he became their sales manager and prior to the purchase of Winterthur by 3M in 2011, he held the position of chief marketing officer for the entire Winterthur Group.

Booth# N-7127

AUGUST 2014 59

Two companies make the most of their swarf with RUF Briquetting.

By Greg Tucholski

CASESTUDY

COMPANY:

CUSTOMER:

RUF Briquetting Systems

Corrugated Replacements, Inc. and Horsburg-Scott

BBRIQUETTING IS A WAY TO REGAIN VALUE FROM THE MATERIALS YOU ALREADY HAVE.

GEAR GRINDING OPERATIONS ARE FINDING THE VALUE THEY THOUGHT WAS LOST IN THE

GRINDING SLUDGE. THE BONUSES OF INCREASED OPERATIONAL EFFICIENCIES AND SAFER

WORKING CONDITIONS ARE REALIZED ONCE COMPANIES START USING A BRIQUETTING

SYSTEM.

Corrugated Replacements, Inc., a developer of machine replacement parts for the steel, poultry, and satellite industries, and Horsburgh-Scott, a leading provider of industrial gears and custom gear drives for steel, alu-minum, tire, rubber plants, and wind turbines, are just two of the many companies who looked to RUF Briquetting Systems to help squeeze value out of product they previously viewed as lost.

In 2013, managing month-ly expenses of time, money, and resources dealing with swarf produced in the grinding pro-cess was a reality for Corrugated Replacements. Before purchasing a briquetting system, dirty swarf was stored in barrels on the production f loor, and then disposed of by a costly hazardous waste removal company. With the briquetting sys-tem, things have changed.

“We were able to turn something that was a 100 percent expendi-ture process into a prof itable rev-enue stream and reuse reclaimed coolant,” sa id Corrugated Replacements plant and engineer-ing manager Scott Wallis. “It has been a win-win for our business.”

Similarly, the Horsburgh-Scott production process was positively impacted after the installation of a briquetting system in February of this year.

“The briquetter has helped our operation reclaim more than 1,650 gallons of oil from our swarf,” said Horsburgh-Scott manufacturing engineer Luciana Talpa. “The RUF machine works amazingly; it simpli-f ied the business and will pay for itself in less than a year.”

Horsburgh-Scott’s grinding sludge contained 63 percent oil by weight. The briquetting process was able to

reclaim nearly all of the oil from this saturated grinding sludge. The reclaimed oil is then reused, reduc-

AUGUST 2014 61

ing the amount of new oil purchases needed for their gear grind-ing process.

Reducing oil and coolant loss is just part of the added eff icien-cy of the briquetting system. Both companies have also reduced or eliminated hazardous waste costs, turning it into a revenue stream by selling the briquettes as scrap to steel mills.

Although it was not part of the initial goal, by improving operation eff iciency and reducing expenses for wasted material and swarf, briquetting and reclaiming product has made for a safer work environment.

“The barrels where swarf was previously stored, waiting for disposal, created a heat safety issue,” said Wallis. “Not only did we regain a signif icant amount of f loor space, but we also elimi-nated the need to store hazardous waste.”

These two companies, along with others in the metal grind-ing industry, have improved eff iciency, safety, productivity and developed a new revenue stream, simply by recycling their own product through the briquetting process.

ABOUT THE AUTHORS Greg Tucholski is the president of RUF US, Inc., an equipment supplier to the automotive, aerospace, agriculture, recycling, furniture, flooring, health products and heavy equipment industries since 2008. Tucholski, who has a BS in mechanical engineering, has been with RUF since 2001 and has more than 20 years of manufacturing and material handling experience.

Located near Cleveland in North Olmstead, Ohio, RUF is the North American subsidiary of RUF GmbH & Co. K in Germany—a global pioneer of advanced briquetting systems for more than 40 years. The quality and performance of its briquetting systems are proven worldwide with more than 3,000 currently in operation. For more information, visit www.RUF-Briquetter.com or call 440-779-2747.

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Intelligence in Production.Gear manufacturing technology innovations from Liebherr.

Gear hobbing machine LCH 180 two• Multi-cut strategy with roll / press deburr-chamfering• Primary hobbing time is done in parallel to the load / unload,

and roll / press deburr-chamfering, between two cuts – on two work-tables

Gear hobbing machine LC 180 Chamfer Cut• High chamfer quality with one-cut hobbing strategy• Primary hobbing time is done in parallel to chamfering

in a second machining position

Generating grinding machine LGG 180 / LGG 280• A single-table solution for gear grinding

of workpieces up to Ø 180 mm, or up to Ø 280 mm, and workpiece lengths up to 500 mm

• Extremely fast load/unload times of 4 seconds, chip-to-chip, with a single-table

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During development of our innovations, we place particular emphasis on choosing an optimal solution for the respective application. The result: Process stability and an outstanding quality of manufactured components – with the highest level of economy possible.

The Group

Liebherr Gear Technology, Inc.1465 Woodland DriveSaline, Michigan 48176-1259Phone.: +1 734 429 72 25E-mail: [email protected]

Visit us at:Chicago, Il. - USASeptember 8 - 13, 2014North Hall,Booth N-6930

2014-502_004 LVT_010_EMO_GB.indd 1 18.06.14 15:03

Principal Design Parameters Of Gearing With Non-Parallel Axes Of Rotations

Examples of gearing with non-parallel axes can be easily found in the industry.

By Stephen P. Radzevich, Ph.D., Dr. (Eng) Sci

TTHIS PAPER PERTAINS TO GEARING WITH NON-PARALLEL AXES OF ROTATION OF THE DRIVING

AND THE DRIVEN MEMBERS. EXAMPLES OF THE GEARING CAN BE EASILY FOUND IN THE

INDUSTRY – ALL GEARINGS WITH CROSSED AXES OF ROTATIONS (FURTHER, CA-GEARING

FOR SIMPLICITY), AND ALL GEARINGS WITH INTERSECTED AXES OF ROTATIONS (FURTHER

IA-GEARING FOR SIMPLICITY) FEATURE THE AXES OF ROTATIONS OF THE GEAR AND THE

PINION THAT ARE NOT PARALLEL TO EACH OTHER.

The kinematics and geometry of gearing with non-parallel axes of rotation are much less understood compared to that in parallel-axis gearing (further, PA-gearing for sim-plicity).

In PA-gearing, all the design parameters of the gear pair can be expressed in terms of the principal design parameters, that is, in terms of the profile angle, base pitch, base helix angle, contact ratio, and so forth [1]. It can be assumed at this point that a corresponding set of the principal design parameters can be assigned to gearing with non-parallel axes of rotation. It is shown in this paper that such the assumption is correct. Once been introduced, use of the principal design parameters makes it pos-sible a calculation of all the design parameters of a gear pair, both IA-and CA-gearing, similar to that in PA-gearing.

It should be noticed from the very beginning that the principal design parameters under consideration are not covered either by AGMA stan-dards or by other national and international standards on gearing with non-intersecting axes of rota-tion.

Transmitting of a rotation and torque from a driving shaft to a driven shaft is the main purpose of gearing with non-parallel axes of rotation. The input and the output rotations are commonly given, as well as the torques on the driving and the driven shafts. Therefore, it makes sense to express all the design parameters of a gear pair in terms of the rotations and torques. For a particular application, such

an approach gives an opportunity to synthesize a gear pair with the desired (that is, the most favorable) performance, and with a highest permissible power density.

The approach discussed in this paper was developed for the pur-pose of synthesizing of the most favorable bevel gearing widely used in the design of power tools, those produced by Apex Tool Group, LLC. Later on, the approach was generalized to gearing with non-parallel axes in more general sense, that is, to CA-gearing.

Let us begin the discussion from the kinematics of CA-gearing (IA-gearing can be interpreted as a degenerate case of CA-gearing for which the centerdistance is zero). An example of a gear pair with crossing axes of rotation of the gear, Og, and the pinion, Op, is shown in Fig.1.

In the CA-gearing shown in Fig.1, the driving pinion is rotated about

its axis of rotation, Op. The pinion rotation is designated as wp. The driven gear is rotated about its axis of rotation, Og. The gear rotation is designated as wg. The axes of rotation,Og and Op, are at a center distance, C, apart from one another.

The gear and the pinion rota-tions, wg and wp, can be interpreted as vectors wg and wp that act along the corresponding axes of rota-tion, Og and Op, [2]. The rotation vectors, wg and wp, make an angle, which is commonly denoted by S,[ S= (wg, wp)]. Often, the angle S equals to the right angle (that is, S=90º).

For a given configuration of the rotation vectors, wg and wp, a vector of instant rotation, wpl, can be cal-culated as the difference wpl

= wp -wg [2]. The axis of instant rotation, Pln, of the pinion about the gear is along the rotation vector wpl (Fig. 2).

Points of intersection of the cen-ter-line, CL , by the axes of rotation,

Figure 1: Kinematics of a gear pair with crossing axes rotations.

AUGUST 2014 65

Og,Op, and Pln, are designated as Ag, Ap, and Apa, respectively. As it is shown later on in this paper, points Ag, Ap, and Apa are the apexes of the base cones of the gear, the pinion, and the plane of action respec-tively.

The distances between the apexes Ag and Apa, as well as between the apexes Ap and Apa are labeled as rw.g and rw.p , respectively. It is shown [2] that the radii rw.g and rw.p can be expressed in terms of parameters of the kinematics of the CA-gear pair:

(1)

(2)

The radii rw.g and rw.p are signed values. Both of them are positive for an external gear pair, and the radius rw.g is negative in a case of internal gearing*.

It is convenient to apply the rotation vectors wg, wp, and wpl at the points Ag, Ap, and Apa of intersection of the center-line,CL , with the axis of rotation of the gear, Og, of the pinion, Op, and the axis of the instant rotation, Pln. Once the rotation vectors wg, wp, and wpl are constructed, then one can proceed with the calculation of the gear and the pinion angles Sg and Sp, respectively. By definition, these angles are equal to Sg= (wpl, wg) and Sp,[ S= (wpl, wp, respectively. The angles Sg and Sp can be xpressed in terms of the parameters of the kinematics of CA-gearing [2]:

(3)

(4)

In a case of IA-gearing, the angles Sg and Sp are equal to the corresponding pitch cone angles, G and g, of the gear and the pinion. In a more general case of CA-gearing, the angles Sg and Sp can be used for the calculation of the cone angles for the cones that locally (within the face width) approximate the pitch surfaces of the gear and the pinion that in the case

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Figure 2: Base cones and the plane of action PA, in an orthogonal crossed-axis gear pair.

66 gearsolutions.com

under consideration are shaped in the form of one-sheet-hyperboloids of revolution.

The rotation vectors, wg, wp, and wpl, are helpful for the constructing of the plane of action in a CA-gearing. The plane of action, PA, is a plane through the vector of instant rotation, wpl (that is, a plane through the axis of instant rotation, Pln). The plane of action, PA, makes a transverse pressure angle, ft.w, with a plane through the axis Pln perpen-dicular to the center-line, CL , as depicted in Fig. 2. The plane of action, PA, is rotated, wpa, about an axis,Opa (not shown in Fig. 2), that is a straight line through the apex, Apa. The transverse pressure angle, ft.w, complements to 90º the angle that make the center-line, CL , and the axis of rotation, Opa, of the plane of action, PA.

The plane of action, PA, can be used to construct the base cone of the gear in a CA-gearing. For this purpose, consider the plane of action, PA, that is rotated about the gear axis of rotation,Og. The base cone of the gear is generated as the enveloping surface to consecutive positions of the plane of action, PA, in such the rotation. This immediately allows for an expression for the base cone angle of the gear, Gb:

(5)

Similarly, the base cone of the pinion in a CA-gearing can be constructed. For this purpose, consider the plane of Figure 3: An example of the desired line of contact, LC.

68 gearsolutions.com

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action, PA, that is rotated about the pinion axis of rotation, Op. The base cone of the pinion is generated as the enveloping sur-face to consecutive positions of the plane of action, PA, in such the rotation. This immediately allows for an expression for the base cone angle of the pinion, gb:

(6)

When the gears rotate, the plane of action, PA, is unwrapping from the base cone of the driving member of the gear pair (commonly, this is the pinion), and is wrapping on the base cone of the driven member of the gear pair (obviously, this is the gear). No slippage is observed when the plane of action rolls over the base cones of the gear and the pinion in a CA-gearing.

The rotation of the plane of action, wpa, correlates to the rotations, wg and wp, of the gear and the pinion and to the base cone angles, Gb and gb, in accordance to the ratio:

(7)

At this point, neither the gear tooth flank, G, nor the pinion tooth flank, P, are constructed yet. However, the gear designer is free to select a desired line of contact between the tooth flanks of the gear and the pinion.

The desired line of contact, LC between the tooth flank of the gear, G, and the tooth flank of the pinion, P, is a planar curve that is entirely located within the plane of action, PA. There is a certain freedom in selecting the geometry of the desired line of contact. As an example, consider a desired line of contact, LCi, that is shaped in the form of an arc of a circle of a radius RLC as illustrated in Fig. 3. An arbitrary point mi is chosen within the line of contact, LCi. The point mi is at a distance Rm from the plane of action apex, Apa.

An adjacent desired line of contact, LCi+1 (that is, the line of contact for the neighboring pair of teeth of the gear and the pinion in a CA-gearing), is located within the plane of action, PA, at an angle jb.op in relation to the desired line of con-tact, LCi. The angle jb.op is referred to as the operating base pitch. For a specified CA-gear pair, the operating base pitch is of constant value for all points within the desired line of contact between the tooth flank of the gear, G, and the tooth flank of the pinion, P (that is, jb.op=const) regard-less of the distance, Rm, of a point mi from the apex Apa.

For a specified CA-gear pair, three design parameters:

• the operating base pitch, jb.op,• the gear base pitch, jb.g, and• the pinion base pitch, jb.p,

must be equal to one another:

(8)

Any and all gearings must meet the requirement specified by Eq. (8).

70 gearsolutions.com

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In cases of ideal gearing, that is, when no axis misalignment is taken into consideration, all three base pitches, jb.op, jb.g, and jb.p, are of constant value.

The operating base helix angle, yb.op, is measured between the radius to a point of interest, mi, and the tangential line to the desired line of contact at that same point, mi. At a specified distance, Rm, the operating base helix angle is equal at all the points mi, mi+1 and so on. However, the operating base helix angle, yb.op, may vary as a function of the distance Rm.

The field of action (or the zone of action, in other terminol-ogy) is a portion of the plane of action, PA, that is between two circular arcs of the radii rpa and r1.pa (Fig. 3), and that is cut by the outside surfaces of the gear and of the mating pinion. The angle Fpa spans over the field of action, FA. The design param-eters of the field of action are used in the approach under consideration for the calculation of contact ratio in CA-gearing. Without going into details of the calculation of contact ratio, let’s just mention that in a simple case of straight bevel gearing, the transverse contact ratio, mp (and the total contact ratio as well), equals to the ratio:

(9)

The discussed in this paper design parameters in aCA-gearing are referred to as the principal design parameters of the gear Figure 4: Pitch plane, PP, in an ortogonal crossed-axis gear pair.

72 gearsolutions.com

pair. Calculation of the remaining design parameters is a rou-tine procedure known to most of gear experts in the field (see Table 11.2 on page 382 in [2]). For this purpose, an additional plane, that is, the pitch plane of the gear pair needs to be intro-duced. Tooth thickness, space width, backlash are specified in the pitch plane, PP, of the gear pair. The pitch plane is a plane through the apex of the plane of action, Apa, perpendicular to the center-line CL, (Fig. 4).

Methods of cutting gears for gear pairs with non-parallel axes of rotation of the gear and the pinion are summarized by the author [3].

CONCLUSIONThe principal features of designing of gears for gear pairs with non-intersecting axes of rotation, that is, for CA-and LA-gearing are discussed in the paper. The novel concepts of:

• The plane of action, PA• The base cones• The operating base pitch, operating base pitch of the gear and

pinion• Base helix angle are introduced.

These concepts are not covered either by AGMA standards or by other national and international standards on gearing with non-intersecting axes of rotation.

Definitions to the newly introduced design parameters in a CA-gearing are given. Formulas for the calculation of the princi-pal design parameters of gearing with non-parallel axes of rota-tions are provided.

REFERENCES[1] Radzevich, S.P., Dudley’s Handbook of Practical Gear Design

and Manufacture, CRC Press, Boca Raton, Florida, 2012, 878 pages.

[2] Radzevich, S.P., Theory of Gearing: Kinematics, Geometry, and Synthesis, CRC Press, Boca Raton, Florida, 2012, 743 pages.

[3] Radzevich, S.P., Gear Cutting Tools: Fundamentals of Design and Computation, CRC Press, Boca Raton, Florida, 2010, 786 pages.

ABOUT THE AUTHOR

Stephen P. Radzevich, Ph.D. is with the Innovation Center in the Eaton Corporation’s automotive business

segment. He can be reached at (248) 226-6831 or [email protected].

Go online to www.eaton.com.

HOTELS

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HOTELS/RESTAURANTS/BARS

AUGUST 2014 73

PRODUCTSHOWCASENew products, equipment, and resources

Gleason to Demonstrate Advanced Machines, Tooling, and Global Customer Support Services At IMTS 2014

Gleason will cover a wide array of processes for the complete production and inspection of all types of bevel and cylindrical gears at this year’s IMTS. Visitors to Gleason Booth #N-7000 will be introduced to these products and technologies. Among the technologies exhibited at the show will be:

• The new Genesis 200GX Threaded Wheel Grinding Machine - an innovative platform for automotive gearbox parts and more.

• The Gleason 300PS Power Skiving Machine, delivers significant productivity and quality gains for cylindrical external and internal gears up to 300 mm in diameter.

• The Phoenix II 280G Bevel Gear Grinding Machine: Highly Productive New Design is Simpler, More Reliable and Easier to Operate and Maintain for Bevel Gear Grinding up to 280mm in Diameter.

• The Gleason 300GMS Analytical Gear Inspection Machine: Faster complete inspection of automotive transmission gears and other smaller gears, gear cutting tools and non-gear parts.

Come visit Gleason at IMTS to kick-off their 150th anniversary in 2015. More information about Gleason Corporation is available at www.gleason.com.

74 gearsolutions.com

AUGUST 2014 75

Lexair’s new Multi Mini Rhinobar bar feeder makes multi-diameter bar stock processing faster and easier with a feedtube cartridge that automatically centers and feeds three sizes of small-diameter bar stock to Swiss-style CNC screw machines and sliding-head lathes. Cartridges are available in three size ranges: 0.25 in/0.375 in/0.5 in, 0.25 in/0.5 in/0.75 in and 0.375 in/0.5 in/0.635 in, and each three-tube cartridge is enclosed in a standard aluminum barrel. The Multi Mini helps achieve maximum throughput for high-production runs of automotive components, medical devices, motor shafts and other small-diameter parts. Two models are available for processing either six- or 12-foot bar stock. The bar feeder’s ergonomic design features an upgraded safety interlock system, and includes a front swing-out mechanism for easy reloading and sub 3-minute feed tube changes.

Lexair’s single-valve design controls oil flow and pressure for increased bar control, accuracy, and vibration-free operation. A completely enclosed fluid recuperator keeps oil off the floor and contaminants out of the hydraulic system. The outer barrel is a precision-extruded aluminum tube, held in place with a single clamp to further minimize barrel vibration and control Z-axis motion. A removable pendant allows the operator to control the bar feeder remotely, while a positive pusher retention system ensures high efficiency operation with minimal labor.

With an overall length of 11 feet (3.35 m) for the 6-foot bar model and 17 feet (5.18 m) for the 12-foot bar model, the Multi Mini Rhinobar’s compact size makes it suitable for small or large shops. The U.S.-built bar feeder is available for immediate delivery.

For for details, visit lexairinc.com or call 859-255-5001.

Lexair Multi Mini Rhinobar Bar Feeder

IMTS CONFERENCESProcess InnovationsMonday, September 8

Machining Turbine Blades - Best Practices 3:15 PM - 4:10 PM— W-192A

Tuesday, September 9 Anatomy of a CNC Machine Tool Retrofit 9:00 AM - 9:55 AM — W-192C Honing of Thermal Coated Cylinder Bores 11:00 AM - 11:55 AM — W-192A

Breaking Traditions in Turning - Are We Limiting Ourselves? 11:00 AM - 11:55 AM — W-192B

A Comparison of Three Strategies for Cost Effective Machining of Titanium 11:00 AM - 11:55 AM — W-192C Getting Started with MTConnect 1:15 PM - 2:10 PM — W-194B Tool Failure Analysis and Decision Making 2:15 PM - 3:10 PM — W-192A New Research on Mass Finishing for 3D Printed Parts 2:15 PM - 3:10 PM — W-192B Machining Intelligently 2:15 PM - 3:10 PM — W-192C

Choosing a Toolholder Technology that Best Fits Your Process 3:15 PM - 4:10 PM — W-193B Wednesday, September 10 Reduce Cost and Increase Throughput for Large Parts with Multi-Tasking Universal Machines 10:00 AM - 10:55 AM — W-194B

Experiencing Accelerated Business Growth 1:15 PM - 2:10 PM — W-193B Magnetic Workholding "Then and Now" 1:15 PM - 2:10 PM — W-194B

6-Side Flexible Machining - A New Approach 2:15 PM - 3:10 PM — W-192B

Thursday, September 11

High-Efficiency Machining of Aluminum Aircraft Structural Components 9:00 AM - 9:55 AM — W-192C Demystifying 5-Axis Machining 10:00 AM - 10:55 AM — W-193B Machining Optimization of Composite Materials 10:00 AM - 10:55 AM — W-194B Combination Tools. . . When They Make Sense 10:00 AM - 10:55 AM — W-195 Productivity and Quality Improvements for Tape Laying Machines 11:00 AM - 11:55 AM — W-192B Implementing Modular Solutions for Tool Holders and Workholding 11:00 AM - 11:55 AM — W-192C Demands Placed Upon Machine Tools for Processing Difficult to Machine Materials1:15 PM - 2:10 PM — W-193B

Advanced Implementation of Quick-Change Fixturing Technologies Across Machine Platforms 1:15 PM - 2:10 PM — W-195 Material Trends and Their Challenges on Future Machinability 2:15 PM - 3:10 PM — W-192B

Quality / Metrology

Monday, September 8

High Speed In-Line Inspection of Surface and Internal Defects 10:00 AM - 10:55 AM W-192C

Manufacturing the Future 1:15 PM - 2:10 PM W-192B

Achieving the Best Possible Straightness and Hole Tolerance in Deep Hole Drilling 1:15 PM - 2:10 PM W-192C

Tuesday, September 9 Measurement Systems to Optimize Automation Processes 1:15 PM - 2:10 PM W-195 Wednesday, September 10 Increasing Part-Inspection Throughput Using Inline Optical Sensors 1:15 PM - 2:10 PM W-195

Laser Scanners Redefine Non-Contact Measurement Excellence 3:15 PM - 4:10 PM W-193B

Thursday, September 11

MQL 101 9:00 AM - 9:55 AM W-192B

Resonant Inspection of Small Metal Parts 11:00 AM - 11:55 AM W-192A

76 gearsolutions.com

Geometric will preview its latest release of CNC programming automation solution, CAMWorks 2015, in Booth E-3320, IMTS 2014 in Chicago, Illinois from September 8 – 13, 2014.

In today’s environment, manufacturers need to be able to do more with less — less design time, program time, setup time, and machining time. CAMWorks 2015 focuses on making the entire design to part cycle shorter.

CAMWorks 2015 has over a dozen enhancements focused on shortening the programming time. One example is the color based identification of complex surfaces making it easier and quicker to define features by avoiding the traditional chains and profiles methodology. CAMWorks 2015 has bolstered its

ability to interpret non-prismatic surfaces on solid models as machinable entities automatically. This enhanced ability to leverage feature-based machining for complex requirements in combination with Intelligent Knowledge Base (TechDB) allows end users to eliminate the routine elements in CNC programming and focus on their core expertise.

For a job shop, setup time is critical. With an integrated true G-code simulation, CAMWorks Virtual Machine, users can make sure that the costly process of dry-runs on the shopfloor are minimized with one-click verification. The use of G-code for verification is absolutely critical if you are dealing with sub-programs, macros, sub-spindle transfers, tail-stocks, and steady rests.

On the other hand, for production shops, machining time is the key. Users need to makes sure that what they are machining is not only correct but most efficient. The ultra-high performance tool paths from CAMWorks VoluMill, has enhanced capability to handle more complex geometries like multi-step irregular islands, that can be very difficult to address with trochoidal tool paths which a number of other systems try to use to address this critical challenge.

For more information, visit www.camworks.com.

Geometric’s CAMWorks: ‘Quicker is Better’ at IMTS 2014

AUGUST 2014 77

Enerpac has announced its upgraded Collet-Lok® family of hydraulic workholding with “Depressurized Holding Technology.™” Designed to protect against unintentional loss of clamping, Collet-Lok requires no hydraulics to maintain clamping force. Compared to traditional workholding, which requires continuous hydraulic pressure, Enerpac Collet-Lok uses an internal mechanical locking system to maintain the clamping force—automatically, without hydraulic pressure, indefinitely. To satisfy diverse workholding applications, Enerpac has improved its Collet-Lok product family through standard Viton seals for better performance in high temperature applications and enhanced chemical resistance to common coolants. Bottom flange models come standard with dual porting built-in, bottom and side ports, allowing flexible installation options. Quick lead-time response capability for the complete range of standard Collet-Lok products.

“Loss of clamping force during machining can be costly—from scraped parts to machine damage and downtime. Anyone involved in the industry knows this can occur,” said Douglas Lacina, global marketing & engineering leader for Enerpac. “With the automation of hydraulic actuation, combined with the security of an internal locking mechanism, Collet-Lok ensures continuous clamping and support, even if a hydraulic line is accidentally cut during machining. Plus, with an upgraded design and fast availability, Collet-Lok is ideal for our customers’ diverse machining requirements.”

The Collet-Lok family of hydraulic workholding products includes swing clamps, work supports and push cylinders. Available in multiple sizes and mounting methods, Collet-Lok provides all the clamping products needed for typical fixture applications.

For more information, visit www.enerpac.com.

Enerpac Enhances Collet-Lok Family of Hydraulic Workholding

820 Cochran Street • Statesville, NC 28677F: 704.872.5777 • [email protected] • www.rpmachine.com

866.256.3708

USED

Fellows RemanufacturedService

Keep pace with technology advances - without the expense of buy-ing new equipment - with our full line of Fellows remanufactured CNC gear shapers. These gear shapers are completely remanufac-tured using the latest components from manufacturers such as Heidenhain, FANUC, Allen Bradley, and many others. Each machine is equipped with a new reliable CNC control with all the latest tech-nology. These solid core machines are brought up to date with many additional options available. Each machine is remanufactured to your individual part requirements.

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

We understand each of our customers have unique gear cut-ting requirements, that is why we carry such a large gear machine inventory. We carry such brands as Gleason, G&E, Fellows, Barber Colman, Liebherr, Pfauter, and many more. You will find hundreds of machines on our website at all times; from gear cutting machines to finishing and inspec-tion machines. Don’t forget, if you can’t find what you need on our website, let us know and we can try and find it for you.

HeraOur line of new Hera cnc gear hobbers, manufactured by Yunil Machinery Mfg. Co., combines high quality and efficiency with affordable pricing. Since its inception in 1963, Yunil Machinery has specialized in the manufacturing of gear machines. Their 6 axis gear hobbing machine has been the most favored product, globally. Based on 40 years of knowledge and experience, Yunil developed the HERA series CNC hobbing machine line. The com-bination of quality components, exceptional craftsmanship, and flexibility in design make this full line of horizontal and vertical machines tough to beat.

820 Cochran Street • Statesville, NC 28677F: 704.872.5777 • [email protected] • www.rpmachine.com

866.256.3708

G&EGould & Eberhardt is a pioneer in highspeed gear gashing with large diameter carbide-inserted cutters. Our new line of machines has a rigid design and heads engineered with state of the art gear gashing cutter technology. The exceptional results achieved in gear gashing technology have opened a wide range of applications for gear cutting in wind energy, mining, off highway construction and other coarse pitch gearing.

Since its establishment in 1972, Tokyo Technical Instruments Inc. (TTi) has been dedicated to the manufacturing of gear measuring instruments. We are proud to be the official North American distributor of this extensive line of inspection equip-ment. The TTi line of gear inspection equipment can be found in manufacturing facilities all over the world, proven to be high quality and long lasting machines. TTi maintains their products from the development of the program software to the aftercare maintenance. With patented software and components, the TTi product line is sure to become the industry leader.

TTi

Booth#N-7030

80 gearsolutions.com

GEAR ACCESSORIES, PARTS & TOOLINGFELLOWS Model #10-4/10-2, All Parts Available REF#102Tilt Tables for 10-2/10-4, Qty 2 REF#102FELLOWS Parts Available For All Models REF#103BARBER-COLMAN – PARTS AVAILABLE FOR ALL MODELS REF#103 G&E – PARTS AVAILABLE FOR ALL MODELS REF#103

GEAR HOBBERS/CUTTERS CNCPFAUTER #PE-150, 6-Axis CNC, 6” Dia, 5 DP, 6” Face, Fanuc 18MI REF#103G&E #60 S-2 CNC Gasher/Hobber REF#103BARBER-COLMAN #16-36, 16” Dia, 4-Axis, 6 DP, 36” Face REF#103MUIR CNC Gear Hobber, 4-Axis, 118” Dia REF#103LIEBHERR #L-252 3-Axis, 9.8” Dia, recontrolled 2008 REF#103LIEBHERR #ET-1802 CNC – 98” Dia Internal, 3-Axis REF#103G&E #120GH, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42” Face, ‘94 REF#103PFAUTER P400H, 5-Axis, 18” Dia, 1 DP, Recontrolled ‘03 REF#103G&E #96GH, CNC, Gasher/Hobber, New ‘09 REF#103PFAUTER PE 300 AW CNC 6-Axis REF#103Pfauter PE150, 15MB Fanuc, Chip Conveyor, Auto Load REF#107Pfauter PE150, Siemens 3M, Magnetic Chip Conveyor, Oil Chiller REF#107Pfauter PE150, Fanuc 15, with light hob slide 8” REF#107Pfauter PE80, 15MB Control, Auto Load, Light Curtain REF#107Liebherr LC82 15M Fanuc Control, Auto Load REF#107

GEAR HOBBERS/CUTTERSPFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#102PFAUTER (1) RS-00 s/n 17593 REF#102BARBER COLEMAN (1) 16-36 multi cycle s/n 4404 REF#102

BARBER-COLMAN #16-16, Multi-Cycle, Dual Thread Worm and/or Single Thread Worm REF#103G&E #48H 48” Dia, 18” Face 2 DP, Universal REF#103G&E #48H, 48” Dia, 35” Face, 3 DP, Gooseneck Attachment REF#103BARBER-COLMAN #6-16, 6 Multi-Cycle REF#103G&E #36H Differential, Excellent Condition REF#103BARBER-COLMAN #14-30, 14” Dia, 30” Face, 3.5DP REF#103BARBER-COLMAN #14-15, 14” Dia, 15” Face, 1 to 4 Start Worm, Several REF#103BARBER-COLMAN #16-16, 16” Dia, 16” Face, 6DP REF#103BARBER-COLMAN #16-36, 24” Dia, C-Frame Style, 4 1/8” Bore REF#103BARBER-COLMAN #16-56, 16” Dia, 56” Face, Differential REF#103G&E #24H Universal Head, Infeed, Tailstock, Differential, ‘50’s REF#103LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New ‘70’s REF#103G&E #16H Gear Hobber, 16"Dia REF#103BARBER-COLMAN #6-10, 6” Dia, 10” Face, 16 DP REF#103KOEPFER #140 , 2.75” DIa, 4” Face REF#103 LANSING #GH-50, 50” Dia, 17.75” Face, 2 DP REF#103LIEBHERR #L-252, 9.8” Dia, 7.9” Face, 4.2 DP REF#103BARBER-COLMAN TYPE T REF#103G&E #36HS 36”Dia, 14” Face 3 DP REF#103PFAUTER #P-3000, 120” Dia, Single Index REF#103SCHIESS RFW-10-S 55” Dia REF#103SCHIESS 1 RF-10, Dia 60” 150” L, .50 DP REF#103G&E #40TWG, 48” Dia, 18” Face, 3 DP REF#103G&E #60S, 72” Dia, 14” Face, 1.25 DP REF#103G&E #72H, 72” Dia, 24” Face, 1 DP REF#103 G&E #96H, 104” Dia, .50 Face, 1.25 DP REF#103PFAUTER #P-630, 25” Dia REF#103 PFAUTER P250 10” Dia REF#103GE/Fitchburg Hobber 32” Dia, 72” Face 1.25DP REF#103JF Reinecker 40” Dia 35” Face REF#103LIEBHERR L-160-R 6.5” Dia REF#103MIKRON #102.04 , 4’ Dia, 5” Face REF#103PFAUTER P-900 36” Dia REF#103BARBER-COLMAN #25-15 25” Dia, 15” Face, 2.5 DP REF#103PFAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#103BARBER-COLMAN 2 1/2 -4, S/N 119, ’62 Hi-Production Spur Gear REF#104BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#104BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#104BARBER-COLMAN 6-10, S/N 4626, ’57 Triple Thrd 3” Hob Slide REF#104BARBER-COLMAN 6-10, S/N 4659R, ’56 Triple Thrd Adj Ctr Assy REF#104BARBER-COLMAN 6-10, S/N 4665, ’57 Fine Pitch Prec Triple Thrd REF#104BARBER-COLMAN 6-10, S/N 4701, ’58 Triple Thrd w/Power Down Feed REF#104BARBER-COLMAN 6-10 M/C, S/N 4755, ’59 Triple Thrd w/MC Conversion REF#104BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, ’60 (’87 Rebuild), Sgl Thrd Hi-Spd REF#104BARBER-COLMAN 6-10 M/C, S/N 4913, ’63 Triple Thrd w/90 Deg Hob Slide REF#104BARBER-COLMAN 6-10 Multicycle, S/N 5055, ’66 Triple Thrd, 800 RPM REF#104BARBER-COLMAN 6-10, S/N 5141, ’67 Triple Thrd w/Prec Hob Shift REF#104BARBER-COLMAN 6-10 Multicycle, S/N 5148, ’68 Triple Thrd, 800 RPM REF#104BARBER-COLMAN 6-10 Multicycle, S/N 5259, ’75 Triple Thrd w/Auto Hob Shift REF#104BARBER-COLMAN 6-10, S/N 5353, ’77 Triple Thrd w/3” Hob Slide, 800 RPM REF#104BARBER-COLMAN 6-10, S/N 5394, ’81 Fine Pitch Triple Thrd w/Dwell & Hob Rev REF#104BARBER-COLMAN 6-16 M/C, S/N 5238, ’70 Triple Thrd, Recon ‘02 REF#104BARBER-COLMAN 6-10, S/N 5407, ’82 Auto w/PLC Control REF#104BARBER-COLMAN DHM, S/N 105, ’42 Double Thrd REF#104BARBER-COLMAN 14-15, S/N 635R, ’53 Dbl Thrd, Fact Reb REF#104BARBER-COLMAN 14-15, S/N 745, ’55 Dbl Thrd w/Dwell REF#104BARBER-COLMAN 14-15 Dual Fd, S/N 938, ’62 Dbl Thrd, Comp Reco REF#104BARBER-COLMAN 14-15, S/N 1055, ’65 Dbl Thrd w/New Hyd Sys REF#104BARBER-COLMAN 14-15, S/N 1131, ’66 Dbl Thrd w/Hyd Tailctr REF#104BARBER-COLMAN 14-15 Dual Fd, S/N 1261, ’67 Dbl Thrd w/Hyd Live Ctr REF#104BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, ’68 Dbl Thrd w/4-1/8” Bore REF#104BARBER-COLMAN 14-30 Dual Fd, S/N 1371, ’71 4-Thrd w/Sizing Cycle REF#104BARBER-COLMAN 22-15, S/N 923, ’62 Dbl Thrd, Dbl Cut REF#104BARBER-COLMAN 16-11, S/N 184, ’50 Dbl Thrd w/Vert DRO REF#104BARBER-COLMAN AHM, S/N 1896, ’42 Sgl Thrd w/3 Jaw Chuck REF#104BARBER-COLMAN 16-16, S/N 2745, ’51 Sgl Thrd w/90 Deg Hd REF#104BARBER-COLMAN 16-16, S/N 3171, ’53 Dbl Thrd, Spanish Nameplates REF#104BARBER-COLMAN 16-16, S/N 3580, ’59 Dbl Thrd w/Diff & Auto Hobshift REF#104BARBER-COLMAN 16-16 Multicycle, S/N 3641, ’60 Dbl Thrd w/Diff REF#104

BARBER-COLMAN 16-16, S/N 3660, ’57 Sgl Thrd REF#104BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, “C” Style End Brace w/Diff REF#104BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle “C” Style REF#104BARBER-COLMAN 16-16, S/N 4473, ’73 4-Thrd w/Workclamp Cyl “C” Style REF#104BARBER-COLMAN 16-16 Multicycle, S/N 4520, ’75 Dbl Thrd w/Gooseneck Slide REF#104BARBER-COLMAN 16-16 Multicycle, S/N 4631, ’79 “C” Style End Brace, 4W Adj Ctr REF#104BARBER-COLMAN AHM (36”), S/N 1152, ’42 Dbl Thrd REF#104BARBER-COLMAN 16-36, S/N 4090, ’66 Dbl Thrd, “C” Style End Brace REF#104BARBER-COLMAN 16-36 Multicycle, S/N 4232, ’68 Dbl Thrd “C” Style End Brace w/Diff REF#104BARBER-COLMAN 16-56, S/N 3136R84, ’53 (Reb ’84), Dbl Thrd REF#104BARBER-COLMAN 10-20, S/N 6700045890, ’76 Dbl Thrd w/2 Cut Cycle REF#104TOS OFA Series Conventional Gear Hobbers, 12” & 40” Dia REF#105TOS OHA Series Conventional Gear Shapers, 12” & 40” Dia REF#105TOS FO-16 with single index 72” cap. REF#106

GEAR PINION HOBBERS & SPLINE MILLERS

HURTH #KF-32A 15” Dia, 59” Face, ‘67 REF#103GE/Fitchuburg Pinion Hob 32” Dia, 72” Face REF#103MICHIGAN Tool #3237 REF#103FITCHBURG Pinion Hobber 42” Dia, 72” Dia REF#103Craven horizontal 36” dia 96” length 73/4” hole REF#106

GEAR HOB & CUTTER SHARPENERS (incl CNC)

BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, ‘57 REF#103FELLOWS #6SB, Helical Cutter Sharpener, 6” Dia, up to 50 Degrees REF#103KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#103KAPP #AS204GT, 10” Dia, Wet Grinding, CBN Wheels, ‘82 REF#103REDRING MODEL #SGH "PREIFORM" SHAVE CUTTER GRINDER/SHARPENER REF#103STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#103BARBER-COLMAN 2-2 1/2 , 2.5” Dia REF#103KAPP #AST-305B, 27.5” Dia, REF#103KAPP AS-410B REF#103GLEASON #12 Sharpener, 3-18” Cone REF#103Red Ring Shaving Cutter sharpener Periform REF#103Star #6 Gear Cutter Sharpener REF#103Star 4HS Hob sharpener REF#103Star HHS Horizontal Hob Sharpener CNC, Max Dia 10” Max length 12” New 1990 REF#103BARBER-COLMAN 2 1/2-2, S/N 16, ’66 Wet w/Auto Feed REF#104BARBER-COLMAN 6-5, S/N 110R, ’55 Wet w/Auto Dress & Sparkout REF#104BARBER-COLMAN 6-5, S/N 396, ’66 Wet w/Auto Dress & Sparkout REF#104BARBER-COLMAN 6-5, S/N 433, ’69 Wet w/Auto Dress & Sparkout REF#104BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC Control, Fact Reb ‘83 REF#104TOS OHA Series CNC Gear Shapers, 12” & 40” Diameter REF#105 TOS OFA Series CNC Gear Hobbers, 12” & 40” Diameter REF#105

GEAR SHAPERS CNC

36” Shapers, 14” Throat Risers, 53” of Swing, Qty 3 REF#102FELLOWS #10-4/10-2, Qty 150 REF#102HYDROSTROKE #50-8, Qty 2 REF#102HYDROSTROKE #20-8, Qty 5 REF#102HYDROSTROKE #FS630-125, Qty 1 REF#102HYDROSTROKE #FS400-90, Qty 2 REF#102FELLOWS #20-4, Qty 6 REF#102FELLOWS #48-8Z, Qty 1 REF#102FELLOWS #FS-180, 3-5 Axis, 7” Dia, 1.25” Face., 6 DP, New ‘88 REF#103LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#103LORENZ # LS-180, 4-Axis CNC, 11” OD, 2” Stroke, 5 DP REF#103LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#103FELLOWS FS400-125, 16” Dia, 3.5 DP 5” Face REF#103FELLOWS #10-4 3-Axis (A/B), 10" Dia, 4" Face, 4 DP New .’09 REF#103 FELLOWS #10-4 2-Axis, 10” Dia 4” Face REF#103FELLOWS #20-4 3-Axis 10” Dia, 4” Face REF#103FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15.7" REF#103Fellows 20-8, CNC Gear Shaper, Remanufactured and recontrolled REF#103Fellows Model Z gear Shaper REF#103Lorenz SN4 Gear Shaper, Max OD 7”, 2” Face, Max 6 DP with Loader REF#103RP/ Stanko 48-8 Remanufactured Gear Shaper, Fanuc 3 Axis, 18i M Control, new 2010 REF#103

GEAR HOBBERS

Barber Colman Model 4-4HRS, Hob Sharpener 4” Max OD, 4” Length REF#103Fellows FH 200 Gear hobber, universal hobbing Machine REF#103Barber Colman 6-10, CNC, CRt 5 Axis, 6” Dia, 10.5” travel, 6 DP REF#103

FEATUREDSUPPLIERSMidwest Gear Corporation — REF #101Phone: 330-425-4419 • Fax: 330-425-8600Email: [email protected]: www.mwgear.com

New England Gear — REF #102Phone: 860-223-7778 • Fax: 860-223-7776Email: [email protected]: www.newenglandgear.com

R. P. Machine Enterprises, Inc. — REF #103Phone: 704-872-8888 • Fax: 704-872-5777Email: [email protected]: www.rpmachine.com

Repair Parts, Inc. — REF #104Phone: 815-968-4499 • Fax: 815-968-4694Email: [email protected] Website: www.repair-parts-inc.com

Havlik International Machinery, Inc. — REF #105Phone: 519-624-2100 • Fax: 519-624-6994Email: [email protected]: www.havlikinternational.com

GQ Machinery Inc. — REF #106Phone: 516-867-4040 • Fax: 516-223-1195Email: [email protected]: www.gqmachinery.com

Gibbs Machinery Company — REF #107Phone: 586-755-5353 Fax: 586-755-0304Email: [email protected]: www.gibbsmachinery.com

MACHINERYContact Gear Solutions at 800-366-2185 to list your machinery.

AUGUST 2014 81

Barber Colman Hobber Type T REF#103Barber Colman model #14-15 Gear Hobber, horizontal Heavy Duty REF#103Barber Colman Model #16-36 GearHobber REF#103Barber Colman Model #16-56, 16” dia, 56” Face, adj. Air Tailstock REF#103Barber Colman Model 2.5-2 gear hobber, 2” length Manual Dresser REF#103G&E Model 5.2 CNC Internal Gear gashing head REF#103Jeil JDH-3, Gear hobber, Max Dia 31.5”, 3DP, 22.8 Table Diameter REF#103Jeil JDP-2, Gear hobber, Max Dia 26”, 4 DP, 19.5” Table Dia, Differential and tailstock REF#103Liebherr ET 1802, Internal Gashing head, Fanuc 16i Control, 98”Max dist 17” Face REF#103Liebherr L-402 Gear hobbing Machine, New 1977 REF#103Liebherr LC 752, 6 Axis CNC Hobber, Max OD 29.5”, Max Face width 23.6” REF#103Micron Model 120.01 w/bevel Cutting Attachment, New 1975, 1.6” dia, 25.4 DP REF#103Nihon Kakai Model NTM-3000, Spline Hobbing Machine, Max dia 400mm, 3150mm between Center REF#103Pfauter P900 Reman and Recontrolled, Max OD 120” REF#103Pfauter Model PE125 CNC Gear hobber REF#103Pfauter model PE300 CNC, Max OD 12”, Max gear face 15”, 3 DP, 6 Axis REF#103Reinecker Heavy Duty Gear Hobber REF#103Scheiss Model RF10 Horizontal Hobber, 60” dia, 144” face, 180”cc, 8 DP REF#103G&E 96H, roughing & finishing 104” dia. REF#106TOS FO-16 single index 80” dia. Yr 1980 REF#106Craven spline & pinion hobber 36” x 96” REF#106G & E 48H 48” dia. Diff, OB, change gears REF#106Pfauter hobber P-1800 70” dia. 29” face yr 1980 REF#106Lees Bradner 7VH, 8”PD, 10” Face, , Magnetic Chip Conveyor , Hob Shift REF#107Lees Bradner 7VH, 8”PD, 4PD, Magnetic Chip Conveyor, Hob Shift REF#107Mitsubishi Model GH300, 15.7”, 3 DP, Differential, 2 Cut REF#107Tos 32A, 320mm Gear Dia.,3.6 DP, Differential, 2 Cut REF#107Gleason 775 8”PD, High Helix Head, Infeed, Very Light Use REF#107Barber C. 16-15, 7 ½” Hob, Crowning, Differential, 2 Cut REF#107Barber Colman 14-15, 2 Cut, Fast Approach, 4” Bore REF#107Barber Colman 16-36, Type A – Very Good, Double Thread Index REF#107G & E Model 48HS 48”PD, 18” Face, 2.5 DP REF#107

GEAR SHAPERS

FELLOWS #10-2, (10” Dia), 2” Face REF#102FELLOWS #10-4, (10” Dia), 4” Face REF#102FELLOWS (200) 10-4 / 10-2 Shapers REF#102FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009) REF#102FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009 REF#102 FELLOWS (1) #7 125A Face Gear Machine REF#102FELLOWS (2) #3 Face Gear Machine REF#102(1) 4ags with adjustable Helical Guide s/n 30634 REF#102(1) #7 125A adjustable Helical Guide REF#102FELLOWS (1) FS630-200 Hydrostroke Shaper s/n 36943 w/ 6 axis 16iMB Fanuc (2009) REF#102FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009) REF#102FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#102FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc (2009) REF#102FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009) REF#102FELLOWS (1) 48-8Z Shaper w/ 14” throated riser (53” of swing) REF#102FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#102FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller s/n 34326 REF#102FELLOWS (1) 36-10 Gear Shaper REF#102FELLOWS (1) 10x6 Horizontal Z Shaper REF#102FELLOWS (1) 36-6 Gear Shaper w/ 13” riser s/n 27364 REF#102FELLOWS (1) 10-4 Shaper w/ 3” riser w/ 4 axis 21i Fanuc Controller (2009) REF#102All Parts for 10-4/10-2 Fellows Gear Shapers REF#102FELLOWS #36-8, 36” Dia, 8” Face REF#103FELLOWS #100-8 100” Dia, 8” Face REF#103FELLOWS #612A, 615A, #645A REF#103FELLOWS #10-4, 10” Dia, 4” Face, 4 DP REF#103FELLOWS #4A Versa, 10” Dia, 3” Face, 4 DP, New ‘70’s REF#103FELLOWS #10-2, 10” Dia, 4” Face, 4 DP REF#103FELLOWS #20-4, 20” Dia, 4” Face, 4 DP, ‘70’s REF#103FELLOWS #3-1,/3GS, 3” Max Dia, 1” Face, Pinion Supp, High Precision REF#103FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#103MAAG #SH-150, 57" Dia.12.6" Face REF#103PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#103

FELLOWS #36-6 Max Dia 36” 6” Face, 3 DP REF#103FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5” REF#103FELLOWS #4GS & 4AGS, 6” Dia, 2” Face, 4DP, ’68, Ref.# Several REF#103FELLOWS #624A, 18” Max Dia, 5” Face REF#103FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7” Dia, 0-12” Risers, Several Avail REF#103MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#103FELLOWS Model Z Shaper, 5" Stroke, ‘50’s REF#103STAEHELY SHS-605, Gear Shaper REF#103FELLOWS #6, #6A, #61S, From 18”-35” Dia, 0-12” Risers REF#103FELLOWS #8AGS Vertical Gear Shaper, 8” Dia, 2” Face, 6-7 DP REF#103TOS OHA50 CNC 5 20” Dia 5” Face REF#105Fellows 36-6 Shaper (2) 12.5" Risers 6" Stroke Mint YR 1969 id 3616 REF#106Fellows 36-6, shaper W/6” riser, change gears REF#106Magg shaper SH4580-500S, 206”dia. 26” face REF#106Magg shaper SH250, 98” dia. 26” face REF#106Fellows #10-4,7” riser yr 1980 REF#106Fellows 3”, 6”, 7”, 10”, 18”, 42”, 100, Some CNC REF#107

GEAR DEBURRING/CHAMFERING/POINTING

CROSS #50 Gear Tooth Chamferer, 18” Dia, Single Spindle REF#103REDIN #20D, 20” Dia, Twin Spindle, Deburrer/Chamfer REF#103SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14” Dia, 5” Face, ‘82 REF#103SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10” Max Dia, (3) New ‘96 REF#103REDIN #24 CNC Dia 4” Setup Gear Deburring REF#103 CROSS #60 Gear Tooth Chamferer, 10” Dia, Single Spindle REF#103FELLOWS #100-180/60 CNC Max Dia 180”, Single Spindle REF#103CIMTEC #50 Finisher REF#103CROSS #54 Gear Deburrer, 30” Dia, 18” Face REF#103RED RING #24 Twin Spindle Dia 4” REF#103GLEASON GTR-250 VG CNC 5-Axis REF#103Gleason- Hurth Model ZEA 4, Max Dia 250mm, Max Module 5mm REF#103Redin Model 36 universal Chamfering and Deburring Machine, Max OD 36”, Twin spindle, Tilt table REF#103Samputensili SCT3 13.7”, SM2TA 10”, (5), 2003 REF#107Mitsubishi MA30 CNC, 11”PD, Fanuc, Powermate, 1999 (2) REF#107

GEAR HONERS

Kapp #CX120 Coroning 4.7” Dia REF#103Red Ring GHD-12, 12” Dia, 5.5 Stroke REF#103Red Ring GHG, 12” Dia, 5.5 Stroke REF#103Kapp #VAC65 Coroning 10” Dia REF#103

GEAR SHAVERS

Red Ring #GCX-24" Shaver, 24” Dia, 33” Stroke REF#103Red Ring #GCU-12, 12” Dia, 5” Stroke REF#103 Red Ring #GCY-12, 12” Dia, 5” Stroke REF#103Red Ring GCI 24, 12.75” Dia, 5” Stroke REF#103Kanzaki model GSP 320 Gear shaver REF#103Red Ring GCU 12 Crowning, 1956 to 1988 (6) REF#107Mitsubishi FB30, 12.2 CNC Fanuc, 1997 REF#107Sicmat Raso 100, CNC Fanuc 16M, New, Guarantee REF#107

GEAR GENERATORSGLEASON #37 Str. Bevel Planer, 6” Dia REF#103GLEASON #496 Straight.& Spiral. 7.5” Dia REF#103GLEASON 725-Revacycle, 6” Dia REF#103GLEASON 726-Revacycle, 5” Dia REF#103Farrel Sykes Model 12C herringbone max dia 264”, max face width 60” REF#103Farrel Model 5B herringbone gear generator. REF#103Gleason 529 gear quench press, Auto cycle 16” Diam, New 1980 REF#103Gleason 614 hypoid finishing machine, 10.5” pitch, dia 5.25” Max cone dist REF#103Oerlikon/klingelnburg Model C28, Max dia 320 mm, Max Module 7.5 mm REF#103Gleason Model 26 Quench press and Hypoid Generator Max OD 16”, Max face Width Air Cylinder REF#103Gleason Model 36 Gear Quenching Press, Max Ring 28” OD, 8” Face, Universal REF#103 Gleason Model 450 HC CNC Hypoid Cutter, Face width 2.6”, fanuc 150 Controls REF#103Gleason 24 Rougher, Gears, Finishing Tool Holder REF#10712” Gleason, Gears, Gauges Tool Blocks REF#107Gleason 116 Rougher & Finisher (6) REF#107Gleason Phoenix 175HC CNC – 1994 REF#107Gleason 22 Rougher & Finisher (8) REF#107Gleason 610 Combination Rougher & Finisher, 1988 REF#107Gleason 608 & 609 Rougher & Finisher REF#107Gleason 7A, 7”PD Helical Motion, Gears & Cams REF#107Gleason Cutters, 3” to 25” in stock, 1000 REF#107

GEAR GRINDERS#27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder generating Cams (2 full sets) REF#102Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103GLEASON #463, 15” Dia REF#103Hofler model Rapid 2000L, CNC Grinder, Max OD 78”, CNC Dressing REF#103Matrix model 78, Reman CNC Thread grinder, 24” Dia, 86” grind Length, 106 between centers REF#103Mitsu Seiki Model GSW-1000 Gear Grinder REF#103Reishauer RZ 362 AS, CNC Grinder, Max Dia 360mm REF#103Sundstrand/Arter Model D12 Grinder REF#103Teledyne-Landis Gear Roll Finishing Machine, 5” Diam, 42k lbs Rolling Force REF#103Reishauer RZ301AS CNC, 13” Measuring System (3) REF#107Reishauer ZB, 27.5” PD Gears, Coolant REF#107

GEAR RACK MILLERS/SHAPERSMIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, ‘80 REF#103Fellows 4 – 60 Rapid Traverse, 2 Cut REF#107

GEAR THREAD & WORM, MILLERS/GRINDERSBARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#103EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#103EXCELLO #33 Thread Grinder 6” Dia 18” Length REF#103HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88” REF#103LEES BRADNER #HT12x102, Extra Large Capacity REF#103LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#103 LEES BRADNER # LT 8” x 24” 8” Dia REF#103 HOLROYD 5A 24.8 “ Dia REF#103 LEES BRADBER WORM MILLER REF#103 Dranke CNC Internal Ball Nut Grinder REF#107

GEAR TESTERS/CHECKERS (incl CNC)FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#102FELLOWS (1) 24H Lead Checker s/n 32289 REF#102GLEASON (1) #14 Tester s/n 31907 REF#102GLEASON (1) #6 Tester s/n 19316 REF#102FELLOWS (1) 20 M Roller Checker REF#102FELLOWS (1) 20 M w/ 30” Swing Roller Checker REF#102FELLOWS (1) #8 Micaodex s/n 36279 REF#102David Brown #24 Worm Tester REF#103Gleason #4, #6, #13 and #17 Testers REF#103Hofler EMZ-2602 Int/Ext Gear Tester 102” REF#103Klingelnberg #PFSU-1600 Gear Tester-2001 REF#103Kapp Hob Checker WM 410 REF#103Maag #ES-430 Gear Tester REF#103Maag #SP-130 Lead and Involute Tester REF#103National Broach Gear Tester GSJ-12 REF#103Oerlikon #ST2-004 Soft Tester REF#103Maag #SP-60- Electronic Tester REF#103Parkson #42N Worm Gear Tester REF#103Vinco Dividing Head Optical Inspection REF#103Gleason model 511 Hypoid tester Max Dia 20”, max spindle centerline 3.5” REF#103Klingelnberg Model PFSU-1600 63” Dia, 1.02 DP, Rebuilt REF#103MAAG ES401 Pitch tester With Process Computer REF#103Fellows 12 & 24M Involute, 12 & 24 Lead REF#107Fellows 36” Space Tester, Hot Pen Guaranteed REF#107Gleason 17A Running or Rebuilt Guaranteed REF#107Gleason 511, 20” Reconditioned in 2010 Guaranteed REF#107Gleason 27, 26”, Guaranteed REF#107Gleason 515, 24” REF#107Gleason 523, 20” Reconditioned, 2010 REF#107

MISCELLANEOUSWARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80” Centers, 12” Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#101Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102GLEASON #529 Quench, 16" Diameter REF#103Klingelnberg Model LRK-631 Gear Lapper REF#103VERTICAL TURNING LATHES AND MORE - Please Check Our Website To View Our Entire Inventory REF#103TOS SU & SUS Series Conv Lathes REF#105TOS SUA Series CNC Flat-Bed Lathes REF#105Change gears for G & E hobber REF#106

82 gearsolutions.com

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

MARKETPLACE

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Incorporatefor as little as$99

Visit www.incorporate.comor call 888-743-7440

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SHARP HOBSChange Downtime To Productivity

You Need Your Tools Back FAST– Eliminating Downtime &Tuned To Meet or Surpass Original Design Specsand That’s Where We Come In

• Stripping & Re-Coating

• Gear Shaper Sharpening

• Milling Cutter Sharpening

• Gear Tool Certifications

Tel: 216-642-5900 • Fax: 216-642-8837 • 5755 Canal Road • Valley View, OH 44125Email: [email protected] WWW.GALLENCO.COM

Providing quality service since 1985.

1/8" to 24"O.D.180 D.P. to 4 D.P.Module

1pc. to production, Machine breakdowns, Prototype and Rush orders

Competitive pricing and quick turn around!

Capabilities: Shaping internal and externalHobbing helical, spur, pinions, splines, serrations, pulleys, ratchets, worms and worm gears, segments, special tooth forms

Carmona Gear Cutting, Inc.2415 Kishwaukee St. • Rockford, IL 61104

ph.815-963-8236 • fax 815-963-9203 E-mail us a quote today [email protected]

Gear Manufacturing(from singles to production & reverse-engineering services)

SPUR - HELICAL - SPLINE - WORM - BEVEL - RACK

Gear Hobbing • Gear Shaping • Gear Rack • SprocketsBroaching • CNC Turning • CNC Milling • Automatic Sawing

A HANDFUL OR A TRUCKLOAD!

LAWLER GEAR CORP.1320 S.E. Hamblen Road • Lee’s Summit, MO 64081

Toll Free: 800-346-3038Missouri: 816-525-0002 • Fax: 816-525-1113

INVO–QUALITYINVO–QUALITYINVO–QUALITY

Invo Spline’s policy of using only the highest quality steel available, along with our own 100% inspec-tion procedures has made us the nation’s leader in ultra-precision master gears and spline gages.

AUGUST 2014 83

ADVERTISERINDEX

COMPANY NAME .............. PAGE NO.ALD Thermal Treatment ............................................................. 48All Metals & Forge Group ........................................................... 49Allen Adams Shaper Services .................................................... 82Apollo Broach ............................................................................ 82Bourn & Koch ............................................................................ 83C-B Gear & Machine Inc ............................................................ 67Carmona Gear Cutting ............................................................... 82Circle Gear & Machine ............................................................... 83Clarke Gear Co .......................................................................... 76CNC Machinery Sales Inc .......................................................... 58Colonial Tool Group ................................................................... 12Cosen Saws .............................................................................. 66DMG Mori .................................................................................. 21Drewco ...................................................................................... 53DT Technologies ........................................................................ 34Encoder Products ...................................................................... 68Engineered Tools Corporation ...............................................40-41Erwin Junker Maschinenfabrik GmbH ......................................... 35Forest City Gear ....................................................................... IBCGear Solutions ........................................................................... 71Gleason Corporation .................................................................. 16GMTA (German Machine Tools of America) ................................ 27Havlik Gear ................................................................................ 69Hilco Industrial LLC .................................................................... 51Index Technologies .................................................................... 82Ingersoll Cutting Tools ................................................... 9,11,13,15Innovative Rack & Gear ............................................................. 46Invo Spline Inc ........................................................................... 82IOSSO Metal Processes ............................................................. 76Ipsen International...................................................................... 55KAPP Technologies ................................................................... IFCKISSsoft USA LLC ..................................................................... 34Lawler Gear Co.......................................................................... 82Leistritz Corporation ................................................................... 43Liebherr ..................................................................................... 63Luren Precision Co Ltd .............................................................. 37Machine Tool Builders ................................................................ 38McInnes Rolled Rings ................................................................ 14Micro Gear ................................................................................. 59Mitsubishi Heavy Industries America Inc .................................... BCNew England Gear ....................................................................... 7Norton Industrial ........................................................................ 23P & G Machine & Supply Co Inc ................................................ 58PentaGear Products .................................................................. 50Proto Manufacturing Ltd ............................................................ 70QC American ............................................................................. 39Raycar Gear & Machine Co ........................................................ 46Reishauer .................................................................................. 29Repair Parts Inc ......................................................................... 68Rotek Inc ................................................................................... 25RP Machine Enterprises Inc ..................................................78-79Russell Holbrook & Henderson ................................................... 72Sandvik Coromant ....................................................................... 2STD Precision Gear ................................................................... 38The Broach Masters Inc ............................................................... 4The Company Corporation ......................................................... 82TMFM LLC ................................................................................ 62Toolink Engineering Inc ................................................................ 1Ty-Miles Inc................................................................................ 59U.S. Equipment Co .................................................................... 10Weldon Solutions ....................................................................... 52Wenzel America Ltd ................................................................... 42

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

CIRCLE GEAR and MACHINESTRAIGHT BEVEL GEARS

SPIRAL BEVEL GEARS

.25” to 34 ½” Diameter

32 DP to 1.5 DP

.5 Module to 16 Module

.25” to 33” Diameter

32 DP to 2 DP

.5 Module to 12 Module

Booth#N-6924

84 gearsolutions.com

GS: You purchased Advanced Cutting Tools in 2007. How has the transition been?BF: It’s been quite smooth. We recently moved them into our facility in Windsor. Advanced manufactures indexable broach tools, indexable cutting tools, special motion tools, and a variety of special cutting tools for engine and transmission components such as machine cylinder heads, engine blocks, connecting rods, bearing caps, etc. Sometimes acquisitions and consolidation can be disruptive to customers and employees. However, Advanced assimilated well into the Colonial Tool Group plant.

GS: Tell our readers about Colonial Tool Group’s development south of the border.BF: Our facilities are international, with locations in Canada, U.S., and Mexico. In 2010, we opened a service facility in Mexico as a conduit to our Mexican market. We have seen steady growth in the Mexican market. We trained personnel in Windsor and the U.S. to run the facility in Mexico, as well as to train the Mexican workers.

We recently finished our first Servo Driven High Speed Table-Up Broaching Machine, which is destined for a customer in Puebla, Mexico. This is the second broach machine for that customer, LuK.

GS: What’s the advantage of this type of broaching machine?BF: The Servo Driven High Speed Table-Up Broaching Machine saves a lot of energy, as opposed to the hydraulic machines that consume high energy during the idle and in-cut periods of the cycle time. The Servo Driven Machine is also capable of higher

VICE PRESIDENT OF SALESCOLONIAL TOOL GROUP, INC.

surface speeds. When the machine is idle, there are negligible amounts of energy consumed. We expect this product to have significant sales growth due to its cost saving attributes of productivity increases and energy savings. The Servo Driven High Speed Table-Up Broach Machine is an addition to our other Multi Axis Servo Broach Machines we have sold to the aerospace industry.

GS: Speaking of the future, how are you planning for the future of the company?BF: We will continue to develop and invest in our products, services, people, technology, and new markets. One other product recently introduced into our family of offerings is the Prismatic Work Holding Fixtures for CNC Machines. We have several large customers in Mexico who rely on our engineering expertise to concept and prototype our fixtures for their CNC production needs.

We have also recognized that our workforce is maturing (the average age of our workforce is around 40), so recruitment of new expertise is something we concentrate on. We have an apprentice program for our tradesman and we are continually looking for new raw talent to train.

GS: What is a typical day for an apprentice at Colonial Tool Group?BF: For the first couple of months, they shadow a leader around. But they quickly get into hands-on activities, and the leaders watch them to make sure they’re making the best decisions. They do make mistakes, but that’s how they learn. You need people to learn and develop in order to expand and grow the business.

GS: What kind of repair work do you do?BF: We repair all our products as well as our competitors’ products, but the largest volume of repairs comes from CNC Spindle repairs — although we repair all styles of spindles including motorized, gear driven, belt driven, etc. We offer machinery retools, broach tool regrind, and sharpening. We manufacture most of our new products in Canada and send them to our U.S. or Mexican sales and service facilities for distribution. We also have several foreign customer OEM relationships where we service all their special CNC spindles for their North American installations.

GS: Our “trend” for this month’s issue is subcontracting. You all do quite a bit of your work in house, don’t you?BF: Yes, we are somewhat vertical. Our products are engineered, manufactured, heat treated, built, and repaired or reground in house. We have done that since the beginning. We do subcontract some overflow work out, or small details, but we attempt to retain most critical details or processes.

GS: What other areas have you been growing?BF: Workholding has been very strong for us. We’ve probably been growing about 20 percent every year in that area. Mainly for CNC machines for machining engine blocks, manifolds, bearing caps — things like that.

It’s still a pretty tough, competitive market out there. We offer a one-day turnaround and expedited service, but within a week we can have a spindle running and back to the customer. We manage our costs and quality in the only way possible — with in-house control on design and build, including heat treatment and surface treatments of our products.

Brett FroatsQ&A

TO LEARN MORE:Visit Colonial Tool Group online at www.ctgi.co, or call (866)-611-5119

Operational Work?We’re Armed to the Teeth

11715 Main Street, Roscoe, IL 61073815-623-2168

MISSION: SAVING TIME. Our elite, highly trained Gear Team 6 is heavily armed with the latest gear production and inspection technologies to take on your ‘cut teeth only’ operational work. Cut to part print, inspected, and shipped before your competition even knew what hit them.

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

Learn more about the world-class Mitsubishi gear machines available from stock at www.mitsubishigearcenter.com or contact sales at 248-669-6136.

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Booth# N-7046