CyCloCut

Bevel Gear
produCtion

GrippinG

SyStemS
AdvAnces

for inCreaSed VerSatility

in molded polymer GeArs
Site Safety tooth tipS hot Seat aGMa UpDate

Company profile: Artec Machine Systems Q&a: pat nugent

MAhr FederAl

gearsolutions.com

DeCeMBeR 2011

see What The Future Holds

Predictive Process Control

The NILES ZE Series has NEW features: High feed-rate grinding, Module 25 (1 NDP), High-speed measurement for full contact grinding.
KAPP Technologies 2870 Wilderness Place Boulder, CO 80301 Phone: (303) 447-1130 Fax: (303) 447-1131 kapp-niles.com | kapp-usa.com info@kapp-usa.com

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Cyclocut Bevel Gear Production
By Dr. Hermann J. Stadtfeld

features
Company Profile: Artec Machine Systems

This technical paper from Gleason describes the Cyclocut process for advanced cutting, skiving, and semi-completing of bevel gears in low quantities.

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By Russ Willcutt

Whether youre in the market for drive system design assistance or skilled maintenance and training services, this company has solutions to the challenges you face.

Gripping Systems for Increased Versatility

28

By Jesse Hayes

Comparatively simple grippers are used in an increasing number of applications where various part sizes have to be handled quickly and processed reliably. SCHUNK explains.

Advances in Molded Polymer Gears

50

By Rod Kleiss

Plastic gears can provide a hightorque, high-speed, cost-effective solution for a host of demanding applications, according to the experts at Kleiss Gears.

DECEMBER 2011

Resources
MACHINES

MARKETPLACE

61 65

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

ADVERTISER INDEX

67

Terry McDonald Companies seeking qualified workers should consider members of the armed forces returning from duty, and they should provide a safe working environment.

Site Safety

DeCeMBeR 2011 | VoLUMe 9 / No. 105 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.

William Crosher In this first installment of a series, the author discusses the different types of worm gears and how useful they are in a wide variety of applications.

Tooth Tips Hot Jack Titus Seat

What we need is a nitriding process combining the speed and control of plasma, but without the degree of difficulty. According to the author, stay tuned.

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

No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without permission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All "Industry News" material has either been submitted by the subject company or pulled directly from their corporate web site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to editor@gearsolutions.com.

Pat Nugent, vice president metrology systems

Q&A

Mahr Federal

8 22 23 24 56 68 17

American Gear Manufacturers Association

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

DECEMBER 2011

Letter

From tHe

EDITOR

David C. Cooper
PuBlisher

While discussing the 150th anniversary of the Mahr Group for this months Q&A with Pat Nugent, vice president of metrology systems at Mahr Federal, he described the companys founder as an intelligent man with a healthy sense of curiosity. Seeing the growing popularity of rail travel throughout Europe, Carl Mahr designed a couple of measurement devices for that industry and the rest, as they say, is history. He recognized an opportunity, knew he had the skills to take advantage of it, and began developing products that filled a need, which is the basic formula for any successful entrepreneur. I saw that same drive on exhibit at the AGMAs recent Fall Technical Meeting in Cincinnati, where specialists from around the worldand representing companies such as Rolls-Royce, SKF, General Motors, ALD Vacuum Technologies, and the Eaton Corporation, among many othersdescribed solutions theyve developed to help gear manufacturers work with greater efficiency toward better outcomes. Its always inspiring to hear intelligent people talk about their work, and my hat is off to the AGMA for gathering together such an astute group of professionals this year. One of them was Dr. Hermann J. Stadtfeld of The Gleason Corporation, who appears in this issue discussing a process used for advanced cutting, skiving, and semi-completing of bevel gears in low quantities in Cyclocut Bevel Gear Production. Rod Kleiss of Kleiss Gears describes how plastic gears can provide a high-torque, high-speed, cost-effective solution for a host of demanding applications in Advances in Molded Polymer Gears, and Jesse Hayes of SCHUNK explains the ways in which simple grippers are being used where various part sizes have to be handled quickly and processed reliably in Gripping Systems for Increased Versatility. Jenny Blackford provides a report on the recent Gear Expo in the AGMAs special section, which also lists upcoming educational opportunities. As for our columnists, Jack Titus discusses the need for a nitriding process combining the speed and control of plasma but without the associated difficulties in his Hot Seat column. Bill Crosher begins a multi-part series on worm gears this month in his Tooth Tips column, and you are encouraged to keep returning service members in mind when filling available positionsand to provide them with a safe work environment if theyre dealing with a physical disability in Terry McDonalds Site Safety column. John B. Amendola, Sr.president of Artec Machine Systems, and another presenter at the Fall Technical Meeting this yearwas very kind in sharing his story with me, providing yet another example of someone who definitely possesses the entrepreneurial spark. As we conclude another year of reporting on this fascinating industry, Id like to thank all of you weve come to know both personally and professionally. Gear Expo is always an opportunity to catch up with old friends while making new ones, and it was great to see that everyone is doing so welleven selling machines right off the floor, in some instances. We look forward to supporting your continued growth in the years to come. All best!

Chad Morrison
assOCiaTe PuBlisher

Russ Willcutt
ediTOr

eDitoriAL

Chad Morrison
assOCiaTe PuBlisher

sALes

Teresa Cooper
manager

CirCuLAtion

Kassie Hughey
COOrdinaTOr

Jamie Willett
assisTanT

Jeremy Allen
arT direCTOr

Art

Michele Hall
graPhiC designer

Contributing writers
William P. CrOsher Jesse hayes rOd Kleiss Terry mCdOnald dr. hermann J. sTadTfeld JaCK TiTus

Vertical Logo

Published by Media solutions, inc.

P. O. BOx 1987 Pelham, al 35124 (800) 366-2185 (205) 380-1580 fax

David C. Cooper

russ Willcutt, editor

PresidenT

Gear Solutions magazine editor@gearsolutions.com (800) 366-2185

Chad Morri son

ViCe PresidenT OPeraTiOns

Teresa Cooper

gearsolutions.com

INDUSTRY NeWS
Gear Solutions Names Stor-Loc toolbox Winners at Gear expo 2011

New Products, Trends, Services, and Developments

Three attendees won a heavy-duty toolbox donated by Stor-Loc for Media Solutions, Inc. (MSI)publisher of Gear Solutions and Wind Systems magazinesto raffle during Gear Expo 2011 in Cincinnati, Ohio. Raffle tickets were automatically provided to those visiting the MSI booth and signing up for a free subscription to Gear Solutions magazine. We had a great time at Gear Expo this year, and wed like to congratulate our friends at the American Gear Manufacturers Association for all their hard work, according to David C. Cooper, president and CEO of MSI, adding that he also enjoyed the contribution made by the ASM Heat Treating Society. Their dedication to this industry definitely paid off in Cincinnati, and we were pleased to have the opportunity to publish the biggest issue of the magazine in its history for this show. The AGMA Fall Technical Meeting was held in conjunction with Gear Expo at the Hilton Cincinnati Netherlands Plaza Hotel. I didnt think it was possible, but this years lineup was even more impressive than the one I enjoyed during the 2010 FTM in Milwaukee, if only because there were more of them, according to Russ Willcutt, MSIs executive editor.

The range of topics was expansive, and the authors represented leading companies and academic institutions from around the world. The AGMA truly is an international organization." Winner of the first days drawing was Robert Doshi of Schafer Gear Works, (top right) and Bill Stockwell of Mitsubishi Heavy Industries America won on the second day. Robin Hines Mifsud of Hines Industries was the third winner. She is second from the left in the group photo along with (left to right) Jerrod Nowlin of C-B Gear

Companies wishing to submit materials for inclusion in Industry News should contact Editor Russ Willcutt at editor@gearsolutions.com. Releases accompanied by color images will be given first consideration.

gearsolutions.com

GEARED FOR SUCCESS

At AJAX Rolled Ring and Machine, our dedicated team prides itself in providing our customers with:

& Machine; Chad Morrison, vice president of MSI; Teresa Cooper, circulation manager; Jack Nowlin, president of C-B Gear & Machine; and David Cooper. Jeff Waldroup of TEAM-Industries won as a result of a drawing associated with completing our recent readers survey. To join the AGMA go to [www.agma. org]. To sign up for your free subscription to Gear Solutions visit [www.gearsolutions.com], and to Wind Systems log on to [www.windsystemsmag.com]. Learn more about Media Solutions at [www. msimktg.com].

new facility. With all the equipment in a closed loop environment, the company will deliver optimal results in class blade grinding service to ensure the quality of the spiral bevel gear production. Learn more at www.klingelnberg.com.

Metal powder Group elects officers

Matthew Bulger, president and general manager of NetShape Technologies-MIM in Solon, Ohio, was elected president of the Metal Powder Industries Federation (MPIF) and Bruce Dionne, general manager of Megamet Solid Metals, Inc., in Earth City, Missouri, was elected president of the Metal Injection Molding Association (MIMA). Bulger succeeds Michael E. Lutheran of Royal Metal Powders, Inc. He joined Hawk Corporation in 2001 to run its metal injection molding (MIM) operation, which was sold in 2007 and became NetShape TechnologiesMIM. Prior to this tenure he served as a materials engineer and quality manager for FloMet. Active in the powder metallurgy (PM) industry, he has presented numerous papers at MPIF conferences, is a member of MPIFs technical board, and most recently served as president of MIMA. He has a bachelors degree in physics from Carnegie Mellon University and a masters degree in materials science from Rensselaer Polytechnic Institute. Before joining Megamet in 2005, Dionne was a regional account manager with Texas Instrument, Inc. He has a bachelors degree in geological engineering from the University of Missouri-Rolla and an MBA from Fontbonne University. Comprising six trade associations, MPIF is the umbrella trade federation representing the international metal powder producing and consuming industries. Go online to www.mpif.org.

Klingelnberg opens Blade Grinding Center in Mexico

Outstanding customer service Timely quotes Accurate documentation 2-week lead times On-time delivery Access to our extensive steel inventory

Gear up with AJAX.

C O N TA C T A N A J A X R E P R E S E N TAT I V E TO D AY.

www.ajaxring.com Toll Free: 800.727.6333 Phone: 803.684.3133

Klingelnbergs Mexico site has been moved to a new facility in Quertaro City. This investment is part of the companys long-term strategy for this important market. At the new facility Klingelnberg will soon inaugurate its new Blade Grinding Center with a Grand Opening event. The new Blade Grinding Center will be part of the claim to meet the increasing demands for this service. In the new plant at the existing location in Quertaro, Klingelnberg also offers first hand sales support, spare parts as well as professional customized service engineering and application engineering. We are now able to support to customer even better and more professionally, regarding both our machines and application engineering, says CEO Jan Klingelnberg. In terms of grinding, the customers will benefit from Klingelnbergs state-ofthe-art automated blade grinding cell B 27, the cutter head setting and checking Device CS 200 as well as the stick blade measuring device BC 10 at this

Kleiss Gears attends BioMeDevice

Kleiss Gears, Inc., a world leader in polymer gear design, will be at booth 1203 at BIOMEDevice in San Jose December 6-7, 2011, to highlight the special design and production issues of plastic gears in medical devices. The companys senior design engineer, Mike Weiss, will also present an Innovation Brief entitled Precision Gearing for Medical Devices on Tuesday December 6 at 1:10 to 1:25 p.m. at on the showroom floor at booth 801.

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For nearly 20 years the company has designed hundreds of gears for clients around the globe, contributing substantially to meeting the growing need for truly precision gears. In the last five years Kleiss Gears medical device business has grown significantly as medical device developers recognize the companys exceptional abilities in the gearing industry and the overall lower costs. A large part of this success is attributed to the unique Shape Optimized Gear DesignTM, which results in higher contact ratios, greater strength, and smoother-acting gears. In addition, Kleiss Gears provides the full range of gearing servicesincluding design, tooling, prototyping, testing, manufacturing, and inspectionwhich enables optimum part control. Kleiss Gears has specialized equipment and experience that particularly benefits the medical device industry. Micro molding expertise enables the development and production of polymer gears in the tiniest of medical instruments. Use of nontraditional (exotic) polymers similarly allows for unique applications that were once impossible or impractical to manufacture. Finally, Kleiss Gears experience in medical quality control documentation helps customers speed through FDA filings. Learn more at www.kleissgears.com.

exceed nearly every other major industry and Original Equipment Manufacturers (OEM) specification for industrial gearbox applications. Ideal for a wide range of industrial gearbox applications, the new Mobil SHC Gear lubricants also offer valuable energy efficiency benefits. In statistically validated laboratory tests and field trials, Mobil SHC Gear fluids exhibited

energy savings of up to 3.6 percent compared with conventional oils. For many industrial businesses, gearboxes are a critical source of power transmission. That is why today, as gearbox technology continues to become more advanced, companies are increasingly seeking higher-performing synthetic lubricants, such as our new Mobil SHC Gear

exxonMobil introduces advanced industrial Gear Lubricants

ExxonMobil Lubricants & Petroleum Specialties announces the introduction of its new lineup of high-performance, fully-synthetic industrial gear oils, known as Mobil SHC Gear series. The latest addition to the Mobil SHC brand of highperformance synthetic lubricants, Mobil SHC Gear fluids are approved by Siemens for use in Flender gearboxes and meet or

DECEMBER 2011

11

lubricants, to protect their gearbox investment, says Mike Hawkins, global brand manager, Mobil SHC Brand, ExxonMobil Lubricants & Petroleum Specialties Company, a division of Exxon Mobil Corporation. By leveraging ExxonMobils exceptional application-specific expertise and relationships with leading OEMs, we

were able to ensure that our new Mobil SHC Gear lubricants feature the most advanced technology to help our customers reduce equipment downtime, minimize maintenance costs and maximize their productivity. Backed by extensive research and testing, Mobil SHC Gear oils are expertly

Custom Gears
Latest Equipment & Technology Quality to AS9100 & ISO 9001 Superior Customer Service On-Time Delivery Best Quality + Value
Southern Gear & Machine is a fullservice custom gear manufacturer producing some of the finest precision gears in the industry. We are uniquely equipped to produce your most demanding parts. All turning, milling, grinding, gear cutting, and gear grinding is done in-house providing us with complete control over production, quality, scheduling, and delivery of your job. With more than 50 years of experience and more than one million dollars invested in the past year alone on the most advanced equipment and technology, Southern Gear is your best source for custom precision gears, on time and on budget.

formulated to help deliver a number of performance advantages over conventional gear oil chemistries, including increased protection against conventional wear modes such as scuffing, enhanced resistance to micropitting fatigue, and extended oil life. Indeed, Mobil SHC Gear fluids offer a service life as much as six times longer than competitive mineral oil based gear lubricants. Today, Mobil SHC branded synthetic lubricants are approved for use in more than 10,000 applications and have exclusive/preferential endorsements from leading OEMs for more than 2,200 applications, spanning a wide range of industries. For more information visit www. mobilindustrial.com.

Detroit Free Press again Names Seco tools a top 100 Workplace
For the second year in a row, The Detroit Free Press has named Seco Tools one of the Top 100 Workplaces in the entire state of Michigan, an honor bestowed by the Troy-based companys employees. This is certainly a proud moment for our company, says Jennifer Ostroff, HR programs manager for Seco. Our employees are our most valuable assets and the key to Secos success. Therefore were committed to keeping them motivated, engaged, and inspired. Earning this top workplace distinction a second time further validates our efforts. Employee feedback from a survey administered by Workplace Dynamics served as the foundation for this Top 100 Workplace competition. The survey drew responses from thousands of employees from 215 companies. Each employee responded to a set of statements about his or her workplace, ranging from I believe this organization is going in the right direction to My pay is fair for what I do. Secos commitment to its employees includes: Ensuring leaders inspire and build trust through transparency and accessibility; Offering comprehensive training so employees achieve optimal performance;

Call us today to learn more about our cutting edge services.

3685 NW 106 Street Miami, Florida 33147

Phone: (800) 248-5152 E-mail: sales@southerngear.net www.southerngear.net

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KEEP ASSEMBLY LINES ASSEMBLING.

Because downtime is never an option, WD-40 Multi-Use Product reduces squeaks, loosens parts, and protects

tools from rust, keeping your parts and machinery running smoothly. Which is why the most trusted multipurpose industrial lubricant continues to be an essential tool for your business. Visit wd40.com to learn about a variety of WD-40 products to meet every workplace need, like the larger 16 oz. can for even more uses.

2011 WD-40 Company

 Building cross-functional teams to drive future company growth; Maintaining a comprehensive benefits plan that exceeds traditional practices, and; Providing an environment where employees feel valued and rewarded. In addition to the 2011 Top Workplaces accolade, Seco recently earned its third acknowledgement from Corp! magazine for being one of Metropolitan Detroits 101 Best and Brightest Companies to Work For. The company received the honor for its innovative employee-engagement strategies, which represent best practices in human resources. Seco Tools is a leading provider of metalcutting solutions for milling, turning, holemaking, and toolholding. The company prides itself on building close relationships with customers to effectively understand and address their needs. For more information contact Lisa Seidl at (248) 528-5444 or lseidl@secotools.com. Also visit www.secotools.com/us.

announcements from Bodycote automotive North america

Bodycotes automotive group includes commercial heat treat plants in Ontario, Michigan, Ohio, New York, and Mexico. Recently the plant in Rochester, New York, received its TS16949 certification and was found CQI-9 compliant. In addition the plant maintains ISO-14001, as do all Bodycote plants worldwide. Robert Scorcia has accepted the account manager position for Ontario, Canada. He joins the company from the wire and cable distribution industry where he worked closely with industries including hydro, electrical construction, elevator manufacturing, and security markets. He is a graduate from Sheridan Institute of Technology with honors in business administration and marketing. His office will be at Bodycote Newmarket, Ontario, Canada. Scorcia joins a new and successful team at Bodycote Newmarket led by General Manager Ross Hill, who joined Bodycote in August of 2011.

James Jackson has accepted the account manager position for Northern Ohio and Western Pennsylvania. James has extensive experience working with Ohio manufacturers and meeting their heat treat requirements. He is a United States Air Force Veteran and served during Desert Storm. His office will be at Bodycote Highland Heights, Ohio, near Cleveland, where he will represent Bodycotes automotive region. Bodycote is pleased to announce the opening of a new commercial nitriding plant in Southeast Michigan. Recent developments in the automotive industry created a unique opportunity for Bodycote to enter this dynamic market. Globally Bodycote is the worlds largest provider of commercial nitriding services. The company is now bringing that expertise to the automotive capital of the world. State of the art equipment has been purchased with installation scheduled for fourth quarter 2011. Production will commence the first quarter of 2012. In addi-

NEW RELEASE 03/2011

KISSsoft SOFTWARE
The Industry Benchmark for Gear Design Contact Analysis Shaft Design & Analysis Bearing Design & Analysis Lubrication Analysis Heavy Machinery, Wind, Automotive, Medical Download your free evaluation copy from www.KISSsoft.com KISSsoft USA, LLC 3719 N. Spring Grove Road Johnsburg, Illinois 60051 Phone (815) 363 8823 dan.kondritz@KISSsoft.com

RZ_kisssoft_ad_gearsolutions_quarterpage_march11.indd 1

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tion to conventional gas nitriding, various ferritic nitrocarburizing processes are offered including Bodycotes proprietary Corr-I-Dur process. The new plant will allow Bodycotes multinational customers access to nitiriding processes and technology they are already comfortable with in Europe, Asia, and South America. To learn more visit www.bodycote.com.

Gleason and heller for Strategic alliance for Gear Cutting

Gleason Corporation of Rochester, New York, and Gebr. Heller Maschinenfabrik GmbH of Nrtingen, Germany, announce the formation of a strategic alliance to serve the global gear manufacturing technology markets. Effective immediately, Gleason and Heller will cooperate in the development and sale of five-axis machining centers for gear production applications. Udo Stolz, vice president for worldwide sales and marketing at Gleason Corporation says Hellers gear cutting solutions are complementary to our own, and strengthen our ability to offer the best possible solution to our customers. Hellers innovative solutions are particularly interesting for flexible and highly productive machining of gears in small to medium batch sizes and where combined machining operations are desirable. Gleason will act as the exclusive distributor of machining centers incorporating Hellers existing gear solu-

tions, and the two companies will cooperate to further improve the capabilities of producing gears on such a platform. By leveraging Gleasons global reach and leadership in gear technology, we believe opportunities exist to expand sales of Hellers solutions. Manfred Maier, managing director of Heller, says that Heller has developed alternatives to traditional gear production processes, alternatives that do not require dedicated machines but are very productive and well suited to certain applications. We are excited about our alliance with Gleason that we believe will open our access to those applications and market segments. Gleason Corporations mission is to be The Total Gear Solutions Provider to its global customer base. Gleason is a world leader in the development, manufacture, and sale of gear production machinery and related equipment. The companys products are used by customers in automotive, truck, aircraft, agriculture, mining, wind power, construction, power tool, and marine industries, and by a diverse set of customers serving various industrial equipment markets. Gleason has manufacturing operations in Rochester, New York; Rockford, Illinois; Dayton, Ohio; Munich and Ludwigsburg, Germany; Studen, Switzerland; Bangalore; India; and Suzhou, China. It has sales and service offices throughout North and South America, Europe, and in the AsiaPacific region.

Heller is a manufacturer of four- and five-axis machining centers, flexible manufacturing systems, and machines to manufacture crankshafts and camshafts. It is headquartered in Nrtingen in the Stuttgart region of Germany. The companys products serve a number of industries including automotive manufacturers and their suppliers, machine building industry, contract manufacturers, power engineering, and tool and die manufacturing, as well as aerospace companies. Heller has production facilities around the globe including Germany, the UK, Brazil, and the United States. Additionally, Heller is represented in all major and relevant markets with sales and service bases and qualified service partners, including subsidiaries in Pune, India, as well as in Shanghai and Beijing, China. More information is available at www.gleason.com and www.heller.biz.

New Global president at Sandvik Coromant

On September 1, 2011 Klas Forsstrm took over the position as global president of Sandvik Coromant, the world-leading supplier of cutting tools, tooling solutions, services, and know-how to the metalworking industry. Forsstrm has been with the Sandvik Group for about 17 years, mostly at Sandvik Coromant. His work has included leading positions in R&D, product development, marketing, business development, and sales. Most recently he held the position as president of Sandvik Hard Materials. It is really exciting and inspiring to be back with Sandvik Coromant. I am truly impressed by what the company has achieved in recent years. As the market leader we are perceptive and forward thinking, he says. His first task as president is to manage and further develop the ambitious strategy that Sandvik Coromant has set. This includes an even stronger customer focus through local presence and global knowledge sharing. R&D is part of the very fabric that is Sandvik Coromant. We are always focused on product innovation, premium application knowledge and speed to market. Our ambition and motivation for the future is strong. I believe we will be

DECEMBER 2011

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successful in the further development of customer oriented solutions, Klas Forsstrm explains. Short facts: Education: Klas Forsstrm holds a Master of Science in Materials Physics and an BMA from Uppsala University, Sweden. Born: 1967 in Gvle, Sweden. Family: Married to Marie Forsstrm; children: Matilda, Lovisa, Amanda and Erik. Lives: Sandviken, Sweden Interests: Family life, reading, fishing, and carpentry Sandvik Coromant is the world-leading supplier of cutting tools and tooling systems for the metalworking industry and is represented in 130 countries. Twenty-five state of the art Productivity Centers located around the world provide customers and staff with continuous training in tooling solutions and methods to increase productivity. Sandvik Coromant is part of the Tooling business area of the Sandvik Group. Learn more at www.sandvik.coromant.com/us.

oerlikon GMC 160 Gear Machining Center

diameter can be economically produced on the GMC 160 machining centers. The one machine, two process concept allows the soft cutting as well as the post heat treated hard cutting on the same machine, thereby significantly reducing upfront investment for customers. The tooling in connection with GMC 160 grants a fast, economical, and technological safe production of gears in small batches. For hard-finishing carbide or CBN-blade inserts are used which result in a high degree of surface quality. The hard cutting process (called HPG-S) delivers reproducible DIN 6 quality or better in regular production. The digital drive technology enables highest precision and repeatability. This unique solution can be utilized for the following applications: industrial gear units, marine propulsion technology, conveyors, and pulverizers. With a sturdy machine design, the flexible tooling system, a direct driven hydrostatic workpiece table, and gear technology that is completely integrated into the KIMoS based closed-loop, GMC 160 is a versatile highend solution for the demands of these markets. KIMoS data files can immediately be processed in the CNC control of the machine. Networking with the P-series measuring machines in conjunction with the appropriate hard and software enables bevel gears to be manufactured in the renowned Klingelnberg Closed Loop, i.e. exact production of Cyclo-Palloid spiral bevel gears according to nominal data including machine corrections. On top, the machine can be complemented with optionally available features. Thereby the flexible machining of straight bevel gears and cylindrical gears is also possible. Also, GMC 160 can be laid out for complete machining with turning and milling operations. Additionally available equipment such as a coaxial double spindle workhead, an automatic tool changer for the double spindle or the integrated measuring system for topography and pitch testing complete the performance range of the machine. The Oerlikon T 200 is a machine for testing the contact pattern and run of bevel gears with 90 shaft angles in the area of application of the Oerlikon GMC 160. It enables testing of gears up to 2,000 mm. CNC-controlled servo drives actuate the two linear axes as well as the gear and pinion spindle, direct measurement systems guarantee the precision of the linear axes. The testing machine is used to determine the optimum installation dimension on the basis of the contact pattern. Furthermore, a subjective evaluation of the running noise can be conducted in the speed range of the machine with programmed brake torques. Learn more at www.klingelnberg.com and www.oerlikon.com.

The spiral bevel gear machining center Oerlikon GMC 160 is optimally suited for flexible cutting of spiral bevel gears, straight bevel gears, and cylindrical gears with universal carbide blade insert tools. Gear sets up to 2,000 mm pitch

innovative Gearbox Concept analysis from Romax

Romax Technology is pleased to announce the availability of release R14.0 of the precision bearing, gearbox, and driveline simulation and analysis software, RomaxDesigner, and wind
continued on pg. 64 >

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American Gear Manufacturers Association

Gear Expo Takes Over Cincinnati

during the first week of November Cincinnati was swarmed by gear industry professionals coming to attend Gear expo, the Fall Technical Meeting, and ASMs heat Treat exposition. By all accounts exhibitors were very pleased with Gear expo. A number of the machine tool builders sold equipment from the show floor, and gear manufacturers opened discussions on future sales and relationships. essentially everyone reported that they had had productive meetings with attendees, including major OeMs from a variety of sectors. Gear expo was the second-heaviest event ever held at Cincinnatis duke energy Convention Center. exhibitors brought over 750,000 pounds of equipment to the show, and exhibitors and attendees praised Cincinnati as a location. Unfortunately, our event used the entire center, with no room to expand in the future. The show was comprised of 180 exhibitors using 43,000 net square feet of the duke Center. Gear expo was co-located with the ASMs heat Treating show of 162 exhibitors in 29,500 net square feet. The two shows drew more than 4,500 attendees: 3,000 for AGMA, and 1,500 for ASM. AGMAs attendees came from 45 states in the United States and 28 countries. Both groups offered a major technical conference and several other education courses. One highlight of the educational events was AGMAs Fall Technical Meeting. Over three days, 28 speakers presented the latest results in gear research and new technical information. More than 175 gearing professionals from around the world attended the event to learn and network with some of the best experts in the industry.

during the FTM one of AGMAs most prestigious awards, the distinguished Service Award, was presented to Frank Uherek of rexnord Gear Group. Frank has been involved in AGMA since the early 1980s helping create industry standards, and even now, almost 30 years later, he is still involved in the Mill Gearing, Computer Programming, and helical Gear rating Committees, where he serves as vice chairman. AGMA Chairman Matt Mondek commented when presenting the award that, With every committee Frank has been associated; he is one of the first to step forward and accept responsibility for getting the job done. he is a tireless worker. AGMA is already planning for another great Gear expo in 2013. The 2013 show will be in Indianapolis, Indiana, September 17-19. Unfortunately, the european organizer for the eMO show will not release the dates of their shows until the current years show is underway. We recently learned that there is a conflict with eMO in 2013; this event runs from September 16-21, in conflict with Gear expo. We booked our space before the eMO dates were available, and given the physical requirements for Gear expo we have no option but to continue with the Indiana dates and location. In 2013 Gear expo will once again be co-located with ASMs heat Treat exposition and will also be in conjunction with AGMAs Fall Technical Meeting. If you werent able to attend this years Gear expo, be sure to mark your calendars now for 2013. You dont want to miss the best opportunity in the industry to see the latest technology and to network with several thousand of your gear industry peers. We look forward to seeing everyone in Indianapolis!

Jenny Blackford, director of marketing and communications American Gear Manufacturers Association (703) 684-0211 blackford@agma.org www.agma.org

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2012 Annual Meeting Looks to the Future

2012 will be a pivotal year, filled with the volatility of domestic politics and the international economy, which will culminate with the presidential election next November. The United States, along with the global economy, continues to be challenging and confusing, but critically important and relevant to our lives. At every turn change continues to dominate our daily life, and as much as we try to predict and plan for the future circumstances and eventualities often create a different path. The 2012 AGMA/ABMA Annual Meeting will tackle a few of the many topics that will shape our futureeconomics, politics, demographics, and more. The meeting will be held March 15-17 at the Hyatt Regency Coconut Point Resort & Spa in Bonita Springs, Florida. The keynote presenters include a few well-known names in the industry, and also experts from other fields that influence todays business community. The presentations include:

stand Out From the crowd: How to Out-Think and Out-Perform the competition Connie Podesta, Motivational Speaker, Author, Executive Coach and Industry Expert In todays world there is no such thing as business as usual. The game has changed, and the competition is closing in with new strategies. If you want to stand out and succeed in an environment where dramatic change happens at the click of a mouse, then you will have to outshine past performance, outthink old ideas, and outmaneuver anyone who says it cant be done. You will need to close the gap between where you are now and where you want to be. let your hair down in this first session and join Connie Podesta, whose message of humor and motivation will inspire you to make those personal changes that will put you on the road to success, health, and happiness.

How to Profit from the coming demographic storm Kenneth W. Gronbach, President of KGC Direct, LLC Join author and expert demographer Kenneth W. Gronbach on an exciting journey into the fascinating world of shifting demographics. Kens views are counterintuitive, global, long term, and very macro. Ken is able to forecast societal, political, and economic changes with uncanny accuracy. Ken is forecasting that manufacturing will return to our continent with a vengeance. he will show why changing demography bodes well for the United States and the Americas and why the best days for the United States are ahead, not behind us.

Calendar of Events

Whether youre looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, the AGMA has something to offer you. If you would like more information on any of the following events visit www.agma.org or send e-mail to events@agma.org.
** Event open to AGMA members only. Not a member? Send e-mail to membership@agma.org.

Alexandria, VA WebEx Webinar 1 pm

Concordville, PA Orlando, FL

January

10

Industrial Enclosed Drives Committee

Marine Gearing Committee

17-18

19 19

Charting the Course Through Profound Demographic Change

24-26 24

Technical Division Executive Committee

25

Wormgear Committee Committee

12 & Materials Metallurgy

Committee WebEx

Mill Gearing Committee

Technical Division Executive Committee

25-26

High Speed Committee

Orlando, FL WebEx

Orlando, FL

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successful Business Growth; Five Guiding Principles Steve Barnhart, Manufacturing Specialist of IMEC (Illinois Manufacturing Extension Center) This presentation will focus on how to grow your business by entering new markets and expanding your existing markets or products. Steve will focus on the key operational issues that you need to promote success including how to evaluate your companys readiness for growth through market or product diversification. Armed with the five principles from this presentation, you will be able to assess your companys opportunity for growth; where, when, and how that should occur; and what it takes to complete it. Following this presentation a panel of our industry colleagues will present firsthand accounts of their successes and challenges with business ventures. Panelists include: rock Baty (President and CeO, NN Inc.); eduardo Garza Junco (CeO, Frisa Industries): and dennis racine (President and General Manager, Penn Machine Company). Fork in the road-Growing or slowing? Jim Meil, Vice President and Chief Economist, Eaton Corporation Will the euro currency crisis be the catalyst for catastrophe or is it a problem with a solution? Will the momentum of North American markets be maintained, or muddled up in a Washington morass? What about Chinas bubble or the trouble in Brazil? Will Obama and Boehner fumble and/or Merkel and Sarkozy stumble? Most important of all , will North American and global manufacturing be headed up or down in 2012 and beyond?

Join Jim Meil as he addresses the global economic business concerns that keep us up at night. Jim has been invited back again to offer his keen economic analysis, which is always on point and relevant. he has that unique perspective from within manufacturing and keen knowledge of what impacts our sector of the economy. Political Outlook for november, 2012 Charlie Cook, Editor and Publisher, Cook Political Report Charlie Cook is another returning favorite to the AGMA/ABMA meeting. he will have his pulse completely focused on the 2012 presidential election. By March, 2012, the front runner republican candidates will have changed several times, the battle lines will be formed, and the race will be in full swing. No one can deny the fact that the 2012 election will be truly historic. When Charlie Cook makes a pronouncement based on his analysis of the political scene in America, people who want to be in the know sit up and listen. For more than two decades he has been Washingtons most trusted and most accurate voice on all things political, whether its the outcome of a Congressional, gubernatorial, or presidential election. Cooks expertise has been featured on the ABC, CBS, Good Morning America, The Today Show, Nightline, Meet the Press, and This Week. Cook founded the Cook Political report in 1984 and became a twice-weekly columnist for roll Call, Capitol hills premier newspaper, before joining the National Journal Group in 1998. Cook has also been an election night analyst for CNN and CBS News and for every presidential election since 1994 for NBC News.

San Francisco, CA

Orlando, FL Orlando, FL

Irvine, CA

30-31

Aerospace Gearing Committee

31-1

February

1-2

Fine Pitch Committee

20-21

How to Organize and Manage a Failure Investigation

ISO/TC60/Working Group 13

22-23 23-24
Cutting Tools Committee

Helical Gear Rating Committee

Gear Accuracy Committee

8-9

Powder Metallurgy Committee

21-22
Ft. Myers, FL

March

AGMA/ABMA Annual Meeting

15-17

Orlando, FL Orlando, FL Ft. Myers, FL

Bonita Springs, FL

Available Year-Round

Online Workforce Education

Gain basic gear training in three courses: Fundamentals of Gearing, Gear Inspection, and Hobbing. Go to www.agma.org/events-training/detail/online-workforce-education.

JANUARY 2010

19

AGMA is gearing up for 2012 and another packed year of training opportunities for the gear industry. Whether youre involved in engineering, the shop floor, sales, or management, there are programs designed for your professional development. Most of AGMAs courses sold out in 2011, and the association anticipates strong demand for education again next year. registration is now open for all of the following programs at www.agma.org. January 24-26 Gearbox CSI: Forensic Analysis of Gear & Bearing Failures Concordville, PA March 15-17 Annual Meeting Bonita Springs, FL April 16-20 Basic Training for Gear Manufacturing Chicago, Il May 15-17 Gear Materials - Selection, Metallurgy, Heat Treatment, and Quality Control Milwaukee, WI May 16-17 Spring Marketing and Forecasting Conference Rosemont, IL June 11-13 Gear Failure Analysis Big Sky, MT June 19-21 Gearbox System design: The rest of the Storyeverything But the Gears and Bearings Clearwater Beach, FL september 17-19 Gear Failure Analysis Big Sky, MT October 1-3 International Business Conference (location to be determined) October 1-5 Basic Training for Gear Manufacturing Chicago, IL October 17-18 Fall Marketing and Forecasting Conference Rosemont, IL October 28-30 Fall Technical Meeting Dearborn, MI november 13-15 Gear Manufacturing & Inspection-Methods, Practices, Application & Interpretation for the design engineer Las Vegas, NV december 4-6 Detailed Gear Design-Beyond Simple Service Factors Alexandria, VA In addition to the in-person programs, in 2012 AGMA will also offer monthly webinars, 90-minutes in length on a variety of relevant technical and business topics. For a list of upcoming offerings and access to archived webinars visit www. agma.org.

AGMA Announces 2012 Education Schedule

AGMA Leadership
Board of Directors
Norbert Benik: VP of Industrial Sales, Ontario Drive & Gear, Ltd. Jim Bregi: President, Doppler Gear Company Sulaiman Jamal: Managing Director of Bevel Gears (India) Private Limited Tom Marino: President & CEO, Gear Technology Gordon New: Managing Director, Ronson Gears Pty, Ltd. Bob Phillips: Senior Vice President, Gleason Cutting Tools Corp. Bob Sakuta: President, Delta Gear Kyle Seymour: President & CEO, Xtek, Inc. Mike Smith: Vice President of Sales and Marketing, Capstan Atlantic Mike Suter: Vice President of Marketing, Emerson Industrial Automation dirk Wernecke: Global Manager, Pricing, The Timken Company

Executive Committee
Chairman: Matt Mondek President, Cotta Transmission Company, LLC Treasurer: Louis Ertel President & CEO, Overton Chicago Gear Corp. Chairman, BMEC: John Strickland VP of Marketing and Strategic Planning, Fairfield Manufacturing Co., Inc. Chairman, TDEC: Dr. Phil Terry Chief Metallurgist, Lufkin Industries Chairman Emeritus: Dave Ballard Director of Marketing & Business Development, North & South America, Siemens Industry, Inc.

Staff

Joe T. Franklin, Jr., President Charles Fischer, Vice President Technical Division Jan Potter, Vice President Membership

Contact the AGMA

20

General requests: webmaster@agma.org Membership questions: membership@agma.org Gear Expo information: gearexpo@agma.org Technical/Standards information: tech@agma.org AGMA Foundation: foundation@agma.org

1001 N. Fairfax Street | Fifth Floor Alexandria, VA 22314-1587 (703) 684-0211

www.agma.org gearsolutions.com

Geared on

Value
The target is clear when it comes to supplying the best value in gear inspection. Our mission is to offer the widest selection of reliable, productive and precise Gear Inspection Machines. We aim to be at the pinnacle of design and through our global partnering with the finest manufacturing processes, materials and components, we deliver durable, robust machines with a high degree of up time.

At Wenzel America we believe that when advanced German engineering meets American ingenuity we produce a product line with:

A huge range to inspect any size gear, A Wear-free system design, and Is built sturdy with Granite for stability, accuracy and reliability.

Striving for the Highest Precision Value in

Measurement Gear Inspection 3D Imaging

Wenzel America, Ltd. 46962 Liberty Drive Wixom, Michigan 48393 Phone: 248 295-4300 http://www.wenzelamerica.com

SITESafety
terryMcDonALD
Member of the ANSI Subcommittee on Gear Safety

Companies seeking qualified workers should consider members of the armed forces who are returning from duty overseas, and they should provide a safe working environment.
EvErybody knows thErEs a shortagE of qualified workers in manufacturing here in the United States. There are a lot of organizations out there doing what they can to fill in the gap, like the Society of Manufacturing Engineers Tooling U and many other training programs. Although many seek to attract high school students searching for a career path, others target veterans returning from serving our country overseas, with one example being Save Our Veterans (www. saveourveterans.org). These are people who have been handed a great deal of responsibility, many of them at a very young age, and have received training in technologies that you and I dont even know about. They deserve a chance at a good job, especially if theyve been injured, and those men and women in particular deserve a safe working environment. The reality is that many of these individuals may have special needs. They might be navigating life in a wheelchair, or learning what they can doand how they can do itwith a prosthetic limb. Some may be adjusting to varying degrees of hearing or vision loss. No matter the situation, youll need to consider their abilities in exactly the same way you would anyone elses: what skills am I looking for in this position, and does this person possess those skills or the potential to acquire them? If they do, then that should be your primary consideration. The second one should be making sure your workplace doesnt present your new hire with any unnecessary challenges. You may have noticed in recent years that public spaces such as airports, hotels, and government buildingsthe newer ones, at leastare more open than they were in years past. In some cases this is an example of whats known as Universal Design, in which the needs of people with disabilities are factored into the actual design of a structure, resulting in wider doorways, more ramped exits and entrances, and elevators that are clearly marked to provide access to upper and lower floors. What you also might notice is that this type of design is really better for everyone, with fewer tight corners and more railing around elevated platforms. Think about a ramp at the entrance to a hotel, for instance, and how that makes it easier for everybody to wheel in their luggage, and greater access inside the building allows maintenance workers to move their equipment around more easily as well. While this mostly has to do with

access, it also leads to increased safety, because you dont want someone in a wheelchair or with a cane having to take risks just to get where theyre going. And thats basically what youll need to think about at your own facility. Are the doorways wide enough for someone in a wheelchair or using other devices to get through, both in the offices and on the shop floor? Do you have parking spaces available in your lot for disabled drivers that are clearly marked both in blue and with signage, and is there adequate room on the passenger side for a ramp to drop from an accessible van? Are there graduated ramps throughout your facility for ease of entry to all areas, and are the passages between

Veterans deserve a chance at a good job, especially if theyve been injured, and those men and women in particular deserve a safe working environment.
rooms smooth with no hardware mounted to the floors? Youll want to pay even more attention than usual to containing and cleaning up spills quickly, especially slick lubricants and metalworking fluids, and to make sure that manufacturing cells are contained with no moving parts unexpectedly jutting into passageways. The good news is that the manufacturing environment is generally designed to accommodate big pieces of equipment and products that need to be moved around a lot, so you should concentrate on things like making sure the height of signage, water fountains, eyewash stations, and first aid kits makes them available to everyone. Those who have risked their lives protecting our country deserve our gratitude and respect, but theyre probably more interested in moving on with their lives and getting started on a career than brushing parade confetti off their shoulders. And if theyve returned from military duty with mobility challenges we should do all we can to ease their entry back into the working world.

ABOUT THE AUTHOR:

Terry McDonald is partner and manager of Repair Parts, Inc., and a member and pastchairman of the ANSI B11.11 Subcommittee on Safety Requirements for Construction, Care, and Use of Gear Cutting Equipment. Contact him at (815) 9684499, rpi@repairpartsinc.com, or [www.repairpartsinc.com].

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PrinciPlE: a machinEs Practical mEchanical advantage is defined as the ratio of the force expended by the machine to overcome a resistance to the force applied. The screws mechanical advantage is likely to be greater than that in any other form of machine. The worm gear is a form of screw that makes use of this inherent mechanical advantage. A screw and a worm gear have a cylindrical body with helical grooves cut into the surface. The screws mechanical advantage is the ratio of the distance traveled in one revolution to the force applied to its pitch. A worm gear uses the mechanical advantage of the ratio of plane length to height. When a screw is turned through one revolution, the screw advances the distance between successive threads. This distance is called the pitch of the screw. The inclined plane is another ancient and familiar machine and was used by the Egyptians to move stone blocks into position for the pyramids. The worm gear is also the mechanical application of the inclined plane: a plane that is rolled up in a helical form. If a gearset were assembled so the worm wheel could not rotate and the worm left free to move along its axis, depending on the direction of rotation the revolving worm would move in a forward or backward horizontal motion. The thread of the worm advances in an axial direction. When the worm is held between thrust bearings and the worm wheel is free to rotate, the revolving worm turns the worm wheel. When the worm is considered to be in a stationary fixed position, the resulting conjugate action would be identical to that of a rack and pinion. The worm wheel's pitch circle is a cylinder concentric with the axis. The worm pitch surface, on the other hand, is a plane parallel to the axis of the worm. There are two distinct types of action that take place when the worm and wheel are rotating. These actions are termed approach and recess. The approach action is a sliding action that takes place when the gear tooth slides down the side of the worm flank toward the worms central axis. This is a wearing away action that is harmful to the wheel surface. The recess action takes place when the gear tooth slides out of mesh climbing up the worm tooth away from the central axis. The friction forces are then much lower and in a positive direction. This action improves the contact, and thereby the load capacity. Whenever the worm is the driving member, the recess action is the preferred operating mode. In a full-recess action the worm pitch line coincides with the outside diameter of the gear. It is sometimes necessary

TOOTHtipS
Author, engineer, and former director of the National Conference on Power Transmission

williamCrosher

In this first installment of a series, the author discusses the different types of worm gears and how useful they are in a wide variety of applications.
to add two or three teeth to the worm gear or increase the worms lead. The approach ends and the recess action begins at the pitch line. The reversal in the direction of sliding will have the tendency to break down the oil film that can only be eliminated with all recess action. There are many advantages to the worm gear. From the earliest of times the worm gear has been widely used in many different applications because of several inherent advantages, even though it is a complicated gear to design and manufacture. Worm gears provide within one pair of gears the largest available ratio and the most compact design for gears with ratios > 10:1. Shaft axes can be at a right or acute angle. Due to the high contact ratio and material combination, worm gears have the lowest sound levels of all gear types. According to the German VDI standard 2159, the anticipated sound (noise) level for a worm gear enclosed drive is approximately 7dBa lower than a bevel-helical drive at the same input power and speed. A worm gear has more internal vibration damping than any other gear form. Due to the large area of contact and the material's properties, worm gears have the highest load bearing capacity. They are capable of sustaining high peak torques. Design ratings allow for momentary 300 percent peak loads in comparison with 200 percent for other gear forms. When it is an advantage to the application, self-locking characteristics can be utilized, within limitations. The transfer of motion is smoother than with other gear systems due to the gradual tooth engagement, and precise backlash control with provisions for minimum backlash is obtainable. Lastly, high precision worm gears can be produced with a total angular velocity deviation of less than two arc minutes. Worm gearing is considered by many to be more complex in the understanding of its design, operation, application, manufacturing, and assembly than most other types of gearing. Even so, when properly applied the worm gear is still one of the strongest, most reliable, and long-lived gears that can be selected. When the performance is below what is anticipated, the reason is usually found to have been misapplication or a misunderstanding of either efficiency, lubrication, or the thermal rating. In the application of the worm gear three areas are of special significancethreads, effective length, and tooth thicknesswhich we will consider in the next installment of this column.

ABOUT THE AUTHOR:

William P Crosher is former director of the National Conference on Power . Transmission, as well as former chairman of the AGMAs Marketing Council and Enclosed Drive Committee. He was resident engineer-North America for Thyssen Gear Works, and later at Flender Graffenstaden. He is author of the book Design and Application of the Worm Gear.

DECEMBER 2011

23

jacktitus

HOTSeat

Director of process and developmental engineering, AFC-Holcroft

What we need is a nitriding process combining the speed and control of plasma, but without the degree of difficulty. According to the author, stay tuned.
in thE last four wEEks my work has takEn mE to austria, Slovakia, Wiesbaden, Germany, Russia, and Cincinnati, Ohio, all having to do with heattreating gears. In my October column I stated that carburizing and induction were the two primary competing processes for case hardening gears. I didnt forget about nitriding. Gears are gas nitrided, but in significantly smaller quantities for two main reasons: the long processing time to achieve case strength, and inconsistencies in the white or compound layer especially in high alloy materials. But I believe a long-lost discovery may change the way we view nitriding as a case hardening process. Ive been very fortunate to have traveled throughout the world analyzing and developing all things heat treat, and when I return to the U.S. and contemplate the knowledge gained Im always taken by the way different countries view the heat treating process, primarily case hardening. Its not the science of metallurgy, but more how we view the equipment used to complete the process. Nitriding is a case in point. The historical record has nitriding during the 1920s being developed more or less simultaneously in Europe and the U.S. Initially the salt bath process found favor until machine components requiring surface hardening became more complex, with holes getting so small they were too difficult to clean. Eventually the gaseous process emerged solving many of the earlier problems, but lacked the processing speed of the salt alternative. Enter about 1980 Klockner of Germany who perfected the plasma process that reduced process time while enhancing white layer control. Klockner installed numerous systems in Europe and Asia. In the early eighties I was part of a team tasked with transferring the Klockner process to the U.S. About that same time the digital revolution was sweeping America with PLC development, and the PC was just starting to enter our lexicon. What an opportunity! thought our company management at the time to offer this new high tech process, but we cant keep their existing and outdated analog logic. Those and other resulting decisions affected how the plasma process was to be perceived in the U.S. for years to come. Weve got to Americanize this process because it requires too much operator

ABOUT THE AUTHOR:

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

interaction, and that didnt square with the changing trend in heat-treat process control. Our goals were noble but we overlooked two major issues. First, we overlooked how Klockners thinking process defined and evolved the equipment. Second, as it was similarly described to me in a recent meeting, dont turn a BMW into a Chevy. But thats exactly what I wanted to do. In preparation for my effort to develop the digital process control system for the arc-counting power supply logic, I spent four weeks at Klockners commercial heat treat in Germany learning the process. It was there that the enormity of our task hit me: This so-called state of the art technology required that the German nitride operator had to cover his entire head and furnace view port in a black photographers cape to shield ambient light so that he could analyze the temperature gradient within the complex load he had constructed. Absent from ambient light 950F [510C] has color. Even though the operator had placed thermocouples in the load, the variant of part spacing and holes as the load heated could cause hot spots to occur at too many locations to electronically monitor. I thought to myself, this is Model-T Ford technology, not BMW. But this was how it was done in 1980s Germany, and they thought nothing of it. It was required for the process. Automakers and other OEMs were starting to see the benefits of outsourcing heat treat, so commercial heat treaters suddenly arose as the recipient of our sales effort. How was that going to work? Not well. Constructing a plasma nitriding load requires specific experience, knowledge, and skill, neither of which existed at commercial heat treats at the time. Add to that a brand new process control methodology and new vacuum equipment. We were doomed before the first circular vacuum vessel was fabricated. Gears are expensive to manufacture and difficult to case harden, especially when distortional tolerances must be reduced to a minimum. Gas nitriding is effective, but when tooth contact loads increase so does the case depth required, and the composition of white layer or lack of it to fight fatigue becomes critical. What we need is a nitriding process combining the speed and control of plasma, but without the degree of difficulty. A process operating under the radar in Russia that enhances ammonia, discovered decades ago, has the benefits and even more application than plasma nitriding appears to offer that solution stay tuned.

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What youve been waiting for.

Introducing HybridCarb a better choice from Ipsen

The new HybridCarb from Ipsen is an ultra-efficient gassing system designed to replace endothermic generators and other gassing systems. Its core strength is precision gas control. Instead of burning excess gas off, the process gas is reconditioned and reused, increasing efficiency up to 90%. HybridCarb allows for the reduction of more than 40 tons of CO2 per year the equivalent of planting 220 trees. Other benefits of HybridCarb include: Quick and easy hookup Increased carburizing efficiency Improved hardness uniformity Significantly less expensive to operate than endogenerators Consumes significantly less gas Environmentally friendly and cost efficient

For more information on HybridCarb visit www.IpsenUSA.com/HybridCarb

Visit our ASM Heat Treat 2011/Gear Expo booth #2123/2133

COMPANY profile

Artec Machine systems

Whether youre in the market for drive system design assistance or skilled maintenance and training services, this company has solutions to the challenges you face.
By Russ Willcutt

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gearsolutions.com

It was the early seventies, and after six years spent working as a high-speed gearing specialist for a company on the West Coast, John B. Amendola, Sr., knew that change was in the air. End users of high-speed gears were experiencing a rise in gear failures, and he wanted to work with a company that he could respect and trust. Unable to find a domestic company that struck his interest, he finally decided to approach MAAG, the machine tool manufacturer based in Switzerland. They werent really involved in much of the high-speed gearing market, but they liked being engaged in unique applications so they could apply the experience to their machine designs and keep them on the cutting edge, he says. They didnt have U.S. representation at the time, so I convinced them to let me use my connections to help them establish a foothold. I became their agent in North America, and our relationship lasted for the next 35 years. Theyre not in business anymore, but their remanufactured shaper cutters are still very popular. That relationship was also the foundation for Artec Machine Systems, which Amendola founded in North Branford, Connecticut, in 1972. The first 10 years were spent making inroads with U.S. customers, designing custom drive systems that were then manufactured by MAAG. The business began developing its reputation for tackling complicated installations, designing drive systems for demanding and highly specific applications. Construction on the companys current facility began in 1983, and it was around that time when Amendola realized it was time to establish a service department. In addition to designing gearboxes, customers were asking us to examine drive systems that were giving them trouble, doing forensics to identify and correct the problem, so we were working on all kinds of gears and gearboxes at that point, and the service center in the new building gave us room to do our work.

With each passing year the companys capabilities grew, especially those having to do with its range of technical services. In addition to rebuilding gearboxes and testing them on its API-rated test stand, Artec also offers field services including periodic maintenance inspections, condition reporting and analysis, onsite overhauls and gearbox repairsincluding bearing/rotating equipment replacementvibration analysis and diagnostics, and failure analysis. Other services include gear failure prevention, gear repair analysis, new gearbox installation and commissioning, and specification review and design upgrades. We also perform general gear training seminars with numerous clients, including the U.S. Navy, Amendola says. We provide students with the technical and practical skills theyll need to operate, service, and maintain power transmission equipment. Marine applications have become a new market for the company in recent years, especially in light of its involvement with propulsion systems for the U.S. Navy. The economic downturn of the early eighties convinced Amendola of the value of market diversification, so he has worked hard over the years to balance the companys activities among a healthy selection of industries. In addition to the military and commercial marine market Artec is also involved in high speed oil and gas transmission, heavy duty cement, power generation, ski lift drives, polymer and plastic, pharmaceuticals, and the food industries. Weve worked with customers including General Mills and Malt-O-Meal repairing their extruder drives, he says. Youd be amazed how many there are in your average food processing plant. Amendola says that he and his colleagues have worked hard to position Artec Machine Systems as the go-to company for challenging installations and applications. As an engineering design and maintenance services provider, the company has relationships in place with RENK-MAAG, Euroflex Transmissions, Kissling, and a number of high-precision loose gear manufacturers around the world. Were not interested in commodity gears or standard drive system designs, he says. There are plenty of companies out there doing a fine job with that. What were able to do is sit down with a customer who is faced with a challenging application and provide solutions, whether that involves designing a new system from scratch or examining existing drive systems to determine how they can be upgraded and enhanced. When theres an engineered product involved, were the company to call.

TO leArN MOre:
Call (203) 484-2002, e-mail sales@artec-machine.com, or go online to [www.artec-machine.com].

Gripping Systems for Increased Versatility

Comparatively simple grippers are used in an increasing number of applications where various part sizes have to be handled quickly and processed reliably. SCHUNK explains.
By Jesse Hayes

THOSE IN THE AUTOMOTIVE INDUSTRY WHO WANT TO STAY FLEXIBLE IN MANUFACTURING NEED SPACE FOR GRIPPER STORAGE STATIONS AND CHANGING SYSTEMS. GRIPPER CHANGES OFTEN CAUSE UNPRODUCTIVE AUXILIARY PROCESS TIMES, WHICH REDUCE EFFICIENCY. THEREFORE THE TRENDS IN THE ONE-PIECE SERIES PRODUCTION ARE

HEADING TOWARD UNIVERSAL PLANTS AND FLEXIBLE AUTOMATED SOLUTIONS WITH MULTIFUNCTIONAL, SERVO-ELECTRIC DRIVEN GRIPPING SYSTEMS. THEY ARE VERY FLEXIBLE AND GRIP VARIOUS PARTS IN ALTERNATING SUCCESSION.

Because of the increasing variety in models,

motors and equipment can only be produced profitably if the automated solutions can be flexibly adjusted in a short time. While robots allow a high degree of flexibility during the sequences of movements, the alternating gripping of various components remains a challenge. Comparatively simple grippers are used in an increasing number of applications where various part sizes have to be handled quickly and processed reliably. In the automotive industry, where space and time are extremely critical factors, the trends go to multifunctional, servoelectrically driven gripping systems.

siMuLtAneous engineering requireD

Flexible automated solutions for automotive welding and assembly lines are far more complex. For achieving process-reliable handling, numerous factors have to be considered, such as the large variety of part sizes, varying surfaces, and different positions of possible gripping points, as well as the handling of occurring forces and vibrations. It would be ideal if the parts and plant design could be done at the same time. During the design process of car parts, for example, identical clamping and gripping points can be defined, considerably increasing the plants later degree of efficiency.

Motor AnD geAr MAnufACturing PLAy Pioneering roLe

For motor and gear manufacturing, efficient solutions already exist that allow flexible handling of various crankshafts, cylinder heads, or motor blocks. Special grippers equipped with a compensation unit, for example, can handle four different cylinder head types with a weight of up to 95 kg. For this purpose the compensation unit rests on a floating bearing and is then locked eccentrically. A stroke of 342 mm allows gripping components of different sizes. Due to the compact axes that carry the wheel rims, the gripper has optimized size/contours for confined spaces. The gripper is integrated into the existing robot control unit and does not require any additional control unit or regulator.

fLexibLe Lightweight griPPers

In addition to flexibility, the lightweight gripper now plays an increasing role for the design work of grip-

Fig. 1: A SCHUNK gripping system can easily handle a circular disk, such as a gear. DECEMBER 2011 29

system integrators, and users. A development example resulting from a cooperation between the manufacturer FFT EDAG, the robot manufacturer FANUC Robotics, and SCHUNK provide ideas on how flexible a clamping and gripping system for the vehicle manufacturing could look like. The SCHUNK LEG long-stroke electric gripper is used as a positioning unit of side skirts. The standardized lightweight gripper in the modular design weighs 8.8 kg, disposes of an enormous gripping force of 1140 N, and a variable stroke between 0 mm and 568 mm. For the use in this plant it was equipped with a servo-electric drive from the robot manufacturer. By

Fig. 2: Gripping systems make easy work of handling square objects.

ping systems. Integrated into the system, the lightweight grippers save energy at the same efficiency, or achieve at the same energy consumption a

Fig. 3: Spheres are help securely in a SCHUNK gripping device.

considerably higher efficiency. In both cases efficiency of the complete system increases, which is why lightweight grippers are perfect for manufacturers,

means of a plug-and-play connectivity, the gripper works like an additional robot axis and can be actuated with the same instruction set. The flexible assembly group is combined with a six-axis robot and an additional robot used as a flexible clamping device. Two

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Fig. 4: Rods present no problems for these gripping systems.

degrees of freedom at the gripper, five at the device, and six at the robot open up a new spectrum of possibilities.

CoMPosites Are PoPuLAr

New and considerably more efficient manufacturing methods will assure that lightweight grippers in the future, which are made of composites, will take root in the automotive industry. In this example

Fig. 5: Workholding systems can be designed to handle all weights, sizes, and dimensions.
SCHUNK currently presented a longstroke gripper made of carbon fiber composites with a scalable pneumatic drive. The lightweight scores in energy efficiency and in cost effectiveness. At a weight of 10 kg, the LEG-C disposes of a gripping force of up to 4,000 N and a variable stroke of up to 600 mm. If shortened finger travels are required, the stroke can be individually scaled.

DECEMBER 2011

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HoBS for inVolute Spline din 5482

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Fig. 6: The SDH gripper hand comes in different configurations and is ideal for handling gears.
This minimizes the cycle times and reduces the compressed air consumption, which makes the gripper much more efficient. For offering a continuous lightweight concept, the aluminum fingers are also executed in a lightweight design. They travel on recirculating ball bearing carriages. Via the quantity and the distance between the guiding carriages, the gripper can be exactly adjusted to the individual payload. In case of particularly high gripping forces or extremely long fingers, the distance between the carriages is enlarged. This way, even fingers with a length of more than 1,000 mm can be used. The scope-free belt drive and the synchronized fingers assure that the gripper is working precisely at variable strokes. This is ideal when large and small parts have to be alternately handled.

funCtionAL AsseMbLy grouPs

Automating plants in the automotive industry are becoming more complex and have a more compact performance, while at the same time cost pressure is continuously increasing. Customer-specific functional assembly groups from SCHUNK show how successful this balancing act can be. They combine cost and time advantages of standard components with benefits in productivity and processes of individual special solutions. The result is the highest possible level of process reliability in manufacturing and operating the plant. Moreover, the assembly groups reduce development times and increase the security in planning. The medium and long-term development of the automotive industry will lead to highly flexible manufacturing units that do not need any rigidly defined tools, devices, or gripping systems. Therefore, manufacturing one-piece series should become more economic in future with more-complex, multifaceted, sensor-equipped gripping, and handling systems will be available that will be freely programmable and easy to integrate. Concerning retooling, these all-rounders will become reusable components that can be used in new or modified processing lines repeatedly.

tALenteD griPPer hAnD

In the automotive industry there is a high need for the flexible gripping of various small components, thereby the human hand is surely the best template. The SDH-2 three-finger gripper hand from SCHUNK is structured similarly. With its seven independent degrees of freedom, it can grip and position various objects without having any setup times. The gripper hand dominates in the industrial gripping types three-finger centric, two-finger parallel and cylindrical gripping, and many other versions. A tactile sensor system safely and sensitively monitors the optimum grip and supplies information to the control unit in order to do gripping corrections if necessary. Therefore, even difficult geometries can be reliably handled, positioned, or inserted. For industrial applications, the SDH-2 is protected against dust and moisture.

ABOUT THE AUTHOR:

Jesse Hayes is automation group manager at SCHUNK USA. Call (800) 772-4865 or go online to [www.us.schunk.com].

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g in ll e P o Pr ward r fo
ay an Tod
(Use your smartphone for quick access to our site)

ers thrust in the ls. found vesse an be large ars c ther ese and o vel ge xis, th ur be ships ical a ,o ise y vert Today er cru literall und a aneuv es aro rs can ruste that m 360 degre ding ed th s lea el dvanc tating world a Ro the al bev ically supply rd-cut spir nolog tech e. We g ha a dim oducin rn on tu rs, pr 13. e uality factur MA q manu AG take up to uture gears f the f rs o l be ginee ar wil the en go Ge ever hica p us Wher rton C at kee , Ove next ars th us e ge ing th upply d. s orwar ving f mo

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Cyclocut Bevel Gear Production

The following technical paper from Gleason describes the Cyclocut process for advanced cutting, skiving, and semi-completing of bevel gears in low quantities.
By Dr. Hermann J. Stadtfeld

LOW-QUANTITY BEVEL GEARSETS CAN BE MANUFACTURED WITH THE CYCLO-PALLOID

METHOD. THE CYCLO-PALLOID USES INTERLOCKING FACE HOBBING CUTTERS WITH FIVE

STARTS IN MOST CASES. FOR THE SOFT CUTTING, EACH CUTTER START INCLUDES SEPARATE OUTSIDE AND INSIDE ROUGHING AND FINISHING BLADES. FIGURE 1 SHOWS AN INTERLOCKING CYCLO-PALLOID CUTTER HEAD WHERE THE CENTER PART CARRIES AN

INSIDE ROUGHING BLADE AND AN OUTSIDE FINISHING BLADE. THE INTERLOCKING SECOND PART OF THE CUTTER CARRIES THE OUTSIDE BLADES. THE CUTTER AS SHOWN IN

FIG. 1 IS SET UP FOR THE SOFT CUTTING OPERATION. THE SAME CUTTER HEAD CAN BE

USED FOR HARD FINISHING BY SKIVING.

The finishing blades are replaced by skiving blades,

than nominal. The enlarged outside blade radii generate outside flanks that, in interaction with the nominal inside outside flanks, will lead to length crowning controlled by the amount of outside blade point diameter increase. The graphic in fig. 2 shows how the two different pitch point diameters are arranged to be approximately tangential in the center roll position at the tooth mid-face. In order to accomplish the correct position of the two interlocking cutter parts, a main (outer) spindle carries the outer cutter part, while the inner cutter part is connected to a secondary (inner) spindle. The secondary spindle is positioned at an eccentric position relative to the main spindle, such that the two pitch point circles contact each other at the calculation point in mid-face position and the offset lines of both cutter parts lie on top of each other and are perpendicular to the flank line tangent (fig. 2).

which commonly have brazed on CBN (cubical boron nitride) inserts on the cutting edges. The roughing blade slots are not used during the skiving operation. Cyclo-Palloid is a continuous indexing face hobbing method with parallel depth teeth that is based on conjugacy. This means without any flank corrections the pinion and gear flanks would contact along contact lines in every roll position. While rolling through an entire tooth mesh, the transmission ratio in case of conjugacy is perfectly constant and equal to the ratio of the pinion and gear tooth count. The motivation to use two-part interlocking cutters is based on the idea of applying a mathematically simple method to generate length crowning by combining nominal inside blade diameters with outside blade diameters that are larger

Fig. 1: Interlocking Cyclo-Palloid cutter head.

Fig. 2: Principle of length crowning by different cutter radii. DECEMBER 2011 37

Profile crowning in Cyclo-Palloid is generated with curved blade cutting edges. Both pinion and gear are strictly generated bevel gears; there is no non-generated version of Cyclo-Palloid available [1]. A hypoid offset of the pinion versus the gear is basically possible, but very seldom used in practical applications.

introDuCtion to CyCLoCut
Interlocking face cutters are time consuming to build and have lower stiffness than single part cutters. Also, the provisions on the machine of a main spindle with an adjustable secondary spindle inside requires a complex design and results in reduced stiffness. Cyclocut successfully replaces the interlocking cutter with a single part cutter, which can be used on freeform Phoenix II bevel gear generators in order to produce gears with flank surfaces that match Cyclo-Palloid flanks. Length crowning is generated with single part cutters (in a completing process) by utilizing a cutter head tilt as shown in fig. 3. The untilted cutter to the left requires two cutter parts, rotating about different cutter axes (), like the case in Cyclo-Palloid. It is also possible to tilt a single part cutter about the mid-face flank line tangent and adjust the blade angle by the same amount to achieve identical

Fig. 3: Conversion of an interlocking cutter into a single part cutter.

curvature radii as in the case of different cutter axes for inside and outside blades. The mentioned blade angle adjustment also

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assures the correct pressure angles on both flanks. Figure 4 shows a comparison of a simulated tooth contact analysis based on the Cyclo-Palloid cutters and machine kinematics to the left and based on the single part Cyclocut cutter and machine kinematics to the right. Ease-off, tooth contact, and motion error between Cyclo-Palloid and Cyclocut show the identical characteristics. Practical trials proved that Cyclo-Palloid pinions can roll with Cyclocut gears and vice-versa without significant differences in contact patterns and rolling characteristics [2].

ing. In Cyclocut, the soft cutting prepares the root geometry for the following skiving process with a root skiving distance, a flank stock allowance, and a protuberance between flank and root fillet radius. Figure 6 shows those three geometric elements that are standard features of Cyclocut [3].

CyCLoCut skiving
Cyclocut skiving is a hard cutting process that utilizes coated carbide blades with a chip-forming facet that has a 20 negative side rake angle (T-Land in fig. 7). In the skiving process the blade cutting edge is required to develop a high normal force contact with the flank surface in order to penetrate into the hardened steel and form a chip. The same Pentac cutter as shown in fig. 5 for the previous soft cutting is used for the skiving only the soft cutting blades are exchanged with skiving blades. It is very advantageous to use single-part Pentac cutters instead of interlocking cutters mounted to a double spindle because of the high stiffness requirement between work and tool in the case of skiving. Cyclocut skiving is performed at surface speeds of 120 m/min and removes chip thicknesses of 0.1mm, which is equivalent to an end chip value of 0.34mm. A dry skiving as shown in fig. 8 is possible and might be the process of choice if the Cyclocut soft cutting was already done as high speed dry PowerCutting. However, wet skiving is still the

tooLs AnD Cutting ProCess

The first generation Cyclocut cutter head (shown in fig. 5 to the left) used rectangular blade sticks and was mostly applied to wet cutting with HSS (high speed steel) blades. The second generation Cyclocut cutters (fig. 5, right) utilizes five-sided Pentac slots that provide a positive seating which is beneficial for all applications of carbide blades [1]. Pentac blades eliminate basically all micromovement of the blades in the cutter head slot, which is important in order to reduce or eliminate cutting edge chipping. The machining process for soft cutting is a standard face hobbing cycle with a center plunge and double roll cycle. In order to maximize tool life, the center plunge utilizes a vector feed [2] in order to balance cutting edge wear between inside and outside blades. The preferred hard finishing after heat treatment is skiv-

DECEMBER 2011

39

standard process that delivers better tool lives than dry skiving. Skiving chips for wet cutting have a different formation and color than dry cutting. A comparison of dry and wet chips is shown in the photos of fig. 9. In any case, wet or dry, an all-around coating of the blade cutting edges is recommended in order to achieve optimum tool life results. Future developments will concentrate on a strictly dry skiving process without any tool life penalties compared to wet skiving. A typical Cyclocut gearset with a face width of 112mm and a whole depth of

25mm is shown after hard finishing by skiving in fig. 10. The tool life for the parts shown was 20 ring gears and 24 pinions, amounting to 640 gear slots and 312 pinion slots, which is a remarkable result compared to generally smaller numbers for skiving with CBN cutting edges. The reasons can be found in the carbide blade design and the higher stiffness between blades, cutter head body, supporting machine components, and work piece. Tool spacing measurement results, surface roughness, and waviness of the ring gear are shown in fig. 11. The excel-

lent spacing quality together with the low surface roughness and waviness values also confirm the optimal conditions of the Cyclocut skiving process.

tooth ContACt DeveLoPMent AnD CorreCtions

Also for Cyclocut pinions and gears, 3D measurement of flank surfaces and flank form corrections are available standard features of the Gleason metrology and correction software G-AGE. Smaller manufacturers often have no coordinate measurement

Fig. 4: Tooth contact analysis (TCA) of Cyclo-Palloid (left) and Cyclocut (right). Fig. 5: First (left) and second (right) generation of Cyclocut cutter heads.

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Fig. 6: Semi-finish strategy for skiving.

capability available and like to rely on the tooth contact pattern appearance from roll testing as shown in fig. 12. If a correction of the contact positions is desired, the Gleason Tooth Contact Corrections can be utilized for a profile and face width contact movement on coast and drive side. Figure 13 shows the input screen to the left. The input values show the desire to move the contact bearing on the drive side 5mm toward the toe and 2mm toward the top. As correction target, pinion or gear for soft cutting and skiving is possible. The output of the Tooth Contact Corrections is similar to corrections known from G-AGE, which do address the major basic settings in the Phoenix summary (fig. 13, right side). Cyclocut tooth contact corrections do not require blade modifications, which makes their execution very easy and fast.

seMi-CoMPLeting
In some cases grinding is the desired or required hard finishing process. The Cyclocut flank geometry has three specific geometry features similar to other face hobbing processes. Those features are the parallel depth teeth, the constant slot width taper (which reduces the tooth thickness and slot width proportional to the distance from the pitch apex) and the epicyclical surface function of the flanks in face width direction. Figure 14 shows the face hobbed Cyclocut slot and the difference between a circular and an epicyclical lead function. The tooth depth (parallel or tapered) has no influence on the success of a grinding process. The proportional change in slot width will require grinding

DECEMBER 2011

41

the convex flank with different machine settings than the concave flank (setting change in spiral angle direction). In case of grinding with a cup-shaped grinding wheel the epicyclical lead function will be replaced by a circle, which requires an uneven stock removal. The questions are, to what extent is the uneven stock removal accept-

able, and how will the changed surface lead function influence the properties of a Cyclocut gearset? Large bevel gear sets, which are not quenched in a die, have rather large distortions in the vicinity of 0.15 to 0.3mm. In most of those cases the stock has to be removed in multiple steps by repeating the hard finishing cycle several times. The additional non-uniformity due to a circular flank lead as final surface function seems acceptable in practical cases as long as the magnitude of the non-uniformity is below the maximum permissible stock allowance. The influence of the surface function change on the Cyclocut

Fig. 7: Cutting edge facet (T-Land) with negative side rake.

Fig. 9: Wet skiving chips (left) and dry skiving chips (right).

Fig. 8: Photo of skiving process with Cyclocut cutter on Phoenix II 600HC.

Fig. 10: Typical Cyclocut gearset. Fig. 11: Pitch Variation, surface roughness and waviness of a skived part.

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gearset performance is minimal because of the low number of five cutter starts. With a decreasing number of cutter starts, the face hobbed lead function migrates to a circular function. The V-H characteristic in case of a 17-start cutter system would in fact change dramatically if the epicycloid was replaced by a circle. In case of five starts, the effect is negligible. Since all other properties of the Cyclocut geometry such as parallel tooth depth and proportional slot with taper can be preserved, the remaining question is only how such a Semi-Completing grinding process can be realized, regarding machine settings and motions as well as grinding wheel geometry?

Fig. 12: Tooth contact roll test results.

drive side contact

coast side contact

froM CyCLoCut to seMi-CoMPLeting

The conversion task from Cyclocut to SemiCompleting is basically twofold. 1) A cutter head and blade geometry has to be found which first will assure a larger outside blade point radius than inside blade point radius, and secondly form flank lead curvature which are identical to the Cyclocut lead curvature at a certain point at the face width. 2) Separate basic settings for convex and concave flank grinding have to be calculated which match the slot width taper from face hobbing and minimize the surface deviation between epicycloid and circle. The changes to the cutter head and blade geometry between Cyclocut and SemiCompleting are shown in fig. 15 in two separate steps. Step one, from Cyclocut to Step 1 Completing cutter, requires to the outside blade (arrow tip of ROB) to a reduced radius and the inside blade (arrow tip of RIB) to a larger diameter such that the negative cutter point width from face hobbing becomes positive (see fig. 15, change from top to middle graphic). Step 1 causes a curvature radius change to ROB (larger than RIB), which would produce flank lead curvature that causes negative crowning between pinion and gear. Besides, those curvatures

DECEMBER 2011

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Fig. 13: Tooth contact correction software.

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would also result in rather high deviations in flank form compared to the originally manufactured Cyclocut geometry. In order to reestablish the curvature radii from Cyclocut, the radii ROB and RIB are drawn under the same angle (using the vector length from the top graphic in fig. 15) with their tip pointing at the same profile point as in the middle graphic of fig. 15, resulting in two new vector origin locations (bottom of fig. 15). If the vector origins are connected, the new actual cutter axis and the tilt angle for semi-completing will

be found as shown in the bottom graphic in fig. 15. It has to be mentioned that the graphics in fig. 15 are a 2D simplification of a 3D problem. The correct solution is computed with a 3D vector approach, based on the explained principle.

DifferenCe between ePiCyCLoiD AnD CirCLe

The deviation between epicycloid and circle will be compensated for in the interaction between pinion and gear flank surfaces. They have congruent deviations, which cancel out the differences in the tooth contact and ease-off. Regarding the non-uniform stock removal between soft machining with face hobbing and hard finishing with face milling, the knowledge about the deviations is still an important basis for the minimization of the difference between epicycloid and circle or as a guideline for the required case depth in the heat treatment process. The pinion flank form deviations (soft manufacturing to hard finishing) have been calculated and graphically shown in fig. 16 for the same sample gearset, which has been used throughout this paper to demonstrate the Cyclo-Palloid conversion to Cyclocut with tooth contact analysis (TCAs).

Fig. 14: Difference between epicycloid and circle.

The optimal cutter radius is calculated from the epicyclical curvature in mid-face. The two graphics on top of fig. 16 show the pinion convex and the pinion concave deviations if the spiral angle is matched in the center of the face width. A considerably better surface match was found in the lower two graphics of fig. 16. Since the epicycloid has a constantly increasing radius of curvature from heel to toe, it is possible to find a spiral angle match about 25 percent of the face width away from the heel, and at the same time a spiral angle match 25 percent of the face width away from the toe. If the radial setting, which dictates the spiral angle, is calculated from the epicyclical kinematic from those two positions, then the average value of the two slightly different results will always lead to the optimal match conditions. The Gleason Semicom software automatically calculates the optimal settings for minimum deviations, and therefore minimized stock variations during the hard finishing process.

finAL Conversion to seMi-CoMPLeting

For the final conversion of the Cyclocut basic settings, as well as cutter head and blade specifications, pinion and gear are developed with mirror image generating gear specifications (basic settings). This reduces the influence of different kinds of side effects, like diamond contact bearing in case of highly asymmetric outside and inside blade angles. The result of the Semi-Completing conversion of the example gearset used in this paper is shown in the tooth contact analysis (TCA) results in fig. 17. Bias direction of the tooth contact and motion graph compare well to the original

Fig. 15: Conversion of Cyclocut into a SemiCompleting setup. 46 gearsolutions.com

Cyclo-Palloid analysis. The curved path of contact and the twisted Ease-Off topography (on top in fig. 17) are the result of cutter tilt

and machine setting adjustment in order to accomplish the conversion task. The following steps are performed by the Gleason Cyclocut and Semicom Software to come from Cyclo-Palloid to SemiCompleting: Conversion of Cyclo-Palloid to Cyclocut; Switch face hobbing to face milling; Calculation of optimal average cutter radius and radial distances to achieve minimal deviations like shown in fig. 16, bottom part; Establish positive cutter point width with clearance to the inner slot width (average cutter radius is kept constant), shown in fig. 15 middle part; Calculation of tilt angle from bottom graphic in fig. 15; Contact optimization as required. The restrictions in tooth contact development may seem low because of the single side freedoms a Semi-Completing process offers, but it has to be considered that in contrast to a fixed setting process, a single grinding wheel is used to grind both convex and concave flank. The grinding wheel point width is defined by the inner slot width and the mean radius was derived from the midpoint of the epicyclical kinematic in order to minimize the deviations

between epicycloid and circle. Also the radial distances for the two setups for convex and concave flank grinding are predetermined to minimize the deviation in fig. 16. The final freedoms, cutter tilt combined with tool profile angle changes as well as tool profile curvatures, are used to accommodate the correct effective length and profile curvature. Since the setups of pinion and gear are basically mirror images, the tooth contact will always be central as desired. The exception of the mirror image setups is the case of previously optimized Cyclo-Palloid or Cyclocut designs. The method to use blade angle modification in connection with cutter tilt is a well-known technology that has been used for many years in fixed setting, as well as completing designs, which was originally developed by Gleason in the 1940s [4]. In 1988 the blade angle modification in connection with cutter tilt was expanded by Dr. Gerhard Brandner [5] in order to hard finish previously face hobbed parts with a circular tool in face milling. Brandner describes in his teachings that the same tool can be used in connection with different basic settings in order to finish both the convex and the concave flanks of a bevel gear. This method was later named Semi-Completing.

suMMAry
The flow chart in fig. 18 (see pg. 49) shows the different possibilities of data input. The soft machining process could be per-

DECEMBER 2011

47

cycloid and circle. One grinding wheel with outside and inside profile definition and two sets of basic settings are generated by the Semicom software. The grinding stock is removed on the convex flanks and the concave flanks in two separate passes, which can be accomplished in a up-roll -> convex, down-roll -> concave grinding. In cases of large bevel gear grinding with high amounts of stock removal, the single side grinding can be viewed as an advantage that contributed to high accuracy, good surface finish, and the avoidance of thermal material damages.

referenCes:
1) Krumme, W. Klingelnberg Spiralkegelrder. Springer Verlag, Berlin, Heidelberg, New York, 1976 2) Stadtfeld, H.J. Cyclocut-A Jobbing System for Bevel and Hypoid Gears. Gleason Publication, Rochester, New York, January 1998 3) Stadtfeld, H.J. Advanced Bevel Gear Technology, Manufacturing, Inspection and Optimization. Gleason Publication, Rochester, New York, May 2000 4) NN. Calculating methods for spiral bevel, zerol bevel and hypoid gears on Gleason machines. Gleason Publication, Rochester, New York 5) Brandner, Kegelrder. A1 1988 * Cyclo-Palloid is a registered trademark of the Klingelnberg Corporation. Phoenix, G. Verfahren zum Fer tigbearbeiten vor verzahnter Deutsche

Fig. 16: Actual deviation between epicycloid and circle.

Patentschrift

Demokratische Republik DD 257 781

Fig. 17: Semi-Completing tooth contact analysis (TCA).

PowerCutting and TRI-AC are registered trademarks of The Gleason Works.

formed using Klingelnberg Cyclo-Palloid, Oerlikon Spiroflex/Spirac, or Gleason TRIAC designs. Software modules like Cyclocut and Spiroform convert the input files into Gleason basic machine settings and tool definitions. The processed Cyclocut, Spiroform, and TRI-AC can either be used for soft cutting

and hard skiving or for soft cutting only. In the second case, grinding is possible as the hard finishing process after Semicom converts the face hobbing-completing data into face milling Semi-Completing data. It is an important task of the conversion to minimize the non-uniformity of stock removal due to the difference between epi-

about the authoR:

Dr. Hermann J. Stadtfeld is vice president of bevel gear technology at The Gleason Works. Go online to www.gleason.com.

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Cyclo Palloid Old Style Calculation Output

Cyclo Palloid Neutral Data Output

Spiroflex/Spirac Oerlikon CDS Files

Spiroflex/Spirac Neutral Data Files Gleason Neutral Data Converter to SPA-File

Gleason TRI-AC SPA-File

INT-File ASCII File with Blank and Machine Settings

CDS-File

SPA-File

SPA-File

Gleason CYCLOCUT Cutter System & Basic Settings

AAA-File

CYCLOCUT

Gleason SPIROFORM Cutter System & Basic Settings

SPIROFORM

Conversion SPA-AAA File

AAA-File

Conversion SPA-AAA File

AAA-File

SEMICON Calculation of Semi-Completing Machine Settings and Grinding Wheel

AAC-File

TCA Download File CMM Grinding Summary Subset of UNICAL Fig. 18: Data input and flow for different Semi-Completing gear types.

DECEMBER 2011

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Advances in Molded Polymer Gears

Plastic gears can provide a high-torque, high-speed, cost-effective solution for a host of demanding applications, according to the experts at Kleiss Gears.
By Rod Kleiss

CMM with a 0.3mm probe.

THE PERFORMANCE OF MOLDED POLYMER GEARS CONTINUES TO IMPROVE WITH NEW DESIGN SOLUTIONS, IMPROVED MATERIALS, AND HIGHER-ACCURACY MOLDING. AS A

RESULT, DESIGNERS NOW USE THEM MORE TO SOLVE CHALLENGING PRODUCT REQUIREMENTS, ESPECIALLY WITH REGARD TO MINIATURE AND MICRO-MINIATURE MECHANISMS. PLASTIC GEARS CAN PROVIDE A HIGH-TORQUE, HIGH-SPEED, COST-EFFECTIVE SOLUTION

FOR A HOST OF NEEDS. KLEISS GEARS CURRENTLY PRODUCES MINIATURE GEARS THAT

SPIN AT 200,000RPM, GEAR TRAINS OF 1200:1 REDUCTION RATIO THAT ARE THE SIZE OF A THUMB TIP, AND METERING DEVICES FOR DISPOSABLE DELIVERY SYSTEMS WORN

BY THE PATIENT THAT ARE NECESSARILY QUITE SMALL. A MANUFACTURER WOULD FIND IT

DIFFICULT IF NOT IMPOSSIBLE TO ACHIEVE SUCH APPLICATIONS WITH CUT METAL GEARS,

AND COST WOULD BE EXORBITANT.

ADvAntAge: PLAstiC
Plastics have numerous advantages over metal for miniature gears. One major and significant advantage is that molded gears can be smaller, and with higher accuracy than metal gears. Cut gears can reasonably reach only about 200 DP or .125 module. Kleiss Gears has molded gears 50-percent smaller than that, with length to diameter ratios that would make cut gears difficult to manufacture and cost prohibitive. The molding process can also help solve problems associated with parts handling, inspection, and assembly, which become increasingly difficult the smaller the gears become. Kleiss Gears integrates these subsequent steps into the manufacturing process as full automation, to achieve the required accuracy and cleanliness. After the gear is molded, a robot removes it from the mold. A camera detects part presence and confirms an approximately correct shape. A robot can then drop the gear in a bin, place it in a blister pack, separate it for further inspection, or present it to automated assembly equipment. This handling choice is very important because micro-miniature parts can be quite difficult to re-register in an automated system once they have been released.

For example, a gear tooth that has a 0.25mm whole depth should have approximately 2m flank accuracy. Physical scanning with touch probes, even very small probes of 0.2mm in diameter, can

Plastics and plastic gears bring new opportunities to transmission designers. They also bring challenges and new requirements for confirming accuracy and functionality, especially in the micro-miniature world of gearing.
still appear relatively large to such a very small gear. This translates to an inability to scan the root between gear teeth. Vision inspection systems

testing, testing
A gear manufacturer will likely discover that inspection of very small parts is technically challenging.

DECEMBER 2011

51

Fig. 1: An assortment of tiny gears beside the tip of a ballpoint pen to give an idea of scale.
measure some features quite well, but they are not a complete answer. Molded edges are almost never sharp, and accurate inspection requires edge detection because micro parts must have micro tolerances. Even a large plastic gear must be inspected carefully and the results considered judiciously. Plastic is a soft material, and the pressure of a small probe may indent the material and indicate a size smaller than the actual part size. If the indentation amount is known it can be mathematically compensated, but in general it can be avoided by using light forces and faster scan rates. This in itself becomes a challenge in inspection because a probing force of only a few grams requires heightened scanning control. If the force changes by that few grams while turning a corner on the part, the probe will lift off the part and scanning will terminate. Only a few scanning CMM models in the industry remain stable with such very light forces.

Join AWEA at our Upcoming Educational Seminars

AWEA Wind Environmental Health & Safety Seminar
January 9 10, 2012 4 San Diego, CA Deepen your understanding of issues, demands and challenges facing occupational environmental, health and safety professionals in the wind industry. Hear how others are solving issues to some of the industrys most important challenges. Learn directly from industry experts, interact with other EHS professionals and suppliers, and develop valuable new relationships to help support current and future projects.
www.AWEAHealthandSafety.org

Attend this Seminar and Learn:

4 Tools, tips, and strategies for managing your environmental strategy 4 Issues in industrial hygiene, ergonomics, electrical safety, and confined spaces 4 Behavioral safety principles to reduce injuries at your site 4 Lean and Six Sigma concepts to enhance safety, productivity and culture 4 Results from the wind industrys first incident reporting and safety data survey 4 Safety best practices lockout/tagout, confined spaces, managing your safety program, site logistics/security 4 How to create a culture of safety in the wind industry

AWEA Wind Project Operations, Maintenance & Reliability Seminar

January 10 11, 2012 4 San Diego, CA Learn directly from wind energy industry leaders how to optimize the cost per kWh by implementing operations and maintenance (O&M) best practices and processes. Interact with a solid line-up of the wind energy industrys leading owners, operators, turbine manufacturers, and experts from the national laboratories in attendance, and leave with solid plans and strategies on how best to manage wind projects assets to maximize the bottom line.
www.AWEAOandM.org

Attend this Seminar and Learn:

4 How to maximize productivity and minimize costs from owner/operators 4 OSHAs perspective regarding safety in the wind industry 4 The importance of proactive condition monitoring of key components to increase productivity and reduce costs 4 Breaking information on documented industry-wide availability data 4 Newly-released recommended practices for maintaining major turbine components as well as balance of plant 4 Attend the AWEA membership Operation and Maintenance Working Group meeting to further develop O&M recommended practices

roLL with it
Similar requirements apply to roll testing molded gears. The usual practice in roll testing is to apply a minimum eight ounces of force for the duration of the roll test. This can yield an incorrect result for small plastic gears because of plastics softer quality. Depending on the size of the gear, we vary forces from one to four ounces for an accurate representation of actual size (fig. 2). We expect the roll test to correlate closely to the size indicated by profile inspection. Roll testing has the added benefit of sensing the whole surface of the gear instead of the two dimensional scanning surface measured with a CMM. Such whole surface scanning reveals molding flaws such as flash, tooth distortion, handling damage, and even shrinkage error to some degree.

Learn More About AWEA Events www.awea.org/events

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Fig. 3: An example of gears with mismatched pitch.

MeDiCAL MoDeL
A recent advance in metrology that may have significant value to the gear designer is computer tomography, or CT scanning. The medical field has used this technology for some years to create 3D images of internal organs.

Fig. 2: Roll tester measuring a miniature gear

Without special setup and master gear selection, however, a roll test will not reveal errors of form like barreling, hour-glassing, and taper. Roll testing alone does not adequately inspect molded gears. One reason is the effect of shrinkage error in roll testing. For example, although roll testing can detect base pitch shrinkage via tooth-to-tooth error well in gears with less than 30 teeth, a greater number of teeth in mesh increasingly masks such error. This is because tooth count increases contact ratio. The roll test will indicate merely an increased center distance, which can result from variances in tooth thickness, tilt, or base pitch, among other features. Even a base pitch that is smaller than designed will cause increased roll test center distance. This is because any change in base pitch will result in a mismatched pitch and push the gear away from the master gear. Therefore, once roll testing indicates a possible problem, the inspector must return to profile scanning to pinpoint the source (fig. 3).

In the past few years the technology has been applied to dimensional scanning of parts. It is particularly suited to molded gearing. CT scans can detect voids, fiber orientation, surface defects, contamination, and a variety of other gear features. A scan can establish surfaces and represent them with point clouds for metrology analysis. The current accuracy of this technology is approximately 10m, but its continuing and rapid evolution means that accuracy is bound to improve as the methods value gains greater recognition (fig. 4). Another method of inspection that we embrace is what we call inspection through testing. Transmissions are by nature complex mechanisms with intense interactions between components. One could spend large amounts of time and energy inspecting individual components and still end up with a non-functioning device, because the failing features simply were not looked for. Building the transmission and an automated tester for that transmission can readily solve the problem. Drive it with a calibrated motor. Put on a regulated load. Sense the torque, speed, efficiency, and compliance of the transmission under load. This produces a

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Fig. 5: Gear testing stand for miniature gear transmission.

signature of the operating functionality of the unit. In the design phase, this will confirm or repudiate design expectations. In production, a continuation of the test on the product line will confirm system functionality. Testing is often a necessary complement to inspection. Especially when the transmission operates in several axes, such as transmissions with worm gear meshes, testing proves invaluable for understanding the dynamic relationship between the various geared components. As shown in fig. 5, the tester is usually fully automated with calibrated drivers, loads, speed sensing, and any unique output sensing that may be required.

Fig. 4: Gear scanned using computer tomography (CT).

ConCLusion
Plastics and plastic gears bring new opportunities to transmission designers. They also bring challenges and new requirements for confirming accuracy and functionality, especially in the microminiature world of gearing. Although new tools for production, inspection, and testing are continuously being developed, the real challenge is being smart enough to use those tools effectively for better, smaller, stronger plastic molded products.

ABOUT THE AUTHOR:

Rod Kleiss is president of Kleiss Gears, Inc. Call (715) 598-4492, e-mail info@kleissgears.com, or go online to [www.kleissgears.com]. Photography by Melanie Boerger, mkboerger@gmail.com. DECEMBER 2011 55

PRODUCT
New products, equipment, and resources

ShoWCaSe

Innovative Chip-Breaking technology from emuge

Emuge Corp. has introduced a tap with superb chip-breaking capabilities that is ideally designed for machining applications in the energy and related industries. The new Rekord DZBF Series Taps feature technology that eliminates the formation of long continuous chips that commonly occur when tapping carbon steels, alloy steels, and austenitic stainless steels. The taps are designed with a newly developed cutting face geometry and spiral flute form, which combine to affect chip flow, chip curl and chip length. This innovative Emuge chip-breaking technology (Emuge CBTz) produces short, broken, controllable chip formations that eliminate flute clogging and potential failure of the machine tap due to chipped cutting teeth or breakage. This technology contributes to higher reliability of the threading process, eliminates machine down time required to clean chips, improves tool life, produces a better surface finish and also increases operator safety. Learn more at [www.emuge.com].

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rust Preventative options from Birchwood Casey

Selecting the right rust preventative for a specific product application is easy referencing Birchwood Caseys handy corrosion resistance comparison chart. Manufacturers can quickly choose from 12 different aqueous and solvent-based inhibitors and sealants to prevent rust and corrosion on all metal surfaces. The different product formulations allow for variables such as the type of metal surface in question, level of protection needed, and conditions of exposure in handling, shipping, and storage. Special considerations such as removability and post-treatment operations should be considered in the selection of the correct product. Birchwood Caseys eight solventbased products provide robust protection for various metal surfaces including raw steel/casting inventory, in-process parts, finished products in distributor warehouses, or parts in long-term storage or overseas shipment. Its four water-based products provide a wide range of protection levels and surface appearance. These products include a water-dilutable oil, a satin-gloss acrylic wax, a high-gloss urethane polymer sealant, and a highgloss acrylic polymer emulsion. Go online to [www. birchwoodcasey.com].

Coromant Capto from Sandvik Coromant

For all types of heavy machining operations in large components, Coromant Capto size C10 improves performance by allowing higher feeds and greater depths of cut. A flange diameter of 3.937 inches means a coupling suitable for heavy loads providing extreme stability in milling and turning applications. Designed to increase removal capacity at higher torques, the C10 gives the entire tool set up higher bending strength. The C10 includes a wide range of holders and adapters from shrink fit, SL adapters, and ER chucks to tap adapters. Coromant Capto is the true universal modular tool system. The most stable tool holding system on the market that makes it possible to use only one system for the entire workshop, regardless of machine type: turning center, machining center, multi-task machine; manual or fully automatic. The tool system permits standardization, reduces inventory costs, and simplifies physical and administrative handling of tools. The unique polygon shaped Coromant Capto coupling, introduced in 1990, has proven its excellence over the years and is now an ISO standard (26623). Learn more at [www.sandvik. coromant.com/us]. DECEMBER 2011 57

Compact mICUrA from Carl Zeiss

Carl Zeiss has introduced the new MICURA coordinate measuring machine. This high precision, compact, bridge-type CMM features precision scanning technology with the VAST XT gold active scanning sensor. The MICURA system offers 0.9 micron + L/400 accuracy with low probing force and is excellent for measurements of small and intricate parts often required in the optical, electronic, medical, aerospace and telecommunication industries. As devices from the medical and electronic manufacturers become smaller, so do the components that make them operate optimally. This shift in production is highly dependent on the right quality inspection equipment. The MICURA offers the accuracy to measure delicate parts such as optics and disk drive components while maintaining efficiency. The accuracy of the compact MICURA opens up the door for measurement applications in areas such as labs or companies requiring high precision. A measurement volume of 500 x 500 x 500 mm handles a wide variety of small parts, a balanced range in all three axes for a machine in this size category. Learn more at [www.zeiss.com/metrology].

New m5 Chipbreaker from Seco tools

Secos new versatile M5 positive-lock chipbreaker insert with robust geometry brings productivity and strength to turning and boring applications in steel, stainless steel, cast iron, and superalloys that extend from semi-finishing to the toughest roughing operations in harsh environments. The robust M5 features a highly protected chip groove that helps tackle the most demanding operations, heavy interruptions, and rough material outside skin layers. All the while an open chip groove with well-adapted cutting angles ensures high feed rates and large cuts for efficient machining and best economy. Furthermore, a fine-tuned chip groove provides full control while handling ductile materials. M5 achieves optimal tool life in a wide variety of workpiece materials and applications thanks to a balanced rake face that minimizes the heat transferred to the insert. M5 also can be used with Secos Jetstream Tooling, which delivers coolant to the optimum position close to the cutting edge. The jet of coolant lifts the chip away from the rake face, improving chip control and tool life as well as allowing for increased speeds and feeds. More information is available at [www.secotools.com/us]. 58 gearsolutions.com

CImPerIAL 1072D metalworking Fluid from CImCooL

CIMCOOL Fluid Technology has introduced CIMPERIAL 1072D, a soluble oil recommended for machining and grinding operations with poor water quality. It can be used in heavy to severe duty machining and grinding operations on mild steels, stainless steels, hardened steels, exotics and most aluminum alloys, including MIC 6. The fluid has a good mix stability in high hardness, high sulfate, and high chloride water conditions. The extreme pressure lubricant provides excellent lubricity which extends tool and wheel life while providing superior part quality. CIMCOOL Fluid Technology offers some of the most technologically-advanced fluids available for use in industrial operations with products that boast results including up to 300 percent improved tool life; an increase in productivity; excellent rancidity control; greatly reduced concentrate usage; and operator-friendly use. Visit online at [www.cimcool.com]

880 n. Washington ave. Kankakee, il 60901 toll free: 1.800.786.7562 fax: 1.800.315.8769 email: sales@storloc.com

STOr-LOC MODULAr DrAWEr SYSTEM

Modular Drawer System

www.storloc.com
DECEMBER 2011 59

FEATUREDSupplierS
Midwest Gear Corporation rEF #101 Phone: 330-425-4419 Fax: 330-425-8600 email: sales@mwgear.com Website: www.mwgear.com new England Gear rEF #102 Phone: 860-223-7778 Fax #:860-223-7776 email: jeff@newenglandgear.com Website: www.newenglandgear.com r. p. Machine Enterprises, inc. rEF #103 Phone: 704-872-8888 Fax #:704-872-5777 email: sales@rpmachine.com Website: www.rpmachine.com repair parts, inc. rEF #104 Phone: 815-968-4499 Fax #:815-968-4694 email: rpi@repair-parts-inc.com Website: www.repair-parts-inc.com Havlik international Machinery, inc. rEF #105 Phone: 519-624-2100 Fax: 519-624-6994 email: havlik@bellnet.ca Website: www.havlikinternational.com GQ Machinery inc. rEF #106 Phone: 516.867.4040 Fax: 516.223.1195 email: george@gqmachinery.com Website: www.gqmachinery.com

MAChINerY
Contact Gear Solutions at 800-366-2185 to list your machinery.
BARBER-COLMAN #16-36, 24 Dia, C-Frame Style, 4 1/8 Bore REF#103 BARBER-COLMAN #16-56, 16 Dia, 56 Face, Differential REF#103 BARBER-COLMAN #22-15, 22 Dia, 14 Face, Differential REF#103 DAVID BROWN, 138 Dia, Face 60REF#103 G&E #24H Universal Head, Infeed, Tailstock, Differential, 50s REF#103 HAMAI #120, 4.8 Dia, 4 Face, 12 DP, 70 REF#103 LIEBHERR #L-402, 16 Cap, 2-Cut Cycle, Crowning, 77 REF#103 LIEBHERR #L-650, 26" Dia Cap, 14.5" Face, 2.5 DP, New 70s REF#103 MODUL #ZFZW 800, 29.8 Dia, 16.25 Face, 2.5 DP Crowing, 2-Cut REF#103 BARBER-COLMAN #1600-36, 16" Dia., 39.5" Face, 6 DP REF#103 CHONG QIN #Y3180H, 31.5 Dia., 15" Face, 3 DP REF#103 FELLOWS FH-200 Max Diam 7.87" Max Dia Pitch 5.08" REF#103 G&E #16H Gear Hobber, 16"Dia REF#103 BARBER-COLMAN #3 (6-10), Single & Triple Tread Worm HS REF#103 BARBER-COLMAN #6-10, 6 Dia, 10 Face, 16 DP REF#103 KOEPFER #140 , 2.75 DIa, 4 Face REF#103 KOEPFER #153B, 5.6 Dia, 5.9 Face REF#103 LANSING #GH-50, 50 Dia, 17.75 Face, 2 DP REF#103 LIEBHERR #L-252, 9.8 Dia, 7.9 Face, 4.2 DP REF#103 MIKRON #79 1.5 Dia, 26 DP REF#103 BARBER-COLMAN TYPE T REF#103 IUG Craiova FD-3600 REF#103 LIEBHERR #L-401, 15.7 Dia 11 Face, 3DP REF#103 G&E #36HS 36Dia, 14 Face 3 DP REF#103 PFAUTER #P-3000, 120 Dia, Single Index REF#103 SCHIESS RFW-10-S 55 Dia REF#103 SHIBURA HHC-250A Single Index REF#103 OVERTON #HD-400, 15.7 Dia, 12 Face, 3 DP, New 88 REF#103 SCHIESS 1 RF-10, Dia 60 150 L, .50 DP REF#103 G&E #40TWG, 48 Dia, 18 Face, 3 DP REF#103 G&E #60S, 72 Dia, 14 Face, 1.25 DP REF#103 G&E #72H, 72 Dia, 24 Face, 1 DP REF#103 G&E #96H, 104 Dia, .50 Face, 1.25 DP REF#103 PFAUTER #P-630, 25 Dia REF#103 PFAUTER #2500, 100 Dia REF#103 TOS FO-16, Max Cut w/support 90 REF#103 PFAUTER P250 10 Dia REF#103 GE Hobber 200 Dia, 55 Face REF#103 GE/Fitchburg Hobber 32 Dia, 72 Face 1.25DP REF#103 JF Reinecker 40 Dia 35 Face REF#103 LIEBHERR L-160-R 6.5 Dia REF#103 MIKRON #102.04 , 4 Dia, 5 Face REF#103 NIHON-Kikai NDH-1200 50 Dia REF#103 PFAUTER P-900 36 Dia REF#103 SCHIESS RF 40/60S 240 Dia 100 Face REF#103 BARBER-COLMAN #25-15 25 Dia, 15 Face, 2.5 DP REF#103 CRAVEN Horizontal , 18 Dia and 100 Length REF#103 KOEPFER #173B, .6.1 Dia, 7 Face REF#103 PFAUTER #P-630R, 25" Max. Spur Dia, 12" Max Rotor Dia. 12" REF#103 BARBER-COLMAN 2 1/2 -4, S/N 119, 62 Hi-Production Spur Gear REF#104 BARBER-COLMAN 6-10 SYKES, Triple Thrd w/Lever Operated Collet Assy REF#104 BARBER-COLMAN 6-10 B&C Ltd, S/N 8079, Triple Thrd REF#104 BARBER-COLMAN 6-10, S/N 4626, 57 Triple Thrd 3 Hob Slide REF#104 BARBER-COLMAN 6-10, S/N 4659R, 56 Triple Thrd Adj Ctr Assy REF#104 BARBER-COLMAN 6-10, S/N 4665, 57 Fine Pitch Prec Triple Thrd REF#104 BARBER-COLMAN 6-10, S/N 4701, 58 Triple Thrd w/Power Down Feed REF#104 BARBER-COLMAN 6-10 M/C, S/N 4755, 59 Triple Thrd w/MC Conversion REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 4778R87, 60 (87 Rebuild), Sgl Thrd Hi-Spd REF#104 BARBER-COLMAN 6-10 M/C, S/N 4913, 63 Triple Thrd w/90 Deg Hob Slide REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5055, 66 Triple Thrd, 800 RPM REF#104 BARBER-COLMAN 6-10, S/N 5141, 67 Triple Thrd w/Prec Hob Shift REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5148, 68 Triple Thrd, 800 RPM REF#104 BARBER-COLMAN 6-10 Multicycle, S/N 5259, 75 Triple Thrd w/Auto Hob Shift REF#104 BARBER-COLMAN 6-10, S/N 5353, 77 Triple Thrd w/3 Hob Slide, 800 RPM REF#104 BARBER-COLMAN 6-10, S/N 5394, 81 Fine Pitch Triple Thrd w/Dwell & Hob Rev REF#104 BARBER-COLMAN 6-16 M/C, S/N 5238, 70 Triple Thrd, Recon 02 REF#104 BARBER-COLMAN 6-10, S/N 5407, 82 Auto w/PLC Control REF#104 BARBER-COLMAN DHM, S/N 105, 42 Double Thrd REF#104 BARBER-COLMAN 14-15, S/N 635R, 53 Dbl Thrd, Fact Reb REF#104 BARBER-COLMAN 14-15, S/N 745, 55 Dbl Thrd w/Dwell REF#104 BARBER-COLMAN 14-15 Dual Fd, S/N 938, 62 Dbl Thrd, Comp Reco REF#104 BARBER-COLMAN 14-15, S/N 1055, 65 Dbl Thrd w/New Hyd Sys REF#104 BARBER-COLMAN 14-15, S/N 1131, 66 Dbl Thrd w/Hyd Tailctr REF#104 BARBER-COLMAN 14-15 Dual Fd, S/N 1261, 67 Dbl Thrd w/Hyd Live Ctr REF#104 BARBER-COLMAN 14-15 Dbl Cut, S/N 1278, 68 Dbl Thrd w/4-1/8 Bore REF#104 BARBER-COLMAN 14-30 Dual Fd, S/N 1371, 71 4-Thrd w/Sizing Cycle REF#104 BARBER-COLMAN 22-15, S/N 923, 62 Dbl Thrd, Dbl Cut REF#104 BARBER-COLMAN 16-11, S/N 184, 50 Dbl Thrd w/Vert DRO REF#104 BARBER-COLMAN AHM, S/N 1896, 42 Sgl Thrd w/3 Jaw Chuck REF#104 BARBER-COLMAN 16-16, S/N 2745, 51 Sgl Thrd w/90 Deg Hd REF#104 BARBER-COLMAN 16-16, S/N 3171, 53 Dbl Thrd, Spanish Nameplates REF#104 BARBER-COLMAN 16-16, S/N 3580, 59 Dbl Thrd w/Diff & Auto Hobshift REF#104 BARBER-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#104 BARBER-COLMAN 16-16, S/N 4136, Dbl Thrd, C Style End Brace w/Diff REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4170, Dbl Thrd w/Jump Cut Cycle C Style REF#104 BARBER-COLMAN 16-16, S/N 4473, 73 4-Thrd w/Workclamp Cyl C Style REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4520, 75 Dbl Thrd w/Gooseneck Slide REF#104 BARBER-COLMAN 16-16 Multicycle, S/N 4631, 79 C Style End Brace, 4W Adj Ctr REF#104 BARBER-COLMAN AHM (36), S/N 1152, 42 Dbl Thrd REF#104 BARBER-COLMAN 16-36, S/N 4090, 66 Dbl Thrd, C Style End Brace REF#104 BARBER-COLMAN 16-36 Multicycle, S/N 4232, 68 Dbl Thrd C Style End Brace w/Diff REF#104 BARBER-COLMAN 16-56, S/N 3136R84, 53 (Reb 84), Dbl Thrd REF#104 BARBER-COLMAN 10-20, S/N 6700045890, 76 Dbl Thrd w/2 Cut Cycle REF#104 TOS OFA Series Conventional Gear Hobbers, 12 & 40 Dia REF#105 TOS OHA Series Conventional Gear Shapers, 12 & 40 Dia REF#105 GeAr PINION hOBBerS & SPlINe MIllerS HURTH #KF-32A 15 Dia, 59 Face, 67 REF#103 GE/Fitchuburg Pinion Hob 32 Dia, 72 Face REF#103 MICHIGAN Tool #3237 REF#103 SCHIESS 1 RF-10, 60 Dia REF#103 WANDERER GF 345 CNC Hobbing /Milling Machine 4-Axis 24" Swing x 240 Length REF#103 FITCHBURG Pinion Hobber 42 Dia, 72 Dia REF#103 CRAVEN Horizontal, 18 Dia and 100 Length REF#103 GeAr hOB & CUTTer ShArPeNerS (incl CNC) ARTER #A-12, 12 Rotary Surface Grinder for Sharpening Sharper Cutters REF#103 BARBER-COLMAN #6-5, 6" Dia, 5" Length, Manual Dresser, 57 REF#103 BARBER-COLMAN 10-12, 10" Dia, 12" Length, Spark Out REF#103 FELLOWS #6SB, Helical Cutter Sharpener, 6 Dia, up to 50 Degrees REF#103 KAPP #AS-305GT, 1 DP, 28" Grind Length, 10" Diam., Str. & Spiral REF#103 KAPP #AS204GT, 10 Dia, Wet Grinding, CBN Wheels, 82 REF#103 BARBER-COLMAN #3 HS, Hob Sharpener, 4" Max. OD., 4" REF#103 BARBER-COLMAN #4-4HRS, Hob Sharpener, 4" Max. OD. 4" REF#103 REDRING MODEL #SGH "PREIFORM" SHAVE CUTTER GRINDER/SHARPENER REF#103 STAR 6X8 HOB SHARPENER PRECISION GEAR & SPLINE HOBBER REF#103 BARBER-COLMAN 2-2 1/2 , 2.5 Dia REF#103 KAPP #AST-305B, 27.5 Dia, REF#103 KAPP AS-410B REF#103 GLEASON #12 Sharpener, 3-18 Cone REF#103 BARBER-COLMAN 2 1/2-2, S/N 16, 66 Wet w/Auto Feed REF#104 BARBER-COLMAN 6-5, S/N 110R, 55 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 6-5, S/N 396, 66 Wet w/Auto Dress & Sparkout REF#104

GeAr ACCeSSOrIeS, PArTS & TOOlING FELLOWS Model #10-4/10-2, All Parts Available REF#102 Tilt Tables for 10-2/10-4, Qty 2 REF#102 FELLOWS Parts Available For All Models REF#103 BARBER-COLMAN PARTS AVAILABLE FOR ALL MODELS REF#103 G&E PARTS AVAILABLE FOR ALL MODELS REF#103 GeAr hOBBerS/CUTTerS CNC LIEBHERR #LC-255 CNC, 6-Axis, 10 Dia, 10 Face, 4 DP, 87 REF#103 PFAUTER #PE-150, 6-Axis CNC, 6 Dia, 5 DP, 6 Face, Fanuc 18MI REF#103 SYKES #H160, 4-Axis CNC Hobber, 6 Dia, All the Features, 93 REF#103 G&E #60 S-2 CNC Gasher/Hobber REF#103 G&E #60SB-2C CNC, Gasher/Hobber REF#103 BARBER-COLMAN #16-36, 16 Dia, 4-Axis, 6 DP, 36 Face REF#103 LIEBHERR #LC-502 6-Axis CNC Gear Hobber, 20" Diam. Cap., Loading REF#103 LIEBHERR #L-652, 5-Axis 26 Dia,27 Face, 2 DP 09 REF#103 MUIR CNC Gear Hobber, 4-Axis, 118 Dia REF#103 LIEBHERR #L-252 3-Axis, 9.8 Dia, recontrolled 2008 REF#103 LIEBHERR #ET-1202 CNC - 70 Dia Internal, Single REF#103 LIEBHERR #ET-1802 CNC 98 Dia Internal, 3-Axis REF#103 MITSUBISHI GD-20 CNC, 5-Axis, 8 Dia REF#103 G&E 120/188, CNC Gasher/Hobber, 188 Dia (5 Meter) REF#103 G&E #120GH, CNC, Gasher/Hobber, Twin Stanchion, 1/2 DP, 42 Face, 94 REF#103 PFAUTER P400H, 5-Axis, 18 Dia, 1 DP, Recontrolled 03 REF#103 G&E #160GH, CNC, Gasher/Hobber, New 07 REF#103 G&E #96GH, CNC, Gasher/Hobber, New 09 REF#103 HAMAI 60SP, CNC 4-Axis, 3.5" OD, 9" Face, 12 DP, New 89 REF#103 PFAUTER PE 300 AW CNC 6-Axis REF#103 GeAr hOBBerS/CUTTerS PFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#102 PFAUTER (1) RS-00 s/n 17593 REF#102 BARBER 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#103 G&E #48H 48 Dia, 18 Face 2 DP, Universal REF#103 G&E #48H, 48 Dia, 35 Face, 3 DP, Gooseneck Attachment REF#103 LEES BRADNER HH-144 16 Dia, 144 REF#103 BARBER-COLMAN #6-16, 6 Multi-Cycle REF#103 G&E #36H Differential, Excellent Condition REF#103 BARBER-COLMAN #14-30, 14 Dia, 30 Face, 3.5DP REF#103 PFAUTER P-251 10 Dia, 9.6 Face, 4 DP REF#103 BARBER-COLMAN #14-15, 14 Dia, 15 Face, 1 to 4 Start Worm, Several REF#103 BARBER-COLMAN #16-16, 16 Dia, 16 Face, 6DP REF#103

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BARBER-COLMAN 6-5, S/N 433, 69 Wet w/Auto Dress & Sparkout REF#104 BARBER-COLMAN 10-12, S/N 643R83, Wet w/Auto Dress, PC Control, Fact Reb 83 REF#104 TOS 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#102 FELLOWS #10-4/10-2, Qty 150 REF#102 HYDROSTROKE #50-8, Qty 2 REF#102 HYDROSTROKE #20-8, Qty 5 REF#102 HYDROSTROKE #FS630-125, Qty 1 REF#102 HYDROSTROKE #FS400-90, Qty 2 REF#102 FELLOWS #20-4, Qty 6 REF#102 FELLOWS #48-8Z, Qty 1 REF#102 FELLOWS #FS-180, 3-5 Axis, 7 Dia, 1.25 Face., 6 DP, New 88 REF#103 LIEBHERR #WS-1, 4-Axis CNC, 8" OD, 2" Stroke, Fanuc 18MI REF#103 LORENZ # LS-180, 4-Axis CNC, 11 OD, 2 Stroke, 5 DP REF#103 LORENZ #LS-304 CNC Gear Shaper 5-Axis Heckler & Koch Control REF#103 LORENZ #LS-156 CNC Gear Shaper Dia 6 REF#103 FELLOWS FS400-125, 16 Dia, 3.5 DP 5 Face REF#103 SCHIESS RS-20 S, 12 Stroke, 118 Dia REF#103 FELLOWS #10-4 3-Axis (A/B), 10" Dia, 4" Face, 4 DP New .09 REF#103 RP-GS 800 CNC, 4-Axis, Max Dia 31.5, Face 9, 2.5 DP REF#103 RP-GS 400 CNC, 6-Axis, Max Dia 15 Face 4, 3 DP REF#103 STANKO /RPM #48-8 Gear Shaper CNC, Fanuc 18 REF#103 FELLOWS #10-4 2-Axis, 10 Dia 4 Face REF#103 FELLOWS #20-4 3-Axis 10 Dia, 4 Face REF#103 FELLOWS FS400-90 Hydro-stroke Gear Shaper CNC Nominal Pitch 15.7" REF#103 RP-GS 1500 CNC, 4-Axis, Max Dia 49.2, Face 12, 2 DP REF#103 GeAr ShAPerS FELLOWS #10-2, (10 Dia), 2 Face REF#102 FELLOWS #10-4, (10 Dia), 4 Face REF#102 FELLOWS (200) 10-4 / 10-2 Shapers REF#102 FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009 REF#102 FELLOWS (1) #7 125A Face Gear Machine REF#102 FELLOWS (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#102 FELLOWS (1) FS630-200 Hydrostroke Shaper s/n 36943 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009) REF#102 FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#102 FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#102 FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009) REF#102 FELLOWS (1) 48-8Z Shaper w/ 14 throated riser (53 of swing) REF#102 FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#102 FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller s/n 34326 REF#102 FELLOWS (1) 36-10 Gear Shaper REF#102 FELLOWS (1) 10x6 Horizontal Z Shaper REF#102 FELLOWS (1) 36-6 Gear Shaper w/ 13 riser s/n 27364 REF#102 FELLOWS (1) 10-4 Shaper w/ 3 riser w/ 4 axis 21i Fanuc Controller (2009) REF#102 All Parts for 10-4/10-2 Fellows Gear Shapers REF#102 FELLOWS #36-8, 36 Dia, 8 Face REF#103 FELLOWS #100-8 100 Dia, 8 Face REF#103 FELLOWS #612A, 615A, #645A REF#103 FELLOWS #10-4, 10 Dia, 4 Face, 4 DP REF#103 FELLOWS #4A Versa, 10 Dia, 3 Face, 4 DP, New 70s REF#103 FELLOWS #10-2, 10 Dia, 4 Face, 4 DP REF#103 FELLOWS #20-4, 20 Dia, 4 Face, 4 DP, 70s REF#103 MAAG #SH-100/140, 57 Dia., 12.6 Face, 2 DP, Internal Attachment REF#103 FELLOWS #3-1,/3GS, 3 Max Dia, 1 Face, Pinion Supp, High Precision REF#103 FELLOWS #48-6 INTERNAL GEAR SHAPER ONLY,0-72"OD,6" Face REF#103 LORENZ #SJV00, 7 Dia, 2 Face, 50s REF#103 MAAG #SH-100K 47/12.6/1.7 60s Internal Attachment REF#103 MAAG #SH-150, 57" Dia.12.6" Face REF#103 PFAUTER #SH-180 Shobber 7" capacity hobbing, 9.45" cap REF#103 FELLOWS #36-6 Max Dia 36 6 Face, 3 DP REF#103

FELLOWS #HORZ Z SHAPER, 10 x 6 Dia 27.6 Face 8.5 REF#103 MAAG #SH-75C, 30/8/2.5/52 REF#103 MAAG #SH-600, 235 Dia 36, 1DP REF#103 FELLOWS #4GS & 4AGS, 6 Dia, 2 Face, 4DP, 68, Ref.# Several REF#103 TOS OH-6, Dia 19.7 REF#103 FELLOWS #624A, 18 Max Dia, 5 Face REF#103 FELLOWS #7, #7A, #715,# 75A, #715, #725A, 7 Dia, 0-12 Risers, Several Avail REF#103 MAAG #SH-180-300 , Max Dia 118/ 16.9 Face REF#103 MAAG #SH-350/500, Max Dia 197 REF#103 MICHIGAN #18106 SHEAR-SPEED GEAR SHAPER,14" Dia, 6"Face REF#103 FELLOWS Model Z Shaper, 5" Stroke, 50s REF#103 STAEHELY SHS-605, Gear Shaper REF#103 FELLOWS #6, #6A, #61S, From 18-35 Dia, 0-12 Risers REF#103 FELLOWS #8AGS Vertical Gear Shaper, 8 Dia, 2 Face, 6-7 DP REF#103 TOS OHA50 CNC 5 20 Dia 5 Face REF#105 Fellows 36-6 Shaper (2) 12.5" Risers 6" Stroke Mint YR 1969 id 3616 REF#106 GeAr deBUrrING/ChAMFerING/POINTING CROSS #50 Gear Tooth Chamferer, 18 Dia, Single Spindle REF#103 CROSS #75 Gear Tooth Chamferer, 10 Dia, 10 Face, 52 REF#103 REDIN #18, 28 Dia, 2, 3, 4 Spindle, Deburrer/Chamfer, PLCs, Tilt Table REF#103 REDIN #20D, 20 Dia, Twin Spindle, Deburrer/Chamfer REF#103 SAMPUTENSILI #SCT-3, Chamf/Deburrer, 14 Dia, 5 Face, 82 REF#103 SAMPUTENSILI #SM2TA Gear Chamfering Mach, 10 Max Dia, (3) New 96 REF#103 REDIN #24 CNC Dia 4 Setup Gear Deburring REF#103 CROSS #60 Gear Tooth Chamferer, 10 Dia, Single Spindle REF#103 FELLOWS #100-180/60 CNC Max Dia 180, Single Spindle REF#103 CIMTEC #50 Finisher REF#103 RPM #GC-500 CNC 20 Dia, Single Spindle REF#103 CROSS #54 Gear Deburrer, 30 Dia, 18 Face REF#103 RED RING #24 Twin Spindle Dia 4 REF#103 CROSS #55 Gear Deburrer, 18 Dia, 1.5 Spindle REF#103 GLEASON GTR-250 VG CNC 5-Axis REF#103 GRATOMAT #300L REF#103 GeAr hONerS Fassler #K-400 CNC Hone 16" Dia REF#103 Fassler K-400A CNC Hone 16 Dia REF#103 Kapp #CX120 Coroning 4.7 Dia REF#103 Red Ring GHD-12, 12 Dia, 5.5 Stroke REF#103 Red Ring GHG, 12 Dia, 5.5 Stroke REF#103 Kapp #VAC65 Coroning 10 Dia REF#103 GeAr ShAVerS Red Ring #GCX-24" Shaver, 24 Dia, 33 Stroke REF#103 Red Ring #GCU-12, 12 Dia, 5 Stroke REF#103 Red Ring #GCU-8 Shaver. 8 Dia REF#103 Red Ring #GCY-12, 12 Dia, 5 Stroke REF#103 Red Ring GCI 24, 12.75 Dia, 5 Stroke REF#103 Nachi Raso CNC Shaver, 3-Axis REF#103 Michigan #873-24A, 24 Dia, 15 Face, 2 DP REF#103 GeAr GeNerATOrS, STrAIGhT BeVel GLEASON #37 Str. Bevel Planer, 6 Dia REF#103 GLEASON #54 Str, Bevel Planer, 60 Dia REF#103 GLEASON #496 Straight.& Spiral. 7.5 Dia REF#103 GLEASON 14, Coniflex Straight Bevel REF#103 GLEASON 24A Straight Bevel REF#103 GLEASON 725-Revacycle, 6 Dia REF#103 GLEASON 726-Revacycle, 5 Dia REF#103 GLEASON 2A, 16 Cone REF#103 GLEASON #116, 9 Cone, 2.75 Face REF#103 GLEASON #104 w/Helical Motion, Coniflex, Straight Bevel REF#103 GeAr GeNerATOrS, SPIrAl BeVel (hYPOId) GLEASON #645 Hypoid Generators REF#103 GeAr GrINderS CNC HOGLUND, Model #264, CNC Internal Gear Grinder REF#103 KAPP #VAS-482 CNC GEAR GRINDER, 11.8" SWING DIA REF#103 GLEASON Phoenix 200G Hypoid Grinder CNC REF#103 REISHAUER RZ-801 CNC, 31.4 Dia REF#103 NILES ZSTZ 06-800 CNC, 31.5 Dia, 11 Face REF#103 NILES ZSTZ 08-800 CNC, 32 Dia, 11 Face REF#103 RED RING #SF-500 CNC Int/Ext, 26 Dia, REF#103 GLEASON/TAG 400 CNC, 16 Dia REF#103

HOLFER PROMAT 200 , 7.87 Dia CNC Gear Grinder REF#103 GeAr GrINderS #27, #137, and #463 Gleason Hypoid Spiral Bevel gear grinder generating Cams (2 full sets) REF#102 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 REISHAUER ZA, Gear Grinder, 13" Dia, 6" Face, Strait & Helix REF#103 RED RING #SGJ-18, 18 Dia., 9 Face, Internal Attachment, New 78 REF#103 DETROIT Gear Grinder #GGI-16x3A, Internal Gear Grinding, 16" OD REF#103 MAAG SD-32-X REF#103 GLEASON #463, 15 Dia REF#103 HOFLER BHS H1603-2000, 78.7 Dia REF#103 NILES ZSZT-3500, 139 Dia REF#103 KAPP VAS #331, Gear Grinder REF#103 NILES ZSTZ-1250/5000 49.2Dia REF#103 GeAr rACK MIllerS/ShAPerS MIKRON #134 Rack Shaper, 17.4" Length, 1.1" Width, 16.9 DP REF#103 SYKES VR-72 Vert Rack Shaper, 72" Cut Length, 4DP, 4" Stroke, 80 REF#103 SYKES VR-60 Vert Rack Shaper, 60 Cut Length, 4DP, Stroke 4 REF#103 GeAr ThreAd & WOrM, MIllerS/GrINderS LEES BRADNER #HT 12x54, Dia 12 /54 REF#103 MOREY-SHIELDS THREAD MILLER, Dia 12 REF#103 BARBER-COLMAN #10-40, 10" Dia., 40" Length, 4 DP REF#103 EXCELLO #31L, External Thread Grinder, 5" OD, 20" Grind Length REF#103 EXCELLO #33 Thread Grinder 6 Dia 18 Length REF#103 EXCELLO #35 and #35L Thread Grinder, 84" Between Centers REF#103 EXCELLO #39 Int. Thread Grinder, 9.5" Max Dia., 10" Max. Swing REF#103 HURTH #KF-33A Multi-Purpose Auto-Milling Machine 88 REF#103 LEES BRADNER #HT12x102, Extra Large Capacity REF#103 J&L AUTOMATIC THREAD GRINDER, 6" X 36", 38 REF#103 LEES BRADNER #HT 12"x 144" Thread Mill, 12" Dia, REF#103 WALDRICH COBURG WHIRLING, 3 Dia, 118 Length REF#103 LEES BRADNER # LT 8 x 24 8 Dia REF#103 HOLROYD 5A 24.8 Dia REF#103 HECKERT WMW #ZFWVG REF#103 LEES BRADBER WORM MILLER REF#103 GeAr TeSTerS/CheCKerS (incl CNC) FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#102 FELLOWS (1) 24H Lead Checker s/n 32289 REF#102 GLEASON (1) #14 Tester s/n 31907 REF#102 GLEASON (1) #6 Tester s/n 19316 REF#102 FELLOWS (1) 20 M Roller Checker REF#102 FELLOWS (1) 20 M w/ 30 Swing Roller Checker REF#102 FELLOWS (1) #8 Micaodex s/n 36279 REF#102 David Brown #24 Worm Tester REF#103 Fellows 12H Gear Tester REF#103 Fellows #12M Gear Tester REF#103 Fellows 20M Gear Tester REF#103 Felows #24 Involute Measuring Instrument REF#103 Gleason #4, #6, #13 and #17 Testers REF#103 Hofler EMZ-2602 Int/Ext Gear Tester 102 REF#103 Klingelnberg #PFSU-1200 Gear Tester REF#103 Klingelnberg #PFSU-1600 Gear Tester-2001 REF#103 Klingelnberg PWF-250 Tester REF#103 Kapp Hob Checker WM 410 REF#103 Maag #ES-430 Gear Tester REF#103 Maag #SP-130 Lead and Involute Tester REF#103 National Broach Gear Tester GSJ-12 REF#103 Oerlikon #ST2-004 Soft Tester REF#103 Maag #SP-60- Electronic Tester REF#103 Parkson #42N Worm Gear Tester REF#103 Fellows #24H Tester REF#103 Gleason #104 Tester REF#103 Vinco Dividing Head Optical Inspection REF#103 MISCellANeOUS WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80 Centers, 12 Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#101 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#102 GLEASON #529 Quench, 16" Diameter REF#103 VERTICAL TURNING LATHES AND MORE - Please Check Our Website To View Our Entire Inventory REF#103 TOS SU & SUS Series Conv Lathes REF#105 TOS SUA Series CNC Flat-Bed Lathes REF#105

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Filtermist FX Series from royal

While many companies are aware of the traditional problems associated with oil mist, few are aware that failure to adequately address mist and smoke issues often results in reduced productivity and increased machine downtime. In addition to the obvious effects of oil mist, production is often reduced as a result of employees dialing back on feeds and speeds in order to minimize mist production. An oftenoverlooked maintenance problem is the effect of oil mist on electrical contacts and electronic circuits. Throughout its history the Royal Filtermist has undergone continuous design improvements. The latest version, the Filtermist FX-Series, is the product of extensive computer-aided modeling and laboratory testing. The Royal Filtermist is available in four sizes ranging from 275-1200 cfm, and its flexible design enables it to be mounted in a variety of ways including directly to the top of a machine tool, on a stand, or suspended from a factory ceiling. Go online to [www.royalprod.com].

mahr Federal Unveils marWin 4.5 Software Platform

Mahr Federal has recently unveiled a major upgrade to the software platform for its surface metrology systems. MarWin 4.5 offers increased functionality and ease of use, a range of new features, and a series of special option packages for specific applications. The new MarWin 4.5 platform is available on new systems and as an upgrade to all MarSurf XR, XC, XCR, and XT instruments. MarWin was originally designed as a modular platform to provide a smart interface to all types of measurement systems, simplify operator learning on different systems, and allow quick development of custom applications and routines, says Pat Nugent, vice president of metrology systems for Mahr Federal. With this newest version, MarWin 4.5 has evolved to provide this broad, universal platform to facilitate the needs of everyone. Everything from simplification of the user interface for quick operation on the shop floor, to open interfaces that allow development of complex new parameters and measurement methodologies for dimensional metrology professionals is available. Go online to [www.mahr.com]. DECEMBER 2011 63

< continued from pg. 16

turbine drivetrain specific variant, RomaxWind. The release includes many productivity and feature enhancements and introduces the Concept Modeller module option. The Concept Modeller module revolutionizes the speed with which complex gearbox models can be created, functionally analyzed, and exported to CAD for packaging analysis. The point and click user interface incorporates drag and drop editing and sizing features; resulting in over 10x speed improvement and reduced data entry errors when creating fully compatible RomaxDesigner models. Designers can create gearboxes using conventional stick diagrams that are as easy as pen and paper. Possible gearbox layouts include complex ravigneaux and plus-planet planetary arrangements and the latest dual-clutch arrangements. The Concept Modeller module takes the stick diagram input and generates 2D and 3D representations that can be easily analyzed visually by selecting cut planes through the design. The module allows high speed analysis of the basic properties required to evaluate many design concepts and select those that merit more detailed study. The properties include: powerflow path analysis for each transmission ratio, speed, and torque; gear sizing analysis to aid in the determination of packaging requirements; and calculation of tooth passing frequencies to provide early indications of likely NVH performance. No data re-entry is required on concept designs that are taken forward into RomaxDesigner for precision analysis. We are seeing higher levels of innovation in our customers transmission designs and design processes as they rise to the challenges lower emission vehicle designs with rapidly evolving powertrains, says Younsu Park, director of simulation technology. A recent gearbox project involved the analysis of 58 conceptual layouts, of which six were selected for detailed analysis. RomaxDesigner release R14.0, with our new Concept Modeller option is making significant productivity improvements in this type of workflow The theme of productivity improvement, particularly for automatic gearboxes and wind turbine gearbox certification, is reflected in the other major updates in release R14.0. Multi-plate clutch enhancements have been implemented and the support for complex ravigneaux and plus-planet planetary arrangements is now available at all levels of precision analysis. The certification process for gearboxes designed with RomaxWind, the wind turbine drivetrain specific variant of RomaxDesigner, has become much smoother with the further approval of RomaxWind generated reports by Germanischer Lloyd (GL). Reports now accepted for certification by GL include shaft fatigue, gear pitting, tooth strength rating, and scuffing. Based on extensive feedback from users 20 productivity enhancements have been included in release R14.0. Commonly used functions have been assigned quick-click buttons, tabs during data entry have been re-ordered to match the most common workflows and new visualisations have been added to more easily confirm correct data entry. Learn more at www.romaxtech.com.

Castrol industrial Secures agreement with Siemens

Castrol Industrial has signed a purchase agreement with Siemens Wind Power to use the companys flagship gear oil, Castrol Optigear Synthetic X 320. The award of the new contract has been the impetus for Castrol Industrial starting up the production of Castrol Optigear Synthetic X 320 at its U.S. manufacturing plant in Warminster, Pennsylvania, to help the company better serve Siemens operations in Hutchinson, Kansas, and supply locally-produced lubricants to other customers in the U.S. and surrounding markets. Sven Thiesen, key account manager wind energy, Castrol Industrial, says The deal is the latest in a long-standing working relationship with Siemens, a company that recognizes the importance of working with global partners to ensure consistency and quality in all markets served. We are pleased to be working with such a forward thinking, innovative, and growing business and are incredibly proud to be supporting Siemens global expansion plans. Today Castrol Industrial provides 100 percent fulfilment of all Siemens wind turbine gear box lubrication needs with its Castrol Optigear Synthetic X 320 product, and supply of complementary products, including hydraulic fluids and greases to the companys wind energy business. Over the past five years Castrol Industrial has supplied Siemens Wind Power with gearbox lubricants of consistent high quality and standardized packaging globally for first fill and ongoing maintenance applications. Siemens Wind Power is one of the worlds leading suppliers of wind power solutions for onshore, offshore and coastal sites. Learn more at www.castrol.com.

Mhi to intensify Gear Cutting Machine Marketing in the U.S.

Mitsubishi Heavy Industries, Ltd. (MHI) is poised to further intensify its marketing activities in the U.S. and aggressively explore robust demand from U.S. manufacturers associated with their moves toward establishing new plants overseas. Those moves come amidst rising momentum for plant and equipment investment among U.S. companies, especially in the automobile and construction machinery industries. As one of its initiatives in this direction, MHI exhibited its machine tools at Gear Expo 2011 in Cincinnati, Ohio. Two machines were exhibited: the ZE40A, a gear grinding machine capable of high-precision machining and ideal for production of a wide variety of gears in small lots; and the ST25, a gear shaping machine enabling easy machining of special gears. MHI, working through its local marketing bases, is looking to promote its advanced technologies and broad range of products accommodating needs in all aspects of highprecision gear manufacture. Marketing and servicing of the companys gear cutting machines and other machine tools are handled by the Machine Tool Division of Mitsubishi Heavy Industries America, Inc. (MHIA-MTD). Today U.S. manufacturers are in recovery from the global

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recession that began in 2008. Companies in the auto industry in particular are actively ramping up plans to relocate or construct plants in the newly industrializing economies, including Mexico, and along with those moves demand for gear cutting machines is expanding globally. Because decisions on investment plans are generally made in the U.S., MHI aims to probe global demand for its machines through MHIA-MTD. Meanwhile for the U.S. market, the company will introduce product lines meeting needs from job shops that in many cases undertake wide-variety, small-lot production. The ZE40A, launched earlier this year, is MHIs latest universal gear grinding machine. It enables highly accurate post-heat treatment gear grinding for various sizes and types of workpieces by computerized control. With capability to machine gears of up to 600 millimeters (mm) in diameter, the ZE40A allows users to set even complex gear shapes by numerical control (NC).

advanced technology to U.S. manufacturers. At the same time it will also seek differentiation and enhancement of its presence amid rising competition against inexpensive machines for rough processing available from manufacturers in the emerging economies. Learn more at www.mitsubishigearcenter.com.

Curtiss-Wright Chairman and Ceo Receives Grumman award

Curtiss-Wright Corporation announces that Martin R. Benante, its chairman and CEO, was honored with the Leroy R. Grumman Award presented by the Cradle of Aviation Museum at its Air & Space Gala. The event was in celebration of 100 years of naval aviation. Benante was presented the award in recognition of his outstanding leadership, technical achievement and personal integrity. The Cradle of Aviation established the Leroy R. Grumman Award to honor the legacy of the founder of Grumman Aerospace Corporation. In accepting the award Benante said, I am truly honored to accept the Leroy R. Grumman Award on behalf of all CurtissWright employees. At Curtiss-Wright we are proud of our rich legacy, which stretches from the historic Wright Flyer, to the first landing and take-off of an airplane from an aircraft carrier deck, to the Global Hawk unmanned aerial vehicle. As a company we have come a long way from the first flights of yesterday to developing todays innovative concepts and advanced technology. It has been my pleasure to be involved in the latest chapters of the continuing Curtiss-Wright legacy. Benante is a career employee of Curtiss-Wright, having served in various capacities of increasing responsibility since joining the company in 1978. He began his career in program management for the Flight Systems division, the legacy business of Curtiss-Wright, ultimately becoming vice president of operations responsible for hardware production for the Blackhawk helicopter, the F-14 Tomcat fighter jet, the F-18 Hornet fighter jet, and the F-16 Falcon fighter jet. He joined the Curtiss-Wright corporate staff in April 1999 as COO and became CEO and chairman in April 2000. During his tenure Curtiss-Wright has increased its sales from approximately $300 million to more than $2 billion projected for 2011, and has acquired over 50 businesses. The Cradle of Aviation Museum, located in Garden City, New YOrk, is home to one of the worlds most diverse and outstanding aerospace collections. The museum serves over 250,000 visitors each year. Curtiss-Wright Corporation is an innovative engineering company that provides highly engineered, critical function products, systems and services in the areas of flow control, motion control and metal treatment to the defense, energy, and commercial/industrial markets. The legacy company of Glenn Curtiss and the Wright brothers, Curtiss-Wright has a long tradition of design and manufacturing innovation along with long-standing customer relationships. The company employs approximately 8,700 people worldwide. For more information, visit www.curtisswright.com.

The ST25 is capable of high-speed machining of up to 1,000 cutter strokes per second for pre-heat treatment of gears up to 250 mm in diameter. Setup time has been significantly reduced as the machine automatically sets all cutting conditions upon input of the machining data. The ST25 is also the first machine in the world to realize easy setting of helical angles through NC programming. Since developing the worlds first dry-cutting gear production system using no cutting fluid in 1997, MHI has led the industry with its diverse gear cutting machines and cutting tools for all gear cutting processes from rough machining to finish processing. All machines in its lineup deliver outstanding performance and accuracy while simultaneously addressing global environmental issues. Leveraging its position as a world leader in gear cutting machines, going forward MHI aims to propose its sophisticated machines supported by

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COMPANY NAME .............. PAGE NO.

AJAX Rolled Ring and Machine .................................................. 10 Allen Adams Shaper Services .................................................... 65 AWEA ........................................................................................ 52 Banyan Global Technologies ...................................................... 30 Bourn & Koch ............................................................................ 67 Cincinnati Gearing Systems ....................................................... 31 Circle Gear & Machine ............................................................... 38 Clarke Gear Co .......................................................................... 38 Clifford-Jacobs Forging .............................................................. 41 DT Technologies sa.................................................................... 30 Encoder Products Company ...................................................... 47 Engineered Tools Corporation (ETC) ........................................... 32 Gear Motions ............................................................................. 65 Gear Solutions Online ................................................................ 54 Gleason Corporation .................................................................. 45 Hanik Corporation ...................................................................... 67 Innovative Rack & Gear Co ........................................................ 65 INTECH Corporation .................................................................. 53 Ipsen International...................................................................... 25 KAPP Technologies ...................................................................IFC KISSsoft USA LLC ..................................................................... 14 Kliess Gear Inc........................................................................... 65 Klingelnberg GmbH...................................................................... 2 Lawler Gear Corp ...................................................................... 65 Luren Precision .......................................................................... 44 Mitsubishi Heavy Industries America Inc .................................... BC New England Gear ....................................................................... 7 Niagara Gear Corp..................................................................... 14 Overton Chicago Gear ............................................................... 35 Process Equipment .................................................................... 47 Proto Manufacturing Ltd ............................................................ 11 R P Machine Enterprises Inc ...................................................... 60 Repair Parts Inc ......................................................................... 39 Riverside Spline & Gear Inc ..................................................... 9,43 Russell Holbrook & Henderson................................................... 49 Sandvick Coromant ............................................................ IBC,65 Schafer Gear ............................................................................. 55 Southern Gear & Machine .......................................................... 12 Stock Drive Products/Sterling Instrument ................................... 39 Stor-Loc .................................................................................... 59 The Broach Masters .................................................................... 4 The Company Corporation ......................................................... 65 TMFM LLC ................................................................................ 59 Toolink Engineering Inc ................................................................ 1 WD-40 ....................................................................................... 13 Wenzel America ......................................................................... 21

ADvERTISER iNDeX

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Q&a
Pat nugent,
vICE PRESIDENT OF METROLOGy SySTEMS
MAHR FEDERAL, INC.
at the time, and although Mahr Federal kept that facility, the former Federal Products location of Providence, Rhode Island, was chosen as North American headquarters. Cincinnati was such a great site in terms of its centralized location, however, that Mahr Federal decided to actually build a new, larger facility there, which now houses our Midwestern Customer Resource Center. All of our U.S. manufacturing is performed here in Providence, and we export some of what we build to other Mahr locations around the world and import some of what they make for our market. Each of our manufacturing sites is a center of excellence for certain products or technologies. GS: I understand that your parent company, the Mahr Group, is celebrating its 150th anniversary this year. Tell us a little about its history. PN: Carl Mahr was an intelligent man with a healthy sense of curiosity, and he was something of an inventor as well. As rail travel was growing in popularity throughout Europe he developed a number of devices for measuring the track contours and widths, among other things, launching his company in Esslingen, Germany, in 1861, with two employees. The company became involved in the automotive industry when it began to emerge around the turn of the century, growing into new markets in an organic fashion as opportunities arose. It expanded globally over the years, with sales offices in countries such as France, Switzerland, Mexico, Brazil, the UK, and the United States, and it acquired quite a few companies as well, finally uniting all of them under the Mahr name in 1995. We now have representation around the globe and manufacturing facilities in the U.S., China, Germany, and the Czech Republic. GS: Tell us about your entry into the North American market, and how Mahr Federal came into existence. PN: The Mahr Corporation was established in the early eighties here in the States, leading to the acquisition of Federal Products, Inc., in 1999, which resulted in the creation of Mahr Federal. Mahr was based in Cincinnati, Ohio, GS: Tell us about your products and services that would be of interest to gear manufacturers. PN: We are a broad-range metrology supplier providing our customers with everything from handheld devices such as calipers and micrometers to highly engineered custom measurement systems. Gear manufacturers would be interested in our MarGear line of metrology systems. The GMX 275, 400, and 600 machines were designed specifically for gear measurement, offering the precision and flexibility required by that demanding application. As is the case with any metrology system purchase, installation, calibration, and training are part of the package, and were also available to work with customers who are building new production facilities, redesigning existing cells, or incorporating MarGear machines into their manufacturing process. Thats especially useful for those

With the fifth generation of the Mahr family setting the companys direction, we are focused on making the right decisions for our customers and continuing the success of the last 150 years.
who are embracing automated manufacturing technologies. In addition to standard field services such as maintenance and repair, we also have one of the best-equipped calibration laboratories in the country, if not the world, here in Providence. When it was built the engineers dug underground and straight down to bedrock in order to eliminate vibration and ensure temperature control. We have sensors in there that are so accurate they can detect the oceans tide shifting the bedrock slightly over the course of the day. So were proud of who we are, and of what weve accomplished over such a long period of time. Its rare these days to see a family-owned company thats been around for so long, but thats a key part of our identity. When you have the fifth generation of the Mahr family setting our direction, its clear that were focused on making the right decisions for our customers and that the company will continue to be successful for the next 150 years and beyond.

TO LEARN MORE:
Call (800) 343-2050 or (401) 784-3100, e-mail information@mahr.com, or go online to [www.mahrfederal.com].

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gearsolutions.com

The

E Series
GE
GEAR HOBBERS

Mitsubishi

The Truth be Told

E Could Stand For: Excellence. Extraordinary. Extreme, etc... and one would be forgiven for thinking so, because these descriptions certainly represent the Mitsubishi machines which contain this letter in their model name. However, the simple truth is that the letter E denotes that these machines are the latest iterations of the models which carry it. The SE gear shapers, GE gear hobbers, FE gear shavers and ZE gear grinders epitomize the development of the process technology they have been designed for and so aptly carry out. Research and Development is not just a glib phrase at Mitsubishi; it is a philosophy that the company stands by to stay ahead of its competition and to ensure continuing profitability and the profitability of its customers. Yes, E could stand for many things but with continuous striving for perfection and intense R & D, the E simply means it is as good as it gets. Period. To personally experience the world-class performance of the Mitsubishi E Series of machines visit mitsubishigearcenter.com or contact sales 248-669-6136.

FE

GEAR SHAVERS

SE

GEAR SHAPERS

Machine Tool Division Gear Technology Center 46992 Liberty Drive Wixom, MI 48393

mitsubishigearcenter.com

ZE

GEAR GRINDERS