Big gear iNSPeCTiON iS BOOmiNg

miCropittinG

Oil Additives CAn preVent internAtiOnAl CAlCulAtiOn

methoD for miCropittinG
Site Safety tooth tipS hot Seat aGma UpDate

Company profile:

Ontario Drive & Gears

Q&a: JaCk fiorille Elyria ManufacturinG cOrp.

gearsolutions.com

JUNE 2012

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 [email protected]

Power Skiving A Milestone in Gear Manufacturing

Discover Power Skiving Live:

IMTS CHICAGO

10-15 September 2012

JIMTOF TOKYO

01-06 November 2012

Member of

Power Skiving Klingelnberg Presents its Latest Innovation

The newly developed tool system can be used on Klingelnberg bevel gear cutting machines. It guarantees a productive, stable and precise production process, particularly for internal gears. Klingelnberg enables the breakthrough of Power Skiving by nally unleashing the full potential of this 100 year old manufacturing method. - up to 10 times faster processing times compared to other manufacturing methods - smooth anks with advantageous surface texture - high gear quality due to precise tooling and dynamic machines

Learn more about Power Skiving at www.klingelnberg.com

For the US-market please contact: Liebherr Gear Technology, Inc. 1465 Woodland Drive Saline, Michigan 48176-1259 Phone: 734-429-7225 [email protected] www.klingelnberg.com

40
Big gear inspection is Booming
By Michael Hayes

Features
Company Profile: Ontario Drive & gears

a recent expansion and investment in a precision gear inspection system is helping this Wisconsin company meet customer needs for high quality, fast delivery, and quality control.

28

By Sherri Mabry

this company provides a one-stop powertrain solution from gear and system designs to transmission assembly and performance testing.

Oil additives Can Prevent micropitting

By Michael Hochman and Herman Siebert

30

using advanced additive technologies during the oil change helps gears build new reaction layers on surface of tooth flanks.

international Calculation method for micropitting

46

By Dr. ING. Ulrich Kissling

the safety factor against micropitting can be improved through macro geometry optimization by using profile modifications.

JUNE 2012

resources
maCHiNeS

marKeTPLaCe

59 61

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

63

Terry McDonald thanks to workplace plans and OSHa rules and regulations, deaths and injuries have dropped 60 percent in the past 40 years.

Site Safety

JUNE 2012 | VOLUME 10 / NO. 6 Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210 Pelham AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond Hill, ON L4B4R6. Copyright 2006 by Media Solutions, Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information storage-and-retrieval system without permission in writing from the publisher. The views expressed by those not on the staff on Gear Solutions magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All "Industry News" material has either been submitted by the subject company or pulled directly from their corporate web site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to [email protected].

William Crosher proper lubrication reduces frictional resistance and heat and thus improves the gear efficiency.

Tooth Tips Hot Jack Titus Seat

Shallow case hardening in mesh belt and cast link belt furnaces is acceptable for small gears, shafts, screws and nuts when fixturing is not required.

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

Jack Fiorille, CMFgE

Q&A

Elyria Manufacturing corp.

8 24 25 26 55 64 19

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.

Cover Photo: Merit Gear, LLC

JUNE 2012

LETTER

FROM THE

EDitOr

David C. Cooper
PuBlisher

There is no substitute for hands-on experience. Ive heard that message in several conversations recently and know it to be true from my own experiences. My second week as managing editor of Gear Solutions was spent at the DMG / Mori Seiki USA headquarters watching machines cut, drill, grind and finish metal. Being able to see new equipment in action and having the opportunity to ask questions of engineers and technicians is invaluable, not only to me as an editor, but to anyone who uses equipment in their jobs. Ive spent a lot of time in manufacturing facilities watching pieces of equipment being welded by robots or assembled by skilled-technicians. The parts may be different from one plant to another, but the craftsmanship and technical skills of the people are something to behold. I was talking to an engineer with a precision machine company earlier today I met him at that very same OEM event I mentioned earlier and he was telling me how he worked in machine shops, taking classes and training courses along the way until he had enough experience to land the jobs he wanted, while doing the work he wanted to do at the salary he needed in order to provide for his family. Our conversation progressed to the future of machining metals and manufacturing in general. He echoed the sentiment of this letter to you: In this work you need to have seen it, witnessed it, experienced it, tried it and tested it. I dont think the gear industry is unique when it comes to hands-on training. Another person recently lamented that the time they spent in college provided a good foundation of general or specific knowledge, but it was the internship or the first job that taught them most of what they know and use today. I was reminded of that when I received a news release last week about a community project that is training 21 students in Michigan to fill a need for skilled workers in manufacturing technology, CNC machine tools, mechanical maintenance, and electrical and robotics disciplines. As we all know, Southeastern Michigan, in particular, has been hard hit by the recent economic downturn in the automotive and manufacturing industries. Its good to know that companies and communities are finding ways to educate and employ young people who may have wanted to earn a degree, but probably couldnt afford to do so because of the recent economic downturn. Anyway, editors letters are often the conversational piece of a magazine, so I took the liberty of sharing my thoughts with you. Which reminds me that you are probably wondering who I am. Im the new managing editor of Gear Solutions and have assumed the duties of Russ Willcutt who has chosen to pursue other interests. We are grateful to Russ for his contributions to this publication and the gear manufacturing industry. I havent met Russ, but Ive received many notes of appreciation and fond farewell messages, so I know he will be missed. Hopefully youll find a new friend in me.

Sherri Mabry
manaGinG editOr

eDitoriAL

Chad Morrison
assOciate PuBlisher

sALes

Teresa Cooper
manaGer

CirCuLAtion

Kassie Hughey
cOOrdinatOr

Jamie Willett
assistant

Jeremy Allen
creatiVe directOr

Art

Michele Hall
GraPhic desiGner

Contributing writers
William crOsher michael hayes michael hOchmann dr. inG. ulrich KisslinG terry mcdOnald herman sieBert elias taye JacK titus Vertical Logo

Published by Media solutions, inc.

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

Sherri mabry
managing editor Gear Solutions magazine [email protected] (800) 366-2185 x205

David C. Cooper
President

Chad Morrison
Vice President OPeratiOns

Teresa Cooper

gearsolutions.com

INDUSTRY NEWS
Siemens to Present Innovations at IMTS Exhibit

new products, trends, Services, and Developments

At this years International Manufacturing Technology Show (IMTS) in Chicago, Siemens will introduce new solutions and services for machine tool manufacturers and end-users. Under the theme, Productivity in Motion, the presentation will focus on turnkey solutions for the job shop, aerospace, automotive, mold/die and medical part manufacturing industries. For machine tool builders and end-users, Siemens will exhibit the newest innovations in CNC (Computer Numerical Control), motor and drive technology, as well as new value-adding services ranging from condition monitoring and manufacturing IT to solutions for CNC training and machine tool retrofits. Highlighting the booth for attendees will be a raffle to win a Harley-Davidson motorcycle, as well as the opportunity to register for a 60-day free trial license on Sinutrain, the full suite of Siemens CNC training modules. Siemens will introduce a shop floor CNC specifically designed and engineered for the 230V, three-phase) economy-priced market,

with up to three-axis plus spindle control capability in milling or turning applications. Offered as a package with Siemens Sinamics drives and Simotics motor solutions, this new control will be demonstrated on a knee mill, during the show. This new CNC will be available for both OEM machine builds and in-the-field retrofit. The Sinumerik 828D also will be running on various machines and simulators in the booth. The Sinumerik 828D BASIC T (turning) and BASIC M (milling) expands this range of Siemens CNC to enhance job shop performance. The Sinumerik 828D BASIC T is designed to address the needs of shop floor turning machines. It combines CNC, PLC, operator panel and axis control for five axes/spindles, including live tooling. Milling and drilling operations on a turning machine, both for face and peripheral surfacing, are therefore possible. In tandem with the new Sinamics S120 Combi drives package, the 828D BASIC T represents a new level of efficiency and virtually maintenance-free operation, as the fans, hard disks and batteries of past CNC generations are eliminated.

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

gearsolutions.com

Likewise, the new Sinumerik 828D BASIC M class features the same quality performance as the T class, for use on milling machines. Even in complex mold making operations, mirror-smooth surfacing and reduced machining times are enabled. Again, in tandem with Sinamics S120 Combi drives package and Simotics feed and spindle motors, the 828D BASIC T will operate a milling machine at the highest level of performance possible. Superior axis and spindle dynamics within a broad speed bandwidth yield quality work pieces, every time. All the other benefits of the Siemens CNC family, including the Sinumerik Operate graphical user interface platform as well as Shop Mill and Shop Turn easy programming are offered in these new 828D CNCs. The Sinumerik 828D is capable of full graphical, high-level language command and supports ISO programming that is customary in the United States. This control family is ideal for single-part and small-batch production. Programming time can be further reduced for small-batch production with the use of the ShopMill and ShopTurn graphical

work step programming system, while highlevel language programming can be used in conjunction with program Guide to significantly reduce programming times for large-scale serial production. Also included with this expansion of the Sinumerik 828D family of CNC, modern PC and mobile phone technology are available to the mid-range machine tool. Extensive online help animations and a new type of input prompting system with moving picture sequences provide the basis for exceptional user convenience. USB, Compact Flash (CF) card and Ethernet ports enable high-speed data transfers onto storage media or integration of the control system into corporate networks. Through the use of its Easy Message functionality, the Sinumerik 828D family offers production status monitoring by text messaging (SMS). Depending on the recipients profile settings, the machine tool can transmit information about work piece machining status, report on the tool condition currently in use and send machine maintenance bulletins to a mobile phone, anytime and anywhere.

In Memoriam - Bob Schmitt

7/18/1938 - 4/18/2012

It is with deep sadness that we mourn the loss of long time Process Engineer, Bob Schmitt from Gear Company of America, said Scott Britvec with the company. A graduate of Cleveland State University with a BS in mechanical engineering (Fenn College of Engineering), Bob worked at Gear Company of America for 32 years as a process engineer. He semi-retired in 2002, working part time training the puppies as he used to call us until his passing, Britvec said. He enjoyed Walleye fishing and swing dancing winning multiple competitions and tournaments throughout the years. He was a true ROCK in the gearing community, Britvec said. He is missed by all.

10

gearsolutions.com

These combined functions are designed to help keep machine downtime to a minimum. The Sinumerik 840D sl CNC makes another series of advancements, all being demonstrated at this years show. The system platform offers a comprehensive range of functions for machine tools. This universal control covers wide-ranging machining technologies used in metalworking operations such as turning, drilling, milling, grinding, laser machining, nibbling and punching, plus it can be used in multi-tasking machines such as turn-mill or mill-turn centers. Whatever the application, Sinumerik 840D sl leads to maximum productivity for the job shop or industrial-scale production department, as well as optimum surface quality for all mold and tool building applications. Another new offering at the exhibit is Sinumerik Operate. This is the graphical user interface that provides an integrated milling function for turning machines or integrated turning function for milling machines. With the benefit of modern touchscreen operation, the new Sinumerik operator panel OP 019, now extended to include the new Power Control Unit (PCU) 50.5, allows high-speed key actuation at the large 19-inch glass front, which conforms to the IP66 protection rating. Another feature of the OP 019 design is the wide LEDs, which allow the operator to clearly visualize every key actuation, no matter what the angle of vision. An integrated key lock helps safeguard against operating errors, and the new operator panel is provides a basic machine display with three or four channels showing up to 13 axes. Sinumerik CTRL-E is the new green high achievement in CNC operation, designed for the strict requirements of the international energy efficiency standard EN16001. It provides a full assessment of the energy consumed by the machine tool in every cycle, on every part produced and throughout the machines life cycle. Specific power loads can be shut down automatically during downtimes, plus generated braking energy can be stored or fed back into the power grid. In this way, Siemens Sinamics drive packages are achieving up to 99 percent energy efficiency, while Simotics motors are likewise running at 90 percent levels or better to deliver unprecedented energy and power in the machine tool market. Sinumerik Integrate is an onboard CNC solution that allows machine tool data to be integrated quickly, simply and reliably into other company processes. This IT integration of production processes allows managers, machine

operators, part programmers, maintenance engineers and machine tool builders to be inter-connected with each other and integrated into the overall system by means of defined processes. Sinumerik Integrate facilitates this network by concentrating IT-related functions into a single process suite, using six different available modules that cover every aspect of the machine tool integration process. For the

aerospace market, the Sinumerik 840D sl is the latest in CNC technology that increases performance and user productivity. It is a universal and flexible CNC system featuring the innovative Sinamics S120 drives that can be used with up to 31 axes. It is a distributed, scalable, open and inter-connecting system, offering a wide range of specialized functions for milling, drilling, turning, grinding and handling technologies,

JUNE 2012

11

with full kinematic transformations for optimum machining and surface quality. The Sinumerik 840D offers users innovative features that increase productivity on the manufacturing floor, especially the challenging segments of high-speed and five-axis aerospace machining. Connectivity is the watchword in aerospace at this years show. From a single solution provider, machine builders and end users alike can enjoy full and seamless connectivity of their CNC and PLC technologies, plant wide and worldwide among facilities, as Siemens provides its international network of support to all facilities, in all operating and conversational languages. Hardware and software solutions from a single source are available, to the scale and scope needed by any aerospace OEM or tier vendor. In the automotive industry, Siemens continues to solidify its position with the Transline System Solution for automotive powertrains. This system integrates diverse metal cutting technologies such as milling, drilling, turning and grinding, and the assembly of powertrain

parts, under common system architecture. With the introduction of the Flexible Assembly Configuration System (FACS), Siemens has now also streamlined the line changeover world. By specifying Transline, machine tool users benefit from faster start-up times, better equipment serviceability and increased productivity. Operator cross-training and work cell operation is further enhanced. During the show, Siemens will also have displays of its Totally Integrated Automation (TIA) services, as well as Siemens Safety Integrated and other production network offerings. TIA Portal, enables the design and configuration of all process automation from a single computer screen, along the entire process supply chain. Siemens Safety Integrated for Factory Automation comprises advanced drive technologies, automation systems, operator control and machine monitoring, fail-safe communications and safe industrial control advancements. SinuTrain, the Siemens package of CNC training software on CD-ROM, provides milling and turning machine operators with a high degree of practical hands-on experience, prior to using the

CNCs on their machines. It is designed to run on Windows XP or Windows 7 operating systems and is the optimal solution for machine tool control-identical simulation training. It installs and operates with less memory, so other work can easily be accomplished during simulation of the machining. With SinuTrain, actual NC programs are developed and simulated, using a direct connection to the companys CAD systems to further speed the program generation protocol. In this way, machine tool operators not only learn the control language commands, but they also visualize part programs on a PC screen that are identical to the actual machine screen. As a further benefit, programs generated through SinuTrain on the PC software can then be used on the machines. A free 60-day trial license of Sinutrain is available to all show attendees. The My Documentation Manager allows Siemens CNC users to customize online service and operations manuals to suit their specific machine tools. New mobile apps for iOS and Android devices that are now available

NEW RELEASE 03/2012

KISSsoft Software
The Industry Benchmark for Gearbox Design Gear Optimization Contact Analysis Shaft Design & Analysis Bearing Design & Analysis Industrial Gears, 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 [email protected]

GearSol_KISSsoft_Rel_03_2012_96x124mm.indd 1

12

gearsolutions.com

4/11/2012 10:48:06 AM

from Siemens will be demonstrated, including Easy CNC with G-code compatibility conversion, Motion World, the Siemens customer magazine for CNC automation and CNC4you. Other exhibits on display in the Siemens booth include the new Simotics 1FK7 / 1FT7 high-inertia servomotors, the 1PH8 main spindle motor, linear motors and direct-drive torque motors that contribute to the increase in machine performance. The exhibition will also focus on machine tool retrofit, field service, customer service, spare parts and repair, all of which support the machine tool builder and enduser. Special displays will also feature Siemens solutions for medical part manufacturing and power generation. In the booths theater area, educational seminars about CNC technology, Product Lifecycle Management (PLM) developments, factory automation and more will be presented. Finally, Siemens will have active participation in the Automation Pavilion directly adjacent to the Siemens booth in the East Hall. For more information, visit www.usa.siemens. com/cnc.

and accessories in the United States, recently hired Doug Kelley as its new vice president of product engineering to ensure OMAX exceeds the growing technology demands of its global customers. Kelly earned his Bachelor of Science in mechanical engineering from the University of Washington, and his career diversity ranges from utility subsurface

installation services to enhanced oil well drilling technology and new developments in supercomputers. With more than 30 years as an engineer for a variety of global high-tech industries, Kelly owns 15 patents in a variety of technical applications. His most recent patent came in late 2011 for air conditioning systems for computers and associated methods.

OMAX Appoints New Vice President of Product Engineering

Several industries, from aerospace and medical to food processing and transportation, rely on OMAX Corporations abrasive water jet technology for the fast, precise cutting of various materials, including exotic alloys, glass, rubber, stone and wood. The company, which designs and manufactures all of its machines, pumps

JUNE 2012

13

Our talented engineering team is constantly developing new and improved abrasive water jet technologies to meet the diverse and ever changing needs of manufacturers worldwide, said Dr. John Cheung, CEO of OMAX Corporation. Because innovation is at the core of everything we do, we are extremely excited to have Mr. Kelley as part of our team. His engineering expertise and

proven successes will be a great asset to us and our customers. Before joining OMAX, Kelley spent 13 years as a senior mechanical engineering manager for Cray, Inc., a company that designs and manufactures world-class supercomputers. In this position, he conceptualized and orchestrated the companys first commercial research and development con-

tract, and developed an innovative two-phase cooling system, allowing the worlds most powerful computer to save 1MW of power. Kelley was Crays only hardware engineer to meet for six consecutive years with key customers at the International Supercomputing Convention, the worlds oldest and one of the most important conferences for the highperformance computing community. Prior to Cray, Inc., Kelley was the founding engineer for the start-up UTILX Corp. and was involved in the concept and commercialization through an initial public stock offering of proprietary technology used to install underground utilities without surface restoration. He also was director of engineering for FlowDril Corp., where he promoted leading-edge designs and analysis for highpressure technology for the oil and gas drilling industry. For more information on OMAX products and accessories, contact Sandra McLain at 800-838-0343, or visit www.omax.com.

MicroRidge to Highlight MobileCollect at IMTS 2012

MicroRidge Systems, Inc. will highlight its reliable, flexible and easy-to-use MobileCollect wireless measurement technology at The International Manufacturing Technology Show (IMTS) 2012, at Chicagos McCormick Place, September 10-15. MicroRidges Booth #E-5552 is located in the Quality Assurance, Pavilion, Lakeside Center (East) Building. MobileCollect wireless collects measurements from handheld gages using Mobile Modules that attach securely to the gage or fixture and then sends those measurements wirelessly to a PC for quality control. Highly reliable, MobileCollect wireless is ideal in situations where there is heavy RF, significant machinery, robots or electrical noise. It is often the only collection device that works unaffected all of the time. We have been listening to our customers for nearly three decades, says Mary Chisholm, VP Operations & Marketing. Using customer feedback, in combination with flexibility and technology advances, as our core business philosophy has resulted in the ability to provide our customers with technology that reduces costs, increases production and achieves focused, real-time results. For more information, visit www.microridge. com or call 541-593-1656.

14

gearsolutions.com

Mazak Adds Three Service Technicians to Western Canada Operations

Mazak Canada recently added three new direct service technicians to its western Canada operations to further support the continuous upswing of manufacturing business throughout the region. These new hires, when combined with the certified personnel from the companys distribution partner, Machine Toolworks, Inc., bring Mazaks service team for the provinces of British Columbia, Alberta, Saskatchewan and Manitoba to 10 fully experienced technicians. Overall, Mazak Canada schedules all 22 of its service technicians out of the companys Canadian headquarters in Cambridge, Ontario, where recent facility upgrades further enhance the service teams already impressive customer response times. According to Ray Buxton, general manager for Mazak Canada, developing advanced manufacturing technologies is only part of what Mazak does to help its customers increase their productivity and profitability. The company offers an Optimum Plus program, which includes technical support expertise, to enable Mazak owners to maximize their machine tool investments. We are a single point of contact for all customer questions or concerns, whether related to a machine, control, accessory or an automation system, he said. Our technicians also provide a wide variety of services, such as ball bar qualification and analysis, preventive maintenance plans, and vibration analysis and benchmarking. Training and process improvements are two other facets of Mazaks Optimum Plus program. Mazak Canada, along with its two distribution partners in Canada, have added new applications specialists to their teams for a total of eight highly skilled employees to handle training and process improvements. Additionally, Mazak Canada, which offers a tiered learning program that ranges from hands-on teaching to real-world examples, has expanded its training course schedules in both Edmonton (Machine Toolworks) and Cambridge (Mazak headquarters), offering several courses per month at these locations. For more information, visit www.mazakcanada.com.

Heimatec Relocates to Larger Facility

Heimatec, Inc., the North American operation for a world leader in live tools, angle heads and multi-spindle drill heads, today announces it has relocated to substantially larger headquarters near Chicago. We made this move to increase our inventory and our staff to better serve the growing ranks of

our customers, both end users and distributors alike, said Heimatec president Preben Hansen. The new location is in Prospect Heights, Illinois, previously home to Heimatec. It represents a 50 percent increase in office and warehouse capacity. Hansen anticipates hiring new staff for the facility soon. In related news, Heimatec introduces a complete lines of tooling, designed for

JUNE 2012

15

specific brands of machine tools, including the major builders of turning machines used in the North American market, such as Haas, Okuma, Mazak, Spinner, Miyano, Nakamura and others. This full-specification literature by machine brand is immediately available from the company in print and online PDF versions. Heimatec also offers its new corporate capability

brochure, in which all lines are presented. For more information or to order a catalog, call 847-749-0633 or email [email protected].

Machine Tool Builder Okuma Enhances Sales Organization

Okuma America Corporation, a leader in CNC machine tools, has enhanced its

For all your peening and cleaning needs

PREMIER SHOT COMPANY

Improved Part Life - Parts exhibit higher and more consistent life than those peened with equivalent size and hardness cast steel shot. Highest Resistance to Fracture - Cut wire shot media tends to wear down and become smaller in size rather than fracture and Lower Dust Generation, Highest durability equals lowest dust levels. Highest Durability - Due to its wrought internal structure with almost no internal defects (cracks, porosity, shrinkage, etc. Improved Consistency - highest consistency from particle to particle in size, shape, hardness and density compared to commonly used metallic media. Substantial Cost Savings - The Increase in useful life of Premier Cut Wire Shot results in savings in media consumption and reclamation, dust removal and containment, surface contamination and equipment maintenance. Operations and Training - In an effort to make your operations more efficient we offer training in shot and grit basics, centrifugal wheel blasting, shot peening machine operations and maintenance.

Premier Shot proudly manufactures shot to meet todays high quality shot peening standards and is used in automotive, medical and aerospace applications worldwide

sales organization to better serve the needs of its distribution network and provide better manufacturing solutions to end-use customers. Tim Thiessen, promoted to vice president of sales from the position of senior regional sales manager in 2011, now manages an extensive group of CNC machine tool sales professionals, including six regional managers, three sales engineers, five product specialists and the inside sales department. Having worked with Okuma for over 20 years, Thiessen is well versed in the duties and responsibilities of each role and can manage the teams resources accordingly. Our customers are busier than ever and are operating leaner organizations, Thiessen said. They need help to continually improve their manufacturing processes and stay competitive. This organizational structure helps us and our distributors focus on the needs at hand, ensuring that the most qualified individual is able to assist the customer. The delineation of the sales roles creates a dynamic that allows each group to focus on specific responsibilities. The regional managers work closely with distribution management and sales staffs, the sales engineers provide product and processing expertise and the product specialists assist the distribution sales staff and customers in identifying the appropriate products and options for given applications and manufacturing needs. In addition to providing sales and engineering expertise, the product specialists also provide product training for both distributors and end-use customers. The organizational structure will provide distributors and end-use customers with specific points of contact within the Okuma organization and will help focus attention on helping manufacturers become more productive and efficient. For more information, visit www.okuma.com.

www.premiershot.com
email: [email protected]
16 gearsolutions.com

(330) 405-0583

Renishaw Introduces Additive Manufacturing Systems

PREMIER SHOT COMPANY
1666 Enterprise Parkway, Twinsburg, Ohio 44087 Fax: (330) 405-0584

Renishaws new laser melting additivemetal manufacturing process is capable of producing fully dense metal parts direct from 3D CAD data using a high-powered fiber laser. Parts are built layer by layer,

in thicknesses ranging from 20 to 100 microns, using a range of fine metal powders that are fully melted in a tightly controlled atmosphere. The current range of machines utilizes a third-generation design representing stateof-the-art manufacturing technology. Key features include variable powder delivery, ultra low oxygen content in the build atmosphere, and an unparalleled safe-change filter system to minimize user contact with materials. Two systems are available: the AM125 and the AM250, both of which feature vacuum technology and low gas consumption. Both utilize machine tool engineering in design, operation, and serviceability, emphasizing ruggedness and ease of operation. The touch-screen operator interface includes menu options for machine preparation and cleans down settings. Consumable costs are minimized through features such as the soft re-coater blade. The blade can be rotated several times before replacement and the use of low-cost filter elements and low gas consumption help to improve system reliability and cost of ownership. Renishaw additive-metal systems process a wide variety of materials, including 316L and 17-4PH SS, H13 tool steel, aluminum Al-Si-12, titanium CP, Ti-6Al-4V and 7Nb, cobalt-chrome (ASTM75), and Inconel 718 and 625. Both systems are designed for rapid material changeover, with the AM125 using a cassette type material delivery system. The AM250 also features a removable hopper, which is useful for materials development or use with a range of materials. To enhance productivity, a valve interlock on the AM250 allows the addition of extra powder while the process is running. Safe processing of reactive materials, such as titanium and aluminum, is ensured with features such as a gas knife that clears away reactive, sooty emissions, and a heated build plate. The AM125 provides a part-build volume of 125 x 125 x 125 mm (X-Y-Z), and the AM250 provides 250 x 250 x 300 mm (X-YZ) with Z axis extendable to 360 mm. Both have build rates of 5 to 20 cm3 per hour, dependent on the material, part density and geometry. The AM125 offers a choice of 100 or 200 W laser, and the AM250 a 200 or 400 W laser.Both the new machines

feature a fully welded vacuum chamber, enabling low-pressure evacuation followed by a recharge with high purity argon gas. Gas consumption, after the initial chamber flood, is extremely low, and allows operation at oxygen concentrations below 50 parts per million. This is crucial when processing reactive materials, and contributes to material integrity and mechanical performance.

All file preparation is completed off-line through a choice of interface with either Marcam Autofab software or Materialise Magics. Once complete, the build file is uploaded to the machine via a secure network or direct connection. Product traceability has been improved by the addition of process data and event logging is standard with various additional process control options on request.

JUNE 2012

17

EMAG Announces Collaboration For Local Training

EMAG L.L.C. announces its receipt of a five-year, $200,000 agreement with Oakland Community College (OCC), through the Michigan New Jobs Training (MNJT) program, for the training of 21 new employees in manufacturing technology, CNC machine tools, mechanical maintenance, electrical and robotics disciplines. Peter Loetzner, EMAG CEO, accepted the award from Dr. Timothy Meyer, chancellor of Oakland Community College, and J. Brooks Patterson, Oakland County Executive, during the Oakland County Economic Outlook Luncheon. OCC Chancellor, Dr. Timothy Meyer noted the critical importance of education and training in the creation and retention of manufacturing jobs in Southeastern Michigan, an area hard hit by the recent economic downturn in the auto industry and other manufacturing sectors of the

economy. He then introduced Oakland County Executive J. Brooks Patterson, who continued this theme, citing the recent creation of 36,000 new jobs in Oakland County as well as other awards made to companies whove chosen to locate in the area. Introducing Peter Loetzner, Meyer detailed the collaboration between OCC and EMAG, noting how the study of mechatronics would raise the skill level of both engineers and the plant workforce to higher levels of technical competence and multi-functional abilities. During his remarks, Loetzner recounted his own experience as a student in this now rapidly growing field of mechatronics, where mechanical engineering melds with electrical and electronic engineering to help students better understand the interrelationship of components on a machine. Mechatronic engineers and field technicians are now highly valued individuals in many industries, Loetzner noted. He added that

EMAG might have at least 20 openings in engineering throughout the next few years at his company, the result of increased sales and the EMAG commitment to serving the North American market from its expanding headquarters in the Detroit area. He further commented how such programs have the dual advantages of growing the manufacturing base in the area, as well as raising the skill level of the employees, which in turn attracts more businesses to Oakland County. EMAG has engaged in training for its employees as well as its customers programming, operator and maintenance personnel throughout the companys history, both in Germany and in America. The company sells its machines to job shops and original equipment manufacturers metalworking departments worldwide, with a heavy concentration in the automotive and off-highway machinery markets. For more information, call EMAG at 248477-7440 or [email protected], www. emag.com.

WEDNESDAY & THURSDAY, JUNE 27TH & 28TH

Complete plant closure of over 2 million sq. ft. facility of

HILCO WEBCAST / ONSITE AUCTION

Previews are by appointment only. Please contact Ken Planet at 248.254.9999 x33 or email [email protected] to schedule an appt.
Preview Info:

Asset Location: 6900 English Avenue, Indianapolis IN 46219 Location: Hilton Garden Inn Airport, 8910 Hatfield Drive, Indianapolis IN 46231

Unprecedented Offering of Late Model CNC Gear & CNC Machining Equipment including Ford Escape Steering Line
CNC Gear Hobbers - (6) Yr 2006 Kashifuji & Liebherr LC-82 CNC Gear Inspection Klingenberg P-26 CNC Turmat Triflex CNC Horizontal Machining Centers - (10) Makino A-71 CNC Turning Centers - Mori Seiki, Hardinge, Star CNC Twin Spindle Turning Centers - Muratec MW 120G
To Schedule an auction, please call us at 1-877-37-HILCO
A Buyers Premium Is In Effect for All Sales Hilco Industrial, LLC Indiana Auctioneer & License: Tim Pfister License #AU11000094 IN License #AC31100034 IL License #444.000215

CNC Combination Lathes Techno Wasino CNC Centerless Grinders - Gold Crown & Cincinnati CNC Vertical Machining Centers CNC Gun Drills CNC Cutter Grinders Anca & Walter CNC Grinders - (10) Magerle, Weldun & Landis CNC Straighteners - Galdabini PAS4

Fanuc Gantry Mounted Robots Inspection Equipment Broaches Heat Treat Rolling Stock Fabricating Equipment Tool Room Overhead Cranes Office Equipment

www.maynards.com www.hilcoind.com

For further information, please visit us on the

18

gearsolutions.com

American Gear Manufacturers Association

Keep Up to Date on Gear Industry News

These days were all bombarded with information online, e-mail,TV, but where are the best resources for the latest gear industry information? Obviously, publications such as this one are great sources of information, but are you are aware of the resources AGMA has to offer even if you are not a member of the Association?
AGMA strives to keep its membership and the industry at large up to date through our website, www.agma.org, Facebook page (American Gear Manufacturers Association), and through its two e-newsletters the Gear Industry Update and the AGMA NewsBrief.

AGMA Website www.agma.org

Gear Industry Update

A bi-weekly (Thursdays) e-mail informs subscribers of industry activities from member news to industry events to new programs and other related news. The Update presents an overview of important developments from AGMA and its members. For every issue, AGMA staff visit every single member company website to collect the latest news product releases, personnel changes, and new business announcements providing an invaluable collection of information in one convenient digest.

The AGMA website is updated daily with Industry News, news from AGMAs members and other information pertinent to the gear industry. Register for events, find new job opportunities, post a job (members only), download publications, explore online training, locate peers, and more. Employees of member companies are also encouraged to review the How to Utilize Your Company Membership under the membership tab. Outlined for you are suggested ways to plug in for various job titles within member sites including: Executives, machinists, engineers, salespersons, and human resource specialists. Find a list that best suits your individual needs.

Industry Product Locator

AGMA Newsbrief

This e-newsletter tracks the latest news in the gear manufacturing and power transmission industries - from more than 14,500 hand-picked, editorially ranked information sources ranging from the New York Times to Industry Week and other manufacturing associations. This newsletter provides an overview of the latest manufacturing trends, both economic and product-related. The Newsbrief is delivered weekly (Tuesdays) as an email summary to subscribers, and is open to nonmember subscribers.

If youre researching new vendors, a great place to start is AGMAs Product Locator. Its a comprehensive, searchable list of members product and service offerings; the guide also lists all companies and contacts for each product or service offering. Find a link in the middle of the AGMA Home Page. So check out the AGMA Website, sign up for a free newsletter, friend us on Facebook, or just contact Mary Ellen Doran, AGMA Web Communications Manager at [email protected] with your individual questions and stay at the forefront of the gear industry!

Mary Ellen Doran Web Communications Manager American Gear Manufacturers Association P: 703.838.0063 [email protected] JANUARY 2010 19

AGMA Welcomes Its Newest Members

The AGMA membership continues to grow with more than 20 companies joining the Association since the beginning of 2012. AGMA now represents more than 430 companies in 35 countries on six continents.
ACCIONA North America www.acciona-na.com ACCIONAs group of North American companies are subsidiaries of ACCIONA S.A., a company that ranks among the worlds leading sustainabilityfocused businesses centered around renewable energy, infrastructure and water treatment. Acciona is committed to pioneering and developing a lasting foundation of sustainability in the U.S. and Canada. Acciona Windpower North America LLC www.acciona-na.com. CFT A/S www.cft.dk CFT A/S offers a variety of machine tools with or without teeth for the cement and wind turbine industries. Small batch sizes are welcome, but they are also very well trained in high production. CFT A/S processes all materials and offers various subsequent surface and heat treatments. Damen Schelde Gears www.damengears.com Damen Schelde Gears (DSG) is a technology driven company specializing in support, consultancy and problem solving for all technical and commercial aspect of gears and other rotating equipment. DSG has an extensive experience of more than 90 years in the design and production of main propulsion gear for naval and merchant marine applications. Over the years more than 335 naval and merchant ships have been equipped with propulsion gears designs from DSG. Dee-Kay Gears www.deekaygears.com Dee-Kay Gears located in India provides: Bevel Gears, Cooling Tower Components, Cooling Towers, Gear Boxes, Gears, Other, Helical Gears, Mechanical Drives, Steering Gearboxes . Ellwood City Forge www.ellwoodcityforge.com Ellwood City Forge, founded in 1910, manufactures concentric and eccentric contoured forgings and single cross-section products including hollow and disc forgings. Sizes up to 94 inches in diameter, 55 feet in length and 110,000 pounds in weight are available. ECF also makes crankshafts, plastic mold steels, forging die blocks, and a variety of other cus-

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

Online

WebEx

Clearwater Beach, FL

June

AGMA Webinar Series: Analytical Gear Chart Interpretation (Part 2): Solving Manufacturing Problems

19-21 11-13 Gear Failure Analysis

Seminar

Gearbox System Design

July

12

Nomenclature Committee Meeting

Big Sky, MT

20

gearsolutions.com

tom forgings to stringent mechanical property requirements. Gear Consultancy www.gearconsultancy.com Gear Consultancy is a Mumbai based company which carries out consultancy work in the field of gear engineering. Hainbuch America Corporation Workholding Tech www.hainbuch.com Hainbuch is a world leader in the design and manufacturing of extremely precise and exceptionally rigid work holding solutions. Hainbuch specializes in difficult applications yielding exceptional results. High Performance Gear www.hpgear.net High Performance Gear produces transaxles and transmission components for demanding road, race, and marine applications. The company operates a full-service gear manufacturing facility with one-off to production run capacity. IIT Bombay www.iitb.ac.in IIT Bombay, set up by an Act of Parliament, was established in 1958, at Powai, a northern suburb of Mumbai. Today the Institute is recognised as one of the centres of academic excellence in the country. Over the years, there has been dynamic progress at IIT Bombay in all academic and research activities, and a parallel improvement in facilities and infrastructure, to keep it on par with the best institutions in the world. The Lubrizol Corporation www.lubrizol.com The Lubrizol Corporation, a Berkshire Hathaway company, is an innovative specialty chemical company that produces and supplies technologies to customers in the global transportation, indus-

trial and consumer markets. These technologies include lubricant additives for engine oils, other transportation-related fluids and industrial lubricants, as well as fuel additives for gasoline and diesel fuel. In addition, Lubrizol makes ingredients and additives for personal care products and pharmaceuticals; specialty materials, including plastics technology and performance coatings in the form of specialty resins and additives. P .van Der Wegen Gears B.V. www.vanderwegen.com Since 1880 P van der Wegen Gears BV, as a mem. ber of the privately owned PWT-Group, is a World leading designer and manufacturer of open gearsets, gears, gear-boxes, pinions and worm-gears based in Tilburg, The Netherlands. Petron Corporation www.petroncorp.com Petron Corporation of New Berlin, Wisconsin, is a worldwide supplier of quality engineered lubricants. Petron Corporation designs and manufactures a diverse product line that serves the mining, cement, power generation and private label markets. Pizo Technologies Worldwide www.pizotech.com PIZO, an abbreviation for Pig Iron and Zinc Oxide, continuously manufactures three commercially saleable products, including: crude zinc oxide (CZO), pig iron and slag. The dusts and by-products that are 100% reused by PIZO, have historically been processed for land disposal or partially recycled by the steel industry or offsite vendors. Reich USA Corporation www.reichusa.com The Reich USA Corporation is a wholly owned subsidiary of the Reich-Kupplungen company of Bochum Germany. For more than 65 years, ReichKupplungen has produced torsionally flexible couplings at their manufacturing facilities.

Slone Gear International www.slonegear.com Slone Gear International is focused on providing gear component sourcing, gaging and production solutions. Their products include spline gages/master gears, functional gear roll testers, roundness measurement systems, work holding/ arbors, gear/spline cutters and production machines. Walchandnager Industries Limited www.walchand.com Walchandnagar Industries Limited, PUNE, an ISO 9001: 2008 certified Indian company with global presence and diversified business portfolio in Projects, Products & High-tech Manufacturing. They are closely associated with the design, manufacture and supply of gear boxes for various programs of the Indian Navy for Leander class Frigates, Survey Vessels, Aircraft Carrier, Corvette class vessels, Fleet tankers etc. with horse power up to 24000 hp. Western Precision Aero LLC www.westernprecisionaero.com Western Precision Aero is an independently owned small business dedicated to providing high quality components and assemblies to the Aerospace, Defense, and Automotive industries. ZF Wind Power Antwerpen NV www.zf.com/windpower Manufactures gear units and industrial transmissions. The Companys products are used in water treatment, material handling, mixers, cooling towers, paper and pulp mills, and wind generators. To find out more about these companies, visit their websites. To find out more about AGMA and how membership can benefit your company, visit www.agma.org or e-mail membership@ agma.org.

26 Committee Meeting Spline

August

8-9 Drives for Industrial Enclosed

Applications Committee Meeting

16 Gearing Committee Vehicle

Meeting

WebEx

WebEx

WebEx

Available Year-Round force Education

Online Work-

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

21

Learn How to Avoid Gear Failures

The ever-popular Gear Failure Analysis seminar will hold its last face-to-face offering of 2012 September 17-19, in Big Sky, Montana. Gear Failure Analysis gives participants skills necessary to diagnose gear failures and prescribe remedies. The seminar covers six classes of gear tooth failure: overload, bending fatigue, hertzian fatigue, wear, scuffing, and cracking. Each failure mode is illustrated by color slides and field samples of failed gears. Students will receive a full color course manual that includes copies of text slides, Gear & Bearing Failure Analysis A textbook for the gear and bearing failure analyst, Gear Failure Atlas, and several relevant reference papers. For more than 20 years, Robert Errichello has been teaching this course staying current with the issues of the day for AGMA. More than 1,200 students have saved their companies millions of dollars by utilizing the information they have learned. This course is offered in Big Sky two times each year, but it is also available as a 10-hour online course. The online course was taped during a classroom offering of this course and provides the same great information, course manual, and other valuable materials. Both classroom and online students receive a certificate of completion for this seminar upon successful completion of the exam. Robert Errichello heads his own gear consulting firm, GEARTECH, and is founder of GEARTECH Software, Inc. He is a registered professional engineer who holds bachelors and masters degrees in mechanical engineering, and a master of engineering degree in structural dynamics from the University of California at Berkeley. He helped to introduce the Worlds first gearing standard for wind turbines and is very active in AGMA standards development and nomenclature. He has extensive teaching experience and has taught college courses on machine design, fracture mechanics, vibration, and material science. To register, visit www.agma.org or contact Jan Alfieri, education manager, AGMA at 703-684-0211 or email [email protected].

AGMA Leadership
Board of Directors
norbert Benik: VP of industrial sales, ontario drive & Gear, ltd. Dean Burrows, President, nixon Gear Sulaiman Jamal: Managing director of bevel Gears (india) Private limited Steve Janke, President, brelie Gear co., inc. Jan Klingelnberg, ceo, Klingelnberg Group tom Marino: President & ceo, Gear technology Mark Michaud, president, ReM surface engineering Gordon new: Managing director, Ronson Gears Pty, ltd. Bob Sakuta: President, delta Gear 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

22

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

1001 n. Fairfax street | Fifth Floor alexandria, Va 22314-1587 (703) 684-0211

www.agma.org gearsolutions.com

SHIFT YOUR AUTOMOTIVE GEAR PRODUCTION INTO OVERDRIVE

The race is on for quieter, smoother, more dependable automotive transmission gears. Only Gleason provides the complete array of solutions, including hobbing of gears and shafts with integrated chamfering and deburring, shaping, shaving, threaded wheel grinding, honing and inspection. Ready to leave your competition behind? Download our White Paper at:
See us at Booth #N7000

www.gleason.com/autogears

SOFT PROCESSING, HARD FINISHING, AND INSPECTION OF GEARS AND SHAFTS UP TO 300 mm For worldwide sales locations and additional information, visit:

www.gleason.com [email protected]

SITESAFETY
terryMcDonALD
Member of the ANSI Subcommittee on Gear Safety

Thanks to workplace plans and OSHA rules and regulations, deaths and injuries have dropped 60 percent in the past 40 years.
I was talkIng to a frIend the other day who works in manufacturing for a decent sized company. He was complaining that his employer is no longer buying the steel-toed safety shoes he and his coworkers wear for their jobs. Because they are struggling financially, the company told us we could either buy our own boots or go without, he said. My boots are as important to me in my work as a fall-protection harness is to someone working on top of a building. Boots have been provided each year to all employees working in dangerous conditions. Why was it important enough for them to buy boots in the past, but not now? Of course knowing a little about this company and the situation they are in, I have some background. This company has historically purchased safety boots for its workers in certain departments. Because they traditionally paid this expense, they created an expectation with workers that this would be paid in the future. This company also provides work pants and shirts for field workers. In other words, by creating a belief among employees that safety boots were part of the uniform and important equipment to certain jobs, the company instilled this value with its employees. The workers still think the boots are important. As a matter-of-fact they know they are important. It only takes one worker to rip his foot apart by stepping on a sharp metal stake to know its important. It only takes one broken foot when a steel beam falls to know that the safety boot would have prevented that injury. As more companies tighten their belts and try to find ways to cut expenses, some are finding ways to avoid providing basic safety prevention and protection equipment at the expense of their employees and their companys reputation. Maybe steel-toed boots arent important in your line of work, but what if you showed up to your job one day where you handle chemicals that should not be inhaled and the supervisor told you that because of budget constraints, the company could no longer afford to provide respirators for its workers? You can buy a respirator for yourself if you think you need one, but we just cant afford to get one for you. Of course in this modern day, we assume Federal workplace safety standards will prevent this from happening to us, but we all know that some people operate on the Act first / Get permission later mentality. Lets hope none of you are in this situation. In every industry, we hear grumblings about Big Brother and how the laws and regulations enforced by the Occupational

Safety Health Agency (OSHA) is expensive and meddlesome. The other side of that argument is that OSHA rules make the workplace safer for everyone and rules and regulations are necessary for those companies that would not otherwise choose to protect their own people. One thing is certain; people are much safer on their jobs today than they were 40 or 50 years ago before OSHA was signed into law. Workplace injuries and deaths have dropped 60 percent since OSHA was created, thanks in part to employees who care enough to demand a safe place to work and employers who listen and understand that keeping their employees safe is not only the responsible thing to do, but also the financially prudent thing to do.

My boots are as important to me in my work as a fallprotection harness is to someone working on top of a building.
Take a look around your jobsite and see if your safety program needs to be updated. Every worksite is different so the plan you create may be totally different from the one the business next door creates for its employees. To give you an idea of the types of areas you should address, consider this list of the Top 10 Most Frequently Cited Standards reported by OSHA in 2011. The list from 1 to 10: Scaffolding Fall protection Hazard communication Respiratory protection Lockout/Tagout Electrical, wiring methods Powered industrial trucks Ladders (construction) Electrical, General requirements Machine guarding

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, [email protected], or [www.repairpartsinc.com].

As you can see, injuries can happen in many industries and in many different ways, but with proper planning, training and equipment, most injuries and deaths can be avoided.

24

gearsolutions.com

CrItICal to a gear's operatIon is the lubrication type and method of application. Lubrication is a science and for new applications consulting with the supplier/ manufacturer is advisable. As we are all aware, gear tooth meshing action subjects the tooth flank contacting surfaces to destructive damage. Lubrication should alleviate this damage, improve the efficiencies and dissipate the heat. These surfaces that are subject to friction, even when properly lubricated, can generate enough heat to raise the temperature of any high spots beyond their melting point. Under a number of different conditions, lubrication should slow and even prevent this deterioration. Assisting the work of the lubrication is the selection and treatment of the gears material, including the geometry of the teeth, surface finish, and application of the lubricant in the correct quantity and location. The lubrication film thickness must reduce the possibility of service failure from scuffing, tooth flank fatigue failure, micropitting and pitting in and of itself. The lubricants function is to reduce the frictional resistance and thereby improve efficiency, and as a consequence, generate less heat. It is now several decades since the common belief was that just adding oil or grease between the mating surfaces would bring about the desired result. The Exxon Company lists three Ps as the challenge for industrial lubricants Performance, Protection, and Prevention. When the friction is reduced there will be a corresponding reduction in the wear rate, and corrosion, scoring and welding, and an improvement in oxidation resistance. In an enclosed gear system it is also essential to promote the rheology of air and provide resistance to water contamination. An enclosed gear unit is constantly breathing in the surrounding atmosphere and then expelling it, leaving moisture behind along with oxidation. With the exception of hypoid gears, all other gear teeth have pure rolling contact at the pitch line, and in all other positions, a sliding action. Hypoids have some sliding even at the pitch line and their early introduction was hindered by the lack of a suitable lubricant. Conditions and the type of tooth form affect the lubricant selection, including the pitch velocities, the loads, ambient and operating temperatures, humidity, oil change periods, and compatibility of seals and paints. In the theory of lubrication between any two surfaces that have relative motion there exists either a thick film (hydrodynamic) or thin film (boundary). The former is associated with the sliding action. Elasto-hydrodynamic is the term associated with a films thickness present with rolling action. Rheology is the term for the study of a lubricants flow, deformation, and its viscosity. The theory considers four

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

williamCrosher

Proper lubrication reduces frictional resistance and heat and thus improves the gear efficiency.
conditions that can exist at the point of contact between two mating surfaces. These are hydrodynamic, elastohydrodynamic (EHD or EHL), Boundary, and Quasihydrodynamic. In the first condition the oil film is thicker than the roughness. The contact stress does not significantly deform the contacting surfaces. In the second condition the oil film is considered to be the same thickness as the roughness of the two surfaces. In the contact zone elastic deformation takes place with high-speed gears, this must be taken into consideration. The EHD film is the result of the elastic deformation of the surfaces and the lubricants hydrodynamic action. The third condition boundary is the most complex. This is the thin film in which surface to surface contact takes place. There are five classes of boundary lubricants and they include polar and Extreme Pressure. In the EP a boundary film is formed by the chemical reaction between the anti scuff additives and the metal surfaces. This condition is frequently found when the gears are open and slow running. The film thickness may be less than the surface roughness. The film must withstand greater mechanical stress and higher temperatures than the bearings. The last condition is a transition stage between boundary and EHD conditions. The surface-to-surface contact increases with the film thickness reduction. The accepted Bloks Contact Temperature Theory states: Scuffing will occur in gear teeth that are sliding under boundary-lubricated conditions when the maximum contact temperature of the gear teeth reach a critical magnitude. Tests have concluded that it is more important for the lubricant film to minimize the generation of heat -- thereby reducing the lubricants temperature rise -- than selecting a lubricant for its potential in heat removal. The lubricant film thickness and temperature will determine the effectiveness of the lubrication. Gear teeth function in three temperature zones. They start in an ambient condition that continues to rise from the friction until a steady state is reached. At this level the heat entering the gear equates with the heat leaving the gear. The distribution of the heat is affected by the lubrication. We have contact and bulk temperature; the latter is calculated at the contact points along the contact path. It is the temperature that is considered to be in equilibrium attained by the gear teeth prior to entering the mesh, and it can be significantly higher than the lubricant. During the meshing, each tooth face will experience a sudden temperature rise, and 80 degrees F is not unusual. The temperature is restricted to the immediate contact area, so almost immediately the temperature is dissipated into the gear and is known as the Flash temperature.

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.

JUNE 2012

25

HOTSEAT
jacktitus
Director of process and developmental engineering, AFC-Holcroft

Shallow case hardening in mesh belt and cast link belt furnaces is acceptable for small gears, shafts, screws and nuts when fixturing is not required.
Images of pushers are the lIkely style that comes to mind when people first think of continuous furnaces. When deep case and fixtured quenching is required pushers are the system of choice, but not all case hardened gears or other drivetrain parts require the same treatment. Small gears, shafts, screws, nuts, anything that does not need fixturing, can be shallow case hardened in mesh belt and cast link belt furnaces. The style, mesh belt or cast-link depends on the part weight and production rate; loading or pounds per square foot of belt area dictates which style is more appropriate. The accepted criteria for loading in mesh belts cannot exceed about 15 to 20 pounds per square foot, beyond that cast belt is the option when processing larger parts. Although both conveyor systems discharge parts to the quench the same way, loading the belts can be completely different. Mesh belt furnaces by their design have the belts charge end outside of the hot zone so parts can be manually or automatically placed on the belt. How parts are placed, their orientation on the belt, in large part dictates the quenched distortion result. Cast belt furnaces requiring a protective and controlled atmosphere like that for case hardening, due to the belt design have the charge end of the belt enclosed within the hot zone necessitating a different loading method, that eliminates the manual loading option. Some cast belt furnaces where the atmosphere is meant to reduce oxygen only, have their charge end belt outside of the hot zone to facilitate more critical loading. Generally speaking conveyor furnaces have seen greater acceptance in the fastener industry where small parts can be automatically loaded via vibratory feeders that distribute parts evenly across the belt width. Heavier parts, gear blank forgings and castings are routinely normalized in cast link belt furnaces where no or little atmosphere is required and the load end is outside of the hot zone where parts are dumped into waiting tubs. There is one major caution when dealing with mesh or cast belt furnaces: Make sure no debris such as metal chips or other fine material like sand can get to the belt. Its not so much an issue for fine weave belts but particles can get lodged in the cast belt links causing excessive wear, and worse, the debris can occupy the space between the link shoe and the cross rod.

aBOut tHE autHOr:

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

All cast link belts rely on a certain amount of tolerance between the cross rods and the link shoe so the belt has freedom to move around the drive rolls and take-up rolls providing a catenary between the lower support rolls. When the tolerance space is removed by debris the belt is no longer allowed to form around the radiuses and tensile stresses are magnified leading to belt and drive roll failure. Three primary quench media for either furnace is oil, polymer and salt for martemperting and austempering. As for the case hardening process there are three areas the heat treater must take care for: loading density, atmosphere control and quench tank drop depth. Loading density can be troublesome because the nature of conveyor furnaces is that the parts must reach the appropriate austenite soak time before quenching, allowing for belt speed. If the part loading is too dense some parts will miss the expected hardness. Likewise if shallow case carburizing is the desire, small, densely loaded parts may risk lean case depth. But the most problematic area is quenching; most notably in the drop depth. Case hardening in batch or pusher furnaces where parts are submerged in agitated media for a given time allow martensite transformation. In conveyor furnaces parts fall off the end of the belt and free fall through the fluid to the quench conveyor. Some agitation is directed at the parts as they lay on the quench conveyor but if the parts have not started transforming to martensite prior to hitting the belt theres no guarantee they will while resting on the belt. To avoid bainite and other NMTP a simple test (for a well-equipped maintenance department) can be conducted to determine if theres a problem. You need a 6-inch diameter clear plastic pipe about 6 feet long sealed with a plumbers plug on one end and filled with clean water. Supported vertically, obviously, heat one part with a welders torch held on a steel pan to red then orange. When hot enough allow the part to fall through the water and observe the color of the part as it reaches the bottom. If you can still see color this works better in a darkened area theres no way the part will form martensite especially in oil. If you really want to get a more accurate test, lengthen the plastic pipe and repeat. This test can be conducted with small gears or screws by heating a cup full and dumping the whole bunch into the water; a slug of parts falling through the water will cool slower than a few parts due to the localized vapor formed as the parts fall through the water. If youre lucky enough to have clear quench oil use that. Dont try this at home.

26

gearsolutions.com

Ipsens ATLAS integral quench furnaces are highly engineered, sophisticated machines that are easy to operate and maintain, all while being extremely cost effective. ATLAS delivers top quality uniformity through cutting-edge technology and design: Intelligent controls, Carb-o-Prof, provide you with your very own electronic metallurgist SuperQuench with adjustable oil speed and four 40HP agitators Muffle system for uniform temperature control Safety all ATLAS furnaces are water-free for maximum safety 30% less gas consumption Recon burners single ended recuperated tubes (SERT)

The unique HybridCarb gassing system 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%. Other benefits of HybridCarb include: Quick and easy hookup Increased carburizing efficiency Reduces CO2 emissions by 90% Significantly less expensive to operate than endogenerators Consumes significantly less gas Environmentally friendly and cost efficient Lowers heat output creating a more comfortable work environment Powers up and down at anytime, quickly and easily

For more information please visit www.IpsenUSA.com

www.IpsenUSA.com

SPEED UNIFORMITY EFFICIENCY

Ontario Drive & gears

this company provides a one-stop powertrain solution from gear and system designs to transmission assembly and performance testing.
By Sherri Mabry

COMPANY P rOFile

28

gearsolutions.com

Whether providing solutions for transmission assemblies or individual components, Ontario Drive and Gear Ltd. (ODG) has the ability to develop, prototype and manufacture to meet its customer needs. Celebrating its 50th anniversary this year, Joel Wright, general manager of ODG, says, 50 years is a major accomplishment and a cornerstone to the companys historical contributions. Founded in 1962 in Kitchener, Ontario, ODG is a subsidiary of a German company. It started out as a machine shop manufacturing gears. It grew into making transmissions for all-terrain vehicles. By 1967 ODG decided to build its own vehicle, and hence the ARGO was born. Today the ARGO is the world leader in amphibious vehicles and can be found in the most extreme conditions in applications such as exploration, search and rescue, industrial, hunting and recreational applications. ARGO is even busy working on a space rover, that one day will hopefully travel to Mars. ODG as a corporation is divided into two business units, the Vehicle and the Gear division. In the early years both divisions were under one roof and all the ODG gear capacity went into the ARGO. In 1985 a strategic decision was made to look for other external customers that fit in a similar manufacturing niche as the ARGO. Today ODG Gear boasts sales of $25M, with 115 employees in a stand-alone 60,000 sq. ft. state of the art facility. The ARGO taught us how to make a dependable bullet proof transmission. With the ARGO and where it goes, there is simply no room for failure. Today ARGO represents only 20 percent of the ODG Gear capacity. ODG Gear manufactures over 850 different SKUs on a reoccurring basis. It is a high quality, high mix, low volume machine shop, says Wright. Weve invested significantly in the last five years, spending over $10 million on the latest technology. Customers are always impressed with our gear hobbing, shaping and grinding capabilities. ODGs core competencies go beyond just gear manufacturing. The company offers a one-stop power-train solution by offering gear and systems design, transmission assembly and performance testing. We are uniquely positioned for a job shop. Very few gear manufacturers can say they design, manufacture, assemble and test. Better yet we can offer this in a low volume, niche market. We saw a market need for the one stop solution. Especially when everyone came out of this last recession only the large OEMs had the resources and gear expertise to design transmissions. Many other OEMs do not understand the nuances of gear design and those that did, cut back in these areas of gear engineering. ODG has the capabilities to optimize a given gear set. Often we are asked how to make a gear quiet or how to improve a gears loading carrying capabilities. ODG uses many advanced engineering design methods such as

FEA and Ohio State GearLab LDP. ODG design capabilities go as far as being able to offer black box systems capability. Give us the input, the output and the size and we can design gears and transmission for any application. As a result, ODG Gear serves customers in North America and around the world. Recently ODG has begun to brand its products with a Geared by ODG. ODG is in many products in the industrial, material handling, off-highway, agriculture, military, construction, and allterrain vehicle sectors. Our top 10 customers are in 10 different markets, added Norbert Benik, VP of Sales. Many of our customers are household names that people recognize. It is a feather in our cap to be associated with such companies and to know they all are geared by ODG. Another major undertaking was the adoption and application of lean manufacturing principles. Today we are the house of lean Wright said. We built a foundation of employee training, maintenance excellence,

Weve invested significantly in the last five years, spending over $10 million on the latest technology. Customers are always impressed with our gear hobbing, shaping and grinding capabilities.
5S workplace organization and, employee engagement. We followed up with a standardized problem solving technique using A3 problem solving. This gave us built in quality and just in time delivery. This ultimately lets us offer our customers the fastest process, at the highest quality and the lowest cost. Its all kind of a metamorphosis of where weve been and where we are headed. Weve come full circle. We started as a gear machine shop, built an ARGO business and once again were known as a world-class gear manufacturer. It has taken 50 years and we are proud to say we are doing well. To celebrate their 50th Anniversary, ODG is planning a three-day event, which will include tours of the facility, a golf tournament, media and supplier functions, a formal dinner and a family day for the employees and the community.

tO lEarn MOrE:
See www.odg.com or www.argoutv.com, or call 519-662-2840.

Oil Additives Can Prevent Micropitting

Using advanced additive technologies during the oil change helps gears build new reaction layers on surface of tooth flanks.
By Michael Hochman and Herman Siebert

M
MiCropitting geAr FAiLure
Micropitting is a type of fatigue failure occurring on hardened tooth flanks of highly loaded gears. This failure consists of very small cracks and pores on the surface of tooth flanks. Micropitting looks greyish and causes material loss and a change in the profile form of the tooth flanks, which can lead to pitting and breakdown of the gears. A typical micropitting gear failure of an industrial gearbox is shown in Fig. 2. In this case, misalignment was the reason for micropitting formation. In modern gearboxes, the gears are often highly loaded and run under conditions of mixed lubrication. In this case, the tooth flanks of the mating gears are not fully separated by the lubricant film and the additives of the lubricant have to protect the tooth flanks against micropitting formation.

MICROPITTING FORMATION IS OFTEN REPORTED TO OCCUR IN FIELD APPLICATIONS EVEN THOUGH INDUSTRIAL GEAR OILS WITH A HIGH MICROPITTING LOAD-CARRYING CAPACITY ARE USED, SUCH OILS OFFER GOOD MICROPITTING PROTECTION DETERMINED IN THE LOAD STAGE TEST OF THE MICROPITTING TEST ACCORDING TO FVA 54/7 [5], BUT SHOW A LOW ENDURANCE MICROPITTING PERFORMANCE. THEREFORE, THE POSSIBILITY OF STOPPING MICROPITTING FORMATION, WHICH OCCURRED WITH THESE GEAR OILS, WAS INVESTIGATED BY USING HIGHPERFORMANCE GEAR OILS. DUE TO ADVANCED ADDITIVE TECHNOLOGIES, THESE HIGH-PERFORMANCE GEAR OILS SHOW A HIGH MICROPITTING LOAD-CARRYING CAPACITY IN THE MICROPITTING LOAD STAGE TEST AS WELL AS A HIGH ENDURANCE MICROPITTING PERFORMANCE. THE FORMATION OF MICROPITTING DEPENDS ON DIFFERENT INFLUENCES. BESIDES MATERIAL, SURFACE ROUGHNESS, AND GEOMETRY OF THE TOOTH FLANKS, IT IS THE LUBRICANT AND THE OPERATING CONDITIONS WHICH HAVE A MAJOR INFLUENCE ON MICROPITTING FORMATION. SEE TABLE 1.
For this purpose, the specific lubricant film thickness of a practical gear is compared with a minimum required specific lubricant film thickness. The latter is the specific film thickness where no micropitting risk is given for a lubricant and can be determined by performing a micropitting test according to FVA 54/7 [5]. first test gears, the load stage test is repeated with new test gears to check repeatability. After each test period, the test

stAnDArD MiCropitting test

The micropitting test according to FVA 54/7 [5] consists of a load stage test and an endurance test. Test gears type C-GF run at a circumferential speed of 8.3 m/s and a lubricant temperature of 90C or 60C. The load and the test periods are varied. In the load stage test, the load is increased stepwise from load stage LS 5 to load stage LS 10 with a running time of 16 h per load stage. After the load stage test, an endurance test with a running time of 80 h in load stage LS 8 and 5 x 80 h in load stage LS 10 is performed. The pinion torque and the corresponding Hertzian pressure of the different load stages are given in Table 2. At the end of the load stage test and the endurance test with the

Fig. 1: Shows typical limits of the load-carrying capacity for case hardened gears according to Niemann [7].

MiCopitting LoADCArrying CApACity

The micropitting load-carrying capacity of gears can be calculated according to ISO TR 15144-1 [4], where the influence of lubricant, operating conditions, and surface roughness is considered with the specific lubricant film thickness.

Fig. 2: Micropitting gear failure of an industrial gearbox. 31

JUNE 2012

HOBs FOr invOlute sPline din 5482

Complete line of Gear Tooling. Cutter Body Reconditioning to O.E.M. Specifications and Cutter Body Maintenance Program. Resharpening and Recoating Service, Hobs and Shapers.
BlAde sets FOr sPirAl & HyPOid GeArs

NeW and reCONDiTiONeD CUTTer BODieS for sale.

HuB tyPe GeAr sHAPer Cutter

Same O.e.m. Quality, great Low Prices.

Bell tyPe GeAr sHAPer Cutter

ETC
engineeredtools.com
engineered tools Corporation

engineered Tools Corporation 2710 West caro rd., caro, Mi 48723 PH: (989) 673-8733 FAX: (989) 673-5886 engineered Tools Corporation 1307 E. Maple rd., Suite G, troy, Mi 48083 PH: (248) 619-1616 FAX: (248) 619-1717

gears are disassembled and the profile of the tested flanks is measured using a 3D measurement system. In the load stage test, the failure criterion has been reached if the mean profile form deviation due to micropitting exceeds the limiting value of 7.5 m. The load stage in which the failure criterion is reached is called failure load stage. An overview regarding the classification of test results obtained in the micropitting test is given in Table 3. Lubricants with a high micropitting loadcarrying capacity reach the failure criterion of a profile form deviation of 7.5 m due to micropitting in load stage >= LS 10 of the load stage test. Examples for the evaluation of the micropitting test are given in Fig. 3 and Fig. 4. In the endurance test, a stagnation of micropitting formation compared with the micropitting area at the end of the load stage test is preferred but not required. For high-performance gear oil on the basis of polyglycol with a high micropitting performance, a typical test result is given

Fig. 3: Pinion type C-GF with measurement of the profile, nearly no micropitting failure.

Fig. 4: Pinion type C-GF with measurement of the profile, micropitting failure in the range of the failure criterion.
in Fig. 5 showing the profile form deviation due to micropitting. The profile form deviation of the pinion is below the failure criterion for the whole load stage test. In the endurance test, the profile form deviation stagnates compared with the step test.

34

gearsolutions.com

test as well as a high endurance performance can stop micropitting formation. The oil temperature is set to 60 degrees C. compared to an oil temperature of 90 degrees C, the lubricant film thickness in the gear mesh is higher, but the formation of a reaction layer on the tooth flank surfaces is more difficult. The latter is more critical regarding the formation of micropitting.

bACk-to-bACk geAr test rig

Fig. 5: Micropitting test of high-performance gear oil (polyglycol), measurement of the profile form deviation.

MoDiFiCAtion oF the stAnDArD MiCropitting test

The aim of research is whether changing from oils with low endurance micropitting performance to oil with high endurance micropitting performance can stop micropitting formation. Therefore the standard micropitting test according to FVA 54/7

[5] was modified. For oil with a high micropitting load-carrying capacity, but low endurance performance, a load stage test and an endurance test are performed with the first test gears. After the repeated load stage test with new test gears, an oil change is made. The subsequent endurance test is conducted to find out whether a product with a high micropitting load-carrying capacity in the load stage

Could using high-performance gear oils on a FZG back-to-back gear test rig stop micropitting? [3]. The schematic setup of the FZG back-to-back gear test rig is shown in Fig. 6. The FZG back-to-back gear test rig utilizes a re-circulating power loop principle, also known as a foursquare configuration, in order to provide a fixed torque (load) to a pair of test gears. The test gearbox and drive gearbox are connected with two torsion shafts. One shaft is divided into two parts and contains a load coupling

Innovation For Your Gear Business...

Coming to IMTS Fall 2012 - Booth # N-6133 Stay Tuned...

Phone: (937) 667-4451

Email: [email protected]

Website: www.peco-us.com

Address: 6555 South State Route 202, Tipp City Ohio, 45371

JUNE 2012

35

Fig. 7: Stopping micropitting by using a high-performance gear oil (mineral oil). Fig. 6: FZG back-to-back gear test rig.
used to apply the torque (load) through the use of weights hung on the loading arm. A separate oil aggregate contains heating and cooling elements to control the oil temperature as required by the operating test conditions. Before the oil is injected into the gear mesh of the test gears, it is filtered with a 10m filter. In order to investigate if micropitting can be stopped, test gears type C-GF of the standard micropitting test according to FVA 54/7 [5] are used. The geometrical data and manufacturing details of the test gears type C-GF are shown in Table 4 and Table 5. of micropitting formation in the endurance test according to FVA 54/7 [5] by selection of advanced additive technologies. See also Fig. 5. These industrial gear oils show excellent micropitting protection not only at an oil temperature of 90C, but also at a lower oil temperature of 60C, and the advanced additive technologies can react on the surface of the tooth flanks and protect them against micropitting formation.

LubriCAnts testeD
A specialty lubricant manufacturers goal is to supply industrial gear oils on the basis of mineral oil, polyalphaolefin, or polyglycol showing a high micropitting load-carrying capacity of failure load stage >= LS 10 in the load stage test as well as a stagnation

GEARING AHEAD TO MEET INDUSTRY'S DEMAND FOR PRECISION

--Serving-Aircraft Aerospace Actuation Instrumentation Optic Robotics Radar Medical Marine Defense Experimental Prototype Production Hi-Performance Automotive

Precision Gear Products (up to AGMA Q14): Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, Clutch Gears, Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, Bevel Gears, Miter Gears, Metric Gears, Internal Gears, Idler Gears, Gear Rack & Pinion, Worms, Wormshafts, Splines, Spline Shafts, Serrated Shafts.

STD Precision Gear & Instrument, Inc.

318 Manley St. Unit 5 West Bridgewater, MA 02379 (888) STD-GEAR or (508) 580-0035 Fax (888) FAX-4STD or (508) 580-0071 E-mail [email protected] Web site: www.stdgear.com

36

gearsolutions.com

Fig. 8: Stopping micropitting by using a high-performance gear oil (polyalphaolefin).

Additionally, the tests questioned whether micropitting formation occurred with other gear oils and whether changing to high-performance gear oils can stop micropitting. The oil data of the tested gear oils are shown in Table 6 and Table 7. Both the high-performance gear oils and the reference oil are of ISO VG 320 and possess a high micropitting load-carrying capacity according to FVA 54/7. All tested gear oils are specified according to DIN 51517 [2], which includes the minimum requirements for industrial gear oils and is similar to AGMA 9005 [1]. For the reference oil, the micropitting load-carrying capacity was only tested at an oil temperature of 60C because at this oil temperature, it was to be investigated if micropitting formation can be stopped. See also Fig. 7 to Fig.1 9. 12-04-03 3:12 PM ODG-more than gears.pdf

Fig. 9: Stopping micropitting by using a high-performance gear oil (polyglycol).

Table 1: Influences on the micropitting load-carrying capacity.

DESIGNMANUFACTUREASSEMBLETEST

CM

MY

CY

CMY

More than just gear cutting

Specializing in "Black Box" Transmission Design and Assembly
Ontario Drive & Gear Limited New Hamburg, ON, Canada 1.888.662.2840 www.ODG.com
JUNE 2012 37

Table 2: Load stages of the micropitting test.

Description Low micropitting load--carrying capacity Medium micropitting load-carrying capacity High micropitting load-carrying capacity Failure load stage LS 7 LS 8 -- LS 9 LS 10 Micropitted area Sometimes more than 50% About 30% Less than 20% GF- class GFT--low GFT--medium GFT--high

Table 3: Classification of test results of the micropitting test.

For reference oil with a high micropitting load-carrying capacity, but low endurance performance, a load stage test and an endurance test were performed with the first test gears according to FVA 54/7 [5]. The reference oil always showed the test result GFThigh at the end of the load stage test. But in the subsequent endurance test, micropitting formation increased. The endurance test was finished due to pitting formation. Then the load stage test was repeated for the reference oil using new test gears. All repeated test runs of the reference oil showed a good repeatability compared with the first load stage test of this oil. See Fig. 7, Fig. 8, and Fig. 9.

After the repeated load stage test for the reference oil, an oil change to highperformance gear oil on basis of mineral oil with a high micropitting load-carrying capacity as well as a high endurance micropitting performance was conducted. This oil change to a high-performance mineral gear oil using advanced additive technologies stopped micropitting formation compared with the reference oil. This shows that these advanced additive technologies can react at the surface of the tooth flanks after an oil change and build up a new improved reaction layer. Further micropitting formation was stopped and the micropitting area stagnated. See Fig. 7. The oil change to high-performance gear oil on the basis of polyalphaolefin with a high micropitting load-carrying capacity as well as a high endurance micropitting performance can also stop the micropitting formation compared with the reference oil. The reason for the stagnation of the micropitting areas are, again, the advanced additive technologies in this high-performance polyalphaolefin gear oil. Even after an oil change, these advanced addi-

38

gearsolutions.com

area, which occurred with other gear oils, stagnates after changeover to high-performance gear oils. Therefore, these high-performance gear oils are strongly recommended to stop micropitting formation in field applications.

reFerenCes:
1) AGMA 9005-E02: Industrial gear lubrication, 2002 2) DIN 51517-3: Schmierstoffe Schmierle Teil 3: Schmierle CLP; Minderstanforderungen, 2009 3) ISO 14635-1: Gears FZG test procedures Part 1: FZG test method A/8.3/90 for relative scuffing load-carrying capacity of oils, 2000. 4) ISO TR 15144-1: Calculation of micropitting load capacity of cylindrical spur and helical gears Part 1: Introduction and basic principles, 2010 5) FVA 54/7: Test procedure for the investigation of the micro-pitting capacity of gear lubricants, FVA information sheet, Forschungsvereinigung Antriebstechnik e.V., 1993 6) Gregorius H.: Verzahnungsschden an Getrieben Ursachen, Schadensbilder, Abhilfe, Tribologie-Kolloquium, TZN Technologiezentrum Niederrhein, 2006 7) Niemann G.: Maschinenelemente, Band 2: Getriebe allgemein, Zahnradgetriebe Grundlagen, Stirnradgetriebe, Springer Verlag, 2003

Table 4: Geometrical data of the test gears type C-GF.

Table 5: Manufacturing details of the test gears type C-GF.

Table 6: Oil data of the reference oil.

aBOut tHE autHOrS:

Michael Hochmann is Manager Application Engineering Marketing and Technology KLBER LUBRICATION MNCHEN. Contact him at +49-8978 76 621 or visit www.klueber.com. Hermann Siebert is Head of Application Engineering Marketing and Technology with KLBER LUBRICATION MNCHEN KG Geisenhausenerstrae. Contact him by phone at +49-89-78 76 713 ,or email [email protected].

Table 7: Oil data of the high-performance gear oils.

tive technologies can react at the surface of the tooth flanks and build up a new improved reaction layer. See Fig. 8. Finally, also high-performance gear oil on the basis of polyglycol with a high micropitting load-carrying capacity as well as a high endurance micropitting performance can stop micropitting formation after an oil change compared with the reference oil due to the advanced additive technologies. See Fig. 9. All endurance tests for the high-performance gear oils on the basis of mineral oil, polyalphaolefin, and polyglycol were stopped after the same running time as the reference oil but without any pitting formation. High-performance gear oils on the basis of mineral oil, polyalphaolefin, or polyglycol show a high micropitting load-carrying capacity of failure load stage >= LS 10 in the load stage test as well as a stagnation of micropitting formation in the endurance test according to FVA 54/7 [5] by selection of advanced additive technologies. The new test results showed that highperformance gear oils using advanced additive technologies can react at the surface of the tooth flanks after an oil change and stop further micropitting formation. The micropitting

acKnOWlEDGMEntS:
Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, 5th Floor, Alexandria, Virginia 22314. Statements presented in this paper are those of the Authors and may not represent the position or opinion of the American Gear Manufacturers Association. JUNE 2012 39

Big Gear Inspection is Booming

A recent expansion and investment in a precision gear inspection system is helping this Wisconsin company meet customer needs for high quality, fast delivery, and quality control.
By Michael Hayes

N
one stop shop

NORTHERN WISCONSINS MERIT GEAR IS BAGGING MORE BIG GEAR BUSINESS FROM SURGING

ENERGY, MINING, CONSTRUCTION AND TRANSPORTATION INDUSTRIES WITH THE HELP OF ITS GLEASON 3000GMM SERIES ANALYTICAL GEAR INSPECTION SYSTEM. IF YOU THINK RURAL NORTH CENTRAL WISCONSIN IS AN UNLIKELY PLACE TO FIND A WORLDCLASS GEAR PRODUCTION FACILITY THEN GUESS AGAIN. THE 116,000 SQ. FT. FACTORY AND 123 EMPLOYEES OF ANTIGO, WISCONSINS MERIT GEAR HAVE NEVER BEEN BUSIER, RUNNING AROUND

THE CLOCK, SIX DAYS A WEEK TO KEEP PACE WITH THE DEMAND FOR SPUR AND HELICAL GEARING BIG GEAR BUSINESS IS BOOMING, DESPITE A LOCATION MORE CONDUCIVE TO TROPHY SIZED

AS LARGE AS 3,500 MM IN DIAMETER, WITH QUALITY LEVELS AS HIGH AS AGMA 15. DEER AND MUSKIE, SAYS MERIT GEARS PRESIDENT AND CEO THOMAS ROUSE. BACK IN 1951

OUR TWO FOUNDERS CAME HERE LOOKING FOR GOOD HUNTING AND FISHING, SAYS ROUSE.

They put down roots and soon found that the north woods can be fertile ground for gear production too. Sixty years later, weve recently completed investment in a precision large gear plant expansion thats helping us land new customers requiring production of the highest quality gears and gearboxes for everything from wind turbines to oil well drilling rigs; rail cars to electric mining shovels.

the Gleason 3000GMM gear inspection system all under one roof are critical to achieving both.

trust, but veriFy

While Merit Gears large gear production expansion included two new large profile grinding machines with on-board inspection, it was clear to Merit Gear Quality Manager, Carl Kakes, that this alone would not be sufficient to meet the quality verification standards of many, if not all, of Merit Gears fast expanding large gear customer base. This was particularly true of Merit Gears fast-growing wind turbine gear business, where 100 percent part inspection is the rule, not the exception. Nor could Merit Gear afford to take the days, even weeks of extra time required to outsource finished gears for inspection elsewhere. So Kakes and his team went shopping. We looked at five inspection systems and the other four didnt even come close to the Gleason 3000GMMs capabilities, says Kakes. In fact, it was the only one with a 3,000 mm workpiece diameter capacity that could meet the inspection criteria of an important wind turbine gear and pinion assembly, where that assembly had to be precisely timed to an apex point in space. This was a deal-breaker for the other systems.

Merit Gears investment in turnkey production facilities everything from cutting to heat treat, gear grinding and inspection are on site gives the company an important strategic advantage, according to Merit Gear Vice President of Operations Friedrich Neuhoff. Lot sizes can range from one piece to several thousand, but most orders today are in the range of just 25 to 200 parts, Neuhoff explains. These parts are as diverse as a 3,000 mm internal ring gear for a planetary gear system for a wind turbine, to a complex eight-gear assembly for an offshore oil rig gearbox, to the gearbox housing itself. Yet all these parts have at least two things in common: the need for high quality and faster throughput. The investments weve made to put resources like

MAking LiFe eAsy in the QC LAb

The Gleason GMM is equipped with a series of Renishaw SP80H 3-D scanning probes, with various stylus sizes and configurations, all interchangeable from an automatic probe changer. These 3-D probes acquire data much faster and more accurately on even the most complex gear tooth profiles.
A recent visit to Merit Gears QC Lab found Merit Gear Lab Technician Marshall Williams hard at work setting up, programming and conducting an inspection on a typical Merit Gear workpiece: an important gear assembly used on an offshore oil rig platform of one of North Americas largest platform drilling contractors. Or maybe not so hard at work, explains Williams. Despite the complexities of this particular assembly

JUNE 2012

41

Gleason 3000GMM Analytical Gear Inspection System gives Merit Gear a critical gear quality verification capability for gear and non-gear work pieces as large as 3,000 mm in diameter, and weighing up to 19,000 kg.
and the inspection requirements two dual helicals, the need to verify a precise timing relationship between the two, and so on the Gleason system does all of the heavy lifting, says Williams. In fact, programming is so intuitive, and setup and operation so fully automated, that almost anyone could become a reasonably competent operator of this system in a matter of hours. With 14 years experience, Williams makes set up of this particular part seem simple, single-handedly lowering the part onto a universal chuck, and zeroing it in to a pre-established starting point with the help of the GMMs unique Journal Reference software. All an operator has to do is position the part anywhere to within 10 mm of the desired location and then the Journal Reference software takes over from there. It automatically

Merit Gear Lab Technician Marshall Williams can quickly and easily set up any work piece with minimal time spent truing the part up with the help of the Gleason GMMs unique Journal Reference software.

probes to determine the actual location of a datum such as the O.D., takes a radial and axial measurement, and corrects for the new zero location so that no additional painstakingly slow manual truing up of the part is required. Then Williams uses the GMMs GAMA (Gleason Automated Measurement and Analysis) operating software to simplify programming and completely automate the inspection process. GAMA is a powerful Windows based application that puts a host of features right at the fingertips of the operator in a simple, highly intuitive graphical user interface (GUI).

important gear and specific test information is shown down the left side of the screen, with tabs and forms making it easy for the operator to quickly and accurately establish gear parameters. The majority of the screen is used to chart the inspection results of, say, lead and involute tests, which appear in real time as the tests are performed. (Williams particularly likes the fact that a digital image of the part being inspected is also shown on-screen for visual confirmation). 2) The operator starts the process by either recalling, loading and activating existing part programs with the click of a mouse, or by creating a completely new part program, which can be done in just minutes in a few easy steps. The operator simply

heres how it works:

1) A typical GAMA screen has quick buttons across the top giving the operator immediate access to the most common system operations. All

42

gearsolutions.com

selects from a list of typical machine configurations, enters a part number, and clicks a create button. A series of tabs then appears across the top of the screen. The operator clicks on these tabs one by one, filling out the necessary fields with pertinent gear data, special tests required for highly modified gear profiles and geometry, and the type of analysis required. 3) Depending on the requirements of the customer, GAMA can provide test results to meet any global industrial standard, including DIN, AGMA, JIS, ISO, GB, GOST, UNI, etc. The operator can also select a variety of options for how a permanent record of the inspection is stored, whether in PDF format, Scalable Vector Graphics, or even HTML for easy emailing.

Lot sizes can range from one piece to several thousand, but most orders today are in the range of just 25 to 200 parts.

brAins AnD brAwn

If the Gleason 3000GMM is the smartest gear inspection system Williams has ever operated, its also the most physically capable as well. Its equipped, for example, with a series of Renishaw SP80H 3-D scanning probes, with various stylus sizes and configurations, all interchangeable from an automatic probe changer. The Renishaw probe is reputed to be light years ahead of older proprietary model 2-D and 3-D scanning probes; it can acquire data much faster and more accurately on even the most complex gear tooth profiles. In addition, the 3000GMM features a solid granite base, providing considerably more stability for, gears weighing as much as 19,500 kg (42,900 lbs.), as compared to competitive models with cast-iron bases. Its Meehanite cast iron slide assemblies provide vastly better damping characteristics as well.

gMM As CMM
According to Vice President of Operations, Friedrich Neuhoff, Merit Gear is now embarking on a new program calling for the use of the 3000GMM as a true Coordinate Measuring Machine (CMM). One of the unique advantages of the Gleason system is that it can also be used for inspection of non-gear related

A progressive gear manufacturer understands it needs to go above and beyond traditional expectations. Todays customers demand and deserve the latest technology, a wide range of capabilities and an unrelenting commitment to prompt and effective customer service. When it comes to exceeding expectations, Schafer Gear is truly light years ahead. Our investment in the latest production equipment assures that we can provide gears for many industrial applications including transportation, medical, mining, gas and energy, agricultural equipment and many specialty applications. And every gear we make comes with one thing standard the willingness to go to the ends of the earth to serve our customers well.

Find out more at www.schafergear.com or call us at 574-234-4116.

JUNE 2012

43

GMMs GAMA, a simple, highly intuitive graphical user interface, greatly simplifies programming and helps to completely automate the inspection process.

features found on a prismatic part, says Neuhoff. We will soon be producing a gearbox housing and cover where we will need to use the Gleason system as if it were a CMM, to inspect features on the housing such as center distances, perpendicularities and so on. It is yet another example of the critical versatility the Gleason system gives us, as we produce new products and enter new markets.

fOr MOrE infOrMatiOn:

Contact Merit Gear, LLC 810 Hudson St. Antigo, WI 54409-0486, or call 1-800-756-3748 or visit www.meritgear.com. For more information on Gleason Corporation, contact them at 1000 University Ave. P Box 22970 Rochester, NY .O. 14692-2970 or call 585-473-1000 or visit www.gleason.com.

Clarke Gear Co.

58 Years of Gears One Gear at a Time!
Precision Gears for Aerospace and Commercial Applications Complete Gear Manufacture CNC Gear Hobbing CNC Gear Shaping CNC Gear Grinding CNC Inspection & Analysis CNC Machining CNC Hob Sharpening BAC Coolants Splines Serrations Spur Worms Internal & External to 12" Dia. AS9100 REV C ISO 9001:2008 EN/JISQ

Global pricing with personal service 1 to 10,000 pieces

408.723.0700

www.ClarkeGear.com
Phone: 888-827-GEAR or 818-768-0690 Fax: 818-767-5577 [email protected]

270 Hillsdale Avenue | San Jose, CA 95136 Fax: 408.723.0710 E-mail: [email protected]

www.ws2coating.com

44

gearsolutions.com

Seeking OppOrtunity?
Scan the new Gear Solutions Web site to enjoy a host of features, including:
Our new jobs listing, for employers and job seekers alike Events calendar to keep you informed A searchable articles archive, downloadable individually View the digital magazine, or download entire issues Vendor listings, along with our annual Buyers Guide Company profiles and Q&As Connect to the gear industry through social media Gear industry news from around the world

Visit www.gearsolutions.com today, and get connected!

International Calculation Method for Micropitting

The safety factor against micropitting can be improved through macro geometry optimization by using profile modifications.
By Dr. ING. Ulrich Kissling

THE FIRST EDITION OF THE INTERNATIONAL CALCULATION METHOD FOR MICROPITTING, ISO TR 15144-1:2010, WAS JUST PUBLISHED LAST DECEMBER. IT IS THE FIRST OFFICIAL INTERNATIONAL CALCULATION METHOD TO CHECK FOR THE RISK OF MICROPITTING EVER PUBLISHED. YEARS AGO, AGMA PUBLISHED A METHOD FOR THE CALCULATION OF THE SPECIFIC OIL FILM THICKNESS CONTAINING SOME COMMENTS ABOUT MICROPITTING, AND THE GERMAN FVA PUBLISHED A CALCULATION METHOD BASED ON INTENSIVE RESEARCH RESULTS. THE FVA AND THE AGMA ARE CLOSE TO THE ISO TR. HOWEVER THE CALCULATION OF THE MICROPITTING SAFETY FACTORS IS NEW. AN ISO TR IS A TECHNICAL REPORT, WHICH NORMALLY AFTER THREE YEARS WILL BECOME AN INTERNATIONAL STANDARD. DURING THE LAST YEARS, MICROPITTING HAS BECOME A VERY IMPORTANT TOPIC IN GEARBOX DESIGN, SPECIFICALLY FOR WIND TURBINES. THEREFORE, EVEN BEFORE THE OFFICIAL PUBLICATION, THE EVALUATION OF THE RISK OF MICROPITTING BASED ON ISO 15144 IS REQUESTED BY SOME AUTHORITIES SUCH AS THE GERMANISCHE LLOYD, FOR EXAMPLE.
checked combined with different user defined torque levels. Any modifications including flank twist and arc-like profile modifications can be combined. The result is presented in a table, showing the safety factor against micropitting for different subsets of profile/flank modifications, depending on the torque level. Additionally Peak-to-Peak-Transmission-Error, maximum Hertzian stress and wear is documented. This is a tool to show the possibilities to reduce the micropitting risk with profile modifications and is very helpful for designing an optimum gear modification for varying torque levels. Three different gear sets with micropitting problems, example D (spur gear, module 10.93 mm, Z 18:18), example U( helical gear b=19.578, module 4.5 mm, Z 33:34) and example F (helical gear b=9, module 30 mm, Z 19:76) will be discussed.

In this paper the ISO TR 15144 will be explained briefly. The technical report presents two calculation rules, method A and B. Method A needs as input the Hertzian pressure on every point of the tooth flank. This is based on an accurate calculation of the meshing of the gear pair considering tooth and shaft deflections to get the load distribution over the flank line in every meshing position. Such a calculation is time consuming when using an FEM tool. Alternatively specific analytical programs, which are commercially available (such as LDP, RIKOR, KISSsoft), may be used. In either case, the use of Method A without such an advanced tool is impossible. Method B is much simpler; the load distribution is defined for different cases as spur or helical gears, with and without profile modifications. Method B can be programmed as standalone software and may even be used in Excel. However, a restriction, which arose in the last meeting of the ISO working group responsible for this topic limits considerably the application of method B: If gears with profile modification have to be verified, the tip relief Ca must correspond exactly to a proposed value Ceff. If not, the method for gears without any profile modifications has to be used. As modern gear design implies profile modifications of different kinds, this is a critical limitation for the application of method B in ISO TR 15144. The risk of micropitting is highly influenced by profile and flank line modifications. A new software tool can evaluate the risk of micropitting for gears by automatically varying different combinations of tip reliefs, other profile modifications, and flank line modifications, in combination with different torque levels, using method A. The user can define the number of steps for variation of the amount of modification (for example tip relief Ca from 30 to 70 mm in 4 steps, crowning value Ca form 10 to 40 mm). Then all possible combinations Ca =30 (with Cb =10,20,30,40), Ca =40 (), etc are

2. MiCropitting As A phenoMenon
Micropitting is well explained in ISO TR 15144 [1]. Micropitting is a phenomenon that occurs in Hertzian type of rolling and sliding contact that operates in elastohydrodynamic or boundary lubrication regimes. Micropitting is influenced by operating conditions such as load, speed, sliding, temperature, surface topography, specific lubricant film thickness and chemical composition of the lubricant. Micropitting is more commonly observed on materials with a high surface hardness. Micropitting is the generation of numerous surface cracks. The cracks grow at a shallow angle to the surface forming micropits. The micropits are small relative to the size of the contact zone, typically of the order 10 - 20 mm deep. The micropits can coalesce to produce a continuous fractured surface, which appears as a dull, matte surface during unmagnified visual inspection. Micropitting is the preferred name for this phenomenon, but it has also been referred to as grey staining, grey fleck-

JUNE 2012

47

Fig. 1: Traces of micropitting at the root of the flank of the pinion (Photo: CMD, France); and corresponding result of safety against micropitting (Method A). Curves for left side, middle and right side of face width. Gear example F (Helical gear, mn=30 mm, b=9, Z 19:76).
ing, frosting and peeling. Micropitting may stop but if it continues to progress, it may result in reduced gear tooth accuracy, increased dynamic loads and noise. If it does not stop and continues to propagate it can develop into macropitting and other modes of gear failure. Classic pitting (also called macropitting) is a completely different phenomenon. In this case the cracks start in a certain depth under the surface, where shear stress due to Hertzian pressure is highest. This effect is well explained in the ISO 6336-2 standard.

Fig. 2: Significant points on the path of contact, where micropitting has to be checked, when using ISO 15144, method B. (Point A: Begin of contact, SAP; point E: End of contact, EAP.)

3. the iso teChniCAL report 15144

The Technical Report ISO 15144-1 provides principles for the calculation of the micropitting load capacity of cylindrical involute spur and helical gears with external teeth. The basis for the calculation of the micropitting load capacity of a gear set is the model of the minimum operating specific lubricant film thickness in the contact zone, GF,min. For the calculation of the risk of micropitting, a safety factor S is defined as ratio between GF,min and the permissible specific film thickness GFP. The permissible specific lubricant film thickness GFP is calculated from the critical specific lubricant film thickness GFT which is the result of any standardized test method applicable to evaluate the micropitting load capacity of

lubricants or materials by means of defined test gears operated under specified test conditions. GFT is a function of the temperature, oil viscosity, base oil and additive chemistry and can be calculated in the contact point of the defined test gears where the minimum specific lubricant film thickness is found and for the test conditions where the failure limit concerning micropitting in the standardized test procedure has been reached. The most widely used test procedure is the FVA-FZGmicropitting test [2]. Several oil providers already document the micropitting load stage following the FVA test in their oil specification. The ISO TR 15144, part 1, was published in December 2010. Part 1 contains the basic calculation method. The ISO committee responsible for this topic is currently working on part 2, which will contain some examples of gear sets having micropitting. Part 2 will be very helpful to understand better the application of the calculation rules as described in part 1. The Technical Report presents two calculation rules, method A and B. The Technical Report stipulates, that for method A experimental investigations or service experience relating to micropitting on real gears are used. This is not very practical when designing new gears. As it will be shown in part 2 of the Technical Report, a more practical approach when using method A, is to first calculate the

Fig. 3: Required specific film thickness, GFP, for mineral oil.

load distribution over the flank line in every meshing position. Than the Hertzian pressure on every point of the tooth flank, based on an accurate calculation of the meshing of the gear pair, considering tooth and shaft deflections. This is a most complicated contact analysis problem, which could be solved using a FEM tool. However such a calculation is very time consuming when using a FEA tool. Alternatively, specific commercially available analytical programs may be used. Once the local Hertzian pressure and the sliding velocity are determined, the local specific lubricant film thickness GF is calculated using the formulas of the Technical Report. The use of method B is much simpler; the Hertzian pressure is defined by formulas for such cases as spur or helical gears, with and without profile modifications. The formulas for the calculation of the local pressure and velocities are based on an unmodified involute tooth form. The calculation is performed for some of the critical points in the tooth mesh-

48

gearsolutions.com

ing cycle, which are points A, AB, B, C, D, DE and E (fig. 2) [1, 3]. In these points, the specific lubricant film thickness GF is then calculated. Research on micropitting is relatively new, therefore the Technical Report states, there are many influence parameters, such as surface topology, contact stress level, and lubricant chemistry. Whilst these parameters are known to effect the performance of micropitting for a gear set it must be stated that the subject area remains a topic of research and as such the science has not yet developed to allow these specific parameters to be directly included in the calculation methods. Also the correct application of tip and root relief (involute modification) has been found to greatly influence micropitting therefore application of the suitable values should be applied. Surface finish is another crucial parameter and at present Ra is used but other aspects such as Rz or skewness have been observed to have significant effects which could be reflected in the finishing process applied.

Case hardening steel, austenite <= 25% Case hardening steel, austenite > 25% Gas nitrided (HV > 850) Induction- or flame hardened steel Through hardening steel
Table 1: Material factor WW (ISO TR 15144)
Where (3) (4) GF,Y Ra Ra1 Ra2 hY rel,Y G0

Ww 1.00 0.95 1.50 0.65 0.50

4. overview on the CALCuLAtion proCeDure

Calculation of the safety factor against micropitting For the calculation of the risk of micropitting, a safety factor S is defined as follows: (1)

GF,min = min (GF,Y) is the lowest specific film thickness over the meshing cycle GFP is the permissible specific film thickness; it may be determined by different methods S,min is the required safety factor, to be agreed on between supplier and purchaser of the gearbox The lowest specific film thickness (GF,min) is defined as the minimum of all locally calculated film thickness values GF,Y as per equation (2). The permissible film thickness GFP is calculated as per equation (5). The ratio between these two values (GF,min/GFP) results in a safety factor against micropitting S, which then has to be equal or higher than the required safety factor S,min. As the calculation method is quite new, and relatively few known data points are available, the general idea for the interpretation of the micropitting safety S is to have a range between low and high risk limits: Safety S > 2: Low risk of micropitting 1 <= Safety S <= 2: Limited risk of micropitting Safety S < 1: High risk of micropitting Calculation of the Specific Film Thickness For the calculation of the safety factor S , the local film thickness in the contact of the gears hY must be known for the whole meshing cycle. It is then compared to the effective surface roughness:

UY WY SGF,Y

local specific film thickness arithmetic surface roughness of the contact arithmetic surface roughness of the contact of gear 1 arithmetic surface roughness of the contact of gear 2 the local film thickness relative radius of curvature of the flanks in point Y (the point of contact between the gears) parameter for pressure viscosity, describing the influence of the equivalent Youngs modulus Er and the pressure viscosity of the lubricant at mass temperature 0 the local velocity factor the local relative load factor the local sliding factor

Determination of the permissible Specific Film Thickness GFP The determination of the permissible Specific Film Thickness, GFP, is the most difficult part to understand when using the Technical Report. There is a simple, but inaccurate, way to get this value using a diagram [4], where for mineral oils the permissible specific film thickness GFP as a function of the viscosity of the lubricant n and the load capacity number SKS of the lubricant (fig. 3) is found. (5) GFT is the specific lubricant film thickness ascertained by tests WW material factor (table 1) SKS is a property of the lubricant and has to be measured similar to the FZG number against scuffing. Modern lubricants as used in wind turbine gearboxes typically have a SKS number of SKS=10, but the data needs to be checked with the oil supplier on a case-by-case basis. The SKS number is determined according to the FVA information sheet [2] and may be found on the lubricant data sheet of the leading suppliers. Note that the above diagram is valid for mineral oils. Synthetic oils will give (for the same viscosity and SKS number) a different, typically lower permissible specific film thickness GFP. Furthermore, it should be observed that the values given for GFP are valid for case carburized gears. The accurate way to get a value for the permissible specific lubricant film thickness is to use data of the oil performance from a FZG test rig.

(2)

JUNE 2012

49

Many oils are tested on such a test rig with gears type FZG C-GF. In the oil specification you will then find the declaration: Failure load stage (SKS) for micropitting test C-GF/8,3/90= n (n = 5 .. 10). The SKS number corresponds to a torque level, at which the gear in the rig with the test oil shows micropitting. If the SKS number of the oil is known the micropitting calculation of the test rig gear is performed with: - Gear data as specified for the C-GF/8,3/90 test rig gear [2] - Torque and Hertzian pressure as specified by Table 2 - Oil data as viscosity, density - Oil temperature according oil of the actual gear reducer (not the oil temperature used on the FZG test rig!). Note: It is recommended, that the FZG test should be performed with the same oil temperature as used in the gear reducer. But normally the FZG test is executed with 90C oil temperature. Therefore data published by oil providers are valid for 90C (if not otherwise declared). The calculation of the test gear with this input data is done for point A, because the minimum specific lubricant film thickness for the FZG type C test gear is always at point A. The resulting specific lubricant film thickness GF, as per formula (2) of ISO procedure, is the specific lubricant film thickness ascertained by tests GFT (used in formula 5). Unfortunately, the description of the method to get GFT is missing in ISO TR 15144, part 1. There will be more information in part 2.

Fig. 4: Tip and root relief as defined in ISO21771 [5]. At the point where the profile modification starts (arrow), a small edge in the tooth flank is formed.
or the edge is reduced after some cycles due to wear. Therefore the pressure is much lower than theoretically assumed. A similar effect is encountered on the gear tip area, at the beginning of the chamfer. Very high pressure will result in a low micropitting safety. There is no official method available to deal with this problem, so the above mentioned programs provide individual solutions, which then will result in somewhat different pressure values for the same tooth form. Use of method B Within method B, the local Hertzian pressure is calculated by formulas. This is relatively simple for involute gears with no profile modification. In this case it is easy to get the load distribution over a meshing cycle. For gears with profile modifications, the load distribution is more complex, because depending on the amount of the tip relief Ca (fig. 4), the load in the beginning and the end of the contact is reduced. Method B proposes currently two different methods to get the load distribution, one for non-modified gears and one for gears with optimum tip relief on one/both gears. The question originates, what is an optimum tip relief? This is defined in the Technical Report with the effective tip relief Ceff. If the tip relief of the pinion Ca1 is equal to Ceff, then the load distribution for optimal tip relief can be adopted, same for the gear if Ca2 is equal to Ceff. If the gears have a tip relief, which is smaller than Ceff, then the actual version of the Technical Report asks to interpolate between the load distribution with and without profile modification. In the future, this may be changed. Many experts demand, that load distribution formulas for gears with profile modification can only be applied, if the modification is optimal. If not, the formulas for non-modified gears have to be adopted.

5. reCoMMenDAtions For the use oF iso tr15144

Use of method A A problem when using method A, which is more difficult than it may first appear, is the calculation of the Hertzian pressure distribution over the tooth flank. It is well known, that if different FEM tools are used to calculate the tooth contact, differences in the resulting pressure may be 30% and more. This depends on the mesh, the boundary conditions and the solution model. Similar problems are present also when using commercially available software written to resolve specifically the tooth meshing contact. To mention one of the problems encountered: A gear with a linear profile modification in the tip area has a small edge at the point the modification begins (fig. 4). In this point the radius of curvature is theoretically zero, so the Hertzian pressure is infinitively high. In reality, the edge does not exist; because it is rounded during the grinding process,

Fig. 5: Result of the fine sizing procedure, possible variants to gear example U (corresponding to number 13 in the list, S=0.744). No. 3 shows best result for micropitting S=1.302, safety factor is increased by 75%. 50 gearsolutions.com

Table 2: Torque T1, line load Fbb and corresponding Hertzian pressure on FZG test rig.

SKS number 5 6 7 8 9 10

Torque T1 (Nm) 70.0 98.9 132.5 171.6 215.6 265.1

Line load Fbb (N/mm) 63.3 89.1 119.0 153.7 192.7 236.3

Hertzian pressure at the pinion at point A (N/mm2) 764.0 906.4 1047.6 1191.0 1333.0 1476.2

The consequence is, that non-modified gears can be calculated with method B, but modified gears should not be. For modified gears, the question is, if the modification is optimal or not. As it will be indicated in clause 6, a study, using method A to find the best micropitting safety factor by varying Ca, shows that the optimum Ca is not at all equivalent with Ceff (fig. 7, 8). So what is an optimum modification? As profile modifications are considered very important for reducing the risk of micropitting, it is a real problem for an engineer who has no access to a tool using method A, because method B may not give realistic results in such a situation. Furthermore, as shown in clause 6, profile crowning or long tip relief (not short tip reliefs as used for method B) gives better results against the micropitting risk. This type of modifications is not covered by method B.

6. optiMiZAtion oF sAFety AgAinst MiCropitting

1. How to Optimize Micropitting is most critical in areas of high pressure and high sliding velocity. Sliding velocity is always highest in the beginning and in the end of the meshing contact. Combined with high pressure in the same areas, the micropitting risk is increased. So an optimization of the macro geometry (as module, tooth number, profile shift) with the aim to reduce the sliding velocities is a good strategy. In the calculation software KISSsoft [7], we developed in 1987 a tool for the optimization of gear pairs and planetary stages [8] called Fine-Sizing-Routine. Based on a user-defined range of parameters (module range, helix angle range, etc.) the software presents a large number of possible solutions covering the full parameter space and presents a list of calculated data (geometry, safety factors, characteristics such as sliding, losses, weight, transmission error) also including the micropitting safety factor according to the users choice of method B or A. As shown in an example (Fig. 5), keeping center distance, face width and helix angle unchanged, reduction ratio variation smaller than 0.5%, just through

JUNE 2012

51

Fig. 6: User interface for the optimization of profile modifications to get best micropitting performance.
variation of module (from 4.0 to 5.0 mm) and the profile shift coefficient x1, the safety factor against micropitting can be raised from 0.744 up to 1.302. It should be noted that the best variant has the lowest sliding velocity of all variants. Using method A with contact analysis for every variant is clearly a large calculation task, total calculation time for these 19 variants was about 10 minutes. But note that for doing the same using a FEA tool would require days. It is easily possible to improve the safety factors even more, if a wider range of module and/or pressure and helix angle is used. There are limits in what can be achieved, when module or tooth number should not be changed. In this case, further optimization can be acquired by profile modifications. 2. Optimization of Profile Modifications The risk of micropitting is highly influenced by profile and flank line modifications. A new extension in KISSsoft [8] can evaluate the risk of micropitting for gears by automatically varying different combinations of tip reliefs, other profile modifications and flank line modifications, in combination with different torque levels, using method A. The user can define the number of steps for variation of the amount of modification (for example tip relief Ca from 30 to 70 mm in 4 steps, crowning value Cb form 10 to 40 mm, fig.6). Then all possible combinations Ca=30 (with Cb =10,20,30,40), Ca =40 (), etc are checked, combined with different (user defined) torque levels. Any modifications including flank twist, arc-like profile modifications, etc. can be combined. The result is presented in a table, showing the safety factor against micropitting (method A) for different subsets of profile/flank modifications, depending on the torque level. Additionally Peak-toPeak-Transmission-Error, maximum Hertzian stress, wear etc. is documented. This table is very helpful to show the possibilities to reduce the micropitting risk with profile modifications and to find an optimum gear modification for different torque levels. The effect of different variants of profile modifications on the micropitting safety factor is obvious, as fig. 7 and 8 show very well. It is interesting to see, that in these examples the highest safety factor S is

Fig. 7: Effect of different tip relief Ca and profile modification type on micropitting safety factor S, example F (Helical gear, mn=30 mm, b=9, Z 19:76).

Fig. 8: Effect of different tip relief Ca and profile modification type on micropitting safety factor S, example U (Helical gear, module 4.5 mm, b=19.578, Z 33:34).

Fig. 9: Effect of different tip relief Ca and profile modification type on micropitting safety factor S, example D (Spur gear, module 10.93 mm, Z 18:18).

52

gearsolutions.com

reached at a tip relief Ca, which is significantly lower than the optimum relief Ceff, as defined by ISO TR 14155. This is another indication that method B (which is based on Ceff for teeth with profile modifications) is of limited accuracy, when using profile modifications. In the case of the spur gear (fig. 9), a surprisingly small effect of the different modifications is found. It is also very interesting, that profile crowning or long (linear or arc-like) profile modifications have normally higher safety factors than short profile modifications. Best results are obtained with profile crowning.

ISO, but in points with high flash temperature, AGMA calculates a much higher oil film thickness, as shown in fig. 11 [7]. It is known, that the central film thickness is about 32% greater than the minimum film thickness (see also the factor 1.316 in AGMA 925 [5], which is used to get the risk assessment for wear). When we compared the two methods, we

found approximately this difference between the values in ISO and AGMA for the oil film thickness (fig. 11).

FinAL AnALysis
The first edition of an international standard for micropitting, the ISO TR 15144:2010, is an interesting document, which proposes a

AgMA 925
AGMA 925-A03 [5] is an enhancement of annex A of ANSI/AGMA 2101. Various effects of gear surface distress are included, such as scuffing and wear, and in addition, micro and macropitting. Both methods use the Blok [11] equation for the determination of the flash temperature. As not all factors used are exactly identical, the flash temperature (increased gear surface temperature in the contact) calculated following AGMA or ISO are slightly different, as fig. 10 shows. The difference is mostly originated due to a different definition of the mean friction coefficient. Concerning micropitting, in AGMA 925 the calculation of the lubricant and specific lubricant film thickness is defined, but not a resulting safety factor for micropitting. Although the calculation of specific lubricant film thickness does not provide a direct method for assessing micropitting load capacity, it can provide an evaluation criterion when applied as part of a suitable comparative procedure based on known gear performance. The calculation procedure for the local film thickness (hy, see formula 4) in ISO TR 15144 and the line contact central film thickness in AGMA 925 (hc in [5]) are both based on the same theory developed by D. Dowson [6, 10]. Some factors are slightly different. The main difference in ISO is the local sliding factor S, which takes the flash temperature into account. AGMA uses always the mean tooth temperature M for local lubricant viscosity, where ISO uses the local contact temperature B. The contact temperature is the sum of the mean tooth temperature plus the flash temperature. Therefore, in the meshing point C (where the flash temperature is zero), there is a smaller difference between AGMA and

JUNE 2012

53

Fig. 10: Calculation of the local tooth temperature according ISO 15144 and AGMA 925. Data used of example D (Spur gear, mn=10.93 mm, Z 18:18).
method to predict the risk of micropitting. The concept and most important formulas are explained. The method B, which is relatively simple to apply, is of limited use for gears with profile modifications. For such gears, method A has to be used. However method A needs a software tool, able to model the tooth contact to get the local Hertzian pressure distribution, which is a complex task. The safety factor against micropitting can be improved through macro geometry optimization. With an example it is shown that without changing the overall dimensions of the gear set, the micropitting safety factor can be improved significantly (by 100% and more). A generally used method to improve the safety against micropitting is to use profile modifications. In some examples the effect of the variation of the tip relief and of the type of modification is shown. To perform this optimization easily, a new software tool was developed, which permits to automatically check

Fig. 11: Calculation of the oil film thickness according ISO 15144 (local film thickness) and AGMA 925 (central film thickness). Data used of example D (Spur gear, mn=10.93 mm, Z 18:18).
many variants automatically. Profile crowning or long (linear or arc-like) profile modifications have normally higher safety factors than short profile modifications. Best results are obtained with profile crowning.

reFerenCes
[1] ISO TR 15144-1:2010, Calculation of micropitting load capacity of cylindrical spur and helical Gears, ISO, Geneva. [2] FVA-Information Sheet 54/7: Test procedure for the investigation of the micropitting capacity of gear lubricants. 1993. [3] ISO21771: 2007, Gears Cylindrical involute gears and gear pairs Concepts and geometry, ISO, Geneva. [4] J.Theissen, Berechnung der Sicherheit gegen Graufleckenbildung von Industriegetrieben auf der Grundlage des neuen Rechenverfahrens nach FVA 259, DMK 2003. [5] AGMA 925-A03, Effect of Lubrication on Gear Surface Distress; AGMA, Alexandria, 2003. [6] D. Dowson, G.R. Higginson, Elastohydrodynamic lubrication The fundamentals of roller and gear lubrication, Pergamon press (London), 1966. [7] S. Beermann, KISSsoft Calculates Micropitting for the Wind Energy Sector, Wind Energy System Magazine, Oct 2010. [8] http://www.kisssoft.com [9] Kissling, U.: Konzept fr die effiziente Auslegung und Optimierung von Planetengetrieben nach verschiedenen Kriterien; VDI-Berichte Nr.1460;VDI-Verlag, Dsseldorf, 1999. [10] D. Dowson, S. Toyoda, A central film thickness formula for elastohydrodynamic line contacts, 5th Leeds-Lyon Symposium Proceedings, Paper 11, 1978. [11] Blok, H., Les Tempratures de Surface dans les Conditions de Graissage sans Pression Extrme, Second World Petroleum Congress, Paris, June, 1937.

aBOut tHE autHOr:

Dr. Ulrich Kissling, ING. Is the president of KISSsoft AG in Hombrechtickon, Switzerland. Contact him at +41 55 254 20 50 or visit www.KISSsoft.AG.

54

gearsolutions.com

PRODUCT

new products, equipment, and resources

SHOWCASE

ENDURO-FLEX Finishing Disc Guarantees Long Life

Walter Surface Te c h n o l o g i e s announces the launch of the improved longer life ENDURO-FLEX finishing disc for metal finishing applications. The improved ENDURO-FLEX disc features a totally new design and flap configuration with an exclusive cloth and abrasive composition. Patented backing can be trimmed down adding total longevity to the product. This disc offers a more consistent surface finish, and removes more material, according to the manufacturer. A 5-inch disc with Grit 40 removes up to 2,500 grams over its lifespan. Longevity of the new design lowers costs. Overall this results in less disc changeovers as well as less waste, making it the ideal solution for finishing steel and stainless steel, aluminum, and other alloys. JUNE 2012 55

Nextec Laser Metrology Announces WIZprobe

Nextec Laser Metrology LLC, a corporation serving the quality inspection market, has announced its WIZprobe solution, an advanced noncontact laser-scanning sensor that significantly reduces component inspection time while providing highest precision. WIZprobe offers a large dynamic range that makes it easy to collect thousands of data points quickly and accurately. The Nextec WIZprobe relies upon vision and laser technologies featuring patented optics and image processing to deliver fast, accurate and highly reliable scanning and geometric measurements. It can handle a large variety of materials at varying angles and surface finish types including very shiny surfaces. Additionally, WIZprobe automatically performs self-calibration on the fly via real-time closed loop adaptive control. WIZprobe is available as a stand-alone product kit with customized software packages and motion control for integration into any process control or can be easily integrated into a CMM system. Small in size and featuring a standard PH-10 rotary head interface, it can effectively replace conventional mechanical touch probes. For more information and WIZprobe specifications, visit www.nextec-laser.com.

Complete Gear Manufacturing

In Business Since 1989. (Over 20 Years) Gear Grinding Services featuring newer CNC Gear Grinders Calibrated Analytical Gear Charting Inspection Equipment One to two hundred piece lot sizes ISO 9001:2008

4884 StenStrom road rockford, IL 61109 Phone: 815-874-3948 fax: 815-874-3817

www.raycargear.com

56

gearsolutions.com

DECREASED FRICTION

Basically there are two approaches for subsequent friction reduction in a transmission: chemical and mechanical. One example for mechanical reduction of friction is molybdenum sulfide (MoS2). This is a solid lubricant with a structure similar to graphite. It deposits 310the surface of the metal and acts as Head features absolute setting accuracy The Kaiser Series on EWD Precision Finish Digital Boring a lubricating layer, preventing direct metal-to-metal contact. The shown on a built-in digital display. The robust measurement system shows precise linear movement reduced friction decreases the heat caused by friction, and thus of the tool carrier in both directions during adjustments of .00005 or .001mm. These borthe oil temperature. Moreover, wear is reduced and the service ing heads use existing insert holders from program 310 EWN to allow maximum boring life increased. The benefits of molybdenum sulfide have been range per head, and compatibility with existing special design insert holders. An IP known for some time. During the Second World War the U.S. Air 69K seal rating (highest possible) assures resistance to contamination. Kaisers SW Force added molybdenum sulfide to the motor oil for aircraft Accessory Insert the main objective was neither to increase engines. At that time Holders for the Series 319 SW Rough Boring System are available for intervals nor to back boring purposes. Insert holders for service chamfering and save fuel. The benefit was more direct: chamfering cover the The diameter range of 1.299 to 8.268. The the emergency molybdenum sulfide significantly improved desired chamfering angle is adjustrunning characteristics. When anboring, the new insert holders cover the diameteris no room for downtime due to transable from 15 to 75. For back engine lost its oil after a Fig. 2: There direct hit, the1.732 to 8.307. BIG Daishowas newest solution in extended range of pistons seized up within minutes, necessitating mission failures in this operation. an emergency landing in hostile territory. The (Pat. P), features a unique dynamreach arbor technology, the Smart Damper molybdenum sulfide ic damping system that eliminates vibration and instantaneously reduces remained in the engine even after losing the oil, providing rudimentary for higher productivity in deep hole finish kept the In the chatter lubrication for the engine. This capability boring and extendedcase of chemical friction reduction, special agents engine running longer, saving many pilots from being captured. tend to harden the surface of the metal. One of these agents reach face milling. This translates to better surface finishes and higher Naturally, such emergency running properties are also an advan- is molybdenum, embedded into the surface of the metal under metal removal rates. Models are designed for Kaiser modular boring tage even in non-military applications. In the event of damage, pressure at high temperatures. The surface is smoothed and tools with KAB4-KAB6 connection, and for shell mill arbors with a 1 they help to minimize the consequences, and when no damage microscopically small roughness reduced. This principle was pilot, and all offer center through coolant delivery. For more information, visit the military. A manufacturer of tank cannons is present they reduce friction and therefore wear. also exploited by

BIG Kaiser Expands Line-Up at IMTS Booth W-1600

BIG Kaiser at IMTS Booth W-1600.

Clarke Gear Co.

58 Years of Gears One Gear at a Time!
Precision Gears for Aerospace and Commercial Applications Complete Gear Manufacture CNC Gear Hobbing CNC Gear Shaping CNC Gear Grinding CNC Inspection & Analysis CNC Machining CNC Hob Sharpening BAC Coolants Splines Serrations Spur Worms Internal & External to 12" Dia. AS9100 REV C ISO 9001:2008 EN/JISQ

SWISS MANUFACTURER
O U R P R O D U C TS... Clamping colle ts, feed fingers , Pic kup collets for Gi ldemei ster, Torn os, Index, Schtte , Wickma nn , Pittler.. Collets for Hydro ma t machines Clamping heads G ui de bus he s Parts fo r Tor nos machines Special collets on de mand UP / carbi de / small d ia me ter s

Global pricing with personal service 1 to 10,000 pieces

O U R N EW PR O D U C T
For more in forma tion vis it ou r web s it e: www. d t t ech n ologies. com/en /n e ws

Se ale d c olle ts

DT TECHNOLOGIES SA

www.ClarkeGear.com
Phone: 888-827-GEAR or 818-768-0690 Fax: 818-767-5577 [email protected]

ZI OUEST CHAMP-COLIN 2 CH-1260 NYON - SUISSE Tel. +4122 362 8701 - Fax +4122 362 8702

www.dtte chnologie s.com

[email protected] [email protected]

www.suppac.fr www.suppac.fr

Special collets division:

28

gearsolutions.com

JUNE 2012

57

rce sou r #1 you are ry We hine mac ear or g f

Gould & Eberhardt is a pioneer in highspeed gear gashing with large diameter carbide-inserted cutters. Our new line of machines has a rigid design and heads engineered with state of the art gear gashing cutter technology. The exceptional results achieved in gear gashing technology have opened a wide range of applications for gear cutting in wind energy, mining, offhighway construction and other coarse pitch gearing. Our gasher/hobbers are equipped with the new G&E interchangeable cutter head design. This design provides the option for both internal and external heads on a single column machine with capacities up to 5.5 meters. Please visit our website for all machine offerings or call us today to request a quote.

866.256.3708
F: 704.872.5777

820 Cochran Street Statesville, NC 28677 [email protected] www.rpmachine.com

FEATUREDSupplIErS
midwest Gear Corporation ref #101 Phone: 330-425-4419 Fax: 330-425-8600 Email: [email protected] Website: www.mwgear.com new england Gear ref #102 Phone: 860-223-7778 Fax #:860-223-7776 Email: [email protected] Website: www.newenglandgear.com r. p. machine enterprises, inc. ref #103 Phone: 704-872-8888 Fax #:704-872-5777 Email: [email protected] Website: www.rpmachine.com repair parts, inc. ref #104 Phone: 815-968-4499 Fax #:815-968-4694 Email: [email protected] Website: www.repair-parts-inc.com havlik international machinery, inc. ref #105 Phone: 519-624-2100 Fax: 519-624-6994 Email: [email protected] Website: www.havlikinternational.com GQ machinery inc. ref #106 Phone: 516-867-4040 Fax: 516.223.1195 Email: [email protected] Website: www.gqmachinery.com

MACHINERY
Contact Gear Solutions at 800-366-2185 to list your machinery.
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 baRbeR-colMan tyPe t 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 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 P250 10 dia 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 PFauteR P-900 36 dia REF#103 baRbeR-colMan #25-15 25 dia, 15 Face, 2.5 dP 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 tos Fo-16 with single index 72 cap. REF#106 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 FitchbuRG Pinion hobber 42 dia, 72 dia REF#103 craven horizontal 36 dia 96 length 73/4 hole REF#106 GEAR HOB & CUTTER SHARPENERS (incl CNC) baRbeR-colMan #6-5, 6" dia, 5" length, Manual dresser, 57 REF#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 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 Red Ring shaving cutter sharpener Periform REF#103 star #6 Gear cutter sharpener REF#103 star 4hs hob sharpener REF#103 star hhs horizontal hob sharpener cnc, Max dia 10 Max length 12 new 1990 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 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 FelloWs Fs400-125, 16 dia, 3.5 dP 5 Face REF#103

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 PFauteR #Pe-150, 6-axis cnc, 6 dia, 5 dP, 6 Face, Fanuc 18Mi REF#103 G&e #60 s-2 cnc Gasher/hobber REF#103 baRbeR-colMan #16-36, 16 dia, 4-axis, 6 dP, 36 Face 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-1802 cnc 98 dia internal, 3-axis 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 #96Gh, cnc, Gasher/hobber, new 09 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 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 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 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 G&e #24h universal head, infeed, tailstock, differential, 50s REF#103 liebheRR #l-650, 26" dia cap, 14.5" Face, 2.5 dP, new 70s REF#103 G&e #16h Gear hobber, 16"dia REF#103 baRbeR-colMan #6-10, 6 dia, 10 Face, 16 dP REF#103 KoePFeR #140 , 2.75 dia, 4 Face REF#103

JUNE 2012

59

FelloWs #10-4 3-axis (a/b), 10" dia, 4" Face, 4 dP new .09 REF#103 FelloWs #10-4 2-axis, 10 dia 4 Face REF#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 Fellows 20-8, cnc Gear shaper, Remanufactured and recontrolled REF#103 Fellows Model Z gear shaper REF#103 lorenz sn4 Gear shaper, Max od 7, 2 Face, Max 6 dP with loader REF#103 RP/ stanko 48-8 Remanufactured Gear shaper, Fanuc 3 axis, 18i M control, new 2010 REF#103 GEAR HOBBERS barber colman Model 4-4hRs, hob sharpener 4 Max od, 4 length REF#103 Fellows Fh 200 Gear hobber, universal hobbing Machine REF#103 barber colman 6-10, cnc, cRt 5 axis, 6 dia, 10.5 travel, 6 dP REF#103 barber colman hobber type t REF#103 barber colman model #14-15 Gear hobber, horizontal heavy duty REF#103 barber colman Model #16-36 Gearhobber REF#103 barber colman Model #16-56, 16 dia, 56 Face, adj. air tailstock REF#103 barber colman Model 2.5-2 gear hobber, 2 length Manual dresser REF#103 G&e Model 5.2 cnc internal Gear gashing head REF#103 Jeil Jdh-3, Gear hobber, Max dia 31.5, 3dP, 22.8 table diameter REF#103 Jeil JdP-2, Gear hobber, Max dia 26, 4 dP, 19.5 table dia, differential and tailstock REF#103 liebherr et 1802, internal Gashing head, Fanuc 16i control, 98Max dist 17 Face REF#103 liebherr l-402 Gear hobbing Machine, new 1977 REF#103 liebherr lc 752, 6 axis cnc hobber, Max od 29.5, Max Face width 23.6 REF#103 Micron Model 120.01 w/bevel cutting attachment, new 1975, 1.6 dia, 25.4 dP REF#103 nihon Kakai Model ntM-3000, spline hobbing Machine, Max dia 400mm, 3150mm between center REF#103 Pfauter P900 Reman and Recontrolled, Max od 120 REF#103 Pfauter Model Pe125 cnc Gear hobber REF#103 Pfauter model Pe300 cnc, Max od 12, Max gear face 15, 3 dP, 6 axis REF#103 Reinecker heavy duty Gear hobber REF#103 scheiss Model RF10 horizontal hobber, 60 dia, 144 face, 180cc, 8 dP REF#103 G&e 96h, roughing & finishing 104 dia. REF#106 tos Fo-16 single index 80 dia. yr 1980 REF#106 craven spline & pinion hobber 36 x 96 REF#106 G & e 48h 48 dia. diff, ob, change gears REF#106 Pfauter hobber P-1800 70 dia. 29 face yr 1980 REF#106 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 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 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 FelloWs #4Gs & 4aGs, 6 dia, 2 Face, 4dP, 68, Ref.# several 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 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 Fellows 36-6, shaper W/6 riser, change gears REF#106 Magg shaper sh4580-500s, 206dia. 26 face REF#106 Magg shaper sh250, 98 dia. 26 face REF#106 Fellows #10-4,7 riser yr 1980 REF#106 GEAR DEBURRING/CHAMFERING/POINTING cRoss #50 Gear tooth chamferer, 18 dia, single spindle 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 cRoss #54 Gear deburrer, 30 dia, 18 Face REF#103 Red RinG #24 twin spindle dia 4 REF#103 Gleason GtR-250 VG cnc 5-axis REF#103 Gleason- hurth Model Zea 4, Max dia 250mm, Max Module 5mm REF#103 Redin Model 36 universal chamfering and deburring Machine, Max od 36, twin spindle, tilt table REF#103 GEAR HONERS 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 #Gcy-12, 12 dia, 5 stroke REF#103 Red Ring Gci 24, 12.75 dia, 5 stroke REF#103 Kanzaki model GsP 320 Gear shaver REF#103 GEAR GENERATORS, STRAIGHT BEVEL Gleason #37 str. bevel Planer, 6 dia REF#103 Gleason #496 straight.& spiral. 7.5 dia REF#103 Gleason 725-Revacycle, 6 dia REF#103 Gleason 726-Revacycle, 5 dia REF#103 GEAR GENERATORS, SPIRAL BEVEL (HYPOID) Farrel sykes Model 12c herringbone max dia 264, max face width 60 REF#103 Farrel Model 5b herringbone gear generator. REF#103 Gleason 529 gear quench press, auto cycle 16 diam, new 1980 REF#103 Gleason 614 hypoid finishing machine, 10.5 pitch, dia 5.25 Max cone dist REF#103

oerlikon/klingelnburg Model c28, Max dia 320 mm, Max Module 7.5 mm REF#103 Gleason Model 26 Quench press and hypoid Generator Max od 16, Max face Width air cylinder REF#103 Gleason Model 36 Gear Quenching Press, Max Ring 28 od, 8 Face, universal REF#103 Gleason Model 450 hc cnc hypoid cutter, Face width 2.6, fanuc 150 controls REF#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 Gleason #463, 15 dia REF#103 hofler model Rapid 2000l, cnc Grinder, Max od 78, cnc dressing REF#103 Matrix model 78, Reman cnc thread grinder, 24 dia, 86 grind length, 106 between centers REF#103 Mitsu seiki Model GsW-1000 Gear Grinder REF#103 Reishauer RZ 362 as, cnc Grinder, Max dia 360mm REF#103 sundstrand/arter Model d12 Grinder REF#103 teledyne-landis Gear Roll Finishing Machine, 5 diam, 42k lbs Rolling Force 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 GEAR THREAD & WORM, MILLERS/GRINDERS 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 huRth #KF-33a Multi-Purpose auto-Milling Machine 88 REF#103 lees bRadneR #ht12x102, extra large capacity REF#103 lees bRadneR #ht 12"x 144" thread Mill, 12" dia, REF#103 lees bRadneR # lt 8 x 24 8 dia REF#103 holRoyd 5a 24.8 dia REF#103 lees bRadbeR WoRM MilleR REF#103 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 Gleason #4, #6, #13 and #17 testers REF#103 hofler eMZ-2602 int/ext Gear tester 102 REF#103 Klingelnberg #PFsu-1600 Gear tester-2001 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 Vinco dividing head optical inspection REF#103 Gleason model 511 hypoid tester Max dia 20, max spindle centerline 3.5 REF#103 Klingelnberg Model PFsu-1600 63 dia, 1.02 dP, Rebuilt REF#103 MaaG es401 Pitch tester With Process computer 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 Klingelnberg Model lRK-631 Gear lapper 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 change gears for G & e hobber REF#106

60

gearsolutions.com

MARKET
Manufacturing excellence through quality, integration, materials, maintenance, education, and speed.

placE

Incorporate for as little as $99

Visit www.incorporate.com or call 888-743-7440

Save $25 by scanning this code

JUNE 2012

61

Bio-Circle Parts Washers Eliminate Solvents

LASERSHOWS. FIREWORKS. ROLLERCOASTERS.

THE ONE EVENT TO SEE THE MOST SPECTACULAR METAL FABRICATION TECHNOLOGY. FABTECH 2012.
Experience the ultimate thrill of FABTECH 2012a place where you can see and compare cutting-edge equipment and technology in action. Check out all the new products, network with industry pros and nd solutions to work smarter and be more competitive. eres nothing else like it!
Bio-Circle is a parts cleaning system that uses bioremediation, a natural process where microscopic organisms digest oils and greases and convert them into water and carbon dioxide. The Bio-Circle parts washer includes a full-service maintenance program for Bio-Circle customers, called Bio-Circle CARE Service that makes it even easier for the industrial market to go green. The cleaning system typically includes a washbasin, bioremediation cleaning solution, internal filters to catch debris, and accessories such as nozzles and brushes. Dirty parts are placed in the sink and then soaked with the solution. The parts are scrubbed and rinsed clean and the oil and grease detach themselves from the surface and fall in the tank where they are consumed by the microorganisms inside the liquid. For more information, visit www. biocircle.com.

North Americas Largest Metal Forming, Fabricating, Welding and Finishing Event

November 12-14, 2012 | Las Vegas Convention Center

REGISTER NOW at fabtechexpo.com

Cosponsors:

Scan this code to watch an exciting preview of FABTECH.

Follow us:

62

gearsolutions.com

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

Allen Adams Shaper Services .................................................... 61 Apollo Broach Inc ...................................................................... 61 Bourn & Koch ............................................................................ 63 Cincinnati Gearing Systems ....................................................... 10 Circle Gear ................................................................................ 56 Clarke Gear Co .......................................................................... 44 Cole Manufacturing Systems Inc ................................................ 61 DT Technologies sa.................................................................... 57 Encoder Products Company ...................................................... 57 Engineered Tools Corporation (ETC) ......................................32-33 FABTECH 2012 ......................................................................... 62 Gear Motions Inc ....................................................................... 53 Gear Solutions Online ................................................................ 45 Gleason Corporation .................................................................. 23 Hanik Corporation ...................................................................... 63 Hilco Industrial ........................................................................... 18 Index Technologies .................................................................... 61 Ingersoll Cutting Tools ................................................. 11,13,15,17 Innovative Rack & Gear Co ........................................................ 61 IOSSO Products ........................................................................ 34 Ipsen International...................................................................... 27 KAPP Technologies ...................................................................IFC KISSsoft USA LLC ..................................................................... 12 Klingelnberg GmbH...................................................................... 2 Lawler Gear Co.......................................................................... 61 Micro Surface Corporation ......................................................... 44 MicroGear .................................................................................. 36 Mitsubishi Heavy Industries America Inc .................................... BC New England Gear ....................................................................... 7 Niagara Gear Corp..................................................................... 12 Ontario Drive & Gear Ltd ............................................................ 37 Premier Shot Company .............................................................. 16 Process Equipment Company .................................................... 35 Proto Manufacturing Ltd ............................................................ 14 R P Machine Enterprises Inc ...................................................... 58 Raycar Gear & Machine Co........................................................ 56 Repair Parts Inc ......................................................................... 34 Riverside Spline & Gear Inc ..................................................... 9,51 Russell Holbrook & Henderson................................................... 38 Sandvick Coromant ................................................................. IBC Schafer Gear Works Inc ............................................................. 43 STD Precision Gear & Instrument Inc ......................................... 36 The Broach Masters .................................................................... 4 The Company Corporation ......................................................... 61 TMFM LLC ................................................................................ 54 Toolink Engineering Inc ................................................................ 1

aDvErtiSEr INDEX

JUNE 2012

63

Q&A
Jack FioriLLe
cMfgE
Elyria ManufacturinG cOrp .
Other companies specialize in those steps so it isnt necessary for us to provide that to our customers. GS: What was your background or experience in metalwork and CNC? JF: Its interesting. I came out of high school through a vocational electronics program and I went to work in radio as a broadcasting engineer. I got my FCC license, and while I was doing that, I continued working in the electrical field for about six years. During that time I also worked in machine shops and got interested in CNC programming. I took every weeklong class or course I could find with different colleges and training class in everything from heat-treating to metalworking. I probably completed 30 or more post secondary education courses that helped me work into a position with a company. As a matter of fact Im signed up for another class soon to learn a new technique. One thing for sure is there is a shortage of people out there who are educated in the field. A college degree in engineering doesnt always give a person the experience or education they need to work in this industry unless they have hands-on training. Without hands-on training they arent going to be very good at machining. Fieldwork gives a person the fine-tuning in real world situations to be an effective employee. In this work you need to have seen it, witnessed it, experienced it, tried it and tested it. GS: Some people either dont have the resources or the interest in obtaining a fouryear college degree. Is it possible to enter this field now without a degree? JF: I think its feasible and getting actual experience is a good place to start. I know for a fact that it is possible to work up to a decent salary without a college degree. If you want to enter this field and youre working and going to school after work, it will take you eight to 10 years to get a degree in engineering, and then youll be paying back those loans for years afterward. What the college degree does is get you in the door with large corporations. Many of them wont allow a man to be called an engineer without the degree. The large corporations I worked for in the past called me a technician, but they paid me an engineers salary because I was doing the job of an engineer. I also believe that some people are born with a nack for metalworking. Some things you know instinctively and some people, even when they are taught something, arent able to machine a piece of metal. GS: As more companies fully automate their shops or move to robotics do you think the engineer or machinist will ever become obsolete? JF: No. Thats something I wanted to hit on. The human factor in machining is always going to be necessary. Our company is now completely automated, but the machines cant do what people can do. We just bought a machine from Mori Seiki that does three things at once, and although it runs on a computer program and greater strides are being made in programming computers to think like humans, doing this work still requires a human factor. The software doesnt know how to be creative. Humans must orchestrate this process to merge three different tasks at once to make a product that is profitable as well as successful.

GS: As a manufacturing engineer for Elyria Manufacturing Corp., what are your duties? JF: As a manufacturing engineer my focus is in machining, quoting prices for customers, purchasing tools and tooling up for the process and then programming the CNC to manipulate the metal to exacting tolerances that we call a robust process. We run jobs with 10,000 pieces where it is necessary to invest in more tooling and we do smaller runs on the lathe of hundreds of parts where the tooling doesnt require the same longevity, so I have to know whether a purchase is necessary based on the quality and quantity of a job. Cycle times also come into play. Here at our facility, we machine parts, but we outsource coating, heat-treating, finishing, anodizing, hard coating and other products. GS: What is the reason for outsourcing those steps? JF: We specialize in machining and we do assemblies here and sell those as a unit the assembly work is one of our most profitable sectors of the business. We send our products out for coatings, heat-treating, finishing, or anodizing or for aluminum products because, basically, those are expensive procedures that require a large investment in equipment.

tO lEarn MOrE:
Visit emcprecision.com or call 440-365-4171.

64

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