AUG

2014
IMTS 2014
WHAT YOU SHOULD KNOW | EXHIBITOR BOOTH LISTINGS | WHAT YOU’LL FIND THERE

FEATURE:
HOW HONING CUTS COST,
BOOSTS PRODUCTION

TECHNICAL

ASK THE EXPERT:

FULLY GROUND ROOT FILLETS;
WHY CONTACT PATTERN MATTERS;
LUBRICANT ADDITIVES
FIRST INTERNATIONAL INVOLUTE
GEAR COMPARISON
FATIGUE TESTING OF GEARS IN
POWERTRAIN AXLES, PART I

ADDENDUM

RIDE, SALLY, RIDE

www.geartechnology.com

THE JOURNAL OF GEAR MANUFACTURING

Samputensili G 250
generating and profile
grinding machine

The Samputensili G 250 gear grinding machine has been especially developed for very
low cycle times and for top-quality and efficient mass production of gears with outside
diameters up to 250 mm and shafts with lengths up to 550 mm.

The machine is based on the dual work spindle concept, which eliminates non-productive
times almost completely. By means of this feature, the loading/unloading process of a
workpiece is carried out in masked time, while simultaneously the manufacturing process
proceeds on another workpiece. Simple design concepts in terms of tooling and dressing
technology, fast automation and amazing user friendliness are the strengths behind this
innovative machine.

Phone: 847-649-1450 • [email protected]

5200 Prairie Stone Pkwy. • Ste. 100 • Hoffman Estates • IL 60192
 September 8-13, 2014

The G 250 / G 450 can be easily equipped with

various automation solutions

Visit Star SU (booths N-6924 and W-2258) at IMTS

www.star-su.com/gear-grinding
 contents

AUG
2014
IMTS 2014
20 What You Should Know
26 Exhibitor Booth Listings
30 Show Stoppers
Special Advertising Section
34 Here’s What You’ll Find
20
34

features
60 Gear Honing
Can boost quality and throughput.

60

technical
68 Ask the Expert #1
Pros and cons of fully ground root filets.

71 Ask the Expert #2

Additives: Anti-Wear vs. Anti-Scuff
Is One Better?

72 Ask the Expert #3

Contact pattern in assembly of bevel vs. cylindrical
gears.

74 Setting Load Parameters for Viable Fatigue

Testing of Gears in Powertrain Axles.
Part I: Single-Reduction Axles.

80 First International Involute Gear Comparison

Measurement of gear artifacts compared between
countries.

Vol. 31, No. 6 GEAR TECHNOLOGY, The Journal of Gear Manufacturing (ISSN 0743-6858) is published monthly, except in February, April, October and December by Randall Publications LLC, 1840 Jarvis Avenue, Elk Grove
Village, IL 60007, (847) 437-6604. Cover price $7.00 U.S. Periodical postage paid at Arlington Heights, IL, and at additional mailing office (USPS No. 749-290). Randall Publications makes every effort to ensure that the processes
described in GEAR TECHNOLOGY conform to sound engineering practice. Neither the authors nor the publisher can be held responsible for injuries sustained while following the procedures described. Postmaster: Send
address changes to GEAR TECHNOLOGY, The Journal of Gear Manufacturing, 1840 Jarvis Avenue, Elk Grove Village, IL, 60007. Contents copyrighted ©2014 by RANDALL PUBLICATIONS LLC. No part of this publication may
be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the publisher.
Contents of ads are subject to Publisher’s approval. Canadian Agreement No. 40038760.

2 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
Generating Grinding .8mm to 1.25mm Profile Grinding .8mm to 80mm

Taking care of your needs...

the Smallest and the Largest.
KAPP KX 260 NILES ZP 12 R&P PM 750-1250

BOOTH
N-7036

KAPP Technologies
2870 Wilderness Place Boulder, CO 80301
Phone: (303) 447-1130 Fax: (303) 447-1131 www.kapp-niles.com [email protected]
 contents

Vol. 31, No. 6

departments
06 GT Extras
Gear Technology will feature the latest product and
industry news items related to IMTS on our website,
as well as Twitter and LinkedIn.

08 Publisher’s Page
Beginning, Renewing, Sharing

10 Product News
Latest and greatest in software and hardware

85 Subscriptions
Sign up for Gear Technology for free.

86 Industry News
What’s news; who’s new; comings and goings

92 Calendar of Events
August 26–28: International Gear Conference 2014,
Lyon-Villeurbanne, France;
September 8–10: Gear Failure Analysis Seminar, Big
Sky Resort, Big Sky, Montana;
September 8–13: IMTS 2014, McCormick Place,
Chicago, Illinois.

93 Advertiser Index
How to reach every advertiser in this issue

95 Classifieds
Our products and services marketplace

96 Addendum
Sally Ride Science — Creativity, Collaboration and Fun

AUG
2014
IMTS 2014
WHAT YOU SHOULD KNOW | EXHIBITOR BOOTH LISTINGS | WHAT YOU’LL FIND THERE

FEATURE: How Honing Cuts Cost,

Boosts Production

TECHNICAL

ASK THE EXPERT:

FULLY GROUND ROOT FILLETS;
WHY CONTACT PATTERN MATTERS
LUBRICANT ADDITIVES
LOW NOISE TRANSMISSION
GEARING
FATIGUE TESTING OF GEARS IN
POWERTRAIN AXLES, PART I

ADDENDUM

RIDE, SALLY, RIDE

www.geartechnology.com

THE JOURNAL OF GEAR MANUFACTURING

Ingersoll photo by David Ropinski

4 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
Intelligence in Production.
Liebherr at the IMTS
During development of our innovations, we place particular Visit us at:
emphasis on choosing an optimal solution for the respective Chicago, Il. - USA
application. The result: Process stability and an outstanding September 8 - 13, 2014
quality of manufactured components – with the highest North Hall,
Booth N-6930
level of economy possible.

Generating grinding machine LGG 180 / LGG 280

• A single-table solution for gear grinding of workpieces
up to Ø 180 mm, or up to Ø 280 mm, and workpiece
lengths up to 500 mm
• Extremely fast load / unload times of 4 seconds,
chip-to-chip, with a single-table
• New Palletizing Cell LPC 3400

Liebherr Robot Cell LRC 20

• Flexible robot solution replaces complicated sorting
systems, increases productivity, and alleviates burden
on personnel
• Part weight up to 44 lbs
• Automatic unloading and direct positioning
• Mechanical, magnetic, vacuum grippers

Wenzel Gear Measuring Machine WGT 400

• Longtime stability from granite structure
• Air bearings in all axes for highest precision
• Easy to use software with parameterized input masks
• Max. measurable diameter 400 mm
• Max. face width 500 mm
• Distance between centers 650 mm
• Accuracy according to VDI / VDE 2612 /13 Group 1

Liebherr Gear Technology, Inc.

1465 Woodland Drive
Saline, Michigan 48176-1259
Phone.: +1 734 429 72 25
E-mail: [email protected]
www.liebherr.com
The Group
 GT extras
THE GEAR INDUSTRY’S INFORMATION SOURCE
www.geartechnology.com

GT Videos
The Gleason Phoenix 280C/280CX Bevel RANDALL PUBLICATIONS LLC
Gear Cutting Machine allows users to 1840 JARVIS AVENUE
reduce cycle times by as much as 35% ELK GROVE VILLAGE, IL 60007
on the production of bevel gears and
pinions up to 280 mm in diameter. See (847) 437-6604
a demonstration video of this and other FAX: (847) 437-6618
machine tools on the Gear Technology
homepage at www.geartechnology.com.
EDITORIAL
Publisher & Editor-in-Chief
Michael Goldstein
[email protected]
Associate Publisher & Managing Editor
Randy Stott
[email protected]
Senior Editor
LINKEDIN
Jack McGuinn
The THORS Academy Gears Knowledge Center offers a complete [email protected]
overview and understanding of metallic gears. Users learn the differ- Senior Editor
ent gears available and their classifications based on their relative Matthew Jaster
[email protected]
orientation of the axes of rotation, how they’re manufactured, and the
advantages and disadvantages of using each type. For more infor- Editorial Consultant
Paul R. Goldstein
mation on the Gears Knowledge Center visit www.thors.com.
Technical Editors
William (Bill) Bradley, Robert Errichello,
Octave Labath, P.E., Joseph Mihelick,
Charles D. Schultz, P.E., Robert E. Smith

DESIGN
Art Director
David Ropinski
[email protected]

ADVERTISING
Associate Publisher
& Advertising Sales Manager
Back to Basics Dave Friedman
[email protected]
Looking for a good article on gear
fundamentals? The Gear Technology Materials Coordinator
Dorothy Fiandaca
Articles Archive can be accessed by [email protected]
typing “basics” into the search box on
China Sales Agent
the Gear Technology homepage. Eric Wu
Eastco Industry Co., Ltd.
Tel: (86)(21) 52305107
IMTS 2014 Fax: (86)(21) 52305106
Cell: (86) 13817160576
Gear Technology will continue to fea- [email protected]
ture the latest product and indus-
Stay Connected CIRCULATION
try news items related to IMTS Circulation Manager
2014 taking place September 8-13 Follow us on Twitter
Carol Tratar
[email protected]
at McCormick Place in Chicago. All twitter.com/#!/Gear_Technology
the new technologies, products and RANDALL STAFF
can’t miss events will be available President
Michael Goldstein
on our website as well as Twitter and Connect with us on LinkedIn
LinkedIn. www.linkedin.com/groups/Gear- Accounting
Technology-Magazine-3893880 Luann Harrold

Subscribe Online
www.geartechnology.com/
subscribe.htm

6 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
OUR LINE
JUST GOT
LONGER...
Looking for a partner for your
high-production, multi-station machining,
assembly and finishing operations?
German Machine Tools of America (GMTA) TA) now
offers a broad assortment of vertical turning
g lathes,
lathes
horizontal gear cutters, single and double-side
grinding machines, the patented Scudding® process
for gear internals, honing machinery and now, laser
welding assembly and parts washing equipment.
Our recent additions of the Arnold laser line and
Rosink parts washers mean you have end-to-end
expertise from just one phone call.
We’re not all things to all people,
but we’re getting there!
Plus, you enjoy the advantages of GMTA
application engineering, unmatched experience in
the manufacturing technologies for gears and other
power transmission components, multi-national
support in sales and service, plus the unique
assortment of machine tools and related equipment
to keep your process at peak efficiency.
Cut, clean and combine your power transmission
and other part assemblies with GMTA on your team..
Call Scott Knoy at 734-973-7800 today

See our machines in action!

Gear and Spline with Scudding®

VTL Power Honing Center Drive Turning Parts Washing

Laser Welding

See At Booth N-6670 4630 Freedom Drive | Ann Arbor, MI 48108 | 734-973-7800 | www.gmtamerica.com | Email: [email protected]
 publisher's page

BEGINNING, RENEWING,
SHARING
There’s an IMTS Journey
for Everyone
IMTS is about beginnings. Publisher & Editor-in-Chief
Michael Goldstein
This year’s show takes place September 8-13 at McCormick
Place in Chicago. With more than 1,900 exhibitors expected to
occupy more than 1.2 million square feet of exhibit space, there Finally, IMTS is about sharing.
will be plenty of technology on display—much of which may While it’s one thing to recognize that IMTS has a lot to offer
have potential for you or your company. Your chance to begin you, and that you could potentially have a lot to gain from the
exploring that technology only lasts a week, and it only comes people you meet there, it’s also important to know that you have
every two years. a lot to offer IMTS. Many of you are the experts who have the
More importantly, IMTS gives you the opportunity to begin experience, knowledge and expertise. Many of you have the
relationships with suppliers you may not have worked with contacts and stories to share with others.
before. Expanding your network of contacts gives you access We hope you’ll come to Booth N-7214 and share them
to experience, knowledge and expertise that you wouldn’t oth- with us as well. Our editors will be at the show every day, and
erwise have. Perhaps there’s an expert at Gleason, Liebherr, they’ll be looking for people like you to share their experiences
Klingelnberg or Star-SU who’s already helped solve some of the about gear manufacturing. We want to know what technology
gear manufacturing problems you’re currently working on. But is working for you, what new trends you’re seeing, what gear
you may never know unless you go to IMTS and begin those manufacturing problems need solving. And if you have some
relationships. interesting gear-related stories to tell, we’d love to hear them.
Maybe you’re beginning to think more about your company’s After all, Gear Technology has been part of the gear industry for
marketing, but you don’t know where to start. We can help with 30 years, and we’re all about sharing. We’re here to help spread
that, because we’ll be at IMTS, too. Stop by our booth, N-7214, information to the industry.
and we’ll be happy to discuss with you—in a friendly, no-pres- So no matter what phase of the IMTS journey most interests
sure way—all the tools that are available to help you communi- you, come to Booth N-7214. We look forward to seeing you.
cate your message to the gear industry, to buyers of gears and
geared products and related markets.
IMTS is also about renewals.
Just as important as beginning new relationships is continu-
ing old ones. There’s nothing quite like a trade show for build-
ing camaraderie and rapport among members of an indus-
try. Over my career I’ve been to many events like IMTS, and
I always see old friends catching up. In fact, I’ve noticed that
most gear manufacturers get as much value out of meeting with
their competitors—who sometimes also happen to be friends—
as they do out of meeting potential customers or suppliers.
Perhaps it’s time for you to renew your commitment to
upgrading your facility, to lean manufacturing, to increased
automation, or to whatever other manufacturing initiatives you
know you’re supposed to be working on but haven’t had the
time. IMTS can help with that.
Of course, it’s my duty to remind you that we also need you
to renew your subscriptions to Gear Technology and Power
Transmission Engineering. Both magazines will be at booth
N-7214, and we’ll have quick and easy forms on hand that will
allow you to continue receiving the finest technical information
available for the gear industry for the next two years.

8 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 VISIT US 9001:2000
PRECISION CO., LTD. BOOTH #N-7074
SEPTEMBER 8-13
MEMBER
CERTIFIED

LFG-3540
Horizontal Gear Grinder

Using today’s most advanced technologies Luren presents the LFG-

3540 CNC profile gear grinding machine. Using PC based software, op-
erators can easily learn how to effectively run this gear grinder. With the
use of Fanuc controls, direct drive motors, linear motors and great service,
we can deliver a very precise gear grinding machine with reliability to
match.

get more information at www.lurenchicago.com

Corporate Headquarters North American Headquarters
Luren Precision Co., Ltd. Luren Precision Chicago Co.,Ltd.
No.1-1, Li-Hsin 1st Road, 707 Remington Road, Suite 1,
Service Available
Hsinchu City, Taiwan, 30078 Schaumburg, IL 60173, U.S.A.
Phone : +886-3-578-6767 World-Wide Phone : 1-847-882-1388
Fax : +886-3-578-4933 Fax : 1-847-882-1933
Email : [email protected] Email : [email protected]
 product news

PTG
REVISES MAINTENANCE AND SUPPORT SERVICES
U.K.-based Precision Technologies Manager, Alan Mead. “In creating
Group (PTG) has revised its range our menu of Absolute Care servic-
of machine tool maintenance and es,” he continues, “we have made it
support services, to provide what it simpler than ever for our custom-
believes to be one of the most com- ers to select the precise mainte-
prehensive and cost-effective cus- nance solutions they require, and
tomer care packages available for ensure their PTG machine tools
machine tool users globally. Under provide a long and reliable working
the name of Absolute Care, the com- life. Additionally, by developing a
pany has created a suite of tailored bespoke range of services for owners
maintenance solutions for users of of other machine tools, we provide
its Holroyd ultra-precise milling and the option of having their equipment
grinding machines. A similar range maintained to the uncompromis-
of Absolute Care services is available ingly high standards that Precision
for owners of PTG Heavy Industries’ Technologies Group is renowned for.”
Powerstir friction stir welders, and The Absolute Care services offered
Binns & Berr y/Crawford Swift by Precision Technologies Group
heavy-duty lathes, roll lathes, deep include emergency U.K., EU and
hole boring machines and roll grind- worldwide engineer response, remote
ing machines. machine support and fault diagnosis,
In addition, extensive repair, refur-
bishment and upgrade services, as
well as CNC repair and upgrade solu-
Planned Preventative Maintenance
(PPM), process enhancements, CNC
repairs and upgrades, machine refur-
Vomat
OFFERS FILTRATION
tions, are available for lathes and bishment and reengineering, OEM TECHNOLOGY FOR
machine tools from a wide range of parts, and a brand new dedicated METAL COOLANTS AND
other manufacturers. “At Precision machine tool care plan. LUBRICANTS
Technologies Group, we have always For more information:
strived to offer the highest lev- PTG Holroyd Precision In tool grinding all individual process-
els of machine tool maintenance,” Phone: +(44) 1706 507 831 ing steps are part of a coherent value
www.holroyd.com
comments Customer Care General chain. Therefore it is important that the
filtration process of metal coolants is
integrated seamlessly in this value chain.
When operational requirements or
technical improvements cause chang-
es and flexibility is needed, your fil-
tration system should meet those new
needs. The filtration specialist Vomat
meets these challenges with a line-up of
high-tech systems. From stand alone to
large industrial central filtration systems
Vomat’s offerings are of modular design
and can be adapted quickly and easily to
changing shop and production require-
ments.
Stephan Hecht of oelheld U.S., Inc.,
Vomat’s general agent in Elgin, Illinois,
states: “By design the stand alone
Vomat-FA-series models have a flow
capacity of 120 to 960 liters per minute.
In addition, we provide our customers
with a number of add-on modules which
can be easily integrated, when the need
arises. The array of modules includes

10 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 ing the backflush cycle the operator facility alterations and provides the cli-
always has full oil flow. This allows for ent with more floor space.
energy efficient, time optimized opera- For more information:
tion in sync with the customer’s grind- Vomat (Distributed by Oelheld)
ing machine. The Vomat FA 120 through Phone: (847) 531 8501
www.vomat.de
420 series machines with dimensions of
1 × 1 × 1.6 meters are also significantly
smaller than comparable filtration sys-
tems on the market. This keeps trans-
portation costs low, possibly reduces

displays for the complete visualization

of the filtration process in real time, fre-
quency controlled pumps, internal and
external pre-filters and various cooling
solutions.
In close cooperation with the custom-
er, Vomat tailors a filtration solution to
individual production conditions, which
can be can be altered in case require-
ments change. Hecht adds, “If our client
implements technological improvements
in his production process, Vomat can
help to make sure that the filtration sys-
tem will meet the new requirements.”
Besides the modular expandability of
Vomat systems, it is mainly the inno-
vative filter technology that provides
Vomat customers with economic ben-
efits: Vomat systems filter in full flow
stream and separate dirty from clean
oil 100%, thanks to high capacity pre-
coated filters. The results are lubricants,
which meet NAS 7/8 or 3-5 microns in
terms of purity and cleanliness. Clean
oil is decisive for dimensional accuracy
and surface quality of the finished work
piece.
In addition, Vomat systems adapt
intelligently to changing volumes of
sludge and automatically initiate the
backflush cycle depending filter con-
tamination. Each Vomat machine is
equipped with enough filters, that dur-

August 2014 | GEAR TECHNOLOGY 11

 product news

Krebs & Riedel

OFFER INNOVATIVE GRINDING TECHNOLOGY
Krebs and Riedel is a family-owned oxynitride), guarantee low ther-
company and has been in opera- mal effects on the workpiece, good
tion in Bad Karlshafen Germany retention of profile, and cutting abil-
since 1895. With over 190 dedicated ity with high dressing cycle speeds
employees and an annual turnover and high efficiency.
of €21 million is one of Germany’s The company is certified in accor-
leading manufacturers of advanced dance with ISO 9001:2008 and pro-
grinding wheels. An export share of duces the grinding tools in accor-
approximately 40 percent demon- dance with the internationally valid
strates the international orientation standards EN, ANSI and JIS. Krebs
of the company with exports being and Riedel is a member of the Gear
a major part of their sales program. Research Circle of the Laboratory
Products include conventional for Machine Tools and Production
grinding and cutting wheels using Engineering (WZL) at RWTH
corundum and silicon carbide abra- Aachen University (Germany).
sives. Super abrasive (CBN and dia- The range held in stock includes
mond) tools with a vitrified bond grinding wheels in white high-grade
have been manufactured with ever aluminium oxide and sintered alu-
rapidly growing sales since 1985. minum oxide. Due to their selective
The production of grinding wheels porosity and grain compound, the
takes place on modern machinery grinding wheels guarantee a cool
and profiling of the grinding wheels grind with high profile and abrasion
on the CNC machines PM280T resistance. Most recently, the appli-
& PM550TC with automatic tool cation of dressable vitrified CBN
change manufactured by M/s Burri grinding wheels to gear grinding has
Werkzeugmaschinen with the very also intensified. For this purpose,
latest profiling techniques. Krebs and Riedel can also offer a
The grinding wheel compounds product program that is continuous-
are based on the innovative Multo ly developing.
vitrified bond system and, in con- For more information:
junction with the grinding media Krebs and Riedel
used (high-grade aluminium oxide, Phone: +(49) 5672 1840
www.krebs-riedel.com
micro-crystalline sintered alumin-
ium oxide and the new aluminium

12 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
Hexagon
Metrology
LAUNCHES PC-DMIS 2014
Hexagon Metrology recently launched PC-DMIS
2014, a major release of its measurement software
used for the collection, evaluation, management and
presentation of manufacturing data. PC-DMIS 2014
introduces tools and technologies that will help mea-
surement devices perform better than ever, increase
the effectiveness of inspection planning time, and
make it easier to complete complex inspection rou-
tines. Hexagon Metrology will demon-
strate PC-DMIS 2014 with over 17 major
and 81 minor software enhancements in
Booth 5202 at IMTS 2014. The new software
includes a number of productivity advance-
ments to improve speed of common pro-
gramming tasks and to improve the overall
user experience. “PC-DMIS 2014 delivers
new and improved capabilities based on
real-world user feedback from the PC-DMIS
forum and our technical support teams,”
said Ken Woodbine, president of Hexagon
Metrology software division. “This release
is focused on productivity, and sets the stage
for future user experience enhancements
already in the planning stage and moving
forward.”
Highlights of PC-DMIS 2014 include a
new 1-click “QuickFeature” feature cre-
ation from CAD models, where users can
also create Quick Features by hovering their
mouse over a CAD model to highlight CAD
elements. Contact auto features are created
from a single click on the CAD model with-
out using any menu options or dialog boxes.
There is also a 1-click “QuickAlign” capa-
bility where users can now select valid com-
binations of one, two, or three features to
create a quick alignment. The QuickAlign
feature will also initiate manual and DCC
alignments when used at the beginning of
a part program. These new productivity
tools are packaged in a new QuickMeasure
toolbar giving drop-down access to com-
mon measurement features, giving more
screen real estate to the graphics and the
measurement routine. The new software
version also includes Copy Parameters and
Paste Parameters functions, which copy
parameters from one feature or dimen-
sion, and paste them to another feature(s)
or dimension(s) in the Edit window, making
block changes much faster.
PC-DMIS 2014 also rolls out a new Mini
Routines feature which can be used to mea-

August 2014 | GEAR TECHNOLOGY 13

 product news

sure a selected dimension or group of

dimensions from a long part program.
Mini routines offer characteristic-based
Grieve
OFFERS TWO-
measurement and the ability to measure COMPARTMENT OVEN
a part of a complete measurement rou-
tine. PC-DMIS is the flagship software
package for Hexagon Metrology mea-
No. 978 is a 500°F, electrically-
heated, two-compartment univer-
Geometric
SET TO PREVIEW
surement devices and a wide range of sal style oven from Grieve, current- CAMWORKS 2015
other measurement equipment in the ly used for various machine shop
marketplace. Geometric will preview its latest
For more information: release of CNC programming auto-
Hexagon Metrology mation solution, CAMWorks 2015, in
Phone: (847) 931-0100 Booth E-3320, IMTS 2014 in Chicago.
www.hexagonmetrology.us
In today’s environment, manufactur-
ers need to be able to do more with

Solid less - less design time, program time,

setup time and machining time.

Technical CAMWorks 2015 focuses on making

the entire design to part cycle shorter.

Solutions CAMWorks 2015 has over a dozen

enhancements focused on shortening
the programming time. One exam-
OFFERS TEC-FLON
LUBRICANTS ple is the color based identification of
complex surfaces making it easier and
Solid Technical Solutions recently intro- quicker to define features by avoid-
duced its product line of high-tech lubri- ing the traditional chains and pro-
cant materials, Tec-Flon (GM-approved). files methodology. CAMWorks 2015
The Tec-Flon family of non-hydrocar- operations at the customer’s facil- has bolstered its ability to interpret
bon, non-silicone, fluorinated oils and ity. Workspace dimensions of this non-prismatic surfaces on solid mod-
greases is designed specifically for use oven measure 30" W × 36" D × 36" H els as machinable entities automati-
with plastics, in paint shops where sil- in each of the two heating zones. cally. This enhanced ability to leverage
6.6 KW per zone (13.2 KW total) feature-based machining for complex
are installed in Nichrome wire ele- requirements in combination with
ments to heat the oven chamber, Intelligent Knowledge Base (TechDB)
while a 600 CFM, ½ HP recirculat- allows end users to eliminate the rou-
ing blower provides front-to-rear tine elements in CNC programming
universal airflow to the workload. and focus on their core expertise.
This Grieve universal oven features
4" insulated walls, aluminized steel
exterior, Type 304, 2B finish stain-
less steel interior, double doors and
an integral leg stand. Controls on
No. 978 include a digital indicating
icones are not permitted, or in vacu- temperature controller in each com-
um environments. The products remain partment of the oven, manual reset
effective when used for high-perfor- excess temperature controllers with
mance applications, even in high tem- separate contactors, recirculating
perature settings. Solid Technical blower airflow safety switches and a
Solutions’ Tec-Flon materials meet or 10" diameter circular chart record-
exceed the performance requirements er, one per compartment, to record
of General Motors; and are well-suited part temperatures.
for use in electronics, optics, aerospace, For more information:
cleanrooms, and general assembly appli- Grieve Corporation
cations. Phone: (847) 546-8225
www.grievecorp.com
For more information:
Solid Technical Solutions/Tectorius
Phone: (586) 232-3999
www.tectorius.com

14 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 Fanuc America
OFFERS LATEST MACHINING IMPROVEMENTS
Fanuc America Corporation introduces CNC innovations that improve machin-
ing performance, ease of use and maintenance at IMTS 2014 Booth #S-8919.
These include: introduction of the new Series 0i-F CNC with new commonal-
ity of design and 15" display option, a new CNC platform with built in Bluetooth
technology and digital servo adapter with new EtherCAT interface.
For a job shop, setup time is critical. Fanuc’s new Series 0i-F CNC is the latest generation of the Series 0i CNC that
With an integrated true G-code simu- now has commonality of design to the versatile Series 30i CNC and a 15" dis-
lation, CAMWorks Virtual Machine, play option. The Series 0i-F boasts common operability, maintainability and
users can make sure that the costly networking options as the Series 30i CNC along with having a highly compat-
process of dry-runs on the shop floor
are minimized with one-click verifica-
tion. The use of G-code for verification
is absolutely critical if you are deal-
ing with sub-programs, macros, sub-
spindle transfers, tail-stocks and steady
rests.
On the other hand, for production
shops, machining time is the key. Users
need to makes sure that what they are
machining is not only correct but most
efficient. The ultra-high performance
tool paths from CAMWorks VoluMill,
has enhanced capability to handle
more complex geometries like multi-
step irregular islands, that can be very
difficult to address with trochoidal tool
paths which a number of other systems
try to use to address this critical chal-
lenge.
For more information:
Geometric
Phone: (248) 404-3500
www.geometricglobal.com

August 2014 | GEAR TECHNOLOGY 15

 product news

ible PMC ladder. This translates to easier 0i-TD (turning) and a 2 path system less technology that can operate a CNC
operation and maintenance across the now available on the 0i-MF with 11 total by keyboard or mouse. So, via remote
plant floor. The seamless combination controlled axes, the Series 0i-F is more desktop it is possible to transfer data
of using the same motors, amplifiers, versatile to improve machining perfor- between a tablet and CNC. Advanced
peripheral devices (safety machine oper- mance. Additional new features on the PC applications such as CAD/CAM or
ator’s panel, I/O module/unit, iPendant, Series 0i-F include: 15" display, I/O Link
interface unit for handy machine opera- i, FSSB high speed rigid tapping, func-
tor’s panel) as the Series 30i further sim- tion for loader control, tolerance con-
plifies the ease of use and maintenance trol, axis name expansion, program fold-
of the Series 0i-F. Seamless and common er management, quick program restart,
PMC functions among both the 0i-F and flexible path axis assignment, multi-path
30i-B CNCs include: multi-path PMC, PMC function, ladder dividing manage-
ladder dividing management, function ment, EtherNet/IP and Profinet.
block, multi-language comment and I/O Fanuc’s new standard CNC platform
Link i. With an increased axis number allows for enhanced CNC functionality
of 9 total controlled axes for a 1 path using PC technology. Built in Bluetooth
system for both 0i-MD (milling) and on the CNC allows for the use of wire-

Powered
by precision
NCGuide are now available on the CNC
remotely without leaving the machine.
This improves functionality and use of
the CNC. Other new features of Fanuc’s
new standard CNC platform include:
enhanced 3-D graphics with Manual
Guide i, new data server with larger stor-
age and use of peripheral devices such as
3M™ Abrasives keyboard and mouse.
for Powertrain Fanuc’s Digital Servo Adapter with
new EtherCAT interface adds more
Components power to applications needing high-
speed and high-accuracy. The Digital
3M offers one of the world’s most Servo Adapter allows for Fanuc servo
extensive portfolios of precision motors to be run from a separate con-
abrasives for grinding and finishing troller over EtherCat. From 1 to 8 axes
powertrain components – all can be controlled, including a spin-
engineered to take you to the next dle interface and multiple large servo
level of precision and productivity. motors - up to 3 large servo motors at a
NEW! Driven by Innovation
Gear up with high-performance 3M time for industrial machines. The Digital
abrasives for applications including: A 16-page brochure devoted
Servo Adapter can replace hydraulic and
exclusively to grinding
• Gear grinding and finishing powertrain other brand servo drives with high accu-
components. To receive racy and high performance Fanuc servo
• Camshaft and crankshaft grinding
your free copy – and to find motors. The EtherCat interface is ideal
• Cylindrical grinding additional information on 3M for industrial machines such as: servo
abrasives for powertrain
• Centerless grinding press machines, wire saw machines and
components, visit:
• Microfinishing www.3M.com/PrecisionGTAug electric injection molding machines.
• Dressing and truing For more information:
Fanuc America
© 3M 2014. 3M is a trademark of 3M Company.
Used under license by 3M subsidiaries and affiliates.  Phone: (888) 326-8287
www.fanucamerica.com

16 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
Mahr Federal
INTRODUCES MARVISION MM 320
Mahr Federal will feature the MarVision MM 320, a new
video measuring microscope with image processing capabil-
ity, the flagship product for a new line of Mahr optical mea-
suring instruments, at Booth #E5242 during IMTS. Designed
for the measurement and/or dimensioning of geometric ele-
ments, the MarVision MM 320 incorporates an integrated
CCD color camera with zoom lens, a 23" touchscreen PC
with keyboard and mouse, and easy to use Windows 7-based
M3 software. Automatic edge detection allows
even low contrast features to be measured,
and a Multi Touch function provides quick
and continuous variable magnification using
either touchscreen or mouse.
“MarVision optical measuring instruments
offer a quick and reliable solution to many
different 2-D measurement and inspection
tasks,” said George Schuetz, director preci-
sion gages for Mahr Federal. “Applications
range from cutting tools and precision prod-
ucts for manufacturing, plastics, and medical
technology, to miniaturized electronic com-
ponents. These extremely precise measuring
instruments are designed to meet the highest
quality and production requirements.”
The MarVision MM 320 rests on a robust
hardened granite base with a precision
mounted XY table. An optical incremen-
tal measuring system assures quick and fine
adjustment of the axis, and a laser point-
er assists with part positioning. The CCD
camera and Navitar Zoom lens with 0.7-
4.5× magnification are mounted on a sta-
ble Z-column with 200 mm vertical move-
ment. Coarse and fine height adjustment
knobs are mounted on both sides for precise
focusing. Illumination is provided by a quad-
rant LED ring top light with four individu-
ally controlled segments, and table mounted
Telecentric LED transmitted light for more
focused measurement of rotationally sym-
metric parts.
For more information:
Mahr Federal Inc.
Phone: (401) 784-3100
www.mahr.com

August 2014 | GEAR TECHNOLOGY 17

 product news

TDM Systems
FOCUSES ON TOOL LIFECYCYLE MANAGEMENT SOFTWARE
By realigning its strategy towards Tool how the TDM 4.7 software package for
Lifecycle Management, TDM Systems, Tool Lifecycle Management makes life
a software manufacturer and process easier for machining companies. The
consultant, is putting comprehensive package will also be presented in the
customer benefit first. TDM Systems is Walter (W-1700) and Parlec (W-2300)
a leader in electronic management of Booths.
tools and production equipment. The “By refocusing on Tool Lifecycle
Schaumberg-based company will exhibit Management (TLM), we purposely put
at IMTS 14 Booth No. E-3264, showing the overall process front and center,”
says Managing Director Peter Schneck.
“We want to make sure that not only we,
but especially our existing and future
customers have a clear idea of the dis-
GLOBAL MANUFACTURER
OF INDUSTRIAL FURNACES
tinct advantages of TLM for the entire
production process – from defining the
tools to using them in planning to ensur-
ing a seamless transfer to and use in
production. In particular, a new feature
is that the information from the indi-
vidual process steps is fed back directly
from production, ensuring continuous
improvement of the data.“
However, TDM Systems does not limit
its view to the processes within a closed
production unit. Global networking
is and will remain one of the trends of
the future: Machining industry 4.0. Not
only companies with international pro-
duction have to be networked to ensure
transparent implementation of in-house
production standards. Suppliers, part-
ners and customers also have to build
electronic bridges connecting each other.
So will there also be a Tool Lifecycle
Management 4.0 in the future? “TDM
Systems is currently developing cloud
IT’S THAT SIMPLE. services so that information is avail-
ECM Technologies’ ICBP® Low Pressure Carburizing “LPC” able on the local level at all times on
furnaces use the Infracarb® patented process. Infracarb®
the Internet,“ says Managing Director
consists of alternately injecting hydrocarbon (C2H2 or C3H8).
Schneck. “Our highest priority, however,
This process along with higher carburizing temperatures can
decrease time, save energy and produce higher metallurgical is on continuous further development of
quality parts. We also have the broadest range of quenching interfaces – such as those for connect-
methods, to reduce distortion, available on one system, using ing CAM systems and machine control
oil, high pressure (20 bar) Nitrogen or Helium with vertical or systems – but on the planning and MES
reverse quenching available. Let us help you transition your level as well. In this area, we are advo-
parts to LPC today. cating for international standardization.
That is the only way to implement Tool
Lifecycle Management with maximum
customer benefit.“
For more information:
Low Pressure Vacuum Carburizing • Neutral Hardening • Oil Quenching TDM Systems
20 bar High Pressure Gas Quenching • Carbonitriding • Annealing Phone: (847) 605-1269
www.tdmsystems.com
8920 58th Place, Ste 100 Kenosha, WI 53144-7822 T. 262.605.4810 WWW.ECM-USA.COM

18 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 feature

IMTS 2014:
Jack McGuinn, Senior Editor THIS IS BIG
Well, if it’s 2014 it must be The Event East: Controls and Cad-Cam;
IMTS time. And what a time it should IMTS 2014 is the 30th Edition of the Machine Components/Cleaning/
be, with manufacturing continuing to one-and-only, can’t-be-missed manu- Environmental; EDM
lead the economy — what new? — out of facturing technology show in North South: Metal Cutting
the morass that was the Great Recession. America. At least 1,900 exhibiting com- East: Quality Assurance
The 2012 show was a rousing suc- panies will occupy 1,240,863 net-square- West: Tooling and Workholding
cess — even if not everyone saw it com- feet of the Lakefront exhibit space at the
ing — and this year’s edition should McCormick Place complex immediate- Industrial Automation North
prove to be even better — the element of ly south of Downtown Chicago. IMTS America at IMTS
surprise notwithstanding. Social media is held every even-numbered year in Industrial Automation North America
will continue to play a big role , with Chicago and attracts more than 100,000 brings the international flare and
many exhibitors promising to partici- buyers and sellers from over 112 coun- dynamic excitement of Hannover
pate. Also top of mind this show are 3-D tries. Messe’s Process, Factory and Building
printing, additive manufacturing and Automation sector to IMTS, the most
automation — technologies much talk- IMTS PAVILIONS comprehensive manufacturing tech-
ed about but little understood by most. To save time and laser in on what you’re nology trade show in the Western
Hey — that’s what IMTS is for! really at the show for, the Pavilions with- Hemisphere.
Add on top of all this the co-locat- in each Hall serve that purpose perfectly.
ed Industrial Automation North The Pavilions are where the klieg lights
America and the Motion, Drive & shine brightest, as the booths of the
Automation North America shows leaders — big and small — of each Hall’s
and — whew! — this is really big doings. designated discipline(s) — are concen-
What follows is a bare-bones overview trated for easy access. Think of the
of the show, but it will get you where you Pavilions as a trade show version
need to go—and when. It includes some of a Lean peg board writ large,
basic information of the gear you’ll find i.e. — Every (Exhibitor) in his
spotlighted in each Hall (Pavilion). (And proper place.
don’t miss our Q&A with show manager
Peter Eelman on Page 22.) BUILDING
North: Abrasive
WHAT TO KNOW IF YOU GO Machining/
(Editors’ Note: The following informa- Sawing/Finishing;
tion was correct and current as we went Gear Generation;
to press. But — things change — so you Fabricating/Laser/
may wish to call ahead to confirm certain Additive
dates and times.)

For Related Articles Search

IMTS
at www.geartechnology.com

20 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 Fact Sheet
Name of Show: IMTS 2014 —
International Manufacturing
Need to charge your
Technology Show
Sponsor: AMT — Association for
phone or tablet?
Manufacturing Technology Stop by the Power Transmission
Venue: McCormick Place, Chicago, Engineering charging station
IL U.S. outside the Motion, Drive and
Show Dates: September 8 (Mon.) – Automation Pavilion.
13 (Sat.), 2014

Attendee Hours Booth E-4401

East & West Buildings:
9:00 a.m. – 5:00 p.m.

CUSTOM
North & South Buildings:
10:00 a.m. – 6:00 p.m.
Registration. On-site registration
only is available Monday, Sept.
8 through Saturday, Sept. 13,
8:00 a.m. – 5:00 p.m., in all four BEVEL GEAR
buildings of McCormick Place. MANUFACTURING
Motion, Drive & Automation
North America at IMTS
In 2014, Motion Drive, & Automation
North America (MDA NA) will be
launched at IMTS. This event will fea-
ture technologies and solutions for the
power transmission, motion control and
fluid technology sectors together. REVERSE ENGINEERING
BREAKDOWN SERVICES
Logistics:
Hotel Shuttle. Complimentary shuttle
bus service will be provided during show IN-HOUSE STEEL MATERIAL WAREHOUSE
days to and from the official show hotels STRAIGHT BEVEL GEARS: 80" PD
and McCormick South, West and East SPIRAL BEVEL GEARS: 66" PD
Buildings. FULL HEAT TREATING SERVICES
Coat and Bag Check. At the follow- SPURS, HELICALS, SPLINE SHAFTS
ing locations from 9:00 am - 6:00 pm: GEARBOX REPAIR/REBUILDS
S100bc, E256, and West - by Gate 40
EDM WIRE BURNING
near info counter. $3 per coat; $4 per
bag; the service will not accept laptops.
Re nting S coote rs/Wheel chairs.
On-site location in the Baggage/Coat
Check area, near Gate 4 of the Grand
Concourse, on the Main Level, you can
rent mobility scooters, wheelchairs and
oxygen equipment during IMTS. You
are encouraged to reserve in advance.
To reserve your equipment call toll
free 1-888-441-7575, or go to www.
scootaround.com/rentals/i/imts.
TOLL FREE: 800 • 238 • 0651
[email protected] • www.brgear.com

Machine and Gear Corporation

August 2014 | GEAR TECHNOLOGY 21

 feature

IMTS 2014
Pre-Show Q&A with Peter Eelman, Vice President — Exhibitions and
Communications — Association for Manufacturing Technology

G e a r Tec h n o l o g y (G T ) : I t
appeared that the robust atten-
dance at 2012’s show almost
took some people by surprise;
indeed, the 2012 registration
reached 100,200 — the highest
show-to-show IMTS increase
ever recorded. Can you comment a
bit on the reason for the big numbers of
2012, as well as on what kind of atten-
dance you expect this year?
Peter Eelman (PE): At IMTS 2012
we saw a number of factors converge,
resulting in extremely strong attendance.
Coming out of the recession, manufac-
turers were
very cautious
about equip-
ment invest-
ments. By
IMT S 2012
we saw pent
up demand
for new tech-
nolog y and
automa-
tion to stay
competitive. There was a rebound from
restricted travel and buying teams were
larger. In addition, we changed our mar-
keting strategy, targeting higher-level
executives who make the decision to
send staff and told them they needed to
“Be There” to stay competitive.
Based on early indicators, for 2014
we expect equally strong attendance. As
visitors walk in the doors of IMTS 2014,
they will know for certain that manufac-
turing isn’t just back — it’s growing and
thriving.
Our industry is bringing forth inno-
vation at a pace never seen before. We
BOOTH #
expect automation and additive manu-
E-5814 facturing to be areas of major interest to
our visitors this year. Automation and
additive manufacturing are two tech-
nologies making a big impact in manu-
facturing.

22 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 Manufacturers large and small are homepage of IMTS.com and receive & Automation North America show. Is
investing in factory automation, while a $100 gift card. The contest will run there anything bigger that takes place
the possibilities of additive manufactur- until Sept. 2, and the winner will be in the States?
ing, such as 3-D printing, has piqued the announced on Sept. 4. The photograph PE: IMTS is the largest industrial
imagination of the maker movement and and company information will be dis- trade show, not only in the U.S., but in
sparked a new wave of innovation and played on the homepage on IMTS.com the Western Hemisphere. We fill more
entrepreneurship. from Sept. 4-15. than 1.2 million net square feet of exhib-
Additionally, automation technol- GT: Taken together — in one cen- it space and host more than 1,900 exhib-
ogy is seeing a huge demand surge tral location — you will have the iting companies. Only the Consumer
from manufacturers of all varieties. International Manufacturing Electronics Show is larger.
Automation has become more reliable Technology Show (IMTS) co-located GT: How excited should we be about
and affordable than ever before and is with the Industrial Automation North 3-D printing and additive manufactur-
allowing for more flexible and adaptive America show and the Motion, Drive ing?
operations. Worldwide sales of indus-
trial robots reached an all-time high
in 2013, according to the International Seamless rolled Rings · 4”-144”OD CARBON • ALLOY • STAINLESS
Federation of Robotics. Robots are
becoming more collaborative, able to
work side by side with human work-
ers. While those robots can focus on
the more mundane and repetitive shop
floor tasks, the skilled human workers
are able to focus on more critical setup,
programming, data analysis, and quality
improvement tasks.
GT: I’m sure it gets bigger every STILL WAITING ON
YOUR DELIVERY?
two years, but how pervasive do you
believe social media will be in this
year’s IMTS — for both exhibitors and
attendees? At McInnes Rolled Rings, we take pride in the high level of speed
PE: The IMTS community is very con- and service provided to each of our customers, large or small.
nected through social media. We are
active everywhere and based on what we When you need it now, trust McInnes.
know now, we expect more than half of
IMTS exhibitors are using social media
to reach the community. During the
show Social Media Central will have a
presence in each hall. Our Twitter feed 6
days
will be displayed throughout the halls. ORDERS SHIPPING 8
As part of our social media outreach, days
we are holding the “IMTS: Everywhere IN AS FEW AS
You Look” Photo Contest. We’re invit-
ing visitors and exhibitors to join in the
challenge and spell out I-M-T-S using
5 days! Why wait...
10
days
manufacturing technology, like a 3-D
printer, or use their staff, their product, 20
even their lunch if they want! Share the days
photo on Twitter, Facebook or Instagram 12
days
and use the #IMTS hashtag to be con- 18
sidered. This contest is open to visitors
days
16 14
days
and exhibitors. The visitor winner will days
receive a $100 gift card and be featured TYPICAL M
on the IMTS social media channels. The ARKET LEAD TIMES
contest will run until Sept. 7 and the
winner will be announced at IMTS 2014 www.McInnesRolledRings.com
in Chicago.
The exhibiting company with the most
creative design will be featured on the
1.800.569.1420
August 2014 | GEAR TECHNOLOGY 23
 feature
For Related Articles Search
Additive manufacturing and 3-D sition, ultimately developing additive
printing began creating major buzz at manufacturing capabilities into business IMTS
IMTS 2012 and continues to be on the opportunities. at www.geartechnology.com
tips of everyone’s tongue — and for good In fact, additive manufacturing prom-
reason! The technologies continue to ised to be number one on the “wow” fac- using the material science and advanced
gain popular interest, but that is not tor list in AMT’s Emerging Technology manufacturing techniques available
the most exciting part. The increases Center. We will see the complete con- at the Manufacturing Demonstration
in industrial acceptance and continued struction of an electric car by IMTS Facility (MDF) at Oak Ridge National
improvements in the industrial base pro- partner Local Motors. Local Motors will Laboratory (ORNL), Local Motors will
viding additive parts and services are build and deliver the first direct-digital- produce an electric vehicle purpose-built
now the real story line. America Makes manufactured vehicle at IMTS 2014. for the urban transportation needs of
is providing a bridge from applied Designed by Local Motors and the Chicago.
research to the paths for industrial tran- IMTS global community, and built The team starts from scratch employ-
ing direct digital manufacturing tech-
niques and technology integration to
make the parts and assemble the vehicle.
This is a real-world demonstration of
achieving sustainable manufacturing by
using emerging technologies — such as
additive manufacturing — all integrated
in a digital environment.
Local Motors recently announced the
winners of the first 3-D-Printed Car
Design Challenge that was launched
in April to uncover concepts that will
inform and influence the vehicle. More
than 200 entries, representing submis-
sions from 30-plus countries around the
globe, were submitted during the six-
The quality and precision of our week challenge. After a weeklong vot-
Broaches, Shaper Cutters and Gears ing period and review of all entries by
have won customers world-wide - an independent panel of expert judges,
from the smallest gear shop to
NASA and the Mars Rover.
a total of seven designs were selected as
winning concepts.
The winning concept — Strati, created
by Michele Anoé of Italy — will highly
inspire the full-size 3-D printed proto-
type.
As Lonnie Love, group leader, robot-
ics and manufacturing systems research
at Oak Ridge National Laboratory, said,
“Michele’s design offers an excellent bal-
• Broach & Shaper Cutter
manufacturing & repair
ance between innovation, complexity
and practicality. It has good 3-D lines
• Gear & Spline—
prototype to production
and the retractable roof is really cool.”

• Master Gears & Gages

• Small & fine pitch
Precision. Performance. Perfection.
The First time and every time.
ITY TOO
AL
QU

LS

The B roach Masters, Inc.

E
&

SER “DEDICATED TO EXCELLENCE”

VIC

1605 Industrial Drive

Auburn, CA 95603
Phone: (530) 885-1939
Fax: (530) 885-8157
Web: www.broachmasters.com
Email: [email protected]

24 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 High Quality Gears for the Helicopter Industry
Every day, thousands of pilots around the world rely on the exacting quality from every component of
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With over 65 years experience, Arrow Gear's products have been used in the most advanced aerospace
systems produced by our civilization. With a state-of-the-art production facility and dedicated
personnel who are among the best in the business, Arrow Gear offers the expertise
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Arrow Gear also offers leading edge design and development capabilities ensuring
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When you need quality, expertise, and precision,

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Visit Arrow Gear’s

Virtual Tour at
www.ArrowGear.com/tour w w w. A r r o w G e a r. c o m
6 3 0 . 9 6 9 . 7 6 4 0
 feature

IMTS 2014 The following exhibitors are suppliers of products or services that may be of interest to
gear manufacturers who visit IMTS 2014. The Booth numbers include a letter indicat-
ing the building location (N=North, S=South, E=East, W=West, C=North Building, Hall C).
Bold listings indicate advertisers in this issue.

Alphabetical Company Listings Alphabetical Company Listings

COMPANY BOOTH COMPANY BOOTH
3M Abrasive Systems Division N-7063 Gould & Eberhardt Gear Machinery N-7030
Absolute Machine Tools, Inc. E-5225, S-8536 Guyson Corporation of U.S.A. N-6066
Acme Manufacturing Company N-7255 Hainbuch America Corporation W-2413
Action SuperAbrasive Products N-7217 Hammond Roto-Finish Co. N-6759
Advent Tool & Manufacturing, Inc. N-6799 Hangsterfer’s Laboratories, Incorporated N-7526
Alpha Magnetic Workholding N-7030 Harbin Tool Works W-122
American Broach & Machine Company N-7027 Hassay Savage / Magafor / GMauvaisUSA W-2356
Anca Inc. N-7414 Helios Gear Products N-6918
Andantex USA Inc. E-5146 Hessapp N-6924
Asahi Diamond America, Inc. N-7066 Hexagon Metrology, Inc. E-5202
Atlanta Drive Systems, Inc. N-6046 Höfler div. of Klingelnberg N-6837
Avantec Zerspantechnik GmbH W-211 Honsberg N-6924
Baldor Electric Company E-5748 Horn USA, Inc. W-1722
Barnes Bore Honing & Finishing Systems N-7451 Index Corporation S-8136
Bates Technologies, LLC N-7451 Ingersoll Cutting Tools W-1822
Blum-Novotest, Inc. E-5535 Itaca, SRL E-5602
Bohle Machine Tools, Inc. S-8966 Erwin Junker Machinery, Inc. N-7057
Bourn & Koch Inc. N-6924 Kapp Technologies, LP N-7036
Broaching Machine Specialties Co. N-7229 Kasto, Inc. N-6737
Broach Masters/Universal Gear N-7112 Kennametal Extrude Hone W-1522
Ceratizit USA, Inc. W-2446 Kennametal Inc. W-1522
Chevin Tools, Inc. W-2093 Kitagawa-NorthTech Inc. W-2412
Chongqing Juya Machine Tools Co., Ltd. N-6681 Klingelhofer Corporation N-6737
C.L.C., S.r.l. N-6918 Klingelnberg N-6837
Command Tooling Systems LLC W-1446 Koepfer America, LLC N-6918
Comtorgage Corporation E-5814 Lambert + Wahli, AG N-6918
DMG Mori C-813, S-8900 Lapmaster International, LLC N-7451
Dontyne Gears Ltd. N-6778 Leistritz Advanced Technologies Corp. N-6746
Drake Manufacturing Services Co. N-6948 Liebherr Gear Technology, Inc. N-6930
Dr. Kaiser N-7240 LMT USA, Inc. and LMT Onsrud LP W-1732
DTR Corporation N-6557 LMC Workholding W-1314
Dura-Bar W-1272 Luren Precision N-7074
DVS Group - Diskus Werke AG N-6770 MAG Huller Hille N-6924
Elumatec North America N-7024 MAG Witzig & Frank N-6924
EMAG L.L.C. N-6846 Mahr Federal Inc. E-5242
Emuge Corp. W-1536 Maier Machine Tools, LLC S-8980
Engis Corporation N-6751 Marposs Corporation E-5519, N-7433
Erasteel, Inc. N-6382 Mazak Corporation S-8300, C-858
Euro-Tech Corporation W-2453 MD Tooling, LLC W-1579
Federal Broach & Machine Company, LLC N-7046 Micro-Vu Corporation E-5501
Felsomat USA, Inc. N-7040 Miller Broach Inc. N-6197
FFG Werke GmbH N-6924 Mitsubishi Heavy Industries America, Inc.- MI N-7046
Fives N-7018 Mitsubishi Materials Corporation W-1426
Fives Cincinnati - Metal Cutting | Composites N-7018 Mitts & Merrill L.P. N-7220
Fowler High Precision E-5236 Mitutoyo America Corporation E-5214, S-8640, C-878
Frenco GmbH W-2453 Modul N-6924
Fromag N-7220 Monnier + Zahner AG N-6918
Fuji Machine America Corporation S-9059 D. C. Morrison Company N-7516
Gear Technology N-7214 Nachi America Inc. W-2279
Gehring N-6740 Nagel Precision Inc. N-7072
German Machine Tools of America N-6670 Niles Werkzeugmaschinen GmbH N-7036
Gleason Corporation N-7000 North American Machine & Engineering Co. N-7514
Gleason Cutting Tools Corporation N-7000 Northfield Precision Instrument Corp. W-2145
Gleason K2 Plastics N-7000 Norton Abrasives N-7051

26 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
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with machining centers.
DualTherm®........ high performance via separate
heating and quenching chambers.
MonoTherm®...... high flexibility with a variety of
processes and configurations. ALD-Holcroft Vacuum Technologies
49630 Pontiac Trail
Wixom, MI 48393-2009 USA
Ph: 248.668.4130
Fx: 248.624.3710
E-mail: [email protected]
www.ALD-Holcroft.com
 feature IMTS 2014 COMPANY LISTINGS

Alphabetical Company Listings Listings by Booth Number

COMPANY BOOTH COMPANY BOOTH
Oak Ridge National Laboratory N-650 DMG Mori C-813
oelheld U.S., Inc. N-7475 Richard Daley College - Advanced Manufacturing Program
Oerlikon Balzers USA Inc. W-2380 C-822
Osborn International N-7523
Mazak Corporation C-858
Performance Tooling Solutions Int’l W-2115
Polygon Solutions Inc. W-1954 Mitutoyo America Corporation C-878
Power Transmission Engineering N-7214 Seco Tools, LLC C-884
Pratt & Whitney Measurement Systems Inc. N-7094 Sandvik Coromant C-895
Promess, Inc. E-5382, N-6640 ZF Friedrichshafen AG E-4868
PWS Praezisionswerkzeuge GmbH N-7344 Wittenstein E-4879
Qanzhou JianYue Diamond Wheel Co., Ltd. W-1091, W-2083, Siemens Industry Inc. E-5010
N-6681 Andantex USA Inc. E-5146
QC American LLC N-7027 Redex-Andantex E-5146
Radiac Abrasives, A Tyrolit Company N-7440 SKF USA Inc. E-5185
Redex-Andantex E-5146 Hexagon Metrology, Inc. E-5202
Reishauer Corp. N-7040
Mitutoyo America Corporation E-5214
Richard Daley College - Advanced Manufacturing Program
Absolute Machine Tools, Inc. E-5225
C-822
Fowler High Precision E-5236
Riten Industries, Inc. W-1336
Roeders of America Inc. S-9290 Mahr Federal Inc. E-5242
Rosler Metal Finishing N-7587 Promess, Inc. E-5382
Roto-Flo N-7115 Micro-Vu Corporation E-5501
R.P. Machine Enterprises, Inc. N-7030 Zeiss Industrial Metrology E-5504
R&P Metrology N-7036 Marposs Corporation E-5519
Saacke North America, LLC N-7344 Blum-Novotest, Inc. E-5535
Samp S.p.A. N-6924 Itaca, SRL E-5602
Sandvik Coromant W-1500, C-895
Wenzel America, Ltd. E-5698
Schiess GmbH S-8148
Schneeberger J. Corporation N-6938 Baldor Electric Company E-5748
Schunk, Inc. W-2000 Comtorgage Corporation E-5814
Seco Tools, LLC W-1564, C-884 Atlanta Drive Systems, Inc. N-6046
Setco N-6534 Guyson Corporation of U.S.A. N-6066
SHL Automation N-7263 Miller Broach Inc. N-6197
Siemens Industry Inc. E-5010 Erasteel, Inc. N-6382
SKF USA Inc. E-5185 Solar Atmospheres N-6414
Slater Tools Inc. W-2139 Solar Manufacturing N-6414
S.L. Munson & Company N-7240
Oak Ridge National Laboratory N-650
SMW Autoblok Corporation W-1400
Solar Atmospheres N-6414 Setco N-6534
Solar Manufacturing N-6414 DTR Corporation N-6557
SpeedFam Corporation N-7363 Promess, Inc. N-6640
Speedgrip Chuck-Cameron-Madison W-1279 German Machine Tools of America N-6670
Star SU LLC N-6924 Chongqing Juya Machine Tools Co., Ltd. N-6681
Star SU LLC / Star Cutter Company W-2258 Qanzhou JianYue Diamond Wheel Co., Ltd. N-6681
Studer N-6800 Zhangjiagang Ruizheng Tool Co., Ltd. N-6681
Suhner Industrial Products W-1464 Kasto, Inc. N-6737
Sunnen Products Company N-7400
Supertec Machinery Inc. N-6945 Klingelhofer Corporation N-6737
Ty-Miles, Inc. N-7127 Gehring N-6740
Tyrolit GmbH & Co. KG N-6918 Leistritz Advanced Technologies Corp. N-6746
United Grinding North America, Inc. N-6800 Engis Corporation N-6751
U.S. Gear Tools, Inc. N-7115 Hammond Roto-Finish Co. N-6759
Vargus USA W-2245 DVS Group - Diskus Werke AG N-6770
VDF Boehringer N-6924 Dontyne Gears Ltd. N-6778
Waldrich Coburg GmbH S-8796 Advent Tool & Manufacturing, Inc. N-6799
Wenzel America, Ltd. E-5698, N-6930, E-5510
Studer N-6800
WFL Millturn Technologies GmbH & Co. KG S-8666
Wittenstein E-4879 United Grinding North America, Inc. N-6800
Zeiss Industrial Metrology E-5504 Höfler div. of Klingelnberg N-6837
ZF Friedrichshafen AG E-4868 Klingelnberg N-6837
Zhangjiagang Ruizheng Tool Co., Ltd. N-6681 EMAG L.L.C. N-6846
Zoller Inc. W-2022 C.L.C., S.r.l. N-6918
Helios Gear Products N-6918
Koepfer America, LLC N-6918
Lambert + Wahli, AG N-6918
Monnier + Zahner AG N-6918
Tyrolit GmbH & Co. KG N-6918

28 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
Listings by Booth Number Listings by Booth Number
COMPANY BOOTH COMPANY BOOTH
Wenzel America, Ltd. N-6918 Barnes Bore Honing & Finishing Systems N-7451
Bourn & Koch Inc. N-6924 Bates Technologies, LLC N-7451
FFG Werke GmbH N-6924 Lapmaster International, LLC N-7451
Hessapp N-6924 oelheld U.S., Inc. N-7475
Honsberg N-6924 North American Machine & Engineering Co. N-7514
MAG Huller Hille N-6924 D. C. Morrison Company N-7516
MAG Witzig & Frank N-6924 Osborn International N-7523
Modul N-6924 Hangsterfer’s Laboratories, Incorporated N-7526
Samp S.p.A. N-6924 Rosler Metal Finishing N-7587
Star SU LLC N-6924 Index Corporation S-8136
VDF Boehringer N-6924 Schiess GmbH S-8148
Liebherr Gear Technology, Inc. N-6930 Mazak Corporation S-8300
Schneeberger J. Corporation N-6938 Absolute Machine Tools, Inc. S-8536
Supertec Machinery Inc. N-6945 Mitutoyo America Corporation S-8640
Drake Manufacturing Services Co. N-6948 WFL Millturn Technologies GmbH & Co. KG S-8666
Gleason Corporation N-7000 Waldrich Coburg GmbH S-8796
Gleason Cutting Tools Corporation N-7000 DMG Mori S-8900
Gleason K2 Plastics N-7000 Bohle Machine Tools, Inc. S-8966
Fives N-7018 Maier Machine Tools, LLC S-8980
Fives Cincinnati - Metal Cutting | Composites N-7018 Fuji Machine America Corporation S-9059
Elumatec North America N-7024 Roeders of America Inc. S-9290
American Broach & Machine Company N-7027 Qanzhou JianYue Diamond Wheel Co., Ltd. W-1091
QC American LLC N-7027 Harbin Tool Works W-122
Alpha Magnetic Workholding N-7030 Dura-Bar W-1272
Gould & Eberhardt Gear Machinery N-7030 Speedgrip Chuck-Cameron-Madison W-1279
R.P. Machine Enterprises, Inc. N-7030 LMC Workholding W-1314
Kapp Technologies, LP N-7036 Riten Industries, Inc. W-1336
Niles Werkzeugmaschinen GmbH N-7036 SMW Autoblok Corporation W-1400
R&P Metrology N-7036 Mitsubishi Materials Corporation W-1426
Felsomat USA, Inc. N-7040 Command Tooling Systems LLC W-1446
Reishauer Corp. N-7040 Suhner Industrial Products W-1464
Federal Broach & Machine Company, LLC N-7046 Sandvik Coromant W-1500
Mitsubishi Heavy Industries America, Inc.- MI N-7046 Kennametal Extrude Hone W-1522
Norton Abrasives N-7051 Kennametal Inc. W-1522
Erwin Junker Machinery, Inc. N-7057 Emuge Corp. W-1536
3M Abrasive Systems Division N-7063 Seco Tools, LLC W-1564
Asahi Diamond America, Inc. N-7066 MD Tooling, LLC W-1579
Nagel Precision Inc. N-7072 Horn USA, Inc. W-1722
Luren Precision N-7074 LMT USA, Inc. and LMT Onsrud LP W-1732
Pratt & Whitney Measurement Systems Inc. N-7094 Ingersoll Cutting Tools W-1822
Broach Masters/Universal Gear N-7112 Polygon Solutions Inc. W-1954
Roto-Flo N-7115 Schunk, Inc. W-2000
U.S. Gear Tools, Inc. N-7115 Zoller Inc. W-2022
Ty-Miles, Inc. N-7127 Qanzhou JianYue Diamond Wheel Co., Ltd. W-2083
Gear Technology N-7214 Chevin Tools, Inc. W-2093
Power Transmission Engineering N-7214 Avantec Zerspantechnik GmbH W-211
Action SuperAbrasive Products N-7217 Performance Tooling Solutions Int’l W-2115
Fromag N-7220 Slater Tools Inc. W-2139
Mitts & Merrill L.P. N-7220 Northfield Precision Instrument Corp. W-2145
Broaching Machine Specialties Co. N-7229 Vargus USA W-2245
Dr. Kaiser N-7240 Star SU LLC / Star Cutter Company W-2258
S.L. Munson & Company N-7240 Nachi America Inc. W-2279
Acme Manufacturing Company N-7255 Hassay Savage / Magafor / GMauvaisUSA W-2356
SHL Automation N-7263 Oerlikon Balzers USA Inc. W-2380
PWS Praezisionswerkzeuge GmbH N-7344 Kitagawa-NorthTech Inc. W-2412
Saacke North America, LLC N-7344 Hainbuch America Corporation W-2413
SpeedFam Corporation N-7363 Ceratizit USA, Inc. W-2446
Sunnen Products Company N-7400 Euro-Tech Corporation W-2453
Anca Inc. N-7414 Frenco GmbH W-2453
Marposs Corporation N-7433
Radiac Abrasives, A Tyrolit Company N-7440

August 2014 | GEAR TECHNOLOGY 29

 show stopper IMTS 2014

Gear Carburizing
in vacuum

Solar Atmospheres provides

low pressure vacuum
carburizing (LPVC) that
significantly increases the
surface hardness/strength of
steel parts for improved friction
and wear.
LPVC does not produce inter-
granular oxidation (IGO), min-
imizing grind stock allowance.
Our root-to-pitch ratio is con-
sistent and we can carburize in
blind or small holes. The parts
will be returned to you soot-
free and post-process cleaning
is typically not required.

Call today for a quote!

Visit us at Booth #W-1500

Sandvik VIP Showcase Ad 4.75” x 4.5”

To see how you can

go from O.D. to I.D
to 3-jaw clamping all
within a few minutes,
visit us at

 solaratm.com
 1-855-WE-HEAT-IT Booth W-2413
(934-3284)

Philadelphia Los Angeles 1.800.281.5734 Germantown, WI • www.hainbuchamerica.com

Pittsburgh South Carolina
Visit us at Booth #W-2413
Visit us at Booth #N-6414

30 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
Don’t pass up
our offer to
gear up!

Vacuum furnace supplier

offering gear manufacturers
furnace time to test
carburizing process cycles.

Solar Manufacturing, a leading

manufacturer of advanced LPVC
gear furnaces, is offering furnace
time to test carburizing cycles
of your production-size gears.
Utilizing the carburizing expertise
of affiliate, Solar Atmospheres,
a commercial heat treating
company, Solar Manufacturing Visit us at Booth #N-7475
will demonstrate the capabilities
and ease-of-use of its high
performance LPVC furnace systems
for gear manufacturers.

If you are considering adding

or expanding gear carburizing
processes in-house, contact
Pete Reh, VP of Sales to arrange
your carburizing demo.


267.384.5040 x1509
[email protected]
Advancing Manufacturing
 solarmfg.com with Technology
and Innovation

Introducing our New

Tool Manufacturing Facility
coming soon to Indiana...
Visit
Visit us
us at
at Booth
Booth #W-2279
#W-2279
Greenwood, Indiana
TEL: 877-622-4487 • FAX: 800-622-4439
www.nachi.com
Daily Chances Amazon, Kindle, and Fire are trademarks of Amazon.com, Inc.
or its affiliates. Amazon devices are given away on behalf of
to win a Nachi. Amazon is not a sponsor of this promotion.

Visit us at Booth #N-6414 Visit us at Booth #W-2279

August 2014 | GEAR TECHNOLOGY 31

 show stopper IMTS 2014

COMPLETE LINE OF TOOLS FOR

GEAR HARD FINISHING

MIRA ICE MIRA ULTRA

PROFILE GEAR GENERATING GEAR
GRINDING WHEELS GRINDING WHEELS

Invitation MIRA BEVEL

BEVEL GEAR
MIRA DDG
DIAMOND DRESSING

to our
GRINDING WHEELS GEARS FOR HONING
Learn more about Mira products - 800-851-1095 | radiac.com

GE RMAN
N I GH T
Visit us at Booth N7440

Visit us at Booth #N-7440

RECEPT ION
Tuesday,
September 9, 2014
6:00PM - 8:00PM

McCormick Place
South Building | Level 4
Vista Room Lobby

More information & registration:

www.gaccmidwest.org/german-night

Visit us at Booth #E-4955 EuroTechAd2014.indd 1

Visit us at Booth #W-2453 7/21/2014 1:22:37 PM

32 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 Leader in spline
rolling solutions
Stop by
for 60 years. GEAR TECHNOLOGY
We were the first to com- and meet the editors.
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technology in 1954. Since then • Nearly 80 years of
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consultative support. experience
• Learn more about
Innovation – It’s How We Roll contributing to
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TECHNOLOGY INDIA.
™
• Find out how YOU could
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Visit us at IMTS issue!
Booth N-7115

313-526-7865
BOOTH #N-7214

Visit us at Booth #N-7115

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August 2014 | GEAR TECHNOLOGY 33
 feature

IMTS 2014 PRODUCT PREVIEW

KLINGELNBERG
Booth N-6837

Klingelnberg will once again be exhib- during re-tooling is assisted by conve-

iting its grinding machines for bevel nient auxiliary functions like a standard
gears and cylindrical gears and its pre- semi-automatic grinding wheel changer,
cision measuring technology at IMTS. for example.
Visitors to the event will be able to see
four machines in action including: Helix 400
The Höfler Helix 400 gear grinding
Viper 500 machine is a profile grinding machine
The adaptable Höfler Viper 500 gear for components with a diameter of up to
grinding machine is designed for com- 400 mm. Its well-engineered mechani-
ponent diameters of up to 500 mm, and cal system makes it a reliable partner for
is suited for both the smallest and the sophisticated manufacturing. Apart from
largest lot sizes. It is available in three this, the innovative control and software
different configurations, depending on functions make it suitable for customized
your individual requirements: Profile measurements in the highest accuracy profile and tooth trace modifications in
grinding (Viper 500), small grinding class, directly on the shop floor. Features special series production. The proprie-
wheels and multiple-wheel technology include an ergonomic operator panel, a tary GearPro software guarantees ease of
(Viper 500 K), and generation grind- vibration isolation function and an air- use, even for complex applications.
ing (Viper 500 W). Users with frequent conditioned control unit.
product changes in particular will find
that the flexible machine concept pro- G-60
vides an even more dynamic and effi- The CNC-controlled Oerlikon G 60
cient production process. bevel gear grinding machine from the
G model series provides grinding per-
formance combined with high-precision
final machining of the curved-toothed
bevel gears of any gearing system,
including the teeth of face-type clutch-
es. The G 60 operates up to a ring gear
diameter of 600 mm. All G series spi-
ral bevel gear grinding machines have a
vertical grinding spindle, which ensures
that the swarf drops directly downward.
P-40 A special feature is that all drive units For more information:
Klingelnberg America, Inc.
Klingelnberg will also be introducing are above the grinding area, meaning Phone: (734) 470-6278
the latest P-40 at the exhibition. Due that they are kept free of swarf depos- www.klingelnberg.com
to their comprehensive range of func- its. The entire inner paneling is made
tions, the P series machines replace up of stainless steel – providing a clean and
to four conventional measuring devices. tough working area. All of the necessary
With its basic mechanical accuracy and a additional components are integrated in
modern compensation strategy, the P-40 the closed machine paneling. These are
is a machine with long-term stability accessed through special maintenance
that is capable of performing high-speed doors. The adjusting work that is needed

34 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 Our Technologies, Your Tommorow

HOBBING / SHAPING / S H AV I N G / GRINDING

Increased
Capacity is
AVAILABLE NOW
for Immediate
Delivery...

...FROM THE WORLD’S LARGEST INVENTORY Learn more about the world-class Mitsubishi
gear machines available from stock at
OF CNC GEAR CUTTING MACHINES. www.mitsubishigearcenter.com
No need to scour the globe searching for a machine in order to or contact sales at 248-669-6136.
quickly fill increased production needs. With our vast inventory of
new machines right here in the U.S.A., Mitsubishi Heavy Industries
America can deliver the machine you need—in perfect condition,
optimized for maximum output and all at a moments notice.

BOOTH #
©2014 Mitsubishi Heavy Industries America
N-7046
 feature IMTS 2014 PRODUCT PREVIEW

STAR SU LLC ear motor technology, which eliminates

Booth N-6924 almost all elasticity, backlash, friction
effects, and drive chain vibration typi-
Star SU LLC will showcase the latest in cally found in ball screw and belt driven
linear motor technology offered by Star designs. Both of the NTG rotary axes are
at IMTS 2014 in September. Engineered have integrated torque motors for high
to manufacture complex cutting tools, and precise torques at optimal speeds.
the new Star NTG-4L tool and cutter The machine is suitable for high mix,
grinder is a five axis, CNC controlled low volume jobs due to its quick setup
cutter grinder for manufacturing, sharp- and stability. For the high volume manu- conveniently carried out directly in the
ening and reconditioning a wide variety facturer, an optional robust automation grinding position for better accuracy
of cutting tools. The machine features package utilizes a Fanuc LR Mate robot purposes and minimum changeover
include a mineral cast base for increased allowing for an increase in productivity time. Indeed, only in this position the
damping and thermal stability perfor- without sacrificing quality. meshing can be achieved with micron-
mance. All three axes are driven by lin- The G 250 from Samputensili will also level accuracy. Therefore the G 250 rep-
be featured at IMTS. The G 250 is a gen- resents a suitable solution for those cus-
erating and profile grinding machine, tomers who need very low cycle times
designed for cylindrical gears with a and efficient mass production of gears.
maximum outside diameter of 250 mm In the G 250 the minimum axis distance
and shafts with lengths up to 550 mm. between worktable and grinding wheel is
The machine is based on the dual work only 40 mm, and its grinding spindle can
spindle concept, which eliminates non- achieve 12.000 rpm. Due to the combi-
productive times almost completely. nation of these two unique features, the
By means of this feature, the loading/ grinding process is also possible using
unloading process of a workpiece is car- profile/threaded grinding wheels with
ried out in masked time, while simul- very small outside diameter, mounted on
taneously the manufacturing process the main spindle. Workpieces with tool
proceeds on another workpiece. Unlike diameter limitations, for example shoul-
other applications, the gear meshing is der-type gears, can be ground without

36 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
any additional devices. Similarly, double GLEASON
and triple pinions with very small dis- Booth N-7000
tances can be ground with the prop-
er tooth-to-tooth alignment. An add- Gleason will demonstrate
on optional spindle multiplier up to advanced machines, tooling,
24.000 rpm, with quick connection sys- and global customer support
tem to the main spindle, allows the use services at IMTS 2014, cov-
of electroplated CBN profile grinding ering a wide array of pro-
wheels with outside diameter down to cesses for the complete pro-
25 mm. The grinding spindle with its duction and inspection of all
specifically large tool capacity allows the types of bevel and cylindri-
use of long grinding worms to raise the cal gears. Visitors to Gleason
tool life of single or combination worms Booth #N-7000 will be intro-
of roughing and finishing tools employ- duced to these products and
ing electroplated CBN or ceramic bound technologies. Among the
grinding worms and wheels. Therefore technologies exhibited at the
customers can always rely on the most show will be:
efficient technology or the most ben- Genesis 200GX Threaded Wheel and the ability to interface with Gleason
eficial combination to complete their Grinding Machine: The 200GX is a new GMS machines via QR codes increase
grinding task. addition to the highly popular Genesis productivity. Easily accessible machine
For more information: series. The two spindle concept com- components make maintenance simple
Star SU LLC bines maximum productivity with mini- and efficient while standard dimension
Phone: (847) 649-1450 mized idle and set up times. Fast, easy grinding wheels and dressing tools allow
www.star-su.com
software-guided setup of the machine you to use your existing tools. All of this
allows you to set up your machine from in an energy efficient small footprint
one workpiece to another in just 20 machine designed to meet the needs of
minutes using only one tool. “First Part customers in high-productivity high-
Cycle” - fully automatic workflow after quality environments.
setup until grinding the first workpieces

All The
the Gear Cutting Tools You Will Ever Need are
Are Right Here
DTR is one of the world’s largest producers.
DTR. Your best choice for high quality gear cutting tools.
DTR is a world class supplier of the finest high performance long-life gear
manufacturing tools, for small and large gear cutting applications.
Established in 1976, we are one of the world’s largest producers of cutting
tools, shipping to over 20 countries.

DTR offers a full line of gear cutting tools including:

• Hobs • Chamfering and Deburring Tools
• Carbide Hobs • Broaches
• Shaper Cutters • Master Gears
• Milling Cutters

We can produce virtually any tool you need for auto, aerospace, wind,
mining, construction and other industrial gears.

Every tool is precision-made utilizing high speed steel, premium powder

metal or carbide and the latest in coatings, to achieve superior cutting and
long life. DTR uses top of the line equipment including Reischauer CNC
grinders and Klingelnberg CNC sharpeners and inspection equipment.

Learn more about our outstanding quality tools at www.dragon.co.kr.

Call us at 847-375-8892 for your local sales representative or
Email [email protected] for a quotation. BOOTH #
N-6557
DTR has sales territories available. Call for more information.
U.S. Office Location (Chicago) Headquarters
Email inquiries to: [email protected] 36B-11L, Namdong Industrial Complex, Namdong-Gu, Incheon, Korea
(formerly Dragon Precision Tools) 1865A Hicks Road, Rolling Meadows, IL 60008
PHONE: +82.32.814.1540
WWW.DRAGON.CO.KR PHONE: 847-375-8892 Fax: 224-220-1311 FAX: +82.32.814.5381

August 2014 | GEAR TECHNOLOGY 37

 feature IMTS 2014 PRODUCT PREVIEW

forces, with superior inter- exchanged by hand, while the grinding

nal chip evacuation. Power wheel can be released hydraulically. The
Skiving Technology Software 280G’s automatic stock divider, mounted
enables users to easily simu- in close proximity to the workspindle,
late the entire cutting pro- helps ensure consistently high gear qual-
cess and plan the most effec- ity. The unit automatically determines
tive process strategy. Users the tooth slot position of the pre-fin-
can analyze the influence of ished gear to provide accurate and reli-
different cutting tool geome- able stock division, helping eliminate
tries and process parameters. operator errors.
The Technology Software 300GMS Analytical Gear Inspection
allows you to decide if a Machine: The 300GMS was developed
given part can be safely and specifically to meet the needs of auto-
economically power skived motive transmission gear producers for
300PS Power Skiving Machine: The or whether it would be better a faster, more economical solution for
300PS combines unique machine, cut- shaped, making Power Skiving as simple complete gear and even non-gear parts
ting tool, workholding and power skiv- and familiar as shaping. inspection. It is the first GMS to fea-
ing process expertise to offer users sig- Phoenix 280G: This machine has no ture the new Windows 7-based Gleason
nificant performance improvements, rails, wires, or pipes in the work cham- GAMA 3.0 applications software suite
particularly in operations where shap- ber to collect swarf, keeping the chamber which, like its GAMA 2.0 predecessor,
ing, forming, pressing and broaching are clean for low preventive maintenance. offers users a highly intuitive user inter-
typically used. As compared to shaping, In addition, the 280G offers rapid set-up face and simple input screens for pro-
for example, the 300PS can deliver pro- and all major set-up items can be com- gramming of workpiece and cutting
ductivity rates as much as eight times pleted without tools (tool-less), includ- tool data. The 300GMS is equipped with
higher. The modular tool-less workhold- ing the grinding wheel, coolant head- new ergonomically mounted operator
ing is designed for fast installation and er and workholding. The coolant head- workstations and a Gleason Diagnostic
changeover to handle the highest process er has small blocks that can easily be Module – both designed to greatly

• Hobbing machine
• Shaving machine
• Deburring machine

www.hartech.com.tw

38 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
improve the operator’s effectiveness at KAPP NILES
every stage of the inspection process. Booth N-7036
The Gleason Diagnostic Module puts
a number of powerful tools right at the Two new Kapp Niles gear grind-
operator’s fingertips, including an envi- ers and the latest portable gear
ronmental monitoring station to record inspection system from R&P
temperature and humidity, and video Metrology GmbH will be intro-
telephony, note pad and voice mail mes- duced at Booth N-7036. The ZP
saging capability, enabling the user to 12 marries the best of the ZE
capture video, describe a particular pro- and ZP series machines to offer
gramming issue and transmit it over the a compact yet highly productive
web to others in the customer’s organiza- solution at a great value. The KX
tion or to Gleason for support. 260 Twin has extended the appli-
Additionally, the company will feature cation range of the Twin series
its gear cutting (Pentac Plus RT) and to include long shafts typical of
workholding solutions (Quik-Flex Plus) truck transmissions. R&P’s RPG
and attendees can learn about Gleason’s PM 750/1250 is the first portable gear measured on this machine. The intuitive
new line of hydraulic workholding as checker/CMM with dual functionality software is enhanced to speed the setup
well as its diverse range of global ser- for use in the lab or on the production and optimize stock removal.
vices. floor. The new Kapp Niles KX 260 Twin
For more information: The new Kapp Niles ZP 12 provides is built on a shared modular platform
Gleason Corporation the range to grind any gear diameter up with 500 mm axial travel. The machine
Phone: (585) 473-1000 to 1,250 mm with a fully dressed grind- includes two identical workpiece spin-
www.gleason.com
ing wheel. The direct drive tool spin- dles, arranged at opposite sides of an
dle has increased power, and the dual indexing table for absolute shortest cycle
dressers shorten dressing time. Hob cut- times. A special feature of this machine
ters and worms can now be ground and is the process flexibility for profile and

August 2014 | GEAR TECHNOLOGY 39

 feature IMTS 2014 PRODUCT PREVIEW

generating grinding two gears on one EMAG The VL vertical pick-up lathe series
shaft, in one cycle. Dressable or CBN Booth N-6846 opens up new opportunities for the
plated wheels can profile grind up to machining of a wide range of chucked
module 10 (2.5 NDP) gears. Dressable At IMTS 2014, EMAG will feature man- components. Small gearwheels, plane-
worms grind gears up to 5 module. Kapp ufacturing systems for precision metal tary gears, sun gears, sliding sleeves, syn-
CBN plated worms are utilized for gears components with multiple machines chronizer rings or flanged components,
with constraints for normal grinding. from its new modular standard VL and for example, can be machined with great
R&P Metrology’s RPG PM 750/1250 VT product families on display. These efficiency. The smallest lathe of the VL
is a flexible solution for measuring larg- modular standard machines offer a sys- product family, the VL 2, machines
er gears on production machines that tematic approach that is advantageous to workpieces with a maximum diameter of
may not have on-board inspection. The establishing a highly efficient manufac- four inches and a length up to six inches.
design makes it moveable within the turing process, with different operations Increasing in size, the VL 4, VL 6 and
plant. The optional “docking station” offered on the same platform, allowing VL 8 offer a number of different turn-
with granite base and rotary table allows for easy interlinking and eliminating any ing and milling operations within the
the PM 750/1250 to become a stand- great capital investment for automation. framework of a single closed-loop pro-
alone, fully featured four axis genera-
tive gear inspection machine when not
required for portable measurement.
For more information:
Kapp Technologies
Phone: (303) 447-1130
www.kapp-usa.com

Why play with

uncertainty?
When your reputation relies on achieving absolute
precision, you can’t afford to gamble. That’s why you
need Precision Technologies Group (PTG).
The name behind Holroyd Precision, Binns & Berry,
Crawford Swift, PTG Heavy Industries and Holroyd
Precision Components, we’ve built our reputation
on providing high-precision milling and grinding
technologies, special purpose machine tools and
ultra-precise components for the HVAC, aerospace,
automotive, medical, marine, steel, oil and gas sectors.
Why take a chance with precision? Choose PTG.

e [email protected]
t +44 (0)1706 526590
f +44 (0)1706 353350
www.holroyd.com

Part of the CQME

Group of Companies

40 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
duction process. Specially designed for the EMAG vertical platform, includ- FELSOMAT
the handling of large components, the ing the pick-up design, where the main Booth N-7040
largest vertical turning machine of the spindle removes the raw part from the
series, the VL 8, is suitable for commer- conveyor belt, transfers it to the tail- Felsomat Corporation will feature the
cial vehicle production, handles work- stock flange and removes it from the latest gear honing technology at Booth
pieces up to 16 inches in diameter and machining area after the completion of N-7040. With the introduction of the
12 inches in length. the hobbing cycle. Gears with a maxi- Felsomat Power Speed Honing (Model
Built within the same modular con- mum diameter of 8 inches and module FPSH) machine, they continue to re-
cept is the VT-Series for machining large 4 can be dry-milled at greatly shortened define gear manufacturing technology.
quantities of shaft components. With cycle times. The FPSH 180 is specifically designed
four axes, a self-loading turret and inte- EMAG will also present its entire to be part of the Felsomat Flexline con-
grated automation, the VT 2-4 machines portfolio of production technologies, cept. The FPSH represents the high-
shafts with a max diameter of 2.5 inches from turning, hobbing and grinding to est performance and process stability
and 16 inches in length. Spindle speeds those that complement traditional met- achieved in the field of gear honing.
of up to 6,000 rpm achieve extremely alworking processes, such as its produc- The FPSH begins with the hobbing pro-
short cycle times as the shaft is clamped tion laser welding, heat shrink technol- cess performed by the FHC 180 hob-
vertically between workspindle and tail- ogy and electro-chemical machining bing machine. Next the integration of
stock and machined from two sides. (ECM) capabilities. ECM processes offer
The vertical alignment of the work- non-contact machining with no heat
piece ensures process integrity, where affected zone or mechanical stress to
the unhindered chip flow prevents the components with no tool wear. An ECM
build-up of chip nests in the machining machined blisk will also be on display.
area. For more information:
Integrating the technologies of the EMAG LLC
EMAG Group into these new modular Phone: (248) 477-7440
www.emag.com
standards, the VLC 200 H will make its
North American debut at IMTS 2014.
The VLC 200 H hobbing machine inte-
grates EMAG-Koepfer technology into

August 2014 | GEAR TECHNOLOGY 41

 feature IMTS 2014 PRODUCT PREVIEW

the ALD SyncroTherm inline heat treat- ing process into one uninterrupted REISHAUER
ment process ensures reduced thermal
distortion of the gears. This means that
chain and is comprised of the following
machine/processes: Felsomat Turning CORPORATION
Booth N-7040
less stock needs to be removed from Cell FTC 180, Flex Hobbing Center FHC
the gear flanks resulting in shorter gear 180, Flexline Integrated Heat Treatment The RZ260 features Reishauer’s unique
honing cycle times. The FPSH can hone and the Laser Welding Cell FLW 180. continuous generating gear grinding and
gears up to 160 mm diameter and mod- For more information: is based on the RZ150 series. The RZ260
ule 0.5 – 4.0 mm. Stock removal between Felsomat Corporation has not only been increased in size, all
40–80 microns on each flank is possible Phone: (847) 995-1086 relevant components have been adapted
www.felsomat.de
depending on the heat treatment devia- to handle higher loads and forces that
tion, and grinding burn is not a pos- occur when grinding larger gears. Gears
sibility due to the low cutting speed. In with an outside diameter of 260 mm and
addition to the FPSH, Felsomat’s Flexline modules up to 5 mm can be ground with
integrates the entire gear manufactur- highest reliability in the well-known
Reishauer quality. An important focus
in the design of the machine concept
was adaptability to the different produc-
tion requirements of numerous custom-
ers. The machine can be fitted with one
or two work spindles. The version with
two work spindles is used to minimize
the loading times – as introduced with
the Reishauer RZ150. When investment
and tooling costs must be minimized
and/or the workpiece handling times
are not critical, the RZ260 with a single
work spindle might be a more suitable
choice. When grinding gears with space
limitations or small lot sizes, it might
be advantageous to use the changeable
profile grinding spindle enabling the use
of a small plated or dressable wheel to
grind gears using the discontinuous pro-
file method. Both versions of the RZ260
can be equipped with a fixed or CNC-
controlled axis for swiveling the dressing
tool. With this option, the flexibility of
the dressing tools can be increased since

Booth W-2413

Are you limiting your workholding options to 10-second collet changeovers?

That’s So Last Century
Today, Tonight, Tomorrow illustrates HAINBUCH’s business philosophy - a commitment and focus
to helping our customers solve their immediate and long-term productivity challenges. Our original
SPANNTOP chuck system not only mastered the 10-second collet change, but also allows you to go
from O.D., to I.D., to 3-jaw clamping in a matter of seconds without readjustment. Reliable, flexible
innovation from HAINBUCH, the world leader in quality workholding.

1.800.281.5734
Germantown, WI USA
www.hainbuchamerica.com

42 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
the same tool can be used for a range of LIEBHERR GEAR gearing. According to a Liebherr spokes-
gears as compared to the fixed dresser
where the tools are normally workpiece TECHNOLOGY, INC. man, “With this series of space-saving
machines, vehicle manufacturers can
Booth N-6930
specific. develop a complete production line,
Also on display will be polish grind- With a one-table design and a new- in which all gearing components for a
ing on a beveloid gear used in a marine design grinding head, the new Liebherr passenger vehicle transmission can be
transmission. The grinding wheel has LGG 180 and LGG 280 machines great- ground: planetary and sun gears, bore-
two different sectors and compositions; ly reduce grinding times for twist- type gears, as well as drive and pinion
one area is used to grind and remove the free profile and generating grinding. shafts with lengths up to 500 mm.
heat treat distortion, and the other area The LGG180 will be demonstrated by The advantage to the one-table solu-
is used to polish the tooth surface. This Liebherr at IMTS 2014. The machines tion is higher quality throughout the
process achieves a surface finish of .07 are designed to deliver consistent high entire production. There is one clamping
micron. In addition to the improved sur- large-scale production quality in auto- fixture, one geometry. Every machined
face, the polish ground process rounds motive applications, including conical part is manufactured under the same
out the edges at the transition of the
workpiece flank and face. The topogra-
phy of the flanks remains unchanged.
Like all Reishauer gear grinding
machines, the RZ260 has been devel-
oped for the high demands of the con-
tinuous generating gear grinding pro-
cess, also known as the Reishauer style.
All design characteristics that lead to
the success of other Reishauer machines
have been incorporated in the RZ260.
This includes the Reishauer Generating
Module for highest gear quality,
Reishauer LNS Low Noise Shifting tech-
nology for very low gear noise emis-
sions, Polish Grinding for surface rough-
ness reduction, Reishauer Twist Control
Grinding technology to create defined
PEOPLE AND TECHNOLOGY
values for flank twist and the Reishauer
HMI for fast change over and set-up
MAKE THE DIFFERENCE
times.
For more information:
Reishauer Corporation
Phone: (847) 888-3828
www.reishauer-us.com

At Presrite, our experience, innovation and expertise

ensure that you get the best net and near-net forgings.
Our new Tech Center has state-of-the-art design,
engineering technology and die-making capabilities.

• Dedicated state-of-the-art facility

• Presses up to 6,000 tons of capacity
• .008-.060 stock allowance on gear blanks
• ISO 9001:2008
• TS 16949:2009

www.presrite.com • 216-441-5990

PRS-041_HalfPg.Ad-GearTech.indd 1 3/10/14 10:16 AM

August 2014 | GEAR TECHNOLOGY 43
 feature IMTS 2014 PRODUCT PREVIEW

conditions for the highest reproducibil- holder is a fast and simple process. Also
ity. The one-table approach provides available is a second grinding head for
the statistical capability and reliability featuring a small worm diameter for col-
in continuously producing controlled lision-critical parts.
µ-range finish quality for gear noise opti- The machine will enable undulations
mization. The new grinding head allows to be applied specifically to gear wheel
for rotation speeds up to 10,000 rpm and flanks for noise optimization purposes
has spindle power of 35 kW. With this for the first time. The ability to produce
performance data, the head enables high sub-µ range waviness cost-effectively
cutting speeds and high feed rates. The gives designers a whole new range of
new grinding machine can exploit the optimization options. The touch screen
considerable potential of the innova- user interface on the machine control
tive 3M abrasive Cubitron II. Changing permits easier, intuitive programming
the grinding arbor with HSK-C 100 tool and machine operation and incorpo-

rates an integrated webcam. The control

also can incorporate substantial addi-
tional documentation, such as fixture
layouts and tool mounting instructions.
The LGG machines are easily coupled
with Liebherr automation solutions to
create a fully automated production line
for the highest quality gears in the least
possible cycle times.
Additionally, Liebherr Automation
will demonstrate a smart part handling
solution that can remove randomly
placed items from a container and place
them accurately in a machine or produc-
tion line, utilizing 3-D image recognition
system software, a robot, and a sophis-
ticated handling strategy. This intelli-
Choose from one of our portable or gent removal of items, such as the auto-
laboratory systems, or utilize our ISO 17025 mated picking of unsorted components,
laboratories for accurate and efficient is referred to as random bin-picking.
contract measurement services. Specially developed grippers with addi-
tional axes enable collision-free access
For more information contact us at and the removal of items from the con-
[email protected] or 1-313-965-2900 tainer, and subsequently allows for pre-
cise positioning of the item into a fixture
or pallet.
The Liebherr custom bin-picking solu-
tion, designed for components weigh-
ing between 1 and 50 kilograms, deliver
the potential for productivity and effi-
ciency increases in a range of parts pro-
ducing industries, including automo-
tive, aerospace, general machining, and
LXRD LXRD LXRD iXRD mXRD commercial vehicles. The company has
STANDARD WIDEBODY MODULAR MAPPING STANDARD ULTRA PORTABLE developed process-reliable solutions that

44 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 MARPOSS CORP.
Booth E-5519

Marposs Corp. will introduce its new

G25 gauging probe for contact scan-
ning for pre- and post-process cycles on
gear grinders and machining centers.
Although the G25 device resembles a
touch probe, it is actually a gauge with
the ability to do both part surface scan-
ning and perform touch functions for
part positioning and measurement. The
compact G25 device was developed to

VISIT US AT
IMTS 2014
IN BOOTH
W-1564!
achieve the cycle times and high avail-
ability rates manufacturers require.
The advantages of this scalable auto- Seco applies knowledge of
common and rare materials
mation process include increased pro- to design the tools that will
ductivity, improved machine utilization cut them best. We’ll help you
identify the perfect solution
rates, reduction of the need for addition- for your specific material and
al machines to achieve desired plant pro- then assist in implementing
duction volumes, and more consistent and optimizing it. Visit us at
IMTS 2014 to see how the
production quality. science of materials drives
Liebherr has created complete systems our cutting tool technology.
for, among other sectors, for the automo-
tive industry. This includes the efficient
channeling of non-rotationally symmet-
rical components which arrive random-
ly in a bin and can be placed into pro-
duction lines and hardening ovens. The
beginning of a production line is the key
point where picking from the bin is nec-
essary.
An important breakthrough occurred
with the object recognition system. The
3-D laser scanner precisely recogniz-
es the components for picking. Outside
light of any type in the production build-
SOLUTIONS DESIGNED & TAILORED
TO THE MATERIALS YOU MACHINE
SECOTOOLS.COM/US

ing has zero effect on the ability to pick a

part. It will even recognize black, brown
and rusty parts. The accompanying soft-
ware segments identify and select infor-
mation about items and constraints in
the bin provided.
For more information:
Liebherr Gear Technology
Phone: (734) 429-7225 SCAN THIS QR CODE TO
www.liebherr-us.com LEARN MORE ABOUT SECO!

August 2014 | GEAR TECHNOLOGY 45

 feature IMTS 2014 PRODUCT PREVIEW

gauge parts while still fixtured in the DMG MORI

machine in case reworking is required. Booth S-8900
When used for gear grinding, the G25
gauge identifies the part location and In the last two years, DMG Mori has
tooth spacing for purposes of aligning expanded their gear milling portfolio to
the part with the grinding wheel prior include more machine platforms that
to grinding. The same device is then produce more types of gears. The high-
used to scan the profile of the finished light of the show will be the power skiv-
part in a continuous cycle. The new G25 ing technology displayed on a multi-
gauging probe has excellent measure- tasking machine platform that combines
ment stability at high speeds, enabling a turning operations with milling opera-
significant reduction in inspection time tions and gear production. DMG Mori’s
compared to using a touch probe. Other
applications to which the new G25 gauge
is suited include grinding of non-round
parts where the user needs to check cer-
tain characteristics of the part after it is
ground, or for verifying that a face of the The well-established Bronze, Silver
part is in the correct orientation. The and Gold TMS Tool Management
G25 probe is available with either ana- Solutions packages offer new functional-
log or digital output depending upon the ities such as a regrinding for the coordi-
user’s requirements. nation of grinding cycles and incoming
For more information: goods inspection. Experience the future
Marposs Corporation of modern tool data management live
Phone: (248) 370-0404 at the booth: Tools can be downloaded
www.marposs.com
from the Tooldata-Cloud, provided by
major tool manufacturing companies
ZOLLER and master tool data pools.
Booth W-2022
At IMTS, Zoller will present not only DMC 80 FD duoBLOCK machine will
Zoller offers presetting, measuring, their universal inspection machines demonstrate machining of an ID gear
inspecting and managing of simple to Genius and Smartcheck, but also new using a power skiving process. As com-
complex tools for quality assurance, developments in the Pom series as well as pared to conventional shaping process-
inspection of goods or extensive tool the completely newly designed 3DCheck es, the power skiving process is a high-
management tasks. “Not only measur- and their high-end Titan machine. ly productive process for machining of
ing solutions, but also the use of cutting The 3DCheck is a new six-axis CNC- ID and OD gears. The demonstration
tools. The key to efficient tool usage and operated machine for the three-dimen- will show that the machine and process
optimized tool life along with an eco- sional digitalization of workpieces. A is suitable for even automotive volume
nomic manufacturing process leads to a target-performance comparison with production. The same machine will also
professional tool management system. a CAD model or a pre-scanned tool is demonstrate the machining of a spiral
The still unknown and unused potential now an easy and fast task. The compact bevel gear using the flankmilling pro-
for cost savings in this area is enormous tool inspection unit PomBasic for job- cess. In addition, it will measure the spi-
in many businesses,” explains president shop applications right next to the grind- ral bevel gear using the onboard stan-
and owner Alexander Zoller. ing machine is now also available with a dard measurement probe and a point
high resolution camera for micron tools. cloud generated by the DMG gearMILL
Zoller’s automation solution Roboset software. Using the data gathered by the
in combination with a CNC-operated probe, the Gear Pro involute software
tool presetter is of special interest to all from Zeiss will prepare the flank charts
companies with high tooling through- for the gear. This in-machine checking
put levels such as tool manufacturing of gears is a unique feature and can be
and grinding businesses, as well as in the extremely useful for quick check mea-
quality assurance aspect. Roboset loads surement of large gears before removing
the Zoller presetter automatically and them/unloading them from the machine.
unmanned, 24 hours a day, 7 days a week. This feature is available for measurement
For more information: of all types of gears.
Zoller DMG Mori is also launching its new
Phone: (734) 332-4851 horizontal machining center NHX 4000
www.zoller-usa.com
2nd Generation. This machine provides a
very cost effective way to produce large

46 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
diameter cylindrical gears. The super
accurate B-axis (rotary table) ensures
machining of excellent quality gears
and a pallet changer (standard feature)
eliminates the setup time altogether. The
fast tool changes will reduce the cycle
time and a large tool magazine will keep
the machine running overnight. This
machine will show a 19 in. diameter spur
gear machined using the InvoMilling
process and a 26 in. diameter herring-
bone gear machined using the flankmill-
ing process.
In a d d it i on to t h i s
diverse gear portfolio,
DMG Mori will demon- material and then conventional milling
strate its technological turning processes to remove material
expertise with their hybrid from any unwanted areas. The combi-
manufacturing machine. nation of these two processes on a sin-
This machine combines gle platform and the ability to execute
the additive (3-D printing them sequentially provides unparalleled
in metals) and subtractive freedom to design engineers – enabling
processes into one machine them to design parts in ways they have
to produce a finished part not even imagined.
from just powder. It uses For more information:
a powder spray technique DMG Mori
that gives 20x to 40x depo- Phone: (847) 593-5400
www.dmgmoriseikiusa.com
sition rates for depositing

EXCEL GEAR, INC.

GEARS 1"– 60" - AGMA 15
The EXCEL promise;
We'll excel where others fall short.
• Complete gear design, manufacturing and
reverse engineering services
• Gear hobbing & grinding from 1"– 60"
(To AGMA 15)
• Internal gear grinding from 10"–60"
• Gear shaping to 36" diameter
(9" face width)
• Wind turbine gear boxes, high speed
spindles, gimbal heads and gear boxes
• Competitive prices and quality gear
design and manufacturing with delivery
commitments you can count on!
815-623-3414
A TOTAL SERVICE COMPANY [email protected]
ISO9001-2008 APPROVED www.ExcelGear.com
Introducing Excel-Lent Gear Design Software
providing accurate gear design and analysis that can get anyone
up and running fast – www.excel-lentsoftware.com

August 2014 | GEAR TECHNOLOGY 47

 on display...
150 years of innovation

SOLUTIONS FOR CYLINDRICAL AND BEVEL GEARS OF ALL TYPES

3 Bevel Gear Solutions, 3 Cylindrical Gear Solutions, 3 Metrology Solutions, 3 Cutting Tools and
Up to 2,500 mm Up to 10,000 mm All Types of Gears, Workholding Solutions,
Gear Tools All Processes

for worldwide sales locations and additional information, visit:

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

3 300PS Power Skiving Machine:

much faster than shaping; more
flexible than broaching.
3 PHOENIX® 280G Bevel Gear
Grinding Machine: new design
for greater accuracy, reduced
non-productive time.
3 GENESIS® 200GX Threaded Wheel
Grinding Machine: maximum
productivity, minimal setup time.
3 300GMS: the complete gear
inspection system for automotive,
aerospace and similar sized gears.
3 Tooling solutions for every gear
production challenge.
3 Gleason 4.0: our new ‘smart
factory’ initiative.

See what the future holds at:

www.gleason.com/IMTS.

see us at Booth #n-7000

AND SIzES

3 Global Services, 250 Factory-Trained

Personnel in 30 Countries Worldwide

www.gleason.com • [email protected]
 feature IMTS 2014 PRODUCT PREVIEW

NORTON (SAINT-GOBAIN)
Booth N-7051

Norton will be exhibiting its Norton sive grains, from proprietary Norton GMTA
Vitrium3, the next generation of bond- Quantum ceramic alumina to con- Booth N-6670
ed abrasives products, engineered for ventional aluminum oxide. Norton
maximum performance and cost sav- Vitrium3 features a stronger bond con-
ings in precision grinding. Norton struction that allows suitable form
Vitrium 3 features a patent-pending and corner holding for improved part
quality and higher tolerances, reduced
dressing time and wear, an improved
holding power utilizing less bond-to-
abrasive ratio and an increased poros-
ity that improves coolant flow and chip
clearance to eliminate burn or other
part damage, especially on today’s German Machine Tools of America
tough-to-grind materials, such as high (GMTA) will be showing their
nickel alloys, tool steels and chrome. complete family of gear-making
“Whether the goal is to reduce total machines, grinding, milling and turn-
cost per part, increase throughput, or ing centers, plus the newest additions
improve workpiece quality, Norton to the line, Rosink parts washers and
Vitrium3 is re-shaping the world of pre- Arnold laser machines. Manning
cision grinding to meet these needs,” the booth will be President Walter
said Scott Leonard, director of product Friedrich, VP Scott Knoy and execu-
bond technology developed by the management at Norton Saint-Gobain. tives from the various companies rep-
Saint-Gobain Abrasives R&D team. “This new technology will allow signif- resented by GMTA in North America
This bond features an exclusive chem- icant increases in production and also including Wera, Pittler, WMZ and
istry that promotes excellent grain introduces the possibility of grinding Praewema, in addition to Rosink and
adhesion, resulting in improved prod- instead of conventional machining on Arnold. All are high-quality German
uct versatility across a wide range of some operations.” machinery companies.
applications. Substantial performance For more information:
improvements with Norton Vitrium3 Norton (Saint-Gobain)
are now attainable in all Norton abra- Phone: (508) 795-2833
www.nortonabrasives.com

WENZEL AMERICA
Booth E-5698, N-6930, E-5510

Wenzel America’s metrology exper-

tise will be highlighted in three sep-
arate booths across two pavilions.
Their cutting edge, 3-D Scanning
CORE machine will be featured at For more information:
their own booth in the QA pavilion. GMTA
An XO CMM, featuring Wenzel’s Phone: (248) 921-0122
Phoenix structured light projec- www.gmtamerica.com
tion sensor will also be showcased.
Wenzel’s flagship, LH Generation
CMM with standard Renishaw probe,
will be on display at Renishaw’s
booth, also in the QA pavilion. Their
newest WGT Gear Machines will be
exhibited at Liebherr’s booth in the
Gear Generation Pavilion.
For more information:
Wenzel America, Ltd.
Phone: (248) 295-4300
www.wenzelamerica.com

50 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
KOEPFER AMERICA
Booth N-6918

Koepfer America, LLC will proudly of demonstration machines will repre-

introduce the CLC 200-SZ gear shaping sent Koepfer America’s wide range of
machine at IMTS 2014. This machine gear manufacturing products.
will be the first of its model to meet the For more information:
North American market, and it repre- Koepfer America LLC
sents a competitive and fully customiz- Phone: (847) 931-4192
www.koepferamerica.com
able solution for high-precision, CNC
gear shaping.
CLC has built gear shaping machines
for gears up to 118" (3,000 mm) diameter;
however, the CLC 200-SZ can cut exter-
nal gears up to 7.874" (200 mm) diam-
eter and has a maximum rating of 5 DP
(mn 5.0). The machine will also demon-
strate standard features such as a CNC
electronic guide, stroking speed of 1,000
strokes per minute, a movable cutting
head, and 3.937" (100 mm) stroke length.
The machine can also cut internal gears
up to 11.811" (300 mm) diameter.
CLC machines distinguish themselves
with a rigid construction for cutting
high-precision parts. These gear shapers
can also be customized for a customer’s
specific application. For example, a tilt-
ing column can be provided for cutting
tapered gears. Lastly, these machines
utilize direct-drive torque motors, and,
optionally, either Fanuc or Siemens CNC
controls.
The CLC 200-SZ gear shaping
machine will be Koepfer America’s fea-
tured new product at the show, accom-
panied by a Koepfer Model 160 gear
hobbing machine and a Wenzel WGT
400 gear inspection machine. This group

Leistritz keyseaters outperform all

others for capability and reliability!
By combining proven German engineering with traditional American
customer support, Leistritz customers remain fully satisfied for many
years throughout the long service life of these machines. So whether
you’re cutting a single keyway in a straight bore or a helical spline in
a tapered cylinder, give us a call to discuss how our workholding and
cutting tool solutions can help you improve quality.

201 934-8262 www.leistritzcorp.com

Leistritz Advanced Technologies Corp.
165 Chestnut Street, Allendale, NJ 07401

August 2014 | GEAR TECHNOLOGY 51

 feature IMTS 2014 PRODUCT PREVIEW

ZEISS INDUSTRIAL
EMUGE CORP. METROLOGY
Booth W-1536 Booth E-5504

At IMTS, Emuge Corp. will showcase nates the clearance between clamping Zeiss Industrial Metrology is introduc-
their comprehensive line of clamping sleeve and body, and between clamp- ing the latest generation of the success-
solutions. Emuge’s workholding divi- ing sleeve and workpiece. System SP ful Zeiss Contura. This system provides
sion specializes in providing high- achieves concentricity of < 0.002 mm a platform for flexible, reliable quality
ly accurate, almost maintenance-free (corresponding to < 0.0001 inch). assurance. It is even more precise than
customized solutions for applications For workpieces that have a short its predecessor and offers a large pack-
from low volume job shops to high clamping base or for diameters with age of optical sensors on top of addi-
volume automotive production envi- a very large tolerance, System SZ is an tional measuring ranges. Zeiss Calypso
ronments. “Our workholding group option. By applying an axial force, a 2014 software and a highly tuned over-
stays close to our customers to learn slitted collet is radially expanded by a all system enable Zeiss Contura to
about their unique challenges and cone. Simultaneously an axial move- maintain a high standard in the indus-
production environments. Doing so ment occurs, clamping the work- try. The Contura has made high-per-
helps us develop the best solutions for piece. When the eccentricity between formance measuring technology avail-
their applications,” said David Jones, pitch circle and seating bore is very able to the masses. The latest genera-
precision workholding manager at small, diaphragm clamping System tion will continue on this proven path.
Emuge Corp. The precision work- SM is suitable. It allows clamping of A reliable measuring system is the
holding lineup on display will include the gear wheel at the pitch circle for result of the interaction of its compo-
Emuge’s System SG that is used in machining the seating bore. The gear nents: design, sensors, software and
many machining operations such wheel is clamped in both axial and service. “With Zeiss Contura, custom-
as hobbing, shaping, and shaving radial directions. System SH is a solu- ers receive a well-balanced system and
for gear production, as well as mill- tion if there is not enough room for a thus a guarantee for stable, reproduc-
ing and inspection. The System SG’s mechanical clamping system and for ible precision. Put simply: results you
large surface area contact with the clamping long, thin-walled workpiec- can rely on,” says Andrzej Grzesiak
workpiece provides a clamping solu- es or a number of similar workpieces. from Zeiss Industrial Metrology busi-
tion which is very rigid, accurate and System SH is a closed system which ness group. Thanks to its robust design,
repeatable. The high precision System uses hydraulic pressure to clamp the Zeiss Contura can also be used near pro-
SP is used not only to clamp work- workpieces. duction. The latest and most powerful
pieces but also to clamp tools. By For more information: scanning sensors from Zeiss are avail-
applying an axial force, the clamping Emuge Corp. able for the machine. Another new fea-
sleeves move in the direction of the Phone: (800) 323-3013 ture is the range of measuring volumes.
www.emuge.com
force and expand radially. This elimi- The Zeiss Contura family has eight dif-
ferent sizes starting with a measuring
volume of 700 × 700 × 600 mm up to
1200 × 2400 × 1000 mm.
For more information:
Zeiss Industrial Metrology
Phone: (800) 327-9735
www.zeiss.com/metrology

52 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
DONTYNE GEARS FIXTUREWORKS
Booth N-6778
Booth W-1686
Dontyne Gears is a newly formed
company set up to help in the devel- Fixtureworks, a supplier of workholding to mini, clamping-force options from as
opment of gear systems. DG naturally and machine tool components, fixturing little as 2 to over 2,200 lb. and configu-
uses the versatility of Dontyne Systems accessories and material handling prod- rations that include swing, pull, snap,
software to optimize design for pro- ucts will showcase its extensive prod- hook, toe and side.
duction and performance, but also uct lineup during IMTS 2014, Featured In addition, also on exhibit will be
has access to the highest level of small in the exhibit will be Fairlane Products Kipp spring plungers, rest and riser
and large volume machining equip- full line of fixturing accessories includ- pads, levers, handles, knobs, and hand
ment to produce such components. ing grippers, rest pads, Swivots swivel/ wheels; Imao supports and stops, risers,
These components can be inspected pivoting positioning components, Quick T-nuts, sliding mounts, springs, sup-
on high quality gear inspection equip- Release ball-lock pins, rollers and bum- ports, grid plates and blocks; OK-Vise
ment and tested in test rigs ranging pers. Included in the Fairlane Products single and double wedge clamp designs;
up to 160 mm centers. Proximity and lineup are the new Urethane Covered Mitee-Bite low-profile edge clamps; and
collaborative links to Design Unit and Bearing Rollers. These covered bearings Modern Industries mPower product
Offshore Renewable Energy Catapult have a smooth urethane surface that is line which includes quick change preci-
(formerly NaREC) in the North East of cast directly to a precision sealed ball sion locating and mounting systems and
England ensure a solid knowledge base bearing. They provide smooth, quiet and modular tooling, plates and columns.
for R&D projects of the highest cali- non-marring operation with excellent For more information:
ber and the possibility of larger scale abrasion resistance and durability. They FixtureWorks
development programs. DG will help are available with hardness ranging from Phone: (888) 794-8687
www.fixtureworks.net
define and implement a test program 35 to 95 durometer in 1'to 3'
for standard gearing and custom gear diameters.
forms. The company will also consid- The exhibit will also fea-
er collaborations with machine tool ture the company’s full line-
manufacturers and tooling compa- up of manual clamps from
nies in the development of equipment Imao, OK-Vise and Mitee-
and processes using various produc- Bite. Clamps that provide
tion methods and materials. IMTS is quick and secure fastening for
a chance to get to know the personnel repetitive machining opera-
and discuss potential collaboration. tions and are suitable for easy
For more information: load/unload of workpieces.
Dontyne Gears The clamps come in a vari-
[email protected] ety of sizes from heavy-duty
www.dontynesystems.com

HAAS AUTOMATION
Booth S-8119

Five-axis machining is an effective Automation’s powerful high-speed comes standard with Haas Automation’s
means to reduce setups and increase machining software. Wireless Intuitive Probing System.
accuracy for multi-sided and complex The UMC-750SS’s high-speed, roll- The machine’s 15,000-rpm inline
parts. Machining those parts quickly fur- er-cam trunnion table offers 150 deg/ direct-drive spindle is powered by a
ther increases throughput and improves sec feedrates to quickly position parts
the bottom line. The UMC-750SS uni- to nearly any angle for 5-sided (3+2)
versal machining center from Haas machining, or provide full simulta-
Automation, Inc., is a high-speed solu- neous 5-axis motion for contouring
tion for quickly machining 5-sided (3+2) and complex machining. The trun-
and simultaneous 5-axis parts. nion provides +110 and -35 degrees
The UMC-750SS is a 5-axis, 40-taper of tilt and 360 degrees of rotation for
universal machining center with excellent tool clearance and large part
30" × 20" × 20" travels, 1,200 ipm rap- capacity, and the 630 × 500 mm table
ids, and an integrated high-speed, features standard T-slots and a preci-
dual-axis trunnion table. The machine sion pilot bore for fixturing versatil-
is equipped with a 15,000-rpm inline ity. To simplify job set up, the UMC-
direct-drive spindle, a high-speed 40+1 750SS features Dynamic Work Offsets
tool side-mount tool changer, and Haas and Tool Center Point Control, and

August 2014 | GEAR TECHNOLOGY 53

 Chicago / USA co opera tion susta in s in n o v at i on
September 08 – 13, 2014
South Hall, Booth S-8900

Gear production – complete machining

DMG MORI gearMILL® –

Gear cutting made easy

1-855-DMG-MORI (364-6674)
Support around the clock

Generation of the NC program with

DMG MORI gearMILL® software

DMG MORI gearMILL® software features

all gear types (except internal gears)

Efficient process chain of conventional gears with

any tooth profile in both soft and hard machining

Attainable gear quality: bevel spur gear DIN ≤ 5,

spur gear DIN ≤ 6

from DMG MORI

For more information

visit: www.dmgmori.com
or contact your local DMG MORI distributor
30-horsepower vector drive system that Adveon allows users to: develop their reduce time from design to production
yields 90 ft-lb of cutting torque. The own tool library/database, select tools combined with the ever-increasing com-
Haas inline system couples the spindle for production, overview and maintain plexity of tools makes rapid access to
directly to the motor to reduce heat, the assortment, build tool assemblies accurate and current tool data more crit-
increase power transmission, and pro- quickly and safely, see immediate results ical than ever. Companies can no longer
vide excellent surface finishes. in 2-D and 3-D models and instantly afford to rely on manual data entry and
A wide selection of high-productiv- export to CAM or simulation software. operators need a single tool library that
ity options is available for the UMC- Adveon works with any tooling sup- can manage tools from multiple man-
750SS, as well, including a belt-type chip plier that bases their catalog on the ISO ufacturers. Adveon has been designed
conveyor, high-pressure through-spin- 13399 standard, thus assuring the accu- from the ‘ground up’ to address these
dle coolant systems, expanded program racy of geometrical information. challenges and we are pleased that the
memory, and much more. The advantages of Adveon are far leading CAD/CAM companies have
For more information: reaching. The open catalog area allows integrated the tool library system.”
Haas Automation drastic reduction of time spent on find- Additionally, Sandvik Coromant will
Phone: (805) 278-1800 ing and defining cutting tools, which display its InvoMilling technology at
www.haascnc.com
eliminates the need to search for infor- IMTS as well as its patented Inveio tech-
mation in catalogs or interpret data from nology featured in its newest inserts.
SANDVIK one system to another. This in turn helps Products featured include the CoroMill
COROMANT the manufacturer gain rapid access to
the required cutting tool information
172, Capto MACU, CoroCut QD SL,
CoroDrill R846 and more.
Booth W-1500
in order to source the most suitable For more information:
Cutting tool and tooling systems sup- machining solution paired with the most Sandvik Coromant
plier Sandvik Coromant has announced efficient cutting tool selection. Through Phone: (800) 726-3845
www.sandvik.coromant.com
that leading CAD/CAM software Adveon, users can select the tools used
companies Edgecam, Top Solid and in their daily operations, maintain and
GibbsCAM are integrating the Adveon amend the assortment and create their HWACHEON
Tool Library. Built into software, Adveon
helps customers to further improve
own tool libraries by copying and past-
ing from the catalog area. Virtual tools
MACHINERY
Booth S-8129
machining productivity and security, can be assembled in a fast and secure
and saves time during machine setup. manner and data quickly exported for Hwacheon Machinery America will
By reducing the engineer’s input, both CAM programming and simulation. demonstrate its high-precision machin-
consistency and quality of data are According to CAM system suppliers, ing centers for die-mold applications.
improved. Additional CAD/CAM com- the automated input of cutting tool data Hwacheon’s Sirius range of 3-axis verti-
panies are in the process of integrating to CNC systems can increase the pro- cal machining centers feature 20,000-
Adveon as well. ductivity of a machining process by as rpm high-speed spindles for the UM and
The library has standardized meth- much as 20 percent. UL+ models and 12,000 rpm spindle for
odology, designed specifically to facili- Klas Forsström president of Sandvik the UX model.
tate quick and safe CAM programming. Coromant comments: “Pressure to A number of useful options make
mold-die machining more efficient with
Sirius machines. Equipped with inte-
gral motor spindles with jacket cool-
ing and oil-jet cooled bearings and rigid
roller linear guide ways, the machines
deliver stable performance over long
cycles. According to the company, the
Sirius range of high speed die and mold
machining centers provide the industry
high capability, extreme precision at an
attractive price.
The UM model demonstrated at
Hwacheon’s open house featured a 850
mm (33.46") × 500 mm (19.70") work
table with 800 kg (1,764 lb) load capac-
ity, strokes of (X, Y, Z) of 750 mm
(29.53") × 500 mm (19.70") × 450 mm
(17.72"), and rapid positioning of 24 m/
min. The 40-taper (BBT & HSK option-
al) tools are changed in 2.5 seconds.

August 2014 | GEAR TECHNOLOGY 55

 feature IMTS 2014 PRODUCT PREVIEW

The bilateral gate structure in Sirius-

UM effectively distributes the vibration,
weight, and heat throughout the entire
frame. Finite element analysis meth-
ods help to minimize the frame distor-
tion which may be caused by machin-
ing conditions or environment. The dis-
tance between the spindle and the body
is designed short, so the machine stays
stable after a prolonged operation.
The spindle is integrated with the
motor to limit vibration, noise, and
power loss at high speed rotation. The
cooled jets of oil are injected directly
onto the spindle bearing for effective
cooling, and the motor and the spindle
assembly are jacket-cooled to limit the
displacement caused by heat. To achieve
greater precision, standard Hwacheon
software (HSDC) monitors the spindle
for possible thermal displacement and
makes necessary adjustment in real time.
Sirius-UM provides powerful feed
performance using the Z-axis 6-block
LM guide. The servo motor is coupled HTLD Tool Load Detection software tain consistent cutting load. Features
directly to the drive; and while the ten- provides real time measurement of include a graphic display of tool load
sile preload ball screws provide smooth tool load ensuring consistent and safe and feedrate, convenient operation using
operation, the roller linear guide allows machining. Constantly monitoring tool G-code programming, and a number
for rapid feed and rigid performance. damage and deterioration for prevention of data sets for specific tool and pro-
Before final finish passes, Sirius of complete tool failure causing work cess control. Additionally, highly sensi-
machines can, with Hwacheon HFDC piece damage, this software ensures tive thermal sensors mounted at various
(Hwacheon frame displacement con- accuracy and performance. Such a sys- locations in the machine castings where
trol system) software, dynamically com- tem will measures tool load very fre- thermal displacement is possible can
pensate for any changes that may have quently, such as every 8 msecs. permit software monitoring and correc-
occurred in machine kinematics due to Hwacheon high efficiency contour tion of detected thermal displacement.
temperature, vibration or changes in the control (HECC) system offers an easy Hwacheon spindle displacement con-
tool itself. to use programming interface system trol (HSDC) is also possible with soft-
Hwacheon mold-making machine which provides a precise, custom con- ware. As a spindle rotates at high speed
tools feature standard integrated soft- tour control for the selected work piece centrifugal forces and heat expand the
ware developed in conjunction with while supporting longer machine life spindle taper causing error in Z-axis.
Fanuc CNC for thermal displacement and reduced process time. Such software This axis accuracy is vital to precision
control and compensation. Software will offer different options for cutting mating of die components. In addition
measures thermal conditions in the speed and accuracy, and for surface fin- to a high precision cooled spindle, soft-
machine during the cycle and uses the ish and geometry. A customizable dis- ware can be used to constantly moni-
information collected to dynamically play provides real time monitoring and tor temperature at a number of points
verify and control accuracy. easy access. This software may be used within the spindle assembly predicting
In this way, Hwacheon machine can with existing NC systems and is compat- thermal displacement. The system can
control the kinematics of the machines ible with G-Code programming. then makes necessary adjustments and
for contour machining, optimiz- Optima, a cutting feed optimiza- effectively minimize thermal displace-
ing machine performance for rough- tion routine utilizes an adaptive con- ment, preventing Z-axis error due to
ing, semifinish, and finish machining trol method to regulate the feedrate in taper expansion as the spindle rotates at
without employing a number of different real time to sustain a consistent cutting high speed.
programs. The Sirius machines include load while machining. As a result, cut- For more information:
software that other machines do not or ting tools are less prone to damage and Hwacheon Machine Tools
offer only as options. machining time is reduced. The sys- Phone: (847) 573-0100
www.hwacheon.com
tem controls the feed velocity to main-

56 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
EXSYS The Preci-Flex coni-
Booth W-1671 cal and flat-face planar
interface duplicates the
Exsys Tool, Inc. will exhibit a wide range taper of the standard
of innovative manufacturing technol- ER collet, enabling ER
ogy. Among the products on display will collets, albeit at lesser
be the Preci-Flex modular quick-change repeatability, to be used
tooling system, the compact Eppinger along with Preci-Flex
C3, C4 and C5 Connection Base Holder, adapters to mount col-
Deco-Flex modular adapters for Swiss lets, endmill holders,
automatic machine tools, and modu- expanding collet chucks
lar Gressel vises. The company will also and shrink fit tooling
highlight its comprehensive Exsys Tool on a single base hold-
Repair LLC. service that specializes in er. Operated at the front
repairing and rebuilding driven tooling face of the turret, the
for CNC turning centers. connector provides two
The Preci-Flex modular quick-change tons of clamping force,
tooling system features a selection of and its compact design
adapters engineered to hold different maximizes torque transmission and within a machine tool so it can easily
cutting tool and shank designs. The rigidity, increasing accuracy and pro- handle larger workpieces.
adapters’ common connecting feature ductivity. For Swiss automatic machine tools,
locks into a standard base unit on the Representing another example of Exsys Tool will exhibit Deco-Flex adapt-
machine turret, enabling tool/adapt- advanced modular quick-change tool- ers that have minimal envelope dimen-
er assemblies to be preset offline then ing technology, the compact Eppinger sions so they can increase manufactur-
quickly switch in and out of the base C3, C4 and C5 Connection Base Holder ing flexibility in a Swiss machine envi-
unit. Tool positions repeat within +/- 3 makes fast and simple tool changes pos- ronment. The compact design also
µm, eliminating the need to re-center, sible as well as requires minimal space enhances rigidity, boosting machining
touch off, or make test cuts. efficiency.

August 2014 | GEAR TECHNOLOGY 57

 feature IMTS 2014 PRODUCT PREVIEW

The Deco-Flex connection features

a conical and flat-face planar interface
that ensures concentricity and repeat-
ability. The system also offers specific
adapters that combine with fixed and/
or rotary tool holders to optimize tool
performance and flexibility. Tools can be
preset off the machine, allowing adapter/
tool changes to be completed in seconds
and thereby reducing setup times while
increasing machine uptime.
On the workholding side, at IMTS,
Exsys will present three innova-
tive workpiece clamping systems from
Gressel:
•Gripos modular machine vises clamp
by tension rather than compression, pro-
ducing no deflection of the vise base-
plate, and are gradually and precisely part in a lathe or milling machine with- not only are we sought after for qual-
adjustable from 10 to 100 percent grip- out removing the part from the machine. ity but our total cost for our customer
ping force. Turning a lever 160 degrees Polygon’s rotary broaching system is is less.” Marine Concepts and Polygon
provides mechanical amplification with usually used for making hexagon or Solutions Inc. actively work together
complete clamping in less than a second, square holes in precision machined as members of the Florida’s Southwest
minimizing set-up times. products. The new ‘Made in USA’ broach Regional Manufacturing Association
• Grepos 5-axis power vises feature the will have its official debut at IMTS. (SRMA).
same actuation technology as GRIPOS Polygon Solutions first introduced an Polygon’s new broach is not limited
vises and provide force amplification innovative and award winning adjust- to the ‘Made in USA’ mark. The com-
from 0-40 kN direct on the workpiece. ment free Rotary Broach Tool Holder in pany sells its tools worldwide and is also
The design of the vise permits access
2010, ideal for CNC machines because of developing the system to mark logos,
to the both sides as well as the under-
side of a part, facilitating true 5-axis maintenance free sealed bearings and a slogans and symbols. “We’ve had a few
complete/simultaneous machining. new pressure relief system. The company challenges to get it to work perfectly,”
• Solinos modular single-clamping vises later announced a series of letter broach- says Peter Bagwell, product engineer
for small workpieces feature inter- es in 2012. The broaches have letters or at Polygon. “But we keep working with
changeable jaws and are offered in numbers and are inserted into Polygon’s our customers and our partners to get it
mechanical or hydraulic versions, pro- broach holder to mark parts. The differ- right. Customers re-shoring their parts
viding clamping force up to 20 kN. ent identifying marks improve quality to want to show they are now made in the
Clamping range is adjustable without distinguish between mixed lots of parts United States.”
jaw removal, enabling quick change- made in the same machines. Partners include the Precision
overs between different parts. The The ‘Made in USA’ broach was first M a c h i n e d P r o d u c t A s s o c i at i o n
vises can be directly integrated into tested during Polygon’s annual National and National Tooling & Machining
pallets.
Association of Manufacturers (NAM) Association. Bagwell adds, “We’ve
For more information: Manufacturing Day tour in 2013. Lee learned from our customers that our
Exsys Tool, Inc.
Phone: (800) 397-9748 Virtual School students in Fort Myers, rotary broach holder is very easy to set
www.exsys-tool.com Florida were taught about product devel- up in the machine and very easy to use
opment and how the new rotary broach for making small hexagon and square
POLYGON ‘wobbles’ or displaces material to create
the text. Polygon showcases new prod-
holes. We hope the new ‘Made in USA’
broach helps them achieve an even high-
SOLUTIONS INC. ucts to students in hopes of promoting er level of satisfaction in both their parts
Booth W-1954
the desire for STEM education in a new and ours.”
Polygon Solutions’ latest rotary broach generation of engineers and machinists. For more information:
product not only expands their tooling “Made in America is one of the stron- Polygon Solutions
product line, but it also brings an inno- gest selling points we have, even for our Phone: (239) 628-4800
www.polygonsolutions.com
vative solution to manufacturers hop- U.S. Customers,” says Matt Chambers
ing to capitalize on the ‘Made in USA’ of Marine Concepts in Cape Coral,
re-shoring trend. Polygon Solution Inc.’s Florida.“The quality of the overseas
For Related Articles Search
new ‘Made in USA’ broach is a rotary product has been from the start an infe-
broach with multiple text letters allow- rior product, and as the cost of quality is IMTS
ing machinists to stamp or mark their more than ever being taken into account, at www.geartechnology.com

58 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 Stronger Longer Lasting Gears
Reliable • Precise • Efficient • Innovative

• FEA computer modeling

Just like gears, induction heating is all about
• Single part process monitoring
Precision. Inductoheat’s precision controlled, induction
• Single-shot, scanning, tooth by tooth
gear hardening systems provide ideal metallurgical
• Single-coil dual-frequency technology
patterns, minimum shape distortion, increased wear
resistance and exceptional contact fatigue strength. • Wide range of gear & bearing diameters
• Hypoid ring, spiral bevel, worm and pinion gears

Visit our website to learn more about our induction heat treating equipment! Inductoheat, Inc. • Madison Heights, MI • (248) 585-9393
www.inductoheat.com
 feature

Honing of Gears
Gerhard Flores, Andreas Wiens and Oliver Stammen

Introduction ish.” Furthermore, for the function of ly surface that prevents a breakdown of
The honing of gears — by defini- gear wheels, the quality terms “axial run- the lubricating film on the contact sur-
tion — facilitates ease of operation, low out” and, respectively, “perpendicular- faces. This acts to reduce friction and
noise and smoother performance in a ity” and “radial run-out” (out of round) minimize wear under high loads on the
transmission. Honing also contributes to are relevant. If one also wants to use contact surfaces, as well as under the
reduced friction in the powertrain. Both honing for the finishing of gear wheels, light loads on a rotating idler. Also, the
the intense cutting (roughing process) the process of these broadened quality oblique angles of the honing marks con-
as well as the functionally fine- finishing terms is modified accordingly. tribute to the even distribution of the
of transmission gears can be performed lubricating oil in the lengthwise and cir-
in one setup, on one machine. Honing Function and Quality cumferential direction of the bore.
in mass production is a well-established With the bore in a control wheel, In order to avoid local high surface
process, owing to the intelligent machine i.e. — any free gear in a transmission vs. pressures, there are also tight shape
layout and other combinations with spline-mounted, thus requiring bore fin- and position tolerances of the required
defined cutting geometries. As such, it ishing — the transmission component macro-geometrical conditions for equal
should be technologically and economi- functions as a rotary and translational lubrication gap widths. The tight geo-
cally considered as a serious production slide-way. The tolerances are selected metrical tolerances (axial run-out) and
method. Furthermore, the combined accordingly. The honed surface topogra- radial run-out have a positive effect on
process of flat surfacing and honing on phy with high load bearing area benefits the smooth operation of the gear wheel
one machine is an even more recent the frictional behavior and uniformly sets. This is the purpose of the statistical
innovation for the finish machining distributes the application of force. The tolerance limits. At a machine capacity
of planetary gears in mass production. honed surface profile with a large topo- of cmk ≥ 1.33, for example, the straight-
The design of components for modern graphical contact surface enables a sta- ness is reduced from 3 µm to about
vehicle transmissions such as manual, bilization of the lubricating film, when 2.1 µm, despite very different wall thick-
automatic or dual clutch styles seeks to mixed lubrication condition occurs. nesses.
reduce friction, thereby increasing gear Honing produces a tribologically friend-
efficiency and function. Therefore, for
the gear bores of various active transmis- Table 1  Quality characteristics for honing gears

sion components and planetary gears, Dimensional tolerance Diameter

low-friction and wear-resistant contact
Cylindricity
topographies are required. There is also
the desire for economical finish machin- Shape tolerance Roundness
ing of the bore in one process, whenever
Straightness
possible.
The finish machining of transmis- Parallelism
sion components in mass production Directional tolerance
Perpendicularity
is currently being done using rough
honing and finish honing. In one pro- Run out tolerance Axial run-out, Radial run-out
cess — consisting of two steps on one arithm. mean deviation Ra
Surface tolerance √Rz, Ra
machine — the functionally accurate averaged surface Roughness Rz
shape and position tolerances, as well
as the desired surface structure, can be
achieved. Therefore secondary hard
turning and grinding processes are sel-
dom required as finish processes in mass
production — neither individually nor as
combined processes in a work cell.
The diverse quality characteristics
require an adjustment to individual pro-
cess components of honing. The man-
ufacturing quality of the conventional
hone process is defined by the terms
“dimensional tolerance” and “surface fin-
Figure 1 Machining principle for position correction of gear wheel bores in gear wheels.

60 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 Honing involves the boring of gear Table 2 Layout of honing machines for machining components
Control Wheel Machining
wheels (Ref. 1) (such as planetary gears,
Machine type Rotary indexing machine
transmission gears, switching sleeves, Spindle configuration vertical
lay-shaft gears, bevel gears) of various Fixture Floating single part holder
shape, dimension, material and hard- Qty. of hone operations 2
ness. Honing of transmission gears goes Tools
In-process adjustable multiple stone tools
beyond the previous quality terms. The with CBN-abrasives of various grit
• Load and unload
following tolerances can be defined as • Mechanical pre-gaging
(Table. 1): • Rough honing
In addition to the geometric toler- Machine layout • Pneumatic post-gaging1)
• Finish honing
ances, highly stressed components are • Pneumatic post-gaging
increasingly evaluated according to the • Spin-dry
near surface zone of the functional sur- 1) Instead of pneumatic post-gaging, a pneumatic in-process gage can also be used.
face. The mechanical and thermal stress
of the material due to the machining
forces during the final machining steps
contributes to the residual stresses in
the area near the surface. For example,
abusive grinding imparts detrimental
residual tensile stresses, whereas honing
imparts beneficial compressive stresses
because the honing process has compar-
atively low machining forces and tem-
peratures.

Honing Control Wheels:

Machining Principle
An important feature of honing is the
alignment of both tool axis and bore
axis. In the conventional layout of tool
and part, the expansion of the tool
results in an equiaxial alignment. The
tool-part system has designated degrees-
of-motion freedom that enables the cen-
tering and tilting to identical axis posi-
tioning. An improvement in dimension,
shape and surface quality is achievable
with this mechanical system.
If the position of the bore needs cor-
recting, that is — the perpendicularity
of the bore axis to the front face — or
the axial runout of the front face to the
bore axis — then the angular degree-of-
freedom (tilting) must be replaced by a We only use Rotek rings to ®

rigid, perpendicular repositioning of the manufacture our industry-leading bearings.

tool axis and clamping surface (Ref. 2).
The reference surface for honing is the From rolled rings to fully customized machined rings, we offer
machined front face, which is supported a wide range of sizes that give you the design flexibility
on the clamping level (Fig. 1); centering you need. In fact, whatever your production demands,
on an inaccurate gear tip circle diameter Rotek is behind you every step of the way. For a quote,
is not necessary. visit www.e-rotek.com or call us at (800) 221-8043.
Now, the center of the gear wheel
bore can align itself to the tool via the
floating part holder. In this condition
the radial run-out (bore-to-gear teeth) Rotek Incorporated
remains unchanged; the deviation of Exceptional Rings Lead to Exceptional Bearings

the angle position of the bore axis to

the tool axis is corrected in the subse- © 2014, Rotek Incorporated. All rights reserved.

August 2014 | GEAR TECHNOLOGY 61

 feature HONING OF GEARS

quent material removal. Next, the tool bore is defined by the following quality
machines the raised areas of the lateral terms and tolerances (Table 3):
surface. With the additional clamping, The high stock removal during rough
the entire bore is machined and a new honing with a honing allowance of up
bore axis is established. to 0.350 mm is the prerequisite for the
successful implementation of the hon-
Honing Transmission ing process in the mass production of
Components: Machining Concept gear wheels. This is how honing main-
The common principle among the vari- tains its competitiveness compared to
ous possibilities for gear wheel machin- hard turning. The smoothing of the sur-
ing is the moveable part holder and the face end quality takes place in the sec-
rigid tool holder. Also, the conventional ond machining station only by chang-
honing process with adjustable honing ing the cutting material and adjusting
stones has been carried through. For the process parameter; the radial run-
honing such components, vertical rota- out achieved in pre-machining should
ry indexing machines with the single remain unchanged.
part holder in floating fixtures are used The layout of a machine for machining
(Table 2). gear wheels shows the stations named in
The preparation consists, as a rule, of Table 2. After the load and unload sta-
boring and hardening, so that they must tion, the mechanical pre-gaging is per-
be machined in two honing operations. formed. Here, the minimum dimension
The tools are exclusively loaded with of the bore is checked in order to prevent
CBN-abrasives. Furthermore, fully auto- a collision with the tool. Rough honing
mated production honing machines are
equipped with various standard compo- Table 3 Required machining quality on a
nents such as gage stations, handling sys- hardened gear wheel
tems, force-controlled electromechanical
feed devices (EMZ-F) and electrome-
chanical ball-screw stroke drives. A
B
Honing Transmission 32 G6 0,007 A
Components: Requirements and 0,003
Process Considerations
Because honing of hardened gear wheels 3 Rz
0,04 A - B
has undergone major development in
the past few years, this illustration is pre- 32 G6 = +0,009 / +0,025
sented simply as an example. The hard-
ened gear wheels are mainly machined 22
on fully automatic, multiple-spin-
dle, rotary indexing honing machines. Control wheel 4th gear
The machining concept for individual Total hone allowance ≤ 0.350 mm
machining consists of conventional mul- Cycle time 20 s
Hone time 18 s
tiple stone tools. The attachments are
Machine utilization 120 parts/h at 80%
designed to be interchangeable for vari- Material Forged steel
ous gear wheels. Honing a gear wheel Turned and hardened
Preparation
on 680 HV30

Table 4  Machining parameters for honing gear wheel bores

Rough honing Finish honing
Qty. of honing stones 4 to 6 (depending on diameter)
Cutting material CBN
Grit size B213 B 46
Bond Sinter metal Sinter metal
Dimension 4 × 4 × 25 mm 4 × 4 × 25 mm
Cutting speed 145 m/min 95 m/min
Feed electromechanical (EMZ-F)
Allowance 0.200-0.300 mm 0.015-0.025 mm
Hone time approx. 18 s approx. 18 s
Pneumatic post-gage with feedback
Gage-control Pneumatic in-process gaging
function

62 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 produces less fine-grained dimensional stability and increases cut-
hone sludge. Instead, fine, ting performance and tool life.
long continuous chips in The individual processing with con-
the form of a steel wool ball ventional abrasive tools is the most eco-
result. nomical variation of gear honing. The
The function of CBN stationary fixtures are arranged under
abrasives of a middle con- the two hone spindles. With the rotary
centration (stock removal index movement, the gears are loaded
≤ 0.300 mm in 18 s) is deci- into the fixture. The fixture consists of
sive for the entire process. the floating part holder and the zero-
The use of low-viscosity clearance, hold-down device (Fig. 5).
honing oil (η = 4.6 mm²/s) The part is situated on one of the flat
has a positive effect on the sides of a moveable pallet. The hydro-
cutting behavior and, there- static friction bearing of these pallets
by, on the consistent manu- enables effortless, but not un-damped,
facturing quality and tool movement on the flat. A torque recorder
life. In addition to the con- in the gear teeth has been proven effec-
structive design of the hone tive. This occurs by means of the inser-
tools, the condition of the tion of the gear into an integrated switch
abrasives is of vital impor- sliding sleeve or by applying a safety
tance. They are composed catch. The zero-clearance hold-down to
of a metallic binder, fused accept the upper facing axial force helps
Figure 2  Machining stations for honing gear wheels. with the proper concentra- with the deformation-free fixation of
tion of CBN abrasive crys- the gear. The lower guide stabilizes the
works with robust parameters — espe- tals (Fig. 4). Apart from the selection tool axis to the clamping level at a right
cially at a high cutting speed of about of binder and grain material, the sinter angle.
150 m/min and large removal rates of parameters in the manufacturing pro- The described process design can reli-
about 20-30 µm/s in diameter. The sub- cess of honing abrasives determine the ably achieve the required tolerances.
sequent finish honing operation com- quality. The hone tools are rigidly con- (Note: The roughness and the axial run-
pletely removes the rough profile of nected to the spindle. Below the part, the out are not statistically evaluated here.
the rough honing operation and leaves tool body is formed as a carbide-rein- (With the finish hone stones [B46], the
behind the functional component qual- forced guide shaft. The tools, depend- Rz value amounts to about 1.5 – 2.5 µm,
ity (Fig. 2). Pneumatic post-gaging is the ing on design feasibility, have as many and the axial run-out precision of
final quality assurance; spinning the gear abrasives as possible; this improves the 15 – 25 µm only meets about 40% to 50%
minimizes the spreading of the honing machining accuracy with regard to of the tolerance. The cycle time achieved
oil. is 20 s, with an allowance of ≤ 0.300 mm
The machining parameters are sum-
marized in the following (Table 4):
The high removal rate is primarily
determined by the high delivery rate
and high cutting speed. With increas-
ing rpm, a rise in material removal is
clearly noticeable (Fig. 3). The math-
ematical removal characteristic is deter-
mined by the feed rate; i.e., by the dia-
metric preset diametrical honing stone
feed-per-unit-of-time. The difference
between calculated and measured stock
removal results from feed losses caused
by deflecting the components in the
complete feeding system. The increas-
ing deviation from about 1,500 rpm
is explained by an increase in coolant
flow at increased rpm. The influence
of the stroke speed in the area exam-
ined is not significant. Because of the
material properties and the high cutting
capacity, the rough honing operation Figure 3 Correlation of rpm and stock removal: control wheel diameter 35 × 26 mm; forged steel;
680 HV30; hone time 18 s; L600 honing machine.

August 2014 | GEAR TECHNOLOGY 63

 feature HONING OF GEARS

Figure 4 Hone tools with lower guides and CBN abrasive crystals (B213/B46).

Figure 5  Floating uptake with zero clearance hold-down.

Figure 6  Progression of compressive stress with increasing material depth.

For Related Articles Search

honing
at www.geartechnology.com

64 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 QUALITY PARTS

Figure 7  Process steps for combination machining.

in the first operation (determined by
cycle time). The quality parameters of Honing Planetary Gears in
diameter, roundness and parallelism are Combination Machining REPEATABLE RESULTS
also calculated to meet tolerances and As demonstrated, the combination
satisfy the statistical tolerance limits. machine with the processes of flat fin-
Measuring the residual stresses with ishing, grinding and honing offers a
x-ray diffraction shows the condition of new possibility for machining planetary
the material structure in the area of the gears. This rotary indexing machine
near surface zone of the honed bore sur- completes the processes on the part, one
face. The stress in the area of the func- after another, in one clamping. This ver-
tional surface is substantially influenced satility allows various machining geom- RELIABLE MACHINERY
by the hardening process and the stress etries, such as one bore and one face
of the finishing operation. surface to be machined — each with
The available measurements (Fig. 6) tight tolerances relative to the other. The
were taken with a Stresstech XSTRESS compact machine workspace essential-
3000 instrument; the values were mea- ly consists of a circular rotary table on
sured axially and tangentially. The hone which the rotary-driven units are con-
angle of about 20° causes an uneven dis- structed, and the central column, where
tribution of the compressive stresses in the machining units are assembled to
both directions on the honed surface. the upright surfaces. The result is a self-
With increasing material depths, that sufficient machine with a small foot- TECHNICALLY SAVVY
is, where the surface is traditionally less print and short transport route in the
impacted by the machining forces, the indexing of the part. The circular rotary MTB offers meticulous and quality
uniformity of the clamping method is tables make the machining units eas- craftsmanship in rebuilding and
measurable. This is a good indication of ily accessible for maintenance work and recontrolling gear shapers, hobbers
how the consistency of the impact force tool changes. and grinders. Brands include Lorenz,
in honing differs radically from that of Figure 7 depicts the process steps for Fellows, Kapp, Koepfer, Liebherr,
turning and grinding the same surfaces such combination machining. The part Modul, Pfauter, Gleason Pfauter,
with, for example, extended tooling. The is only pre-machined on the front and in Gleason, Red Ring, and many more.
high residual compressive stresses clearly the bore. The gear wheel is located in the www.machinetoolbuilders.com
exceed the values of such competitive fixture with an unfinished side up, and is Call: 815-636-7502
processes (Ref. 2). clamped radially on the gear teeth. The

August 2014 | GEAR TECHNOLOGY 65

 feature HONING OF GEARS

tip diameter or the involute teeth are the

geometric-identifying elements for the
position of the part. The upper front is
machined by flat finishing 1 (Example
1). Then the part is turned so that the
previously finish-machined end surface
fits in the fixture as the locating surface.
In the subsequent grinding operation
the bore is ID ground centric to the gear
teeth. With this, the desired radial run-
out tolerance is achieved.
The above enables the subsequent sta-
tion to work with a tightly clamped hone
tool, because the alignment is made to
the unchanged clamping fixture and
guarantees the centric ground bore; Figure 8  Machining stations for machining planetary gears.
therefore, a new bore axis will not be
partially processed. The hone process The machine concept is designed such bological effect on the sliding function
consists of a rough hone and finish hone that other process sequences are config- of the gear wheel.
operation. Between the two hone opera- urable. There is also the opportunity to An additional innovative manufac-
tions is a gage station in which a plug integrate modified modular units such turing strategy is the use of machines
gage records the rough hone diameter as deburring, wheel dressers, belt fin- for combination machining; it is espe-
using the principle of pneumatic length ishing or reaming. The concept of com- cially advantageous in the machining
measurement. After finish honing, the bined machining is especially useful in of planetary gears. Here, the process of
flat finishing (Example 2) takes place. the manufacturing of planetary gears. flat finishing, ID grinding, and honing
Here, the second end face is machined Previously, the manufacturing processes are systematically combined in a single
parallel to the first end face. (See Figure for flat finishing, ID grinding and hon- machine.
8’s depiction of the individual machining ing required different machines.
stations.) The consolidation of the process- References
es into one machine allows high cap- 1. Honen von Zahnradbohrungen im Gegensatz
zum Honen von Zahnflanken (z. B. System
ital investment savings, Fässler AG, Präwema Antriebstechnik GmbH,
increased productivity and Gleason-Pfauter Maschinenfabrik GmbH,
reduced operational foot- Kapp GmbH).
print (Fig. 9). For planetary 2. Klink, U. “Wirtschaftliches Honen von
Getrieberadbohrungen,” Werkstatt und
gears, cycle times of 7 s with Betrieb, 116, Jahrgang 1983, Heft 5, S. 283-286
material removal in the bore 3. Shaw, B.A., J.T. Evans, A.S. Wojtas and
of ≤ 0.15 mm are achieved. L. Suominen. “Grinding Process Control
Using the Magnetic Barkhausen Noise
Method,” Third International Workshop on
Summary Electromagnetic Non-Destructive Evaluation,
The possibility of position Reggio Calabria, Italy, 14–16 September, 1997,
correction with high-preci- IOS Press in the Series “Studies in Applied
sion and material removal Electromagnetics and Mechanics.”
of up to 0.350 mm in 18 s
placed the single-machine
honing of control wheels
firmly into current automo-
tive manufacturing technol-
ogy. Despite very high cut-
ting performance, the low
machining forces and tem- Gerhard Flores is manager of process
peratures enable the lowest development at Gehring Technologies GmbH
in Ostfildern, Germany and a lecturer at the
near surface zone variances technical university in Esslingen, Germany.
and high residual compres-
Oliver Stammen is sales manager
sive strength. The surface for Thielenhaus Technologies GmbH in
roughness with a high load Wuppertal, Germany.
bearing area in low cutting Dr. Andreas Wiens is team leader
depth, and the hone angle of process development for Gehring
structure have a positive tri- Technologies GmbH.
Figure 9  Machine for combination machining of gears.

66 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 Operational Work?
We’re Armed to the Teeth

11715 Main Street, Roscoe, IL 61073

815-623-2168

MISSION: SAVING TIME. Our elite, highly trained Gear Team 6

is heavily armed with the latest gear production and
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before your competition even knew what hit them.

Get a quote in 48 hours or less. See if you qualify for our

Guaranteed Lead Times. Call today or visit:
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SCAN NOW!
 ask the expert

Importance of Contact Email your question — along with your name,

job title and company name (if you wish to

Pattern in Assembly of
remain anonymous, no problem) to: jmcguinn@
geartechnology.com; or submit your question by
visiting geartechnology.com.

Bevel Vs Cylindrical Gears

QUESTION
Why is there so much emphasis on the tooth contact pattern for
bevel gears in the assembled condition and not so for cylindrical
gears, etc? Any information would be greatly appreciated. For Related Articles Search

contact pattern
at www.geartechnology.com

Expert Answer Provided by: Dr.

Hermann J. Stadtfeld, Gleason Corp. tion found in the roll testing machine higher-order corrections with the aim
as the optimal build position — regard- of minimizing the sensitivity regarding
Bevel and hypoid gears common- ing tooth contact and noise. This rather contact movement under load while also
ly use a cantilevering pinion. This complicated angular configuration with increasing load-carrying capacity.
means the pinion has, for example, two a possible pinion cone “P” optimization Spur and helical gears — in automo-
tapered roller bearings located on the and the presence of gearbox toleranc- tive transmissions, for example — are
shank — behind the heel — with no bear- es requires an individual adjustment of arranged between two parallel shafts.
ing support on their toe end. While the the gear cone “G”. The gear cone adjust- Under load the gears at the end of the
ring gear is supported on both sides, this ment is mainly done to re-establish the shafts might change their center distance
presents a situation that allows the pin- desired backlash, which changes if the by small increments — mostly caused
ion to bend in the plane of the ring gear pinion position should be optimized. by the transmission housing deforma-
rotation, and in a plane that is defined by In cases where the tooth contact moved tion — while the shaft inclination is still
the pinion axis and is perpendicular to too far away from the required position, acceptably small. The gears towards the
the first plane. In other words, a three- a pinion cone correction (using bearing center of the shafts will change their cen-
dimensional displacement of the pinion shoulder shims of different thickness), in ter distance by higher amounts, while
vs. the gear takes place during regular connection with a re-adjustment of the the inclination is negligible. The involute
operation. This phenomenon increases gear cone, must be performed. Because profile will prevent edge contact at top
in severity in cases where the gearbox of the high three-dimensional displace- and root, if the contact ratio in profile
housing is not of steel, but rather from a ments of the pinion position relative to is above 1.00. Load concentration at the
material with only a fraction of the mod- the gear, bevel and hypoid gears receive ends of the teeth is prevented by the face
ulus of elasticity of steel — such as alumi- a combination of length crowning, pro- contact ratio of helical gears. Spur gears
num alloys. The situation of relative dis- file crowning and flank twist (Fig. 2). are corrected with a first-order end-
placement of bevel and hypoid transmis- Modern bevel and hypoid gears even use relief (Fig. 3, left) (in case of hobbing or
sions — even in cases of optimal straddle
bearing location — is a magnitude larger
than in situations of spur and helical
gears because of the three-dimensional
force situation.
Cylindrical gears have only one
major assembly parameter that is the
center distance. There are four assem-
bly parameters for bevel and hypoid
gears (Fig. 1). Offset “E” and root angle
“Alpha” are given by the gearbox design.
The pinion axial position “P” has to be
adjusted relative to the bearing shoulder
behind the pinion heel to the theoreti-
cal value in order to make the crossing
point of the axes match the theoretically
predetermined position; i.e., the posi-
Figure 1 Bevel gearset — axial, vertical and angular adjustments.

68 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 ask the expert

Figure 2 Flank surface modification elements (crowning) used for bevel gears.

shaping) in order to prevent the concen-

tration of load at the tooth ends. More
sophisticated is a circular length crown-
ing in connection with a protuberance
in the tool profile. A protuberance tool
creates a profile relief like that shown in
Figure 3 (right). Many helical gears that
are ground have this advanced crowning
applied. Crowning in face width direc-
tion and protuberance are also applied in
cases in which the soft manufacturing is
the final operation of a cylindrical gear.
Because the cylindrical gear shafts are
parallel in the stage of building a gear-
box, the gearbox tolerances will basically
influence the center distance. Tolerances
in milling the bearing journal seats can Figure 3 End relief — (left side) and top relief (right side).
normally be ignored because they cause
only a negligible shaft inclination and
generally only result in a center distance
variation. Involute gearing is impervi-
ous to center distance changes, so the
Expert Hermann Stadtfeld checking tooth
emphasis is on verifying the assembly contact of a hypoid gearset after assembly in
result in order to maintain the back- a passenger car gearbox (photo by Jasmin K.
lash within the required limits. Checking Saewe for Gleason Corp).
the tooth contact is often not required
because there are no significant influ-
ences that could greatly influence the
contact conditions. Depending on the
kind of transmission, the final inspec-
tion could still be a backlash and con-
tact pattern check of every gear mesh, or
a structure-borne noise analysis of the
complete gearbox on a test rig.

Do YOU have a question for our experts? Send it to Jack McGuinn,

senior editor, via e-mail at [email protected]. We'll
submit your question to our panel of experts. Suitable questions and
answers will be published in future issues of Gear Technology.

70 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
Additives: Anti-Wear vs. Anti-Scuff
Is One Better?
QUESTION
While I have read a reasonable amount of the literature on the
pros and cons of anti-wear and anti-scuff additives, I find that the
more I read, the more confused I become. I could use some clarity
Expert response provided by Robert in my life. Can you help?
Errichello and Angeline B. Cardis.

Anti-Wear and Anti-Scuff Additives with the parent metal surfaces to pro- sidered normal. At the other extreme,
The natural oxide layer that forms on vide protection under severe loads and scuffing is severe adhesive wear, and it
metals when they are exposed to the high temperatures where the oxide lay- can cause catastrophic damage. Since
atmosphere is the simplest wear pro- ers and chemically adsorbed anti-wear anti-wear and anti-scuff additives both
tection. Unfortunately, under bound- films on metal surfaces are disrupted. act in similar ways, it is best to classify
ary lubrication, the oxide layer is easily Anti-scuff additives contain at least one them in terms of their activation tem-
removed under light load, resulting in chemically reactive nonmetal such as perature. Anti-wear additives become
the risk of metal-to-metal contact. sulfur or phosphorus that readily reacts effective at relatively low temperatures
Anti-wear and anti-scuff additives with exposed metal surfaces to form a and become ineffective at moderate tem-
affect lubricant performance by control- tribofilm with low shear strength. These peratures; anti-scuff additives become
ling wear and friction characteristics sacrificial films reduce friction and wear effective at relatively high temperatures
under boundary lubrication conditions. and help prevent scuffing by forming and remain on gear tooth surfaces until
A properly formulated gear lubricant solid films on gear tooth surfaces and they are rubbed off or melt at relatively
contains additives that protect gear tooth inhibiting true metal-to-metal contact. high temperatures. Therefore, the choice
surfaces at both low and high tempera- The films of iron sulfide and iron phos- between anti-wear and anti-scuff addi-
tures. The additives function by one of phate have high melting points, allow- tives depends on the gear application.
the following mechanisms: ing them to remain on the gear teeth Anti-wear additives such as TCP and
• Physical adsorption even at high contact temperatures up to ZnDDP might be adequate for high-
• Chemical adsorption about 700°C. The formation and loss of speed, lightly loaded gears that are not
• Chemical reaction the tribofilms are determined by com- subjected to shock loads, whereas slow-
Physical adsorption. Lubricants with petition between the opposing processes speed, highly loaded gears that are sub-
polar additives, such as long-chain fatty of chemical reactivity with the metallic jected to shock loads might require anti-
acids, adsorb to the oxide layers on surfaces and mechanical removal of the scuff additives such as those contain-
metal surfaces to form a layer of mol- tribofilms caused by the sliding action of ing sulfur and phosphorus — alone, or
ecules that reduces friction and wear. the gear teeth. This constitutes a form of in combination. In many applications,
These additives are effective at low loads mild corrosion, and if the additives are lubricants with both anti-wear and anti-
and low temperatures, but lose their too chemically reactive, they can pro- scuff additives are required to protect
effectiveness at temperatures between mote chemical wear and polishing. They against the full range of adhesive wear,
80°C and 150°C — depending on the can also react unfavorably with other but care should be taken to avoid aggres-
type of additive. They are called lubricity gearbox components such as seals and sive chemistry that can result in polish-
additives and are often used in lubricants bearing cages. Therefore, lubricant and ing wear, micropitting, or degradation of
for worm gears. additive manufacturers are careful to other components.
Chemical adsorption. Lubricants limit additive reactivity to avoid exces-
with additives such as tricresylphos- sive corrosion.
phate (TCP) or zinc dialkydithiophos- Distinction between anti-wear and
phate (ZnDDP) that chemically bond to anti-scuff additives. Anti-wear and anti- Robert Errichello
the oxide layers or metal surfaces pro- scuff additives are designed to provide
vide anti-wear protection that is more protection over a broad spectrum of
durable than that provided by physical operating conditions; both act to pro-
adsorption. They are effective at mod- tect against adhesive wear that rang-
erate loads and moderate temperatures es from mild to severe. Mild adhesive
up to about 200°C. Beyond this tem- wear is confined to the oxide layers of Angeline B. Cardis
perature, the chemically adsorbed films gear tooth surfaces and it always occurs
desorb or are rubbed off and have lim- with as-manufactured gear teeth. If the
ited load capacity. gears are properly run-in, the asperi-
Chemical reaction. Lubricants with ties are smoothed, the wear usually sub-
anti-scuff additives are designed to react sides with time, and the wear is con-

August 2014 | GEAR TECHNOLOGY 71

 ask the expert

The Pros — And Mostly Cons —

Of Fully Ground Root Fillets
QUESTION
For maximum life in carburized and ground gearing, I have been
advised that fully grinding a radius into the root gives maximum
resistance against fatigue failures. Others have advised that a hobbed
and unground radius root form is best. Which is best, and why?

For Related Articles Search

root fillet
at www.geartechnology.com

EXPERT ANSWER PROVIDED BY: Robert Errichello, the gear tooth surfaces. Therefore, critical gears should
owner/operator of GEARTECH: be surface-temper-etch-inspected to confirm there are no
It depends on the processing. grind-damaged areas. But this extra processing increases
With fully ground root fillets, any distortion due to manufacturing costs, rendering ground root fillets prac-
heat treatment must be very carefully controlled, ensur- tical and cost-effective only for critical gears such as
ing that stock removed during grinding is minimized those used in aerospace applications.
and there remains adequate case depth after grinding. Properly processed gears with unground root fillets
This is practical only for small gears and those that are can have bending fatigue capacity that is nearly the
re-heat-quenched. Furthermore, it requires a quench same as aerospace gears that are processed as described
press to adequately control distortion. Generally, grind- above. However, if the gears are gas-carburized, there
ing is detrimental because it imparts tensile residu- will be intergranular oxidation (IGO). The IGO must
al stresses. Consequently, root fillets are usually shot be controlled to Grade 3 requirements according to
peened after they are ground to ensure they have ben- AGMA 923-B05 to adequately maintain bending fatigue
eficial, compressive residual stresses. In addition, with resistance. Furthermore, the root fillets should be shot
grinding there is always a risk that the heat associated peened to mitigate the effects of IGO. Alternatively, the
with grinding might cause tempering or rehardening of gears can be vacuum-carburized to eliminate the IGO.
Therefore, for most industrial gears, properly processed
gears with unground root fillets are the best choice for
reliable and cost-effective gears.
The above discussion applies only to bending fatigue
resistance and caution should be exercised regarding shot
peening and Hertzian fatigue resistance. The tooth flanks
should not be shot peened because their surfaces will
be made somewhat harder and rougher, and the flanks
might create micropitting on the mating gears. To pre-
vent this problem, the shot peened flanks can be super-
finished. Generally, shot peened flanks that are super-
finished after shot peening have maximum micropitting
and macropitting resistance.

Robert L. Errichello heads

his own gear consulting firm,
GEARTECH ([email protected]),
and is founder and creator of
GEARTECH software, Inc. He
is a technical editor for Gear
Technology magazine and STLE
Tribology Transactions. Bob is also
a recipient of the AGMA TDEC, AGMA E.P. Connell,
AGMA Lifetime Achievement, STLE Wilbur Deutch
The Root Fillet - To Grind or Not To Grind? Memorial, and AWEA Technical Achievement Awards.

72 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
Gear Up Your Quality Control
Robot systems for quality control of surface treatment such as grinding and shot peening
by Barkhausen Noise and X-ray stress measurements.

RoboScan system
• automated inspection
• all surfaces with one set-up
• safe, fast and easy measuring,
also on large and complicated parts
• instant feedback
• quantitative results for production control
• environmentally friendly

For residual stress testing

by X-ray diffraction
Xstress Robot
• reaches hard-to-reach areas
• handles complicated and large parts easily
• provides maximum flexibility and
easy positioning
• is fast and precise

www.stresstechgroup.com
 technical

Setting Load Parameters for Viable Fatigue

Testing of Gears in Powertrain Axles
Part I: Single-Reduction Axles
Ernő Fülöp
This presentation introduces a new procedure that — derived from exact
calculations — aids in determining the parameters of the validation testing of
spiral bevel and hypoid gears in single-reduction axles.

Introduction This study introduces a procedure that Background

It is generally accepted that a newly helps obtain the exact calculation of the The current study deals with determin-
developed product is to be tested for con- parameters of the validation testing of ing the test parameters of bending fatigue
formity — with customer expectations spiral bevel and hypoid type gears in sin- and pitting (tooth flank surface fatigue)
of its design, dimensioning and produc- gle-reduction axles. failure modes (Ref. 2).
tion for loading and lifetime being met, This procedure does not deal with life- Test parameters are defined based on
notwithstanding. As for the axles to be time testing of other parts in the axle lifetime calculations; the determinant
installed in on-road vehicles, further driveline, such as axle shafts, bearings, factors in lifetime calculation — name-
testing is done — regardless of whether differential, etc. ly in determining the number of toler-
the axles meet the safety regulations for Single-reduction axles are usually able tooth loads (N) — are the follow-
on-road traffic. Similarly, the products installed into solo public transport, con- ing: the load level, material grade of the
already in production are subject to tests tact buses and coaches, as well as vans gears (Wöhler curve), and the macro-
at certain intervals in order to check the and trucks. and micro-geometrical data of toothing.
quality of the production process. Tests
are generally carried out in a time shorter
than the lifetime expected in service, and
under higher loading conditions (Ref. 1).
When the test procedure is determined,
some efficiency and technical aspects are
to be considered, such as:

Efficiency:
• Testing should not be over-long, lest it
cause delay in marketing of the product
and increase the costs of testing
• Testing shall be done with existing
equipment; no new, expensive equip-
ment shall be used
Technical:
• In order to simulate the real opera-
tional conditions properly, the loading
parameters applied during the test shall
be determined so that the product shall
be subjected to the same damage in a
short test time as during actual opera- Figure 1 A Wohler Curve diagram showing its three typical sections: Static Load; Limited Life;
tion Long Life.
• Duration of testing shall not be overly
shortened or compressed, as this would Table 1 Five Gleason-type bevel gear sets involved in the analysis, each made of case-
result in excessively high test load- hardened material 20MnCr5 / DIN17210
ing that would cause extremely large Toothing finishing Tooth profile Gear outside pitch
Gear set Toothing type Ratio
deflections in the product. It would mode type diameter(mm)
cause extreme conditions that would 1 Ground Generated Hypoid 38/17 285
never occur to such a large extent in 2 Ground/Waguri Formate Spiral 37/17 390
real operation, leading as well to unre- 3 Ground Formate Hypoid 43/8 420
alistic failures in actual operation. 4 Lapped/5 cut Formate Hypoid 41/11 305
5 Lapped/Completing Formate Spiral 39/8 400

74 GEAR TECHNOLOGY  |  August 2014

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 When the current procedure was Nw is number of load-cycles-to-failure (5)
of the gear tooth in real working m
developed, we checked the stability of
the calculations and whether the pro-
load conditions ΣM
i=1
5
i ui = Mw5 Nw
(NT) marks the load cycles at each
cedure properly simulates the influ- tooth of the pinion and the gear where:
ence of various macro- and micro-geo- bears during the test. As the test m Number of loads during real
metrical dimensions, type of the gears, duration is finite, the following operation
condition exists: Mw (Nm) Torque applied in dimensioning
and the production process applied. (2)
For the above reasons, the following N1 < NT < N2 the gear
five, Gleason-type bevel gear sets were NT is number of load-cycles-to-failure Nw Expected lifetime in working
of the gear tooth in test load condition
involved in the analysis; each of them
condition
is made of case-hardened 20MnCr5/ In dimensioning the pinion and ring
DIN17210. Reference 1 also refers to the test time gear the equivalent torque was applied,
being shortened, on the basis of the which was determined by the following
Bending Fatigue Miner-defined accumulated damage rule equation:
(6)
When we wish to determine the test (Ref. 8). In case of a time-varying load,

√
m
parameters, we already possess all the
macro- and micro-geometrical data of
again according to Miner’s rule, the fail-
ure occurs when: 5 Σ (M  × n  × t )
i=1
5
i i i

(3) Mw =
the pinion and gear to be tested, which m

were determined during designing/ u1 + u2 + u3 + … + ui = 1 Σ (n  × t )

i=1
i i

N1 N2 N3 Ni
dimensioning, using, for example, (Refs. where:
3 and 4), by applying the loading data where:
m Number of service modes
and the expected lifetime specified by the ui Number of load cycles supported by
the gear tooth during the ith load Mi (Nm) Torque in ith service mode;
customer. specified by user
is acting
As a starting point, the Wöhler dia- ni (1/min) Pinion rpm in ith service mode;
Ni Number of load-cycles-to-failure of
gram is used, which corresponds to the the gear tooth if only the ith load specified by user
material grade and heat treatment of the would be acting ti (min) Duration of ith service mode;
pinion and gearset (Fig. 1). specified by user
The Wöhler diagram has three typical Equation 3 can be arranged in the fol- Mw (Nm) Equivalent/dimensioning
torque
sections: Static Load (high loading where lowing form:
(3’)
the gear sets failed in a very short time); In dimensioning, at torque (Mw) the
u1 + u2 + u3 + …+ ui = Nw
Limited Life (the load level, where the number of the tooth loads shall reach the
N1 N2 N3 Ni Nw
gear does not fail immediately, but is not value (Nw). When determining the value
suitable for longer service); and Long life In case of parts, which are rolling and (Nw) proceed as follows:
(load level, which allows long operation). sliding under loading (e.g., roller bear- Equivalent rpm, (Ref. 10):
(7)
These three regions are divided by the ings, mating gears, etc.), the relation
Tw
points (N1,σ1) and (N2,σ2). For example, between lifetime and loading is provid- nw =
t1 t2 ti
for case-hardened material 20MnCr5/ ed by the inverse power law relationship n1 + n2 + …+ ni
DIN17210, at reliability level Pü = 50%: (Ref. 9):
(4) where:
(N1 = 103, σ1 = 1,570 N/mm2), (Ref. 6) and 1
(N2 = 3 × 106, σ2 = 430 N/mm2) (Ref. 7). Ni = nw (1/min) Equivalent rpm
C × Mik
In Figure 1 the probability density dis- Tw (min) Expected lifetime in service
where: conditions; specified by user
tribution type “A” illustrates that the gear
Mi (Nm) Load magnitude; torque ti (min) Duration of ith service mode;
is able to bear the same loading number specified by user
transmitted in case of gears
(N) at various load levels, depending on (8)
C Constant dependence on Nw = nw × Tw
the reliability level of the material grade material, macro- and micro-
(Pü = 10%, Pü = 50%, Pü = 90%). geometrical parameters of gear In Equation 5 the following marking is
The probability density distribution k Exponent of loading/torque introduced:
(9)
type “B” illustrates that at the same load Dw = Mw5 Nw
level (σ) the gear is able to bear vari- Generally accepted (k) values:
where:
ous loading number (N), depending on For ball bearings (Ref. 13)  k = 3.0 Dw Damage frequency the gear bears in
the reliability level of the material grade For roller bearings (Ref. 13)  k = 10/3 real service mode
(Pü = 10%, Pü = 50%, Pü = 90%). For spur gears  k = 4.0
Obviously, the pinion and ring gear are For spiral bevel and hypoid gears As mentioned in the introduction, the
dimensioned, and the toothing geom- k = 5.0 (possibly k = 5.6) test shall be carried out so that the tooth-
etry is determined so that the following Merging the equations (3’) and (4): ing of the pinion and ring gear shall be
condition should be met at working load subject to the same damage in a short
level: test time as it would be subject to during
(1)
Nw >> N2 actual operation:

August 2014 | GEAR TECHNOLOGY 75

 technical
(10)
DT = Dw The important things here are the How to Use the Work Diagram
experience of the test engineer, technical a. The values (Mw) and (Nw) used in
where: designing the particular gear set are
DT Accumulated extensive damage capabilities of the test equipment, etc.
First, the test procedure at one load known
in pinion and ring gear during
testing level is introduced, and then the test pro- b. We want to test in duration (tT), at rpm
(nT) → NT = tT × nT load cycles
Dw Accumulated extensive damage cedure at several levels will be presented.
in pinion and ring gear during c. In Figure 2, the value (kT) is obtained
Testing at one load level from intersection point of (Nw) and
operation Step 1: Taking into account the heat (NT)
Merging Equations 5 and 10: loss capability of the product during the d. Based on Equation 14 the value (MT) is
(11)
test; the proper lubrication; and possi- determined
m

ΣM
i=1
kT
Ti  NTi = Mw5 Nw bilities of the test equipment, the test rpm
(nT) is chosen. Based on economical effi-
e. Using a 3-D model of the axle, the
magnitude of the deflections occur-
where: ciency, a duration (tT) for the test is cho- ring under loading (MT) is checked
t Number of service modes during sen. Thus, the number of tooth loads with FEA analysis
testing (t = 1, 2,…) during the test can be calculated: If deflections are not too high, test-
(13)
kT Torque exponent in test service NT = nT × tT ing can be carried out with the param-
mode eters (MT), (nT) and (tT) — determined as
The curve of the Wöhler diagram Step 2: Using the macro- and micro- described above
shows that the curve σ (N) has different geometrical data of the pinion and ring If deflections are too high, the values
slopes in sections Limited Life and Long gear to be tested, and using the FEA (tT) and (nT) shall be increased and then
Life. As the test service mode is situated T900, Release 8.18 software, the value the points (b, c, d, e) are to be repeated
in the interval of Limited Life, while the (MT) is determined so that lifetime of the In Figure 2 it can be observed that
real service mode is situated in the inter- gear shall be (NT). if the number of the test loads is equal
val of Long Life, then: Step 3: In case of single-step testing, to the number of the loads in service
(12)
kT ≠ kw = 5 Equation 11 can be set up as follows: (NT = Nw = 1,0E + 07), then (kT = kw = 5),
(14) this confirms that the work diagram is
MTkT × NT = Mw5 × Nw
During the dimensioning, using FEA correct.
T900, Release 8.18, macro- and micro- Based on Equation 14, the value (kT) Note: Figure 2 was determined in case
geometrical dimensions of the pinion and can be determined as a function of the of KW = 5. If the previous test results con-
ring gear are determined, so the num- optional chosen (NT) and the values (MT) firm that the material grade used and
ber of tooth loads (Nw) shall be reached already determined. As in the interval the production accuracy requires other
under the loading (Mw). (N1, N2), any value (NT) can optionally be value of (k w ) in the particular case,
None of the parameters on the left side chosen; different values of (kT) are pro- (e.g. — kw = 5.3), then Figure 2 must be
of Equation 11 is known; this study is duced for each chosen value of (NT). rebuilt.
especially aimed at determining these Step 4: Depending on the loading in ser- B. Testing at several load levels (deter-
parameters. vice, a pinion and ring gear set with the mining test cycle)
The person who works out the test same macro- and micro-geometry can In many cases this test method is pre-
makes his decision whether he wants to have various lifetimes (Nw). Based on the ferred, as the changing service load con-
carry out the test at one or several load above, a work diagram (Nw, kT, NT) can be ditions are better modeled by this testing
levels. determined for any gear set; e.g. — Figure mode.
2, which was determined for gear set No. 5. But in this case, we start from the pre-
viously determined work diagram (Fig. 2)
typical to the particular gear set as fol-
lows:
x. Values (N w) and (D w) are known
from the gear set dimensioning phase.
y. As presented above, based on
Miner’s rule, the damage suffered in vari-
ous service modes can be accumulated
linearly. Consequently, the value (Dw) can
also be divided linearly.
Service modes of real operation are
divided into two groups: Primary and
Secondary service modes.
(15)
u
Dw = ΣD
i=1
 + Dws
wi

Figure 2 A working diagram for Gear set No. 5.

where:

76 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 u Number of primary service modes, For some production errors, the tooth the pinion and gear set will withstand the
in general u = 4, 5, …
Dwi = Mwi5 Nwi Damage number of ith surface roughness is of poor quality, and load cycles (NT = 2 × 106).
primary service mode metal to metal contact is allowed between c. Based on the diagram (Fig. 2) typical
Dws Accumulated damage number the mating tooth surfaces, which can lead to the particular gear set, the value (kT)
of secondary service modes; to local seams. was determined by means of the values
negligible The oil quality is not proper, too much (Nw) and (NT).
z. Using Equations 7 and 8, equivalent low viscosity at the testing temperature. Results are presented in Fig. 4:
load numbers Nws of secondary service The diagram in Figure 4 shows that
modes are determined Influence of Macro- and Micro- macro- and microgeometry of the tooth-
z. Using the work diagram in Figure 2 Geometry of Toothing on the Test ing has significant effect on the value of
typical to the particular gearset, the above Torque Exponent test torque exponent, (kT), and hereby
points (b, c, d, e) are separately carried We have already mentioned the influence on determination of the test parameters.
out with the value pairs (Dwi, Nwi). As a of macro- and micro-geometry of the It means that the above process is gear-
result of the above, we get to the param- toothing on the value of the test torque specific, namely the diagram as in Figure
eters (MTu, NTu), of the stepped test load exponent, (kT). In order to demonstrate 2 shall separately be determined for each
process (u), namely: the equivalent (MTu, this effect the following process is carried pinion and gear set. The results shown in
nTu, tTu). out for each pinion and gear set shown in Figure 4 reflect the cumulated effects of
After the test with (u) and steps with the Table 1: macro- and micro-geometry.
the parameters (MTu, nTu, tTu) are carried a. Optional value of (Nw) was chosen The diagram in Figure 4 confirms that
out, the axle will be damaged to exactly (e.g. — Nw = 5 × 109). By using software the value of k added in (Ref. 9) depends
the same extent as it would suffer in real (Ref. 5), the value of service torque (Mw) not only on the material grade, but on
service mode. was determined, at this load the pinion macro- and micro-geometrical data of
and gear set will withstand the load cycles toothing as well, as each gear involved in
Tooth Flank Surface Fatigue (Nw = 5 × 109). the current study was made of material
(Pitting) b. Optional value of (NT) was chosen 20MnCr5/DIN17210.
Surface fatigue mainly results from load- (e.g. — NT = 2 × 106). By using FEA T900,
ing (torque, rpm, time); material grade Release 8.18 software, the value of test
of the gear; the flank topography; and on torque (MT) was determined, at this load
the quality of production (surface rough-
ness, surface harness).
On each gear set involved in this study
we have investigated what torque level is
required at the same value (NT) to induce
bending fatigue or pitting by using FEA
analyzing software (Ref. 5) and macro-
and micro-geometry of the gear set
(Fig. 3).
The diagram (Fig. 3) shows that sig-
nificantly higher torque is required to
have pitting than to have damage (bend-
ing fatigue) occurring. In other words,
during the test bending fatigue appears
earlier than pitting. For this reason, in Figure 3 Bending-pitting test torque results obtained with Gear set No. 5.
every case the test parameters of bending
fatigue shall be used. The same is estab-
lished in Reference 10 as well.
Note: It might happen that during the
test, pitting appears earlier than bending
fatigue, if:
Test torque (MT) is too high and point-
surface-origin macro-pitting appears on
the pinion root due to extreme deflec-
tions (Ref. 11).
For some design errors, convexity of
the tooth surfaces is too high; the design-
er has not adhered to the recommended
values (Ref. 12).
Figure 4 Diagram showing macro- and micro-geometry of toothing has significant effect on
value of test torque exponent (kT), and thus on determination of test parameters.

August 2014 | GEAR TECHNOLOGY 77

 technical

Higher Influence of High Loads on The procedure takes into account the References
Damage material grade of gears and macro- and 1. R eley, Th. N. “Accelerating Validation Testing,”
Gear Technology, January/February 2012.
There are several studies referring to micro-geometrical data of toothing. 2. Kren, L. “Recognizing Gear Failures,” Machine
high loads causing extremely high dam- The above procedure assures that dur- Design.com, 2012, 12/15.
age (Refs. 1 and 11). A pinion and gear ing the test the gear set shall be subject to 3. Gleason Works. Cage4Win, Release 2.0.1.34.
dimensioned to known parameters (Mw, the same damage as will be subject to in 4. Gleason Works. UMC, Release 12.0.1.0.
5. Gleason Works. FEA T900, Release 8.18.
Nw) can be tested for longer (high value real service; realistic character of testing 6. Niemann, G., Maschinenelemente, Springer
NT), or shorter (low value NT) test time. is provided. Verlag, 1960, Tafel 120. Pp. 120-121.
In order to satisfy Equation 14, the lower Test parameters resulting from appli- 7. ISO 6336-5. 1996, Figure 11, page 13.
the value (NT), the higher the value (MT) cation of this procedure are typical to 8. Miner, M.A. “Cumulative Damage in Fatigue,”
Journal of Applied Mechanics, Vol.12, 1945, pp.
should be. the particular gear set only. Thus the test A159-164.
So, the low values (NT) mean high val- parameters determined are always gear- 9. Inverse Power Law Relationship. Reliability Hot
ues (MT). set-specific. Wire Magazine, Issue 116, October 2010.
If the conjugate values (KT,NT,Nw) in In case of the same gear set, quality 10. McVittie, D.R. and R.L. Errichello. “Application
of Miner’s Rule to Industrial Gear Drives, Gear
diagram seen in Figure 2 are shown so of material and production always show Technology, January/February, 1990, pp. 18-48.
that the relation (KT,NT) is shown at vari- certain scattering. That’s why it is prac- 11. Erichello, R. L., C. Hewette and R. Eckert.
ous constant value (Nw), we get to the fol- tical to carry out the validation test on Point-Surface-Origin Macropitting Caused
lowing diagram: at least three sets. The set of values (NT) by Geometric Stress Concentration, Gear
Technology, January/February 2011
The diagram in Figure 5 shows that the obtained as a result of testing shall be 12. ISO 17485:2006, Annex B, Table B1.
lower the value (NT) is, i.e. — the high- processed by means of some statistical 13. SKF 2006, 6,000H, P. 52.
er the loading (MT) is, the higher is the method (e.g., Weibull analysis). 14. Pereira, H.F.S.G., A.M.P. Jesus, Rbeiro, A.S.,
exponent (k T) — which confirms that In the interval of Limited Life, the value and Fernandes, A.A., Fatigue Damage Behavior
of Structural Components Under Variable
the high load will really cause extremely (kT) varies with the number of test tooth Amplitude Loading,” Mecanica Experimental,
high damage due to two reasons: 1) high loads (N T), which is a function of the 2009, Vol. 17, pp. 75-85
(MT) value and 2) higher torque exponent applied load level in case of the particu-
value (kT). lar toothing geometry. This result refers
to the non-linear damage model (Ref. 14).
Conclusions The diagram in Figure 5 confirms that
A procedure is introduced allowing the the high load causes high damage not
determination of validation test param- only by itself, but due to the higher expo-
eters of spiral bevel and hypoid gears in nent (kT) as well.
single-reduction axles.
The study represents that various
torque exponents shall be used in sec-
tions Limited Life and Long Life of the
Wöhler diagram, when accumulat-
ed damage number is calculated. By
its structure, the work diagram (Fig. 2)
allows determination of the value (kT).

Dr.-Ing. E. Fülöp studied mechanical

engineering at the Institutul Politechnic
Bucureşti/Roumania, where in 1984 he
received his Ph.D. in the simulation of hydraulic
controls by computers. In 1990 he began
work as a maintenance engineer for Rába
Axle Company/Hungary, and since 1997 has
been with the Rába Development Institute,
working as a team manager of gear design.
Fülöp’s activities involve the design of spline,
spur, planetary, spiral bevel and hypoid gears;
tooth development; evaluation of test results;
noise measurements and noise analyses; and
Figure 5 Diagram showing that the lower the value (NT), i.e. — the higher the loading (MT) — the feedback of the results of tests and noise
higher the exponent (kT); this confirms that the high load will cause extremely high analyses into optimization of gear toothing.
damage due to two reasons: 1) high (MT) value and 2) higher torque exponent value (kT).

78 GEAR TECHNOLOGY  |  August 2014

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 technical

First International Involute

Gear Comparison
F. Härtig and K. Kniel
Measurement institutions of seven different countries — China, Germany, Japan, Thailand, Ukraine,
United Kingdom and the U.S. — participated in the implementation of the first international comparison
of involute gear measurement standards. The German metrology institute Physikalisch-Technische
Bundesanstalt (PTB) was chosen as the pilot laboratory as well as the organizer. Three typical involute
gear measurement standards provided by the PTB were deployed for this comparison: a profile, a helix
and a pitch measurement standard. In the final analysis, of the results obtained from all participants,
the weighted mean was evaluated as reference value for all 28 measured parameters. However,
besides the measurement standards, the measured parameters, and, most importantly, some of the
comparison results from all participants are anonymously presented. Furthermore, mishandling of the
measurement standards as occurred during the comparison will be illustrated.

Background decided to implement this comparison gy: profile, helix and pitch measurement
International comparisons are required as regional comparison with the involve- standard (Fig. 1). These measurement
to ensure the compatibility and reliabil- ment of other non-European participants. standards were developed by the PTB
ity of measurement results among differ- The PTB was chosen as pilot laboratory and manufactured from high-alloy steel
ent countries. In the field of high accu- and organizer for the intercomparison. more than 30 years ago. The choice of
rate involute gear metrology which is The choice of measurement standards helix, profile and pitch measurement
of enormous economic importance, no to be used, parameters to be measured, standards for this measurement compari-
international comparison measurement potential participants and time schedule son and their suitability were based on a
has been conducted so far. Therefore, it were all decided at the subsequent meet- number of factors. Among them are the
was imperative to organize this compari- ings, while the protocol adopted was later measurement accuracies and long his-
son among five national metrology insti- communicated to all participants. Three tory of measurement stability which have
tutes (Germany (PTB), China (NIM), involute gear measurement standards been observed by the PTB since the time
Japan (AIST), Thailand (NIMT), Ukraine which are typically used in industry were they were manufactured. Furthermore,
(NSC)), one designated institute (United chosen for this comparison. Each partici- geometrical parameters of these measure-
Kingdom (NGML)) and one competent pant was allocated equal amount of spec- ment standards are other important attri-
measurement institutes (U.S. (Y12)). The ified time to carry out the measurements butes for their choice. Particularly their
rules of the comparison following inter- before the measurement standards had to reference bands and flanks possessed
nationally agreed documents published be sent to the next participant. The mea- significantly small form and roughness
by the Bureau international des Poids surement comparison was implemented errors. All participants were asked to
et Mesures (BIPM) (Ref. 1) which task from July 2008 to September 2010. measure each of the measurement stan-
is to ensure world-wide conformity of The measurement standards deployed dards and to evaluate their results accord-
measurements and their traceability to for this comparison represents the three ing to References 7–10.
the International System of Units (SI). most typically measurement standards Profile measurement standard. Figure
The BIPM does this with the authori- in industry for involute gear metrolo- 1a shows the involute profile measure-
ty of the Convention of the
Metre, a diplomatic treaty
between 55 nations. The ter-
minology and symbols used in
this paper follow actual doc-
uments of the BIPM and the
International organization for
Standardization (ISO) (Refs.
2–5).
This first comparison
was initiated by the PTB.
Following the regional meet-
ing in 2007, the Technical
Committee of Length (TC- (a) (b) (c)
L) of EURAMET (Ref. 6)
Figure 1 
(a) Profile measurement standard; (b) Helix measurement standard; (c) Pitch measurement standard.

80 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
ment standard. In a classical design it Table 1 Parameters of the three measurement standards
Measurement Standard Gear Parameter Value
consists of two base discs each of d b
Profile Pressure angle αn 20°
49,997 mm and one centered, involute Helix angle β 0°
shape. Table 1 delineates gear parameters Normal module mn 2.9559134 mm
that are necessary to measure the profile Face width b 3,2 mm
measurement standard on a coordinate Number of teeth z 18
measuring machine (CMM) or other gear Helix Helix angle β 0° 15° 30° 45°
measuring machines (GMM). The fol- Face width b 75 mm 75 mm 75 mm 75 mm
lowing typical measurement parameters Transversal module mt 4 mm 4 mm 4 mm 4 mm
Number of teeth z 50 50 50 50
for the profile evaluation were chosen
Pitch Pressure angle αn 20° 20° 20° 20°
according to (Refs. 7–9): Normal module mn 4 mm
• Profile slope deviation fHα in μm Number of teeth z 37
• Profile form deviation ffα in μm Tip diameter da 156 mm
• Profile total deviation Fα in μm Facewidth b 32 mm
Pressure angle αn 20°
Measurement Procedure
This profile measurement standard was as right hand. The measurements were typical measurement parameters for the
measured along the surface of left flank performed only on the right flank. The pitch evaluation were chosen according
at the centre of the tooth. The measure- corresponding gear parameters are listed to (Refs. 7 and 10):
ment points were selected equidistance in Table 1. The following typical mea- • Cumulative pitch deviation FP in μm
over the length of roll. A spherical sty- surement parameters for the helix evalu- (left and right flank)
lus tip of 8 mm in diameter was chosen ation were chosen according to (Refs. • Single pitch deviation fP in μm (left and
for the measurement because it offers 7–9): right flank)
guaranteed comparability while being • helix slope deviation fHß in μm
observed since the profile measurement • helix form deviation ffß in μm Measurement Procedure
standard has been acquired, and sec- • helix total deviation Fß in μm The pitch measurement standard was
ondly, it enables reduction of the influ- mounted on the measuring machine by
ence of form errors on the flank surface. Measurement Procedure fixing it with an internal three-jaw chuck
The evaluated parameters were measured The helix measurements were per- at the inner side of the hollow shaft. The
within the following limits: formed on a measurement cylinder at pitch was measured in a single-flank
• Start of profile evaluation (expressed in dM = 204 mm. The diameter of the sty- mode. The diameter of stylus sphere used
length of roll): 1 mm lus sphere used is approximately 8.0 mm. was 3.0 mm, while the diameter of the
• End of profile evaluation (expressed in The evaluation is conducted at the range measurement circle was dm = 148 mm.
length of roll): 18 mm of Lß = 70 mm.
References
Measurement References Measurement References The reference axis of the measurement
The reference axis of the measurement The reference axis of the measurement standard was numerically determined.
standard was numerically determined. standard was numerically determined. For this purpose, two circles at two dif-
For this purpose, the reference bands For this purpose, the two reference cyl- ferent locations in the bore were mea-
of approximately 50 mm in diameter of inders of the gear measurement standard sured — one at 10 mm from the reference
the profile measurement standard were were probed. The measurement points surface (upper side) of the gear measure-
probed in the centre of the discs. In each were arranged in two end face planes. ment standard, the other at 40 mm. In
of the transverse planes at least 36 points The end face planes were located at a dis- each case at least 36 points — distribut-
at equally spaced distances were mea- tance of 43 mm from the lateral surface ed and equally spaced over the circum-
sured over the circumference. Through of the cylinders with 30 mm in diam- ference — were recorded. Through these
the points, a circle was fitted in accor- eter. In each of these transversal planes points a circle was fitted in accordance
dance with the least squares method and at least 36 points, which were distrib- with the least squares method and the
the centre was defined. The axis of the uted equally spaced over the circumfer- center was determined. The axis of the
gear measurement standard was defined ence, were recorded. Through the points, gear measurement standard was defined
from the centres of the two circles. The a circle was fitted in accordance with the from the center of each of the two circles.
reference point for the height of the pro- least squares method. The axis of the gear Measurement and handling instruc-
file measurement was determined at the measurement standard was defined from tions. Taking into account the geo-
top of the tooth, 2 mm from the tip circle the centres of the two circles. metrical parameters of each measure-
in the direction of the reference axis. Pitch measurement standard. Figure ment standard, as well as the technical
Helix measurement standard. Figure 1c illustrates the pitch measurement stan- description with all measurement proce-
1b presents a classical helix measurement dard. The specified gearing parameters dures, all valid guidelines and standards
standard; it embodies four different helix embodied in the measurement standard for the comparison were prepared and
angles (0°, 15°, 30°, 45°), left hand as well are delineated in Table 1. The following distributed to all participants. Lengths

August 2014 | GEAR TECHNOLOGY 81

 technical

are required to be measured traceable tence of each of the participating labora- the other NMIs. This means that the En
to the latest realization of the meter as tories. value is the internationally agreed upon
(1)
set out in the current “Mise en Pratique” parameter that shows whether the indi-
n
xi 1
(Ref. 11), irrespective of the instrument xref,w = Σ
  U2 ∙ n vidual value xi — together with its deter-
1
used. The measurement of the tempera-
i=1 i
Σ
i=1 Ui
2 mined expanded measurement uncer-
ture is based on use of the internation- tainty Ui, and the expanded measurement
al temperature scale of 1990 (ITS-90). The calculation of the reference value uncertainty of the corresponding refer-
Similarly, the uncertainty of measure- for each measurand (Ed.’s Note: A physi- ence value Uref, w — are reliable in compar-
ment is estimated according to the ISO cal quantity, property, or condition that ison with the calculated reference value
Guide to the Expression of Uncertainty of is measured.) was generally based on all xref, w. The absolute value IEnI must be less
Measurement (Ref. 12). submitted measurement results, with than 1 to meet this quality criterion for
The procedures for the packaging and the exception of three helix measurands. indicating that the laboratory is capable
handling of the measurement standards Following a request by one participant of obtaining a qualified result.
were also stated in the technical descrip- for these measurands, their measurement According to public at ions and
tion adopted for the comparison. The results were not considered for calculat- guidelines, there are slightly different
measurement standards were sent to the ing the corresponding reference values. approaches for the calculation of the En
participants in a customized, self-con- Nevertheless, according to the regulations value; they concern the use of:
tainment case designed for safe transpor- of MRA guidelines for CIPM, key com- Standard measurement uncertainty or
tation. In addition, the case prevents sur- parisons of the measurement results are the expanded measurement uncertainty
face scratches and contamination to the presented in the final report. Arithmetic operator in the denomina-
measurement standards. The packaging A check for statistical consistency of tor (“+” or “-”)
cases are all portable enough to be sent by the results with their associated uncer- Due to prior agreement with the
any courier services. tainties can be made by calculation of the EURAMET TC-L (Ref. 6) and other
Similarly, recommendations on physi- normalized error En for each laboratory experts and guidelines for measurement
cal inspections of the measurement stan- and for each measurand. The En value uncertainty evaluation (Refs. 13–15), the
dards both prior to and after measure- indicates if the measurement value and En value was calculated according to the
ment were given to the participants. The its corresponding measurement uncer- approach shown in Equation 2:
circulation of the measurement stan- tainty are comparable to the results of
dards was carried out in a
loop among the partners. Each
partner was given sufficient Table 2 Overview of the comparability of the measurement results; grey-colored cells indicate where
comparability factor En is not fulfilled
time to conduct the measure- a b c d e f g
ments before sending the mea- fHα 0.14 0.06 0.17 0.51 0.32 0.71 1.53
surement standards to the next profile ffα 0.14 0.09 0.16 0.00 0.14 0.07 0.21
partner. Fα 0.05 0.02 0.18 0.07 0.09 0.32 0.14
Evaluation of reference val- fHβ 0.06 0.46 0.17 0.21 0.38 1.09
helix
ues and comparison. The ref- ffβ 0.35 0.03 0.33 0.26 0.43 0.27
0°
Fβ 0.36 0.01 0.25 0.23 0.32 0.20
erence values must be deter-
helix fHβ 0.25 0.50 0.13 0.43 0.30 0.48
mined on the basis of the 15° 0.07 0.17 0.25 0.14 0.15 0.04
ffβ
received measurement results. left hand Fβ 0.39 0.44 0.11 0.22 0.40 0.38
The guidelines — as laid down helix fHβ 0.36 0.18 0.03 0.41 0.18 0.50
by the BIPM — allow the use 15° ffβ 0.02 0.10 0.32 0.23 0.39 0.52
of different methods for the right hand Fβ 0.35 0.02 0.08 0.43 0.13 0.29
no results

evaluation of reference val- helix fHβ 1.34 0.77 0.34 1.04 0.39 0.60
ues. These methods include 30° f fβ 0.10 0.10 0.54 0.48 0.21 0.33
left hand F 0.52 0.69 0.04 0.69 0.62 0.76
simple mean, weighted mean, β

helix f 1.24 0.18 0.07 0.65 1.18 0.73

and median. For the sake Hβ
30° ffβ 0.14 0.16 0.47 0.19 0.19 0.10
of consistency one meth- right hand Fβ 0.25 0.20 0.07 0.45 0.91 0.69
od — the weighted mean xref,w helix fHβ 4.06 0.14 0.03 1.63 0.98 1.70
(Eq. 1) — was chosen as an 45° ffβ 0.50 0.37 0.43 0.12 0.04 0.24
appropriate method. It con- left hand Fβ 1.18 0.19 0.09 1.44 1.00 1.57
siders the n measurement val- helix fHβ 0.44 0.15 0.09 0.79 0.24 0.56
ues x i and the correspond- 45° f fβ 0.01 0.36 0.08 0.74 0.22 0.10
right hand F 0.22 0.33 0.05 0.05 0.35 0.02
ing, expanded measurement β
pitch FP 1.56 0.13 0.32 0.13 0.39 0.06 2.21
uncertainties U i, which ulti- left flank fP 0.36 0.08 0.03 0.01 0.20 0.07 1.00
mately reflect the measure- pitch FP 0.28 0.08 0.12 0.01 0.16 0.22 1.38
ment condition and compe- right flank fP 0.19 0.12 0.09 0.03 0.16 0.15 0.43
Σ En>1 5 0 0 3 2 3 (4+21)

82 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 (2)
xi − xref xi − xref,w
En (k = 2) = 1
k √|ui2 − u2ref| = √|ui2 − u2ref,w|
wherein is

Uref,w (k = 2) = 2 ∙ 1
n
Σ U12
i=1 i

As recommended by the WG-MRA

“Guidance Document” GD-1 (Ref. 15),
the calculation of the En value was based
on the expanded measurement uncer-
tainty. Moreover, in a case of correlation
between the participant measurement
results and the weighted mean reference
value, the measurement uncertainty con-
tributions in the denominator must be
subtracted.
Figure 2 Slope deviations of the profile measurement s.
Measurement Results and
Analysis
The total measured parameters for all
the measurement standards (profile, helix
and pitch) — 28 — were analyzed and
evaluated. En values for each participant
were evaluated (Table 2). The cells of the
measurement parameters are highlight-
ed in grey when the IEnI factor is greater
than 1.
The most relevant values that indicate
the geometrical competence and correct
evaluation of each participant are the
results of the slope error for profile and
helix measurements, and the total error
for pitch measurements. The robust-
ness of the slope evaluation for profile
and helix measurements is based on the
regression algorithm where a single out- Figure 3 Slope deviations of the helix measurements — 45° left hand, right flank.
lier has only a small effect. However, for
form and total errors the influence of a as only one flank (helix angle 45° left) is pants who don’t measure the respective
single outlier is immense. Yet for pitch affected. One possible assumption is that measure and are crossed out.
measurement evaluation, the probabil- such a discrepancy could be caused by In case of the profile slope deviation,
ity that an outlier influences the value of the geometrical errors of the measuring most of the measurement values disperse
the total pitch error is much smaller, as it system. in the limit of 1 µm with the exception of
appears in single pitch error. Figures 2 and 3 show results for the one particular measurement. Moreover, it
Table 2 shows that the magnitude of profile slope, and the 45° left-hand, helix shows that the measurement uncertain-
the evaluated E n- values based on the slope, deviations, respectively. The error ties from most of the participants were
participant results is, in some cases, bars represent the combined, expanded adequately estimated within the optimum
considerably high, meaning the results measurement uncertainties Ui* based on range.
were either too far from the reference the quadratic sum of the single standard Figure 3 shows results of the helix mea-
value and/or the estimated measurement measurement uncertainty ui of each par- surements at the right flank of the left-
uncertainties were underestimated; nei- ticipant, and the standard measurement hand 45° helix. It could be seen that the
ther of these cases is acceptable. uncertainty of the respective reference values and the estimated measurement
However, profile and pitch show more value uref,w (Eq. 3). uncertainties do not overlap sufficiently
(3)
consistency, as compared to helix mea- Ui* = 2 ∙ √ |ui2 − u2ref,w| to fulfil the En criterion for three par-
surement parameters. The discrepancy ticipants. The range of results is approxi-
of the helix results is more pronounced at Participants who don’t fulfil the com- mately 12 µm; this value is five times
higher angle of the helix; this effect can- parability value are highlighted; partici- greater that the allowed tolerance accura-
not be sufficiently explained at this stage,

August 2014 | GEAR TECHNOLOGY 83

 technical

cy grade, according to ISO 1328-1 (Ref. 7)

of the quality requirement.
Damage to the measurement stan-
dards. Despite the precautionary mea-
sures that emphasized good handling of
the measurement standards by all part-
ners, all measurement standards suffered
a number of surface damages. Moreover,
instead of the customized case provided
by the pilot institute, one particular part-
ner used a completely unsuitable pack-
age case with the intention of reducing
the shipping cost by reducing packaging
dimension and weight. The consequenc-
es of such negligence are highly visible
(Fig. 4). This example should serve to re-
emphasize the importance of maintaining
good care of a measurement standard as
“a master piece.” Figure 4 Damages inflicted on the measurement standards surface.
When the measurement standards Evolventenprofil; Profile and Helix Checking of
were returned to PTB, they were re-mea- Acknowledgements. The pilot insti- Involute Cylindrical Gears; 2000.
sured and evaluated. Fortunately, the tute expresses gratitude for the support 10. VDI//VDE 2613; Teilungs- und
Rundlaufprüfung an Verzahnungen
results were almost unchanged; most of of EURAMET and the Consultative Zylinderräder, Schneckenräder, Kegelräder;
the damage was found outside the sur- Committee for Length (CCL) of the BIPM Pitch and Run-Out Testing on Gearings
faces to be measured. One future recom- that made the comparison a success. Also, Cylindrical Gears, Whormwheels, Bevel Gears,
mendation: more attention and emphasis we would like to acknowledge the internal 2003.
11. Mise en pratique: ttpE://www.bipm.org/en/pub-
should be given to safety and handling. support from PTB, as well as colleagues lications/mep.html.
from the coordinate metrology department 12. JCGM 100 (2008. Valuation of Measurement
Summary and Outlook who have contributed in ensuring prompt Data – Guide to the Expression of Uncertainty
• The first international comparison control and analysis of the participant in Measurement www.bipm.org/utils/com-
for involute gears — organized by mon/documents/jcgm/ JCGM_100_2008_E.pdf
results. Most importantly, we express our (access March 2013).
EURAMET — has been successfully thanks to all participants in the compari- 13. DKD-Arbeitsanweisung DKD-AA-5 (2009),
implemented. son for the scientific and financial commit- Ausgabe Nr. 5: Grundsätze und Verfahren für
• The results presented here show that Vergleichsmessungen.
ment that contributed to the success of the
the criteria for comparability were ful- 14. Wöger, W. Remarks on the En-Criterion
comparison. It is a great step forward in a
filled; however, discrepancies in the Used in Measurement Comparisons. PTB-
values of the compared measurement positive direction. Mitteilungen 109, 1/99.
parameters of some participants were 15. Lewis, A. Running of MRA Comparisons
sizable and fell below the expectations. References in Length Metrology and Monitoring Their
1. BIPM. www.bipm.org (access March 2013). Impact on CMCs. CCL/WG-MRA/GD-1,
• The mishandling of the measurement March 2011.
2. ISO. www.iso.org (access March 2013).
standards by one participant demon- 3. VIM. International Vocabulary of Metrology: 16. BIPM Key Comparison database: http://kcdb.
strated the need to improve the metro- Basic and General Concepts and Associated bipm.org/ (access March 2013).
logical skills of this particular institute. Terms VIM, 3rd edition, JCGM 200:2008.
• In summary, the comparison shows 4. ISO-21771. Gears — Cylindrical Involute Gears
that some participants are able to cali- and Gear Pairs — Concepts and Geometry,
brate gear measurement standards 2007.
with the required level of competen- 5. ISO 18653. Gears — Evaluation of instruments
for the Measurement of Individual Gears, 2003.
cies. Contrarily, some participants were 6. EURAMET Technical Committee of Length
unable to adequately demonstrate the (TC-L): www.euramet.org (access March 2013).
level of competence required in terms 7. ISO 1328-1:1995. Cylindrical Gears — ISO
of their measurement values, as well as System of Accuracy — Part 1: Definitions and Dr. Frank Härtig is head of the “mechanics
and acoustics” division. Having more than 30
in the stated measurement uncertain- Allowable Values of Deviations Relevant to
years of experience in the field of metrology,
ties. Corresponding Flanks of Gear Teeth.
Härtig also serves on a number of national and
• Caveats aside, the comparison has 8. VDI/VDE 2607. Rechnergestützte Auswertung
international standardization committees.
von Profil- und Flankenlinienmessungen
been accepted for registration as a an Zylinderrädern mit Evolventenprofil; Dr. Karin Kniel heads the department of
Supplementary Comparison and will Computer-Aided Evaluation of Profile and “coordinate metrology” and the working
be published on the BIPM key compar- Helix Measurements on Cylindrical Gears With group, “gear and thread.” Main working
ison database (KCDB) (Ref. 16). Involute Profile, 2000. areas include: research and development
9. VDI/VDE 2612; Profil- und of measurement standards, measurement
Flankenlinienprüfung an Zylinderrädern mit and simulation procedures for dimensional
measurands.

84 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
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 industry news

Bernhard Kapp
(1921-2014)
Dr.-Ing. E. H. Bernhard Kapp, a passionate entrepenuer
and founder of the Kapp Group, passed away on July 13, 2014
at the age of 93. His inventiveness and leadership spanned over
50 years in the machine tool industry. Following five years in
the military and completing his studies, Dr. Kapp started his
professional life at the firm Waldrich in Coburg as a design
engineer. He became a shareholder and general manager of the
company at the age of 29. He successfully led this company for
27 years with his brother‐in‐law Otto Waldrich. Also at this
time, in 1953 he founded his own
company, Kapp & Co in Coburg,
motivated by the urge to create “This is an important milestone and I am so pleased to com-
something of his own, and to gen- mend Sandvik on this outstanding accomplishment,” Garrett
erate jobs. Today the Kapp Group said. “With its customer-centric approach to business and com-
is among the world's leading manu- mitment to innovation, Sandvik has been a vital asset to New
facturers of machine tools for hard Jersey and the surrounding communities.” Mayor Cosgrove
and soft finishing of gears and pro- added, “Sandvik is a well-known and well respected business
files with 850 employees worldwide entity that gives back to the Fair Lawn community.”
and facilities in Germany, USA, In design and construction of the new building Sandvik
Brazil, Japan and China. made energy efficiency and sustainability a priority. Over 75
Dr. Kapp firmly believed qualified educational support and percent of all waste generated from the construction was divert-
technical training is the most important investment for the ed from landfills by reusing, recycling, and repurposing materi-
future. With this philosophy he started an apprenticeship work- als. Furthermore, Sandvik donated the majority of the furnish-
shop within his manufacturing facility in Coburg. Dr. Kapp’s ing and equipment from previous headquarters to local chari-
expertise and leadership was also in demand by other com- ties, schools, and fire departments throughout the community.
panies. Numerous national and international companies and “Fair Lawn and New Jersey have been home to Sandvik for
institutions have named him to their management and super- nearly 60 years. Like our beloved red oak in front of the main
visory boards including the German Trade Fair and Exhibition entrance, Sandvik looks forward to being part of the Fair Lawn
AG, Gildemeister, Fiat, Krupp Hoesch, Iveco, Internazionale community for many years to come,” states Askin.
Holding Fiat, Werner & Pfleiderer, Trumpf, the Ifo Institute,
the Fraunhofer Society and the University of Coburg. Dr.
Kapp’s ideals continue to flourish today, with the success of the
Kapp Group under the leadership of his son, Martin Kapp. The
Mitutoyo America
OPENS HOUSTON SOLUTION CENTER
machine tool and gear industries have lost a revered man, and
true pioneer with the passing of Dr. Bernhard Kapp. Mitutoyo America Corporation is pleased to announce the
opening of a new M3 Solution Center in the south central

Sandvik United States region, located in Houston, Texas. This new,

8,000 sq. ft. center is conveniently located minutes from the
George Bush Intercontinental Airport. Customers can schedule
CELEBRATES GRAND OPENING OF U.S.
HEADQUARTERS appointments for product demonstrations and acquire assis-
tance with measuring solutions and application challenges.
Sandvik, Inc. celebrated the grand opening of its new U.S. head- “Our goal is to provide timely metrology solutions to our cus-
quarters in Fair Lawn, New Jersey. The 100,000 square foot tomers, in a region that is home to a booming oil industry. The
facility contains a combination of modern office space, exten- benefit of opening this new M3 Solution Center is the acces-
sive meeting facilities and a state of the art Productivity Center
and Aerospace Application Center for customer training, engi-
neering and process development. Among the many attend-
ing the event were Congressman Scott Garrett, Mayor John
Cosgrove and Sandvik CEO Olof Faxander. Garrett praised
Sandvik’s continued commitment to the community and local
economy since the 1950’s and presented the company with a
Certificate of Congressional Recognition. Cosgrove recog-
nized the company with a Proclamation declaring July 1, 2014
“Sandvik, Inc. Day.”

86 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
sibility in offering experienced metrology specialists to our
customers that could provide up to date and knowledgeable
metrology information for any situation they may encoun-
ter,” says Alan Jackson, regional sales manager, South Central
region. For more information, visit www.mitutoyo.com.

Timken
COMPLETES SPINOFF OF TIMKENSTEEL
CORP.
The Timken Company recently announced that it has complet-
ed its spinoff of TimkenSteel Corporation, which begins trading
as an independent public company tomorrow on the New York
Stock Exchange under the symbol “TMST.”
“The spinoff offers exceptional opportunity to drive value
for both The Timken Company and
TimkenSteel Corporation, their
respective employees and sharehold-
ers,” said Richard G. Kyle, presi-
dent and chief executive officer of
The Timken Company. “We offer
congratulations to Tim Timken and
the entire TimkenSteel team on their
launch as an independent steel com-
pany, and wish them every success
in advancing their leadership posi-
tion as a special bar quality steelmaker. At the same time, we
extend a special thanks to Timken associates for their hard
work and commitment in successfully facilitating the separa-
tion.”
Timken announced in September 2013 that it planned to
separate its steel business in a tax-free spinoff to Timken share-
holders. This spring, the Timken board of directors declared a
distribution of all outstanding common shares of TimkenSteel
Corporation through a dividend. At the close of business on
June 30, Timken shareholders received one common share of
TimkenSteel Corporation for every two common shares of
Timken they held as of the close of business on June 23, 2014.

After the spinoff, The Timken Company will continue to

focus on its bearings business as well as power transmission
products and related services, which include gearboxes, chain,
lubrication systems, transmissions, and other related rebuild
and maintenance services. “We are committed to creating value

GEAR CUTTING SOLUTIONS

August 2014 | GEAR TECHNOLOGY 87

 industry news

for our customers and our shareholders,” said Kyle. “The sepa-
ration is now behind us and we are focused on growing our
business in targeted markets across the world.”

PUTTING
A LIFETIME VDMA Machine
OF Vision
GEAR
DESIGN
Board
WELCOMES NEW
EXPERIENCE MEMBERS

TO WORK FOR YOU Donato Montanari, gen-

eral manager of the Machine
Vision Business Unit of Datalogic
• Reverse engineering • Design reviews Automation in Italy, and Lou
• Gearbox upgrades • Bid evaluations
• Custom gearbox design • Tooling design
Hermans, COO at CMOSIS in
• Specification development • Customized gear training Belgium were recently elected by
• Project management • Equipment evaluation the VDMA Machine Vision mem-
• Vendor qualification • Custom machine design bers to strengthen the board of
Charles D. Schultz the VDMA Machine Vision unit.
The election was conducted as a
[email protected] result of the decision taken at the
[630] 209-1652 last Members’ Assembly of VDMA
Robotics + Automation with regard
to the opening of the association
www.beytagear.com to European members. “Becoming
a member of VDMA is natural for CMOSIS since we already
have a very good working relationship with many members of
its Machine Vision Group. There is a big potential for stepping
up the technological leadership of our group if we work close-
ly together, and VDMA Machine Vision provides an excellent
platform for us to do so,” said Hermanns.
Montanari added: “I would like to thank the VDMA and
www.suhner.com

its members for the opportunity of serving on the board. As a

non-German member, I will make it my first goal to increase
the number of non-German companies in the association. I am
convinced that European companies can bring a different and
complementary perspective to the machine vision industry.”
According to the results of the recent VDMA Machine Vision
Market Survey, the industry turnover of the machine vision
industry in Germany increased its turnover by 8% in 2013
reaching the mark of 1.6 billion euro. The growth impetus
came mostly from exports: While domestic turnover stagnated,
exports from Germany went up by 15% in 2013. The export
share rose from 55% to a new all-time high of 58%. Due to a
very favorable order intake in the first five months of this year,
the German machine vision suppliers are expected to expand
Flexible Shafts & their sales volume by 10% in 2014 exceeding a sector turnover
Spiral Bevel Gears
Two different ways to transmit rotary motion.

SUHNER Manufacturing Inc. · Rome, GA 30161

Phone: 706-235-8046 · [email protected]

88 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
of close to 1.8 billion Euro. According to the latest VDMA mar-
ket survey, the sector turnover in Europe grew even by 10%,
with a further growth expectation of 12% in 2014.

Mazak
SOUTHWEST EVENT FOCUSES ON LEAN
MANUFACTURING
Mazak invited manufacturers to its Discover More with Mazak
event in July at the company’s Southwest Technology Center in
Houston, Texas. Attendees had the opportunity to learn how to NEW RELEASE 03/2014
shorten lead times, increase part quality and boost profitability
using the company’s highly versatile machine tools and appli-
cations expertise. The company demonstrated the latest multi- KISSsoft Highlights
tasking, five-axis, milling and turning processes on Mazak ● Strength calculation and 3D models of
machines including the Integrex i-300S multi-tasking machine beveloid gears
that employs a second spindle to efficiently produce medium ● Simulation of flank wear based on
iterative calculation
to large complex parts; the Quick Turn Nexus 550 MY turn-
● Enhanced sizing for gear modifications
ing center that features milling capability and Y-axis function- ● 3D display of shafts and bearings
ality to process long, large-diameter parts in single setups; the ● Efficiency and thermal rating in KISSsys
KISSsoft USA, LLC
● And many more ...
3719 N. Spring Grove Road
Johnsburg, Illinois 60051
Phone (815) 363 8823 Get your free trial version at
[email protected] www.KISSsoft.com

GearTech_KISSsoft_Rel_03_2014_Highlights_89x120_5mm.indd 1 5/5/2014 10:50:19 AM

[ ]
Orbitec 20 large part machining center that can perform a vari-
ety of operations on difficult-to-rotate workpieces in a single Accudrive http://www.accudrv.com/index.html

setup; and the space-saving Vertical Center Universal 400A 5X PRECISION GEAR GRINDING
that uses a five-axis rotary/tilt table.
Applications engineers were also available to discuss new • Spur / Helical up to 59" O.D. – 26" Face
ways attendees can streamline their operations. For example, • Accurate quotes – Competitive prices –
Mazak machines can perform multiple processes in a single Fast turn-around
tel.773-376 4906 fax.773-376 4946

setup, which helps minimize material handling and work-in- • Emergency “breakdown” support
process inventory. Also, the company’s user-friendly CNC tech- • Support system for OEM parts
nology gives operators the flexibility to change setups on Mazak • Full complement of testing
equipment for complete
machines very quickly. Furthermore, the company encouraged and comprehensive
attendees to present their part-production challenges so its charting. Calibrated and
engineers could offer solutions for overcoming such difficulties. certified on a regular
schedule.

H-D Advanced Trusted by OEM, MRO and

Gear Job Shop customers for

Manufacturing
nearly two decades.
Your project is as important to
us as it is to you.
ACQUIRES SUNGEAR, INC.
(773) 376-4906
H-D Advanced Manufacturing Company (H-D) has acquired www.Accudrv.com
Sungear, Inc. (Sungear), a manufacturer of high precision [email protected]
gears and assemblies for the aerospace industry. Sungear is the

August 2014 | GEAR TECHNOLOGY 89

 industry news

fourth acquisition completed under the H-D platform, joining

Overton Chicago Gear Corporation, a manufacturer of large,
high-precision gears and gearboxes, Innovative Mechanical
Solutions (iMECH), a manufacturer of highly engineered, cus-
tom bearings for the directional drilling motor industry and
Leading Edge Heat Treating Services Ltd., a provider of heat
treating solutions.
Headquartered in San Diego, CA, Sungear manufactures
complex, high quality, precision gear components for many of
the world’s leading aerospace suppliers. The company’s loose
gearing and gear assembly products perform critical functions
in engine starters, auxiliary power units and other applications.
Sungear manufactures products for both OEM and aftermarket
applications across a broad range of commercial and defense
platforms. Sungear’s current President, Roger Gizicki, will con-
tinue to lead Sungear within H-D’s gearing division. Raymond Wood, Founder and President of Master
“The addition of Sungear’s expertise and reputation for Metrology added: “Master Metrology is one of a number of fast
quality with some of the world’s largest aerospace customers growing companies that are contributing to the resurgence of
advances H-D’s goal of becoming a leading global manufacturer Maryland manufacturing. The acquisition by Trescal expands
of mission-critical products across a wide range of industries,” our market-leading position and gives our customers access to
said H-D CEO, Chris DiSantis. greater technical capability across a broader geographic foot-
“After over 30 years of growth and relationship development print.” Thibault Basquin, Managing Director in the Mid Cap
as a family-owned business, I am thrilled to lead Sungear in its Buyout team at Ardian, said: “Trescal’s ambitious international
next chapter as a part of H-D,” said Gizicki. “We are eager to growth strategy reflects both the strength of Trescal’s manage-
partner with H-D and its tremendous financial, operational and ment team and the level of support which Ardian always gives
business development resources that can help us take Sungear its portfolio companies.”
to new heights for our customers.”

Trescal PMA
EXPECTS SLIGHT DOWNTURN IN
ANNOUNCES ACQUISITION STRATEGY IN METALFORMING BUSINESS CONDITIONS
NORTH AMERICA
According to the June 2014 Precision Metalforming
Trescal, the international specialist in calibration services, today Association (PMA) Business Conditions Report, metalform-
announces the acquisition of US company Master Metrology, ing companies expect a slight downturn in business conditions
Inc. and Gefran’s Italian metrology assets. Respectively, based during the next three months. Conducted monthly, the report
in Towson (Maryland, USA) and Provaglio d’Iseo (Italy) and is an economic indicator for manufacturing, sampling 124 met-
A2LA and Accredia accredited. With an annual turnover of alforming companies in the United States and Canada.
$2 million and 16 employees including 7 engineers, Master The June report shows that 31% of participants predict that
Metrology increases Trescal’s growing presence in the US and economic activity will improve during the next three months
also broadens its technical offer, notably in the dimensional and (down from 33% in May), 54% expect that activity will remain
torque domains. unchanged (down from 60% last month) and 15% believe that
Gefran’s Italian metrology laboratory, with annual sales economic activity will decline (up from 7% in May).
of €800,000 and 5 employees including 4 engineers, will be Metalforming companies also forecast a dip in incoming
merged with Trescal’s existing laboratory in Brescia, growing orders during the next three months, with 37% predicting an
its lab-based offer in Italy’s humidity, temperature and climatic increase in orders (compared to 43% in May), 45% expect-
chamber calibration sector, within laboratory and on site. The ing no change (up from 43% in May) and 18% predicting a
deals were completed with the support of Trescal’s majority decrease in orders (up from 14% in May).
shareholder, Ardian, the premium independent private invest- Current average daily shipping levels declined in June.
ment company. They are the fifth and the sixth build-up trans- Thirty-five percent of participants report that shipping levels
actions executed following Ardian’s acquisition of Trescal in are above levels of three months ago (down from 45% in May),
July 2013. 46% report that levels are the same as three months ago (up
Guillaume Caroit, General Secretary of Trescal Group, said: from 40% last month), and 19% report a decrease in shipping
“These acquisitions fit perfectly with our development strategy, levels (up from 15% in May).
both in the US where we hope to achieve a leading position in
the next two years and also in Europe, where our ambition is to
extend the technical offer to our clients. We are working on two
or three build-up to be closed before the end of the year.”

90 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
Adcole Corp.
NAMES REECE PRESIDENT AND CEO
Adcole Corporation, a manufac-
turer of special purpose machines
for measuring engine components
such as camshafts, crankshafts, and
pistons, as well as sun angle sen-
sors for space satellites has appoint-
ed Brook Reece president and New stopper technology
for guaranteed radial
CEO. Adcole was founded in 1957 and axial run out
by Addison D. Cole who was presi-
Stoppers are pre-
dent and CEO for 57 years, retired assembled and remain
at age 95, and sold the business to intact when changing inserts
Artemis Capital Partners. Terms of the purchase were not dis-
closed. Reece previously served as vice president sales at Adcole
Corporation for 20 years and is uniquely qualified to lead
the company. “Our heritage is one of innovation and trusted
accuracy and our vision is to be the most trusted and valued
name in the space and industrial metrology industries. We are
presently on an extremely fast product development track in
response to the rapid technological changes in engine develop-
ment. Innovation is our heritage and central to our future busi-
ness strategy,” he said.

Sandvik
SUPPORTS HURCO CHIPMAKER
CHALLENGE
Hurco recently announced that Sandvik Coromant will donate
$1,000 worth of tooling to the champion of the Chipmaker
Challenge, a contest designed to highlight manufacturing
entrepreneurism, which will be held at the International
Manufacturing Technology Show Tuesday (IMTS), Sept. 9, at
1:30 p.m. at the Hurco booth (S-8619). The winner will walk Gear Milling System Advantages
away with their choice of a brand new Hurco VMX42i CNC • Super Fast Machining
mill or TM8i lathe in addition to the Sandvik Coromant tooling • Long Tool Life
of their choice. “The idea of the Chipmaker Challenge evolved • High Accuracy & Quality Machining
as we discussed ways to add some excitement to IMTS and get
• Economical Solution
publicity for the entrepreneurs in our industry who do remark-
able things each and every day,” said Joe Braun, general man-
• High Precision Machining
ager of Hurco North America. “Our customers are competitive, • Simplified Machining
proud of the businesses they’ve built, and the products they
make. We decided to model the Chipmaker Challenge after
the television show Shark Tank in order to create an exciting,
competitive, entertaining event that showcases manufacturing
entrepreneurs and highlights the hi-tech aspect of manufactur- Visit us at
ing in this country." Booth # W-2245

800-828-8765 • www.vargususa.com

August 2014 | GEAR TECHNOLOGY 91

 calendar
August 26–28 — International Gear Conference October 6–8 — Furnaces North America 2014.
2014. Lyon-Villeurbanne, France. Mechanical transmission Nashville Renaissance & Convention Center, Nashville, TN. Heat
components are present in every industrial sector and range treating specialists from around the world will gather to discuss
from nano-gears to large gearboxes. Increasing competitive the latest emerging technologies in heat treating and furnace
pressure and environmental concerns have provided an impe- equipment. FNA will feature 170 suppliers representing every
tus for cleaner, more efficient and quieter units. Moreover, the major area of heat treating. The conference includes five tech-
emergence of relatively new applications in wind turbines, nical tracks with 40 learning sessions. Visitors and exhibitors
hybrid transmissions and jet engines has led to even more severe will have the chance to meet and discuss opportunities in three
constraints. The main objective of this conference is to provide networking sessions. For more information, visit www.furnac-
a forum for the most recent advances, addressing the challenges esnorthamerica.org.
in modern mechanical transmissions. Topics include gear noise,
gear design, gear materials, gear failure, lubrication, gearbox October 8–10 — RMGFS 2014. Boulder, CO. The Rocky
efficiency and more. For more information, visit http://int-gear- Mountain Gear Finishing School (RMGFS) is the premier gear
conf14.sciencesconf.org. finishing school in the western United States.  Kapp-Niles pre-
sents this multi-layered program designed to optimize learning
September 8–10 — Gear Failure Analysis Seminar. and strengthen your understanding of gear finishing processes
Big Sky Resort, Big Sky, Montana. In AGMA’s Gear Failure no matter your experience level. Participants study the underly-
Analysis Seminar, attendees will examine the various types ing principles and mechanics of different gear finishing pro-
of gear failure, such as macropitting, micropitting, scuffing, cesses, apply them through practical sessions on a Kapp-Niles
tooth wear and breakage. Possible causes of these failures will machine, and take part in group workshops for more in-depth
be presented, along with some suggested ways to avoid them. discussions. Kapp encourage attendees to bring applications
A gear failure analysis expert will use lectures, slide presenta- to the school for small group, or one-on-one discussions.
tions, hands-on workshops with failed gears and Q&A sessions Presenters include Jim Buschy, Bill Miller, Dwight Smith, Paul
to give a comprehensive understanding of the reasons for gear Brazda, Michael Ruppert, Sascha Ungewiss, Thomas Schenk,
failure. Participants are encouraged to bring their own failed Nidam Meharzi, Eric Dixon and Hans-Helmut Rauth. For more
gears or photographs and discuss them during the Q&A ses- information, visit www.kapp-usa.com.
sions. The seminar brings together a vast amount of knowledge
and will help you solve everyday problems whether you are a October 22–23 — WZL Gear Conference USA.
gear engineer, user, researcher, maintenance technician, lubri- Gleason Corporation, Rochester, New York. For more than 50
cant expert or manager. The course manual offers more than years the annual WZL Gear Conference in Aachen, Germany,
100 color photos, dozens of illustrations, a textbook and failure has been fostering technical collaboration and communica-
atlas that will become a permanent reference source. For more tion among the members of the WZL Gear Research Circle. The
information, visit www.agma.org. two-day conference is devoted exclusively to the presentation
of the latest research in gear design, manufacturing and testing.
September 8–13 — IMTS 2014. The International Additionally, the software resources of the WZL Gear Research
Manufacturing Technology Show (IMTS) is the largest manufac- Circle are available for examination, including solutions for
turing technology show in the Western Hemisphere. IMTS 2012 gear design and manufacturing process development. With up
drew more than 100,000 industry decision-makers in areas like to 300 participants from Europe and overseas, the WZL Gear
metal cutting, tooling, metal forming, abrasives, controls, CAD- Conference is one of the largest annual events dedicated to
CAM, EDM, gear generation, industrial automation and more. gear technology in Europe. Nine years ago exclusive contents of
The IMTS conference brings the industry together to discuss the Aachen gear conference were first presented in the United
new opportunities and network with the manufacturing commu- States. The Fifth WZL Gear Conference - USA is being hosted by
nity. Other highlights include the Smartforce Student Summit, Gleason Corporation and will provide the opportunity for North
Exhibitor Workshops, the Emerging Technology Center and American companies to connect with WZL and learn about cur-
IMTSTV. IMTS is co-located with Industrial Automation North rent research activities. The conference fee is $260 per attendee.
America and Motion, Drive & Automation North America. For For more information, visit www.wzl.rwth-aachen.de.
more information, visit www.imts.com.
October 27–30 — Gear Dynamics and Gear Noise
September 16–20 — AMB 2014. Stuttgart, Course. Ohio State University. The Gear Dynamics and Gear
Germany. AMB, the international exhibition for metalworking, Noise Short Course has been offered for 35 years and is consid-
has increased the number of exhibitors in 2006, 2008, 2010 and ered extremely valuable for gear designers and noise specialists
2012. All global market and technology leaders will be repre- who encounter gear noise and transmission design problems.
sented in Stuttgart. Exhibitors from over 30 nations present Attendees will learn how to design gears to minimize the major
their new products and services in the area of machines and excitations of gear noise: transmission error, dynamic friction
tools for metalworking. The trade show features more than forces and shuttling forces. Fundamentals of gear noise genera-
105,000 square meters of exhibition space, clear, structured hall tion and gear noise measurement will be covered along with
divisions, and optimal accessibility. Special programs during topics on gear rattle, transmission dynamics and housing acous-
AMB include Art Meets Technology, Metalworking Innovation tics. This four-day course includes extensive demonstrations of
Tour, WorldSkills Germany, Career Walk and more. The topics specialized gear analysis software in addition to the demonstra-
will extend from solving economic problems to searching for tions of many Ohio State gear test rigs. A unique feature of the
production or sales partners.  For more information, visit www. course is the interactive workshop session (on Day 3) that invites
messe-stuttgart.de. attendees to discuss their specific gear and transmission noise
concerns. The roundtable discussions on Day 4 are intended to
foster interactive problem solving discussions on a variety of
topics. Cost is $1,950 per person. For more information, visit
www.nvhgear.org.

92 GEAR TECHNOLOGY  |  August 2014

[www.geartechnology.com]
 ad index
3M Abrasives – page 16 Kapp Technologies — page 3
www.3M.com/PrecisionGTAug www.kapp-usa.com FOR SALE
Accu-Drive Inc. – page 89 KissSoft – page 89 www.gearmachineryexchange.com
www.accudrv.com www.kisssoft.com
ALD-Holcroft Vacuum Technologies – page 27
www.ALD-Holcroft.com
Klingelnberg — Outside Back Cover
www.klingelnberg.com GLEASON
All Metals & Forge Group, LLC — page 12
www.steelforge.com
Koro Sharpening Service – page 95
www.koroind.com
Model 642
G-Plete Hypoid Generator
Arrow Gear Co. – page 25 Leistritz Corp. – page 51
www.arrowgear.com www.leistritzcorp.com 13" (330 mm), 3.4 DP (7.5 Module), Excellent, Pinions,
Ring Gears, Helical Motion, Formate,
B&R Machine & Gear Corp. — page 21 Liebherr – page 5 Extented Tilt, 1982
www.brgear.com www.liebherr.com
Beyta Gear Service – page 88 Luren Precision Co., Ltd. – page 9
www.beytagear.com www.lurenchicago.com
Just Released from Aircraft
Brevini Gear – page 62 Machine Tool Builders Inc. — page 65
brevinigear.com www.machinetoolbuilders.com Gear Manufacturer
McInnes Rolled Rings — page 23
The Broach Masters & Universal Gear – page 24
www.broachmasters.com www.mcinnesrolledrings.com (2) Gleason #2 Hypoids - 1950's
Circle Gear – page 95
www.circlegear.com
Midwest Gear & Tool Inc. — page 87
[email protected]
Gleason Model 106 - 1960
Comtorgage – page 22
www.comtorgage.com
Mitsubishi Heavy Industries — page 35
www.mitsubishigearcenter.com
Gleason Model 108, Helical
DMG Mori – page 54 Mitsubishi Materials – page 64
Motion, 1964
www.dmgmori.com www.mmus.com
DTR Corp. — page 37 Nachi – page 31
Gleason Model 116 - 1967
www.dragon.co.kr www.nachi.com
ECM USA – page 18
www.ecm-usa.com
Norton/St. Gobain Abrasives – page 19
www.nortonindustrial.com
GLEASON
Euro-Tech Corp. – Page 32 Oelheld USA – page 31
INDEX PLATES
www.eurotechcorp.com www.oelheld.com Lift & Drop Cams, Genevas
Excel Gear – page 47
www.excelgear.com
Pentagear Products – page 57
www.gearinspection.com for MODELS
Forest City Gear — page 67 Presrite Corp. — page 43 606, 607, 608 and 609
www.forestcitygear.com/OPS www.presrite.com
Frenco GmbH – page 4 Proto Manufacturing – page 44
Generators
www.frenco.de www.protoxrd.com

GLEASON
Gear Consulting Group – page 95 PTG Holroyd – page 40
www.gearconsultinggroup.com www.holroyd.com
The Gear Machinery Exchange — page 95
www.gearmachineryexchange.com
Radiac Abrasives – page 32
radiac.com
CHANGE GEARS for MODELS
German American Chamber of Commerce – page 32 Rotek Inc. — page 61
2A, 102, 12, 14, 16, 19, 24, 26, 27, 28, 104,
www.gaccmidwest.org/german-night www.rotek-inc.com 106, 112, 114, 116, 118, 463, 606, 607, 645
German Machine Tools of America – page 7 Roto-Flo/U.S. Gear Tools – page 33 2A & 102 CAMS
www.gmtamerica.com www.roto-flo.com

GLEASON
Gleason Corp. — pages 48-49 Sandvik Coromant – pages 30, 69
www.gleason.com www.sandvik.coromant.com/imts
Goldstein Gear Machinery LLC – page 79 Schnyder S.A. — page 87
www.goldsteingearmachinery.com www.hanikcorp.com CONIFLEX CUTTER BODIES
Hainbuch America – pages 30, 42 Seco Tools – page 45 W/BLADES for
www.hainbuchamerica.com secotools.com/us
Hans-Jürgen Geiger Maschinen-Vertrieb — page Solar Atmospheres — pages 30, 41 Gleason Model 104 & 114
36 www.solaratm.com
www.geiger-germany.com
Solar Manufacturing – page 31
Hilco Industrial – page 94 solarmfg.com
www.hilcoind.com
Star SU LLC — pages IFC–1, 95
Hota Industrial – page 38 www.star-su.com
www.hartech.com.tw
Stresstech – page 73
Index Technologies – page 95 www.stresstechgroup.com
www.gallenco.com
Suhner Manufacturing – page 88
Inductoheat – page 59 www.suhner.com
www.inductoheat.com
Vargus USA - page 91
Ingersoll Cutting Tools – pages 11, 13, 15, 17 www.vargususa.com
www.ingersoll-imc.com
Zhengzhou Research Institute of Mechanical
Ipsen International — Inside Back Cover Engineering – page 39
www.ipsenusa.com www.zrime.com.cn

www.gearmachineryexchange.com

August 2014 | GEAR TECHNOLOGY 93

 Hilco WEBCAST AUCTION • SEPTEMBER 4TH
UnprecedentedOfferingof
LateModel,HighPrecision
LateModel,HighPrecision
GearMachineryandHeatTreatEquipment
GearMachineryandHeatTreatEquipment
950 Tollgate Road, Elgin, IL 60123
ForProductionofHeavyIndustrialGearboxesandDrivetrains

CNC GEAR GRINDERS COMPLETE STATE  OF  THE  ART

• (2) Gleason Pfauter P600G (2009) HEAT  TREAT FACILITY including
• (2) Hofler Rapid 1250 (2009) • (10) Aichelin Carburizing &
• (2) Hofler Rapid 800 (2009) Tempering Furnaces (asnewas2011)
CNC GEAR HOBBERS • Aichelin Quench Tanks, Washers,
• Hofler HF1250/1600 (2009) Tempering Ovens (asnewas2009)
• Liebherr LC800 (2009) • (2) Nolzen Pit Furnaces

CNC VERTICAL TURNING LATHE GEAR & MACHINING EQUIPMENT

• Hessapp VDM 1200-11 (2009) Hurth Spline Mill; Hofler & Reishauer
CNC GEAR INSPECTION Gear Grinders; Pfauter Gear Hobbers;
• Klingelnberg P150 (2009) Shigiya Cylindrical Grinders &  much more
• Klingelnberg P100 (2009) REAL  ESTATE  AVAILABLE
14.26 Acres, Over 132,000 Sq. Ft.
• Fromag CNC Key Seater (2009) Magnificent Expandable Facility
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Please contact John Magnuson for additional information on specific assets or entire facility at +1 847.504.3204 or email [email protected]

Offered in partnership with

VisitOurWebsiteformoredetailedinformation
A Hilco Global Company
VestedinYourSuccess

Hilco Industrial, Illinois Auctioneer & License:

www.perfectionindustrial.com www.hilcoind.com Tim Pfister License #441.001667 • IL License #444.000215
 classified

SHARP HOBS School for

Change Downtime To Productivity ear Gear Manufacturing Technology
onsulting Conducted by
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roup
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to cover the practical aspects of gear technology and
geometry aiming toward a logical approach to trouble
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August 2014 | GEAR TECHNOLOGY 95

 addendum

Sally Ride Science:

Creativity, Collaboration and Fun
Founded in 2001 by Dr. Sally Ride, America’s first
woman in space, Sally Ride Science offers pro-
grams and professional development for upper-
elementary and middle school students on sci-
ence and technology topics. The goal is to provide
tools for college and career readiness that can build students’
passion for STEM fields and careers. Former astronaut Wendy
Lawrence will deliver a keynote address during the Smartforce
Student Summit at IMTS 2014. The presentation will take place
Wednesday September 10th in Chicago.
The Smartforce Student Summit is held in conjunction with
IMTS and gives students a first-hand, interactive view of manu-
facturing technology, in addition to promoting careers in the
industry. During IMTS 2012 — less than two months after Ride's
losing battle to pancreatic cancer — more than 9,300 students
and educators from 17 states attended the Smartforce Student
Summit before touring the trade show. “A focus of my keynote will be on the lasting impact teach-
“One of the primary issues facing U.S. manufacturing is a ers — and anyone, really, such as the STEM professionals at the
lack of workers who have the required advanced and high- Summit — can have on students when they expand STEM top-
technology skills necessary in industry today. The Smartforce ics ‘beyond the classroom’ and connect them to careers. Once
Student Summit is a great way to educate students, teachers and students can envision themselves as a marine biologist, engineer,
parents about the career opportunities in manufacturing,” said astronaut, or other STEM professional, there is really no stop-
Greg Jones, vice president - Smartforce Development, AMT. ping them. Introducing students to the wide array of women and
“Additionally, it’s imperative to generate interest among girls men working in STEM—whether through in-person contacts or
and young women for careers in STEM fields, including manu- through Sally Ride Science books, products and programs—is
facturing. Dr. Flammer is a natural fit for bringing this message the best way to build student interest in STEM fields.”
to the attendees at the Smartforce Student Summit.” Long an advocate for improved science education, Ride
Sally Ride Science incorporates career-focused instruction co-wrote seven science books for children, and also initiated
through teacher training programs, books and eBooks (e.g., and directed NASA-funded education projects designed to
the Cool Careers and Key Concepts in Science series), and fuel middle school students’ fascination with science, includ-
various events and services. The company shows students ing Sally Ride EarthKAM and GRAIL MoonKAM. Sally Ride
that science is creative, collaborative, fascinating and fun. “I Science works with numerous public and private partners,
am very much looking forward to speaking at the Smartforce including ExxonMobil, NASA, the Office of Naval Research,
Student Summit, and — on behalf of the entire team at Sally Northrop Grumman, Deloitte and others. Since 2005, Sally
Ride Science — I thank AMT for the invitation," said Lawrence. Ride Science has trained over 10,000 teachers who have reached
“Like Sally Ride Science-a company I have worked with closely almost 1.5 million students with instruction that emphasizes
over many years-I am very passionate about building student career connections to STEM. For more information visit www.
interest in STEM. I can't emphasize enough how important it is sallyridescience.com and www.amtonline.org.
for employers and industry groups like AMT to share that mis-
sion as well."

96 GEAR TECHNOLOGY  |  August 2014

 Choose the best solutions

Pusher

Mass Production

When it comes to the mass production of

components necessary for executing critical
functions in large, heavy-duty machines, these
components need to meet strict industry
specifications. Keeping up with this growing list of
specifications and the demand is easier when you
choose Ipsen. We know the challenges you face and
design equipment that allows you to achieve low cost
per part, all while maintaining the quality and quantity of
parts you need and your customers demand.

Pusher Furnaces
When your output is measured by the hundreds of thousands or even millions of parts – and when those
parts need to meet precise carburizing or nitriding depths and hardness specifications – choose Ipsen’s
controlled-atmosphere Pusher furnaces.

With single-, double- or triple-row configurations and free and/or press quenching capabilities, Ipsen
Pushers will drive your parts through the full carburizing and nitriding process, including: preheating,
washing, tempering and cooling. All these processes are conducted in a fully-automated, “lights-out”
system with customized layouts to fit your needs.

Rotary Hearth Furnaces

Designed for both carburizing shallow case depths and reheating pretreated work pieces, this robust
furnace type is extremely versatile. Its high throughput makes it particularly suitable for heat treating
large quantities of the same parts.

The Rotary Hearth furnace can operate as a stand-alone unit with either
manual or automatic loading/unloading and can also interlink with other
plant components.

Visit IpsenUSA.com/Atmosphere for more information.

PERFECT MATCH.
MAXIMUM ACCURACY SOLUTIONS
FOR GEAR MANUFACTURERS
BY KLINGELNBERG

Only a perfect pass, a perfect catch and an optimal score make a perfect

SUBJECT TO CHANGES.
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For example the Höfler RAPID 1250K with a special spindle for smaller
grinding wheels increasing your application range and the Klingelnberg
P 100L measuring center safeguarding highest precision – perfectly
NEXT FAIRS:
matched machines. A dream team within the Klingelnberg system.
IMTS, Sep 08-13, 2014
Booth N-6837
McCormick Place,
Become a player in cylindrical gear technology – Chicago, IL, USA

with the perfect Klingelnberg match.

Perfect Match: KLINGELNBERG America, Inc.

www.klingelnberg.com p. +1 734 470 6278
www.hofler.com e. [email protected]

OERLIKON HÖFLER KLINGELNBERG KLINGELNBERG

BEVEL GEAR TECHNOLOGY CYLINDRICAL GEAR TECHNOLOGY MEASURING TECHNOLOGY DRIVE TECHNOLOGY