GEAR SOLUTIONS MAGAZINE

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

ISSUE FOCUS
Gear Design | Gear Inspection
INTEGRATED OPTIMIZATION OF GEAR DESIGN AND MANUFACTURING

INTEGRATED OPTIMIZATION
OF GEAR DESIGN AND
MANUFACTURING
COMPANY
PROFILE

AVERS MACHINE AND GEAR

FEBRUARY 2022

FEBRUARY 2022
gearsolutions.com
 AMORPHOLOGY

NASA BORN
PATENT DRIVEN

PRECISION GEAR MANUFACTURING

 www.toolink-eng.com
4665 Nautilus Ct. South 502A
Boulder, Colorado 80301
303-776-6212
 FEATURES

26
INTEGRATED OPTIMIZATION
OF GEAR DESIGN AND MANUFACTURING
The integration, optimization, design, and manufacturing of gears using
state-of-the-art software allows cutting tools to be harmonized.

MODELING TOOLS FOR GEAR DESIGN

38 AND FAILURE PREVENTION
Techniques to prevent, predict, and understand gear failure have improved
in part due to advances in computing power and simpler approaches.

IN GEAR WITH METROLOGY

As gear production demands increase, lead times need to be decreased
without compromising quality; therefore, the ability to confidently perform
everything ranging from quick checks to in-depth QC inspections in
44
seconds has never been more important.

QUALITY BUILT INTO EVERY PART

48 COMPANY PROFILE Avers Machine and Gear provides its customers with
a variety of precision machined components and gearing in materials including
aluminum, tool steel, plastics, high-alloy steels, stainless steels, brass, and bronze
with an emphasis on quality of product made to customers’ specifications.

2     gearsolutions.com
 We Measure
Quality in
Microns
WGT 280 - 1200
www.liebherr.com

Metrology

WGT Gear Measuring Machines

Liebherr offers a wide range of gear measuring devices. The combination of
high-precision measuring mechanics and the specially developed gear measuring
software guarantees precise measuring results.

– Highest accuracy is guaranteed by using granite guides, air bearings, precision

rotary table and Renishaw scanning probe
– Low cost of ownership and high uptime
– User-friendly software packages for various types of gears, gear cutting tools and
shaft geometry
– Manufacturer neutral GDE interface for data transmission to production machines

Liebherr Gear Technology, Inc.

[email protected] • www.liebherr.com/measuringdevices February 2022     3
 FEBRUARY 2022 • VOLUME 19, NUMBER 2
DEPARTMENTS
INDUSTRY
8 NEWS
Reports, data, and developments to keep
you aware of what’s happening with your
colleagues in the gear-manufacturing
industry around the country and world.

KISSsoft sets 2022 schedule for training New GWJ module offers online calculation
courses. of Hirth couplings.

15
In this section, the premier supporter of gear manufacturing in the United American
States and beyond shares news of the organization’s activities, upcoming
educational and training opportunities, technical meetings and seminars, Gear Manufacturers
standards development, and the actions of AGMA councils and committees. Association

MATERIALS TOOTH HOT

20 MATTER 22 TIPS 24 SEAT
WILLIAM MARK MCVEA BRIAN DENGEL D. SCOTT MACKENZIE

WORM GEARING TWISTS ITS WAY DO OPPOSITES REALLY ATTRACT? SELECTING A CLEANER FOR
INTO OUR DESIGN SUITE When choosing a gear, it is important to PREWASHING PRIOR TO HEAT
Time-tested, versatile setup offers many understand which gear it mates with. TREATMENT
options, can deliver big impact in tight A number of factors must be considered to
spaces. ensure that soils from previous operations
don’t prevent parts from being carburized
successfully.

PRODUCT Q&A
52 SHOWCASE 56
New products, trends, services, and
developments in the gear industry.

RESOURCES
54 MARKETPLACE

55 ADVERTISER INDEX GLENN GARRETT

Chief Technology Officer at
Amorphology, Inc.
COVER PHOTO: SHUTTERSTOCK

Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway, Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates:
$72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210, Pelham, AL
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All rights reserved.

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

4     gearsolutions.com
February 2022     5
 FROM THE
EDITOR David C. Cooper
PUBLISHER

EDITORIAL
For us, February is the place Kenneth Carter
for gear design EDITOR

Jennifer Jacobson
B y the time you read this, Valentine’s Day will be over and done with, and hopefully, you
are taking advantage of that 80 percent off sale for leftover chocolate.
Gears — as well as life — can be like a box of chocolates sometimes, too. That’s why we
ASSOCIATE EDITOR

Joe Crowe
ASSOCIATE EDITOR | SOCIAL MEDIA
have been busy picking and choosing some exciting content to help you figure out exactly
what you’re going to get.
Our Focus topics for February are intended to do just that as we shine our spotlight on SALES
gear design and gear inspection. Dave Gomez
We start out with an interesting article from Massimiliano Turci, where he shares his NATIONAL SALES MANAGER
insights on the integrated optimization of gear design and manufacturing.
An article from Berly McCoy discusses modeling tools for gear design and failure pre-
Ben Keaten
REGIONAL SALES MANAGER
vention.
And on the subject of gear inspection, CW Moran looks at if lead times for gear produc-
tion are to be decreased without compromising quality, then the ability to perform tasks CIRCULATION
ranging from quick checks to in-depth QC inspections has never been more important. Teresa Cooper
In addition to our feature articles, this month’s issue also showcases some interesting MANAGER
information from our regular columnists.
In Hot Seat, Dr. Scott MacKenzie talks about selecting a cleaner for prewashing prior
Jamie Willett
ASSISTANT
to heat treatment.
Materials Matter columnist Dr. William Mark McVea looks at a time-tested, versatile
setup for worm gearing offers many options that can deliver a big impact in tight spaces. DESIGN
And in Tooth Tips, Brian Dengel shares his unique perspective on understanding which Rick Frennea
gear mates with what when choosing a gear. CREATIVE DIRECTOR
You’ll find all this and more in this month’s Gear Solutions, and the best thing is, these
“treats” are completely calorie free.
Michele Hall
GRAPHIC DESIGNER
So, enjoy, and, as always, thanks for reading!

CONTRIBUTING
WRITERS
REBECCA BRINKLEY
BRIAN DENGEL
D. SCOTT MACKENZIE
BERLY MCCOY
KENNETH CARTER, editor WILLIAM MARK MCVEA
[email protected] CW MORAN
(800) 366-2185 x204 MASSIMILIANO TURCI

Vertical Logo Hor

Coop wants
CALL FOR ARTICLES Have a technical paper or other work with an PUBLISHED BY MEDIA SOLUTIONS, INC.
educational angle? Let Gear Solutions publish it. Contact the editor, P. O. Box 1987 • Pelham, AL 35124
(800) 366-2185 • (205) 380-1580 fax
Kenneth Carter, at [email protected] for how you can share
your expertise with our readers. David C. Cooper Teresa Cooper
PRESIDENT OPERATIONS

6     gearsolutions.com
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HYDROSTROKE SHAPERS • REMANUFACTURED IN 2021

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WE OWN WHAT WE SELL, AND WE KNOW WHAT WE’RE SELLING!

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www.NewEnglandGear.com

343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776 • [email protected]
Xxxxxxxx 20XX     7
 INDUSTRY
NEWS NEW TRENDS, SERVICES & DEVELOPMENTS

New GWJ module offers

online calculation
of Hirth couplings
GWJ Technology GmbH, calculation spe-
cialist from Braunschweig, has added a new
module to its web-based calculation soft-
ware eAssistant that now enables the calcu-
lation of Hirth couplings.
The new module is part of the web-based
calculation software eAssistant in order to
design, recalculate, and optimize classic
machine elements such as shafts, bearings,
gears, cylindrical and bevel gears, etc. The
Hirth coupling (or Hirth serration), a shaft-
hub connection with tapered, symmetri-
cal teeth, is a form-locking, self-centering,
and easily detachable connection compo-
nent. Because of the high torque stability
together with the positioning accuracy, the
Hirth coupling is successfully used across
many industries for various applications,
for example to connect shafts, disks, rotors,
wheels, and cranks. This type of connection
offers a number of significant advantages:
robustness, suitable for changing forces,
Based on the current software release, KISSsoft training courses focus on module-specific topics considering and it requires only minimal space due to
the latest trends in gear manufacturing technology. (Courtesy: KISSsoft)
the small size. Assembly and disassembly
are quick and easy. During assembly, the
KISSsoft sets 2022 in a virtual setting. components are self-centering. Thanks to

schedule for
The schedule for the first half of 2022: modern machine tools and manufacturing
 February 22-23: Gear Calculation processes, the connection can be manufac-
training courses (Basics).
 March 1-2: Shaft and Bearing Calculation
tured cost-effectively by using grinding or
milling operations.
In KISSsoft’s training program 2022 in (Basics). With the input of the number of teeth,
English, there are introductory training  March 22-24: KISSsys — Modeling Gear- outer and inner diameter, flank angle, and
courses, advanced training courses, and boxes (Basics). tooth root radius, the new eAssistant mod-
special training courses on selected topics.  March 29-30: KISSsys — System Cal- ule calculates the geometry of the Hirth
KISSsoft’s goal is to meet the changing culations (Advanced). coupling. Various special cases of the con-
requirements and situations of our users,  M a r c h 31: K I S S s y s — Mo de l nection are also supported. In addition to
be it in the case of a purchase of KISSsoft Customization (Special). the geometry, axial load, preload as well as
calculation programs or in the case of spe-  May 9-12: Fine Pitch Gears in Plastic and the permissible surface pressure and the
cialization and qualification in certain Sintered Material (Special). corresponding safeties are determined at
product areas. This year, it is again offering  June 21-23 / June 28-30: Cylindrical maximum load. All important results are
livestreams, which will allow participants Gear Design, Analysis and Optimization displayed directly in the results overview
flexibility and planning security as well (Advanced). of the calculation module. Common dimen-
as the opportunity to interactively ask sions can be selected easily and quickly from
questions and participate in discussions MORE INFO www.kisssoft.com an integrated database. Here, diameters

SEND US YOUR NEWS Companies wishing to submit materials for inclusion in Industry News should contact the editor,
Kenneth Carter, at [email protected]. Releases accompanied by color images will be given first consideration.

8     gearsolutions.com
 assembly services and better serve our cus- financing options. In addition, a UK demo
tomers, and this new building is perfect showroom will soon be available for cus-
for that.” Less office space was needed due tomers and prospects to see Tormach equip-
to most company employees continuing to ment in person. It will feature Tormach’s
work remotely, said Rogge. PCNC 440, 770M and 1100MX CNC milling
Eight Tormach machines will be housed machines for in-person machine demonstra-
in the new demonstration area in the build- tions. Meanwhile, virtual demonstrations
ing as the company continues to increase its will also be available.
remote machine demonstrations via Zoom, “We are excited to be partnering with
Microsoft Teams, and other platforms. CNC Machine Tools,” said Lori Morrison
CNC Machine Tools Ltd. will be Tormach’s Bufalo, Tormach’s marketing director. “We
exclusive distributor in the United Kingdom have received numerous requests for our
and Eastern Europe. They will offer machine products in the UK, and our customers will
assembly services, training, and leasing and now have the service and support they need

New Hirth coupling calculation module in eAssistant.

(Courtesy: GWJ Technology)

from 50 to 900 mm can be chosen — each

with a suitable number of teeth, inner diam-
eter, and tooth root radius.
The permissible pressures are determined
from material properties. Already existing
materials can be easily selected from the
integrated material database. Additionally,
the user can enter individual materials for
Whether it fails…whether
the calculation.
After completion of the calculation, a
it gets there on time…
detailed calculation report is available to Southern Gear has
the user in HTML and PDF format. The out- the experience and
put of the 3D model of the Hirth coupling is resources to take
also possible directly in a 3D CAD system by all the uncertainty
using the eAssistant 3D CAD plugins. out of your custom
precision gear
MORE INFO www.gwj.de production.
www.eassistant.eu
Aerospace and
defense. Medical
Tormach Inc. expands to marine. When
in United States there’s a lot
at stake and it
and Europe needs to be done
Tormach Inc. has expanded its domestic
right. The ‘whether’
and international operations by moving its is always better at
headquarters and entering into a distribu- Southern Gear.
tion agreement with CNC Machine Tools Ltd.
of Snetterton, Norfolk, England.
The expansion included moving to a new
corporate headquarters facility in Madison,
Wisconsin. Tormach, an industry-leading There’s a Better Way.
supplier of affordable and compact CNC
machines, has moved from its previous
location in Waunakee to a new building in
Madison. The new address is: 4009 Felland
Road Ste. 120; Madison, WI 53718 USA; tele-
phone is (608) 849-8381 (remains the same).
“We are excited with our move to this 800.248.5152 | southerngear.com | 3685 NW 106 St. Miami, FL 33147
new facility,” said Daniel Rogge, Tormach’s
CEO. “We needed less office space but more Established in 1957 | Veteran-Owned | ISO 9001:2015 | AS9100D | ITAR Compliant
warehouse space to expand our machine
February 2022     9
INDUSTRY
NEWS

from a company that is a specialist in the

CNC machining field.”
CNC Machine Tools Ltd is one of the larg-
est and longest established companies spe-
cializing in the servicing, repair, and main-
tenance of all types of machines including
CNC types. CNC Machine Tools Ltd has a
highly experienced team providing a com-
prehensive service to customers across a
range of sectors. These include steel, auto-
motive, motorsport (including F1), aerospace,
oil and gas, energy, general manufacturing,
machine shops, stone cutting, wood, and
heavy industry.
CNC Machine Tools Ltd can provide the
following support for small, medium, and
high-capacity facilities:
 One-off servicing and service contracts. Tormach’s new corporate headquarters facility in Madison, Wisconsin, includes more warehouse space to
 Emergency repair and breakdown. expand its machine assembly services and better serve customers. (Courtesy: Tormach Inc.)
 Embedded total maintenance cover.
 Supplementary maintenance cover.
 Machine relocation.
neered products, technical support, and cus-
tomer service at lowest possible costs to help
Solar Atmospheres
 Machine refurbishment. customers realize goals in CNC by providing adds furnace to reclaim
 Machine guarding.
 PUWER assessments and remedial work.
tools and resources to help transform con-
cepts into real products. titanium and tantalum
 Parts supply. Solar Atmospheres Souderton, Pennsylvania,
 Ballbar checks and thermology. MORE INFO www.tormach.com facility commissioned a new high-produc-
Tormach Inc. provides exceptionally engi- www.cncmachinetools.co.uk tion vacuum furnace, doubling hydriding

Gearbox & Driveline

Design, Analysis &
Optimisation
MASTA enables engineers to design robust,
eecient, light weight and quiet transmissions
from concept design, all the way through to
manufacture.
Run and generate reports on a wide variety
of analyses including NVH, system deeection,
durability, FE & more.
Visit smartmt.com/masta to learn more.

Visit smartmt.com/free-evaluation to request

a FREE evaluation of MASTA for up to 3 months.

10     gearsolutions.com
The vacuum furnace installation incorporates Solar Manufacturing’s latest and most advanced vacuum furnace
technology, aimed at safety and efficiency. (Courtesy: Solar Atmospheres)

and de-hydriding capacity in the reclama- none. Wendy is in constant pursuit to help
tion process of high-value titanium and tan- those in need and less fortunate. Over the
talum materials. years I have personally observed Wendy’s
For decades, Solar Atmospheres has been business acumen at work as she has led a
a globally-recognized leader and innovator world-class, precision gear manufacturing
in the process of reclaiming titanium and company through
tantalum materials through vacuum heat- many difficult peri-
treatment solutions. ods. Wendy often
The installation incorporates Solar is found mentor-
Manufacturing’s latest and most advanced ing and assisting
vacuum furnace technology, aimed at safety associates through
and efficiency. The qualified working zone hardships they were
is 48” x 48” x 72” with a weight capacity of experiencing that
up to 7,500 pounds per batch. were totally unre-
Wendy Young lated to work and
MORE INFO www.solaratm.com business. Wendy’s
spirit, drive, and compassion for excellence
have been instilled in her family and felt and
Forest City Gear CEO noticed by those who know her.”
Forest City Gear is an industry-leading
recognized by Rockford manufacturer of fine and medium pitch

Chamber of Commerce custom gears.

Forest City Gear president and CEO Wendy MORE INFO www.forestcitygear.com
Young was named the 2021 Individual
Business Catalyst of the Year by the Rockford
Chamber of Commerce.
Young began her career at Forest City
Motion completes
Gear in 1983 as a delivery driver, machine acquisition of Kaman
operator and expediter. Young has been
part of Forest City Gear’s leadership team
Distribution Group
for more than 20 years, during which time Motion Industries, Inc. has completed the
she has helped drive significant growth and purchase of Kaman Distribution Group
expansion. Young has been president since (“KDG”) for a purchase price of approxi-
2002 and CEO since 2015. mately $1.3 billion in cash, effective January
According to the Rockford Chamber 3, 2022.
of Commerce, Young’s nominator said, Motion Industries Inc. is a leading distrib-
“Wendy’s energy and dedication to her fam- utor of maintenance, repair, and operation
ily, business, and community are second to replacement parts, and a premier provider
February 2022     11
INDUSTRY
NEWS

of industrial technology solutions. fluid power components to MRO and OEM principles, and ambitions, including our
The strategic addition of KDG to Motion customers. Headquartered in Bloomfield, commitment to providing superior service
will significantly boost the latter’s concentra- Connecticut, KDG’s 1,700 employees serve and value to our customers. We look forward
tion in core industrial products and services more than 50,000 customers. to welcoming the highly talented KDG asso-
as well as in the growing technical/automa- “It’s a very exciting time; this transfor- ciates to the Motion team.”
tion arenas, including precision engineering. mative move will be highly beneficial to
As a leading power transmission, automa- everyone involved, especially for customers MORE INFO www.motion.com
tion and fluid power industrial distributor of our combined entities,” said Motion presi- ec.kamandirect.com/storeus
and solutions organization with operations dent Randy Breaux. “Our customer service
throughout the U.S., KDG provides electro- will be the best it’s ever been with deepened
mechanical products, bearings, power trans- and expanded capabilities. In addition, KDG Klingelnberg honors
employees for
mission, motion control, and electrical and shares many of our same cultural beliefs,

long-term service
In 2021, the Klingelnberg Group continued
its longstanding tradition of celebrating
work anniversaries by honoring 830 total
years of employee service to the company,
and along with it, their experience, knowl-
edge, loyalty, and trust. This year’s honorees
included three employees with 50 years of
service, 12 employees with 40 years of ser-
vice, and eight employees with 25 years of
service.
“Even though celebrations are still diffi-
cult due to the current situation, we can’t
miss the opportunity to express our heart-
felt thanks to our employees celebrating
their service anniversaries. We are especially
proud that we have three employees celebrat-
ing 50 years of service to the company,” said
Christoph Küster, CFO of the Klingelnberg
Group. “Without our exceptional team, we
would not be what we are today — a lead-
ing manufacturer in gear technology.” The
honorees with 50 years of service include
Christian Neuber (warehouse manager),
Werner Hager (production), and Christel
Thiel (order center).
Neuber began his training as a machin-
ist in 1971. For a long time, he worked as a
machinist in single-part production before
becoming a foreman in the lapping and
testing machines in the early 1990s. Today
he heads the warehouse department. “After
50 years of working here, the company has
become like a home to me. I have always
greatly appreciated the family atmosphere
I enjoy with my colleagues. Work colleagues
have become friends. Even with a workforce
of 750 employees, I know everyone, from the
owner to the crane operator,” said Neuber.
There is family history at Klingelnberg.
Neuber’s father was employed as a pattern
maker at Klingelnberg, his brother was an
electrician at the company, and his mother
worked in the factory canteen. “Because I
grew up in a company-owned housing set-
tlement, rather than having a specific type
12     gearsolutions.com
 Klingelnberg, I always refer to it as ‘our place.’
Thiel is now entering her retirement and Machinists Inc.
looks back with positive feelings. “My time From single
at Klingelnberg was well spent.”
In 2021, Klingelnberg also received an
parts to complete
award in the precision measuring cen- manufacturing
ters segment. The company impressed systems
the jury for the 2021 German Innovation
Awards with its “Done-in-One – Complete MI cuts gears
Measurement in a Single Stage” solution. to 250 inches
The German Innovation Awards honor in diameter and
products and solutions across the industry grinds gears to
Klingelnberg service anniversary honorees, from left, that distinguish themselves from earlier 102 inches in
Christel Thiel, Christian Neuber, Werner Hager, Karin diameter.
solutions primarily by their user centricity
Hager. (Courtesy: ©Klingelnberg)
and added value. The German Innovation
of training in mind, I really just wanted to Awards are granted by the German Design MI provides full
know what it was that Klingelnberg was Council, which was enacted into law by the service gearbox
looking for,” said Neuber. And now the next German Parliament in 1953 and is funded by repair & testing
generation is working for Klingelnberg: his the Federation of German Industries (BDI). for dependable
son and daughter-in-law are also employed overhaul and
by the machine manufacturing firm. MORE INFO www.klingelnberg.com enhancement of
Hager and his wife, Karin Hager, have gear drives.
been with the company for a combined total
of 90 years. Karin Hager has been employed RadTech announces
new, re-elected
at Klingelnberg since 1981 and today works
as a commercial clerk in the standards
department. “For us, working together in
the same company had many advantages,”
board members
she said. Werner Hager began his career at RadTech, the nonprofit for ultraviolet and
Klingelnberg 10 years earlier. After train- electron beam technologies (UV+EB), elected
ing as a toolmaker, he worked as a boring David Walker, president, CTO and co-found-
mill operator and trained as a technician er of Azul 3D, Inc., as a new RadTech board
in the 1980s. Since 1988, Werner Hager has member. In addition, Karl Swanson, presi-
been working in NC programming. “In my dent of PCT Ebeam
50 years with the company, things have and Integration, and
continually evolved,” Werner Hager said. Evan Benbow, vice-
“During my training period in the early president, research
1970s, there were almost exclusively conven- and development,
tional machines. In 1978, I had the oppor- Nazdar Company,
tunity to work on the first CNC-controlled have been elected
boring mill. At that time, data transfer was to second two-year
still done by means of a mechanical punch terms.
tape reader, and tools had to be inserted by David Walker Todd Fayne of
hand. Today, by contrast, we use only auto- PepsiCo rotated off
matic tool changers in mechanical engineer- the board after reaching term limits. Fayne
ing, resulting in less downtime,” he said, also plans to continue as co-chair of the RadTech
noting other advancements. Sustainability Committee.
Thiel began her training as an office clerk RadTech Board members include:
in 1971 and, during her many years of ser-  Susan Bailey, Michelman, president.
vice with the company, she has worked in  Michael Gould, Rahn USA, president
the purchasing, sales and production depart- elect. Call us about
ments. She has been working as a commercial  Eileen Weber, allnex, immediate past
clerk in the order center since 2002. “After president. your project
my training, I was very happy that I found a  Paul Elias, Miwon, treasurer
position in such a great company. By working  Mike Bonner, St. Clair Systems, treasurer. 800 / 244.4130
in the different departments, I always had a  Evan Benbow, Nazdar. www.machinistsinc.com
lot of variety in my professional life. I partic-  Neil Cramer, Sartomer.
ularly appreciate the fact that Klingelnberg  Jonathan Graunke, INX Intl. ISO 9001 certified
has always been a reliable employer — even  Jennifer Heathcote, GEW.
in difficult times. Whenever I speak of  Jeffrey Klang, Sartomer.

February 2022     13
INDUSTRY
NEWS

 Eric Nelson, 3M.

 Helen Rallis, Sun Chemical
stances, enhanced process control, and fast
efficient throughput. UV+EB is used in a
Solar finds impressive
 Jim Raymont, EIT. wide range of applications, including print- results with new
sintering vacuum furnace
 Jake Staples, Wausau Coated Products, ing, packaging, wood and building prod-
Inc. ucts, electronics, and 3D printing/additive
 Karl Swanson, PCT Ebeam and manufacturing. RadTech serves as an inter- Solar Atmospheres of Western PA has found
Integration. national forum and source of information good results with a retrofitted vacuum fur-
 Dan Theiss, Procter & Gamble. for individuals and organizations involved nace for use in a new metal injection mold-
RadTech is a nonprofit trade association in the use of UV+EB or the supply of equip- ing (MIM) and additive manufacturing (AM)
dedicated to the advancement of UV+EB ment, chemicals, or other materials. binder removal technology application.
technologies, providing users with energy In 2021, the company announced the ret-
savings, lower emissions of harmful sub- MORE INFO www.radtech.org rofit of the vacuum furnace. The goal was
to build a vacuum sintering furnace with a
new innovative hot zone and pumping tech-
nology that would minimize and target the
deposit of detrimental binders evaporating
out of MIM and AM parts. The furnace has
now been in production for over a month
and has produced multiple high tempera-
ture sintering cycles and the results are
impressive.

A PERFECT MESH
The hot zone, after repeated 2,400°F
sintering cycles, remains immaculately
clean. The problematic binders coalesced
American ingenuity, service and support teamed exactly where they were targeted to consoli-
with Japanese efficiency, quality and technology. date — within a separate heated pumping
port while keeping the primary pump and
booster uncontaminated. Most importantly,
the customer reported that their sintered
parts processed in this new furnace never
100+ Years of Manufacturing Gear Hobbing Machines
looked better.
8 Models of Machines from 50 to 1000mm The anticipated maintenance savings on
this dedicated furnace versus processing sin-
tering and AM work with binders in a tradi-
tional vacuum furnace will be considerable.
Processing this job in a conventional vacu-
um furnace required a scheduled monthly
shutdown. Solar’s maintenance team had
to extract the hot zone, replace the ceram-
KN 152 CNC ics, clean or replace the power feed through
GEAR HOBBER
KPS 201 GEAR
SKIVING MACHINE
terminals, scrape the cold walls, clean the
diffusion pumps, and scour all the pumping
system pipes. The added labor and material
costs coupled with the lost production time
70+ Years of Manufacturing Gear
Inspection Machines and degradation on the life of the hot zone
cost the company more than $180,000 per
Machine Models to 850 OD Capacity year. The projected maintenance costs on
this newly designed sintering furnace will
be $10,000 per year.
Bob Hill, president of Solar Atmospheres
of Western PA, said, “Knowing the effects of
what MIM and certain AM processing had
CLP-85 DDS
GEAR TESTER done to our equipment in the past, Bill Jones
and the engineers at Solar Manufacturing
GTR 25 DOUBLE developed an innovative solution for us.
FLANK GEAR ROLLER
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14     gearsolutions.com
 American Rebecca
Jenny
AGMA
Blackford
Brinkley
Vice President
Directorof
of
Gear Manufacturers Communications
Member
AGMA
&
Engagement
Communications
Association

Leaders should get away from the office

C
ompany presidents don’t get where they are by staying in
their office all day staring at a computer.
Innovation, research, development, and growth don’t
come from a spreadsheet but instead by working with oth-
ers and listening to new ideas from outside sources.
How does one do this?
We suggest starting at an annual meeting or conference such as
the AGMA/ABMA Annual Meeting.
Harvard Business Review said it clearly:
“When executed well, these meetings are certainly worth the time and added benefit you can share with your team.
expense. They can serve as a powerful catalyst to align leaders, develop solu-
tions to problems, introduce new strategies, and fuel collaboration across the BUILDING UP YOUR TEAM
organization. But many companies squander this rare opportunity to harness Not everyone brings multiple people from their company with them
the collective knowledge of their frontline leaders.” due to expenses but when they do, there are many added benefits.
There are many benefits to taking time away from the daily rou- Most leaders have a VP or director they are grooming or mentoring
tine and getting away from the physical building where you work. for the next level in the company. There is no better way to help build
Here are some great reasons to sign up for a conference or business their confidence and relationships in the industry than by bringing
event today: them to an event where they can meet people in the same space. This
allows you to divide the networking, and it shows your employees
SOLACE IN NUMBERS that you trust them and want them to succeed. It also allows protégés
Chances are someone before you has already gone through what you to build their contact list and meet people they normally wouldn’t
are experiencing. Another company has faced or is currently facing have time for.
the same challenges as you and your team. Hearing from your peers On the back end, when you leave the office, you are showing your
shows you are not alone, and it can lead to solid solutions that make managers you trust them to handle whatever comes their way. It
everyone stronger in the long run. demonstrates to your employees that you have complete faith that
Sitting at a table and talking to one of your competitors might not they will get the work done, and you don’t need to be there watching
seem like a good place to air your dirty laundry, however, the idea their every step. This kind of hands-off leadership allows new leaders
of these conferences isn’t to see your industry get smaller and less to emerge and feel confident back at the factory.
important in the world of manufacturing, it is to come together for
the betterment as a whole. Your competition might just have the solu- TAKE A BREAK
tion you need. Interactions such as these can build lasting relation- Lastly, but probably most importantly, going to an event or confer-
ships among leaders and might even lead to future business ventures. ence is a much needed break from the routine that can set in at the
office. Creative thinking doesn’t happen in a space where you are
EXPERT INSIGHTS seeing the same computer screen every day inside the same four
Another reason you should go to a conference is you are going to walls, sitting in the same old office chair. In fact, for some leaders,
get the latest information available about challenges the industry is that office only means work and stress.
facing. A good event presents attendees with subject matter experts Giving yourself the opportunity to get away from your plant, your
in areas important to members (economic forecasts, workforce chal- company, your home, or even your town and state, can free the mind
lenges, succession planning, R&D, supply chain, and so much more). to look at things with a fresh perspective. It will allow you to take
Access to these experts gives you the chance to ask questions you time for just yourself to think. Today, we don’t have much time to
might never get to otherwise. think about anything, much less anything new and exciting, because
Bringing these experts in house could cost $30,000 (easily) for one we are usually putting out fires and handling what is in front of us.
visit — but with your registration fee, you get access to four or five of Don’t become chained to your desk chair. Don’t get stuck in a
them while still getting the same great information you can bring routine that doesn’t allow for new ideas or innovation. Sign up for a
back to your plant floor or company. It is an investment that will have summit; join a roundtable exercise, or travel for a conference (such
an ROI for years to come. Additionally, many of these conferences or as the AGMA/ABMA Annual Meeting) and see what kind of thinking
events give you presentations that you can reference later. This is an you can really do when you give your mind the time.
February 2022     15
Upcoming Education

Fundamentals of Gear Design and Analysis Detailed Gear Design

January 18-20 | Clearwater Beach, Florida February 22-24
Gain a solid and fundamental understanding of gear geometry, There is a distinct difference between “designing” a gear and “opti-
types and arrangements, and design principles. Starting with mizing” a gear design. In this course, we will address the optimi-
the basic definitions of gears, conjugate motion and the Laws of zation process via an understanding of those factors beyond basic
Gearing, learn the tools needed to understand the inter-relation bending and pitting ratings. Optimization may focus on load capac-
and coordinated motion operating within gear pairs and multi-gear ity, economy of production, or minimization of overall gear system
trains. Basic gear system design process and gear measurement envelope. In this course, we will learn how to improve gear designs
and inspection techniques will also be explained. In addition, the via optimization and gain new insight into concepts presented
fundamentals of understanding the step-wise process of working through illustrations and demonstrations. Explore all factors that
through the iterative design process required to generate a gear go into good gear design from life cycle, load, torque, tooth, optimi-
pair will be reviewed. Learn the steps and issues involved in design zation, and evaluating consequences.
refinement and some manufacturing considerations. An explana-
tion of basic gear measurement techniques, how measurement
equipment and test machines implement these techniques, and Networking
how to interpret the results from these basic measurements will
also be covered. 2022 Fall Technical Meeting Call for Papers
Deadline: January 14
Analytical Gear Chart Interpretation It is required that all drafts of your paper be submitted electroni-
February 10 cally via the online portal as a Microsoft Word document. Read
This course is an introduction to the methodology of analytical gear AGMA’s Guidelines for the Preparation of FTM Technical Papers to
inspection and the evaluation and interpretation of the resulting assist you in the preparation of your paper. Note: Please review the
data. The application of this information to identify and correct guidelines carefully even if you have previously presented an FTM
manufacturing errors will be explored. Additionally, it reviews chart paper, as various items have changed. Take a deep dive into the gear
interpretation and applies inspection data to understand the causes industry at AGMA’s Fall Technical Meeting (FTM). This meeting brings
and cures of manufacturing errors. Many chart examples are used together top researchers from across the globe who will provide the
to understand cause and effect. latest information on their peer-reviewed gear industry research.

American
Gear Manufacturers
Association
16     gearsolutions.com
Network with the industry experts, academics, and engineers; ask SPEAKERS
your burning questions; and see what is in the future of this industry.  Ken Gronbach: Demographer, futurist, and author, KGC Direct.
 Jim Meil: Principal industry analyst and economist for ACT
AGMA/ABMAAnnualMeetingSpeakersAnnounced Research Co.
2022 AGMA/ABMA Annual Meeting  Afshin Molavi: Director, emerge85 Lab, Johns Hopkins University
March 31 – April 2 | Palm Beach Gardens, Florida School of Advanced International Studies.
The exclusive, members-only meeting is back in person with an  Erica Orange: Executive vice president & chief operating officer,
unparalleled lineup. From supply chain management to economic The Future Hunters.
forecasts, this year’s meeting will host some of the greatest experts  Zal Phiroz, Ph.D.: Business & supply chain expert, InsightEconomics.
in the industry to speak directly to the gear and bearing leaders.  Joe Theismann: Entrepreneur, former quarterback, Washington
There will even be a curated roundtable workshop for a hands-on Redskins, ESPN & NFL network analyst.
experience that will leave you with great ideas to bring back for
your strategic plan. Register today: www.agma.org/events/agma-abma-annual-meeting

Ken Gronbach Jim Meil Afshin Molavi Erica Orange Zal Phiroz Joe Theismann

AGMA has over 1,000 Twitter followers! Join the conversation @agma

1001 N. Fairfax Street | Suite 500 | Alexandria, VA 22314 | (703) 684-0211 | www.agma.org
February 2022     17
 CALENDAR OF EVENTS
Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard
in the standards process, AGMA has something to offer you. If you would like more information on any of the
following events, visit www.agma.org or send an email to [email protected].
FEBRUARY

February 22-24 — Detailed Gear Design — WebEx

February 23 — Aerospace Committee Meeting — WebEx
February 24 — Metals and Metallurgy Committee Meeting — WebEx

March 1 — Gear Accuracy Committee Meeting — WebEx

March 2 — Lubrication Committee Meeting — WebEx
March 3 — Nomenclature Committee Meeting — WebEx
MARCH

March 1-3 — Detailed Gear Design — Online

March 9-10 — Integration and Trade-offs in Gear and Bearing Systems — Virtual Course
March 22-24 — Gearbox CSI — Concordville, Pennsylvania
March 31-April 2 — AGMA/ABMA Annual Meeting — Palm Beach Gardens, Florida
APRIL

April 4-8 — Basic Training for Gear Manufacturing — Chicago, Illinois

April 14 — Gear Accuracy Committee Meeting — WebEx
C

CM

MY

CY

CMY

AGMA LEADERSHIP K

Greg Schulte: Chairman Craig Burriss: Industrial Gear Group

EXECUTIVE COMMITTEE

Bonfiglioli USA
Michael Cinquemani: Treasurer Zen Cichon: Innovative Rack & Gear Company
Master Power Transmission Brian Coclich: CGI, Inc.
BOARD OF DIRECTORS

Michael McKernin: Chairman, BMEC

Milans Machining and Gear Manufacturing Greg Estell: The Estell Group LLC
Todd Praneis: Chairman, TDEC Adam Gimpert: Helios Gear Products
Cotta Transmission Company, LLC
John Cross: Chairman Emeritus Mushtaq Jamal: Bevel Gears India, Pvt, Ltd.
ASI Drives
Ruth Johnston: Croix Gear & Machining
Scott Miller: Caterpillar, Inc.
Matt Croson: President
Eric Van Rens: Schafer Industries
Amir Aboutaleb: VP, Technical Division
STAFF

Jenny Blackford: VP, Marketing Robert Rye: Cincinnati Gear Co.

Randy Stott: VP, AGMA Media Sara Zimmerman: Sumitomo Drive Technologies
General requests: [email protected] | Membership questions: [email protected] | AGMA Foundation: [email protected]
Technical/Standards information: [email protected] | MPT Expo information: [email protected]
18     gearsolutions.com
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© 2020 Forest City Gear. All Rights Reserved

February 2022     19
 MATERIALS DR. WILLIAM MARK MCVEA, P.E.

MATTER PRESIDENT AND PRINCIPAL ENGINEER  KBE+

Worm gearing twists its way into our design suite

Time-tested, versatile setup offers many of contact, there are five active profile designations typically used
worldwide. They are classified as ZA, ZK, ZC, ZN, and ZI. The vari-
options, can deliver big impact in tight spaces. ous profiles are a function of both design application and manufac-
turing. The tooth form in part defines the interaction between the

W orm gearing has many benefits and usable attributes that are
unique to this geometry. Gearing of this type dates to 4000 B.C.
The “worm” as a form first appeared as a screw thread and was devel-
teeth. It is generally accepted that one would not mix any of the ‘Z’
designates with any other.
ZA: Worm gear with straight-line (trapezoidal) tooth profile in axial
oped by Archimedes as a means to move water, a water pump, up section. The tooth sides are slightly convex in the normal section; the
a sluice. At this point the worm was not interacting with a wheel, cross-section results in the spiral of Archimedes. The elements in the
there was no mesh, but the concept of sliding
interaction was employed. The geometry pro-
gressed into a screw thread used to convert
rotatory motion, the turning of the screw,
into linear motion, the action of the collar.
This conversion of motion is still very
commonly used today and we know it as
a nut and bolt. However, we need a system
that, instead of converting rotary to linear
motion, couples input rotary motion to rota-
ry motion. In our case, we can use the gear
geometry to turn the power flow through a
right angle (or other angle but we will focus
on right angle for the time being).
There are a number of configurations
with various names (Figure 1). The general
term used is Globoidal Gears. Each configu-
ration trades power density with wear rate.
Worm gearing is a special case of screw gear-
ing with the angle of axes 90° and a low num-
ber of pinion/worm teeth (mostly z1=1-4).
There is a fourth tooth form configura-
tion but it is rarely, if ever, used. One could
consider it the first step toward the Double
Enveloping or Full Globoidal Gear form, sim-
ply labeled as Globoid Worm / Cylindrical
Wheel (Figure 2). Note the straight wheel (no
curvature). This adaptation does not provide
much in the way of additional contact area,
as such it is seldom used (if at all any more).
Worm gearing types are distinguished by Figure 1: Configurations and nomenclature.
shape and labeled and described as follows:
 Straight or Cross-Axis Helical or Cylindrical Wheel / Cylindrical Worm: axial section are usually standardized (i.e. mx=m, ax=a). The gearing is
Kinematical, non-power transmissions, low torque, manual drive, produced using lathes or thread-cutting machines (the worm resembles
adjusting mechanisms, point contact of teeth, low cost. a motion screw with trapezoidal threads). A tool shaped as the basic
 Cylindrical Worm / Globoid Wheel: Most frequent for power trans- profile is applied onto the workpiece in the axial plane. With larger g
missions, compact design, divided by cylindrical worm shape. angles, different cutting angles occur in the forming tool on the lateral
 Globoid Worm / Cylindrical Wheel: Generally, not used. edges, which results in unequal cutting-edge loading and blunting. The
 Globoid Wheel and Worm: High outputs, compact design, special lateral worm areas can only be sharpened using a special form grind-
production, highest quality, generally the highest cost. ing wheel. Therefore, spiral gearing is used in worms with a low pitch
We further subdivide the geometry of worm and wheel gear- angle (g<10°) in those cases when tooth sides are not treated thermally
ing by classifying the tooth form. We use a two-letter designator to and do not require regrinding.
define tooth form geometry. In addition to the various designations ZN: Worm with a straight-line tooth profile in normal tooth sec-

20     gearsolutions.com
tion, namely; In terms of the working contact patch
 a) On the mean helix of space. and service life, worm gearing does not share
 b) On the mean helix of tooth. the contact parameters that parallel axis
In the axial section, tooth sides are slightly involute-based gearing does. Parallel axis
convex and the cross-section results in a gen- gearing based on the involute tooth profile
eral evolvent curve (in an extended or short- runs through a point during the engage-
ened evolvent). The elements in the normal ment mesh where the two teeth exhibit no
plane are standardized, (i.e. mn=m, an=a). sliding, only rolling action. We define this
The gearing is worked in case with one and contact point or rotational relationship as
in case and with two forming in the normal the pitch point. Worm gears have no point
plane. The cutting angles are identical with of pure rolling during their mesh engage-
great angles g. Thermally treated sides can be ment. Thus, all contact action is sliding.
ground using a grinding wheel with straight- Interestingly enough, the predicted service
line bevel areas on thread grinding machines. life of a worm gear set is based largely on
This grinding process results in non-straight- the wear rate as a function of the amount
line lateral areas which, however, rather of material that can be sacrificed, the thick-
approximate the theoretical ones. If also the ness of the tooth. Since predicted service
screw milling cutter used to produce worm life is based on wear rate and lubrication,
Figure 2.
gear toothing is subject to this grinding pro- and since the output wheel typically rotates
cess, the worm and the worm gear create a slowly, traditional elastohydrodynamic
theoretically proper pair. The common gear- Worm gearing is most lubricant development is difficult to develop
ing is also suitable for worms with greater
angles g and for worms with thermally treat- commonly used for high or maintain. Thus, we usually rely on grease
or a more adhesive lubricant and lubrication
ed tooth sides that require regrinding.
ZI: Worm with an evolvent profile (a
ratio reduction and system to keep the gear teeth from touching.
We also employ subtle geometric features of
straight-line tooth profile in a plane tangen-
tial to the main cylinder). The tooth sides are
increased precision the tooth face, generally called a lubrication
entry gap. The concept is to promote devel-
convex in both the centerline and normal positioning. Precision opment of a wedge of lubricant to be drawn
sections and the cross-section results in an
evolvent. The elements in the normal plane in position is gained by into the mesh. The geometric details of the
entry gap are a function of the gear materi-
are standardized (i.e. mn=m, an=a). The gear-
ing is worked using two tools applied onto
high ratio reduction. als, lubrication, and interfacial speed.
Geometry also plays a role in the mesh
the workpiece. The tool cutting edge lies in efficiency. With the worm driving the
the tangent direction toward the helix on the wheel, the mesh efficiency is on the order
main cylinder. The evolvent gearing is used of 60 percent to 80 percent. However, if the
in worms with a higher number of teeth wheel drives the worm, the efficiency is
(e.g. z1 > 4); the worm resembles a cylindri- generally less than 10 percent. From this,
cal gear with helical teeth. Tooth sides can we tend to call worm and wheel gearing as
be ground with the flat side of the grinding non-backdrivable. It is not, but with these
wheel. Special grinding machines must be low efficiencies it is unlikely under typical
used given the relatively small angle g. circumstances that the wheel will effectively
ZK: Profile formed by a cone ground using a wheel and / or shank drive the worm. If, on the other hand, the gear mesh is exposed to an
tool. external vibration source, the wheel driving worm efficiency may
ZH: Concave tooth profile (highest accuracy / precision and most climb as high as 40 percent, which invalidates the concept of non-
expensive). back-drivability.
Worm gearing is most commonly used for high ratio reduction By way of references, I would like to thank William P. Crosher
and increased precision positioning. Precision in position is gained and Illes Dudas for the excellent materials and texts on the subject.
by high ratio reduction. As the ratio increases, the output slows rela- As always, I would like to thank my friends at AGMA for all their
tive to the input, the reduction in backlash is similar to the ratio support, guidance, and the knowledge they shared over the years.
changes. Using worm and wheel designs, as an example, a simple Finally, my mentor — and in my opinion the best source of practical
drive with less than precise rotational position control will experi- knowledge and one of the most patient people I have come across in
ence a significant increase in positional accuracy. my quest to figure all this out — Miroslav Petele, Ing.

ABOUT THE AUTHOR

Dr. William Mark McVea, P.E., is President and Principal Engineer of KBE+, Inc. which develops complete powertrains for automotive and off-
highway vehicles. He is the Principal Engineer with Kinatech, a joint venture with Gear Motions / Nixon Gear. He has published extensively and
holds or is listed as co-inventor on numerous patents related to mechanical power transmissions. Mark, a licensed Professional Engineer, has a B.S.
in Mechanical Engineering from the Rochester Institute of Technology, a Ph.D. in Design Engineering from Purdue University.

February 2022     21
 TOOTH BRIAN DENGEL

TIPS GENER AL MANAGER  KHK-USA

Do opposites really attract?

When choosing a gear, it is important
to understand which gear it mates with.

W ith Valentine’s Day this month, it is time to celebrate with your

partner. Whether you are on your first date with a longtime
crush, or on a casual date with someone you have been communicat-
ing with via the latest app, or you are just enjoying a date night with
your longtime love, we all look forward to spending time with that
unique individual who complements us and who we can refer to as Figure 1.
our better half. Just like us, gears work best
when they are properly matched.
Spur gears are the most common form of
gearing. They match well with either other
spur gears or with gear racks. In order for
them to mesh properly, there are several cri-
teria that need to be met. The most impor-
tant is that the gears are the same pitch.
Whether it be module, circular pitch or
diametral pitch, both gears must be of the
same type and value. In addition to having
the same pitch, the gears must also have the
same pressure angle. If the pressure angles
are different but the pitch is the same, the
gears will not mesh properly. A final con-
sideration for good mesh is the face width.
Although not a firm requirement, it is rec-
ommended that the face width of both gears
be the same, as this will allow for the maxi-
mum contact ratio. If one of the gears has a
face width larger than the other, the gear
with the larger face width is likely to suffer
from premature wear failure.
Helical racks and gears require additional
considerations in order to mesh. Like spur
gears, the pitch and the pressure angles must
be the same, and ideally the face widths
should be equal. However, the helix angles
of the gears need to be considered. In order
for a helical gear to mesh with a helical rack,
they both must have the same helix angle
but the direct of the helix must be opposite.
A right-hand helix pinion will not mesh with
a right-hand helix rack. It will only mate
Table 1: Calculations for a pair of straight miter gears in the Gleason system.
with a left-hand helix rack and vice-versa,
as noted in Figure 1.
Screw gears are a unique subset of helical gears. They have a helix application, then the direction of the helix needs to be the same — for
angle of 45 degrees. For these gears, they need to have the same pitch example, a right-hand driver and a right-hand driven.
and pressure angle, but the direction of helix angle is dependent on For intersecting axes, the most common style of gear is the bevel
the application. If they are to be used in a parallel shaft application, gear. The term bevel gear is used to describe both a specific type of
then the helix direction needs to be opposite — for example, a left- gear and any of a variety of derivatives of this style.
hand driver and a right-hand driven. If they are used in a crossed axis Bevel gears are a very common form of intersecting axis gear-
22     gearsolutions.com
 calculated for a Module 3, 20 tooth pinion
that mates at 90 degrees with another 20
tooth pinion.
In Table 2, the same dimensions, cone
angle, tip angle, and root angle are calcu-
lated, except for a Module 3, 20 tooth pinion
that mates at 90 degrees with a 40 tooth gear.
From these calculations, you can see that
the tooth form of a 20 tooth miter gear dif-
fers greatly from the that of a 20 tooth bevel
pinon and that the cone angle is extremely
important when selecting bevel gears to
mate.
Spiral bevel gears and spiral miter gears
introduce additional criteria to consider
in order to mesh properly. These gears not
only need to have the same pitch, pressure
and the proper cone angle, they also have
to have the same spiral angle and be oppo-
site in hand. When selecting the proper
direction of spiral, it is important to con-
sider the direction of rotation of the input
as this will change the direction of thrust
loading on the bevel pair. If the system is
bi-directional, then this consideration can
be ignored.
Worm gear pairs are another style of
intersecting axes gearing. They consist of
a worm wheel which resembles a helical
gear and its mate, the worm, which resem-
bles a screw. For these gear pairs, the pitch
and the pressure angle must be the same.
For a worm pair, the helix angle is called the
Table 2: Calculations for a pair of straight bevel gears in the Gleason system.
lead angle and similar to helical gears, each
part of a worm pair must have the same
For all gear styles, it is required value. Similar to screw gears, worm pairs must have the same lead
angle direction in order to operate as intersecting gears. The one
that both gears have the same pitch additional factor that needs to match with worm gear pairs is the
number of starts. This value is the number of unique threads that
and pressure angle. For some gear are produced on the worm. It is vital in determining the speed

styles, they must be opposite in ratio of the pair.

For example, if a 30 tooth worm wheel is designed to mate with a
hand in order to mesh, yet other single start worm, the pair will have a speed ratio of 30:1. However,
if the same gear pair is designed such that the 30 tooth worm wheel
styles require that they be the same mates with a double start worm, then the speed ratio is 30:2 or
15:1. If all of the geometry of two worm gear pairs is identical, but
hand in order to mesh. the number of starts changes, the lead angle will also change. For
this reason, you cannot simply replace a single start worm with a
double start worm to change the speed ratio. If you try to do this,
ing. When trying to mesh bevel gears, the pitch and pressure angle then the difference in lead angles will cause an offset to the shaft
must be the same. The differentiators for whether bevel gears will alignments.
mesh is the pitch cone angle and the shaft angle. When the ratio For all gear styles, it is required that both gears have the same
of a bevel gear set is 1:1, and the shaft is set to 90 degrees, then pitch and pressure angle. For some gear styles, they must be opposite
the pitch angle of each gear will be 45 degrees. If the same gear is in hand in order to mesh, yet other styles require that they be the
produced for a different speed ratio then the pitch angle will vary. same hand in order to mesh. Like each of us, gears have a suitable
In Table 1, the values for cone angle, tip angle, and root angle are mate waiting for them, we just have to find it.

ABOUT THE AUTHOR Brian Dengel is general manager of KHK-USA, which is based in Mineola, New York. Go online to www.khkgears.us

February 2022     23
 HOT D. SCOTT MACKENZIE, PH.D., FASM

SEAT
SENIOR RESEARCH SCIENTIST–METALLURGY 
QUAKER HOUGHTON INC.

Selecting a cleaner for prewashing prior to heat treatment

A number of factors must be considered
to ensure that soils from previous operations
don’t prevent parts from being carburized
successfully.

I n this column, we will discuss the selection of a cleaner for pre-

washing prior to carburizing. The choice is critical to avoid forming
a stop-off that prevents proper carbon penetration and removes the
various soils from operations prior to heat treatment.
Cleaning is the removal of dirt and soil from a surface. A cleaner
is a formulated chemical system or product dispersed in water,
which removes unwanted dirt, soil, grease, and other similar mat-
ter from a surface. In general, surface residues are classified as either inorganic or
Cleaners are used in nearly all industrial plants where metal- organic. This does not include particulate or fines that can be dis-
working operations are found. Almost all soils need to be removed lodged by agitation. Typical organics that are found in either prior
to some extent. Thus, if a plant uses coolants, drawing compounds, operations or in cleaners include silicates, sulfonates, phosphates,
rust preventatives, or heat-treating oils, then the plant will likely carbonates, borates, and chlorides. Sodium or potassium in any form
have a strong requirement for cleaning. is also found. These inorganic compounds burn onto the part and
To establish quality cleaning of parts, all process variables should possibly attack the surface at austenitizing temperatures. They do
be considered. This includes previous process and soils from previous not burn off. Organic residues, such as oils or amines, will burn off
processes. The subsequent process should also be considered, as the at the austenitizing temperatures. They can, however, leave a gummy
residues and soils from the previous operation may not be tolerable. carbonaceous deposit on the part.
The washer capability should be understood in terms of the types of Rinsing the part after cleaning is necessary to remove any soil
soils it can remove. The existing water quality should be considered, and residual cleaner film.
including whether water treatment should be considered (excessive The diffusion of carbon into the surface of the part can be blocked
water hardness). The biostability of the cleaner should be reviewed if residues are present on the part during carburizing. It is the goal
to avoid the growth of bacteria and fungus, and to avoid the use of of the cleaner to remove these residues so that proper carburizing
biocides and fungicides. The part orientation should also be consid- can occur. Failure to remove these residues, whether from the prior
ered. The part orientation evaluation should include examination machining operations or residues of the cleaner, will result in soft
of nesting of parts, and the orientation of the spray nozzles with spots in the carburized case, or non-uniform carburizing. In some
relationship to the parts. Finally, the capacity of the washer should cases, the diffusion of carbon is completely blocked, with the residues
be taken into account. The washer should have adequate skimmers to acting as a carburizing “stop-off.”
remove the soils and not be overloaded with soils. If the washer is too
small, it will not clean the soils from the part. The washer should be CLEANER SELECTION
sized appropriately for the number of parts to be processed between There are eight criteria for selecting the proper cleaner. These will
the dump intervals. be discussed individually.
The soil is an important factor in determining the type of cleaner  Product form. It is generally recommended that the product form
to be used as well as conditions for cleaning. For carburized gears, the for cleaners be a liquid. The first reason is that it is easier to add to the
most common soils are machining coolants. Neat oils, soluble oils, washer. Concentration can be easily controlled using a small pump
synthetic and emulsion cutting fluids are readily removable with and a Dosatron™. Powders require operator handling, with the poten-
synthetic and alkaline cleaners. The presence of sulfur and chlorine tial for inhalation of the powders. It is also much easier to overcharge
components may make the soil more difficult to remove with alka- a system with powders, resulting in a high concentration. The high
line cleaners and solvents or emulsions are sometimes necessary. The concentration could lead to elevated pH, and increased soap residues
presence of fatty acids in the cutting fluids promotes better cleaning on the part.
through reaction with the alkaline cleaner.  Alkaline with pH < 10.5. Often, parts are handled or examined
Machining debris is typically made up of large fines and chips after washing, or during the washing process. To minimize risk to
mixed with grit and machining swarf. This type of debris is readily operators, the pH of the washer solution should be below 10.5. The
dislodged from parts using either spray or soaking. Agitation during neat cleaner solution will run higher. However, it really should not
the soak helps remove the debris. be higher than 11 to prevent possible operator injury during transfer
24     gearsolutions.com
 of the cleaner to the washer. As with any chemical solution, proper  Residues. The cleaner should not leave a residue on the part. If
personal protective equipment should be worn. a residue is present, it should be rinsed. Rinsing parts after washing
 Low foaming. The foaming potential of the cleaner should be low. is always recommended practice. When washing dishes, the soap is
This prevents foam from overflowing the washer and potentially spill- always rinsed thoroughly, so as not to leave a soap residue. Otherwise,
ing over to the floor. This is a potential slip and fall hazard, as well as you would taste the soap during dinner. In the same fashion, parts
providing poor cleaning during the wash cycle. should be thoroughly rinsed so that any residue is removed from the
 Rust inhibition. The cleaner should incorporate adequate rust parts. Failure to do so can result in caustic burn, staining, or non-
inhibitors to protect the parts being washed, but also the washer. uniform carburizing. Silicates, chromates, barium, sodium hydroxide,
The cleaner should not stain or attack the parts or the washer. Rust potassium hydroxide, and borates can all leave residues on parts that
inhibitors are amine type and protect ferrous and non-ferrous mate- can act as a “stop-off” and prevent uniform carburizing. Silicate and
rials. A combination of different amines may be present to provide borate residues can form a low temperature glass that reacts with the
adequate protection. surface scale and create a very adherent layer than prevents carbon
 Operator acceptance. The washer operator must be considered in diffusion. Hydroxides can create thick oxide at the surface that can
the selection of a cleaner. The washer shouldn’t emit strong unpleas- impede carbon diffusion.
ant odors or go rancid. The biostability of the cleaner should be con-
sidered to avoid the use of dangerous biocides. The operator is the CONCLUSION
one who is responsible for the process — proper selection of a cleaner In this short article, the types of soils present prior to heat treat-
should make their job as easy as possible. ment are discussed. The reasons for removing these soils to prevent
 Hazardous materials. EPA and individual plant restrictions for staining and carbon “stop-off” during carburizing and non-uniform
hazardous chemicals shall be followed. This means getting approval carburizing were presented. Finally, a series of selection criteria for
by the Environmental Health and Safety person (or committee) for a pre-heat treatment cleaner was provided.
any cleaner brought into a plant. In general, these cleaners should As always, should you have any comments of this or any other
not contain any phenols, phosphates, nitrites, or chlorinated solvents; column, please contact the writer, or the editor. I welcome any topic
however, individual plants may vary on allowed chemicals. suggestions for new articles.

ABOUT THE AUTHOR D. Scott MacKenzie, Ph.D., FASM, is senior research scientist-metallurgy at Quaker Houghton. He is the past president
of IFHTSE, and a member of the executive council of IFHTSE. For more information, go to www.houghtonintl.com.

RHH, Inc.
Quality since 1915

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February 2022     25

GearSol_KISSsoft_Release2021_92_25x123_83mm.indd 1 26.05.2021 14:01:07

ISSUE GEAR DESIGN / GEAR INSPECTION
FOCUS

INTEGRATED
OPTIMIZATION OF
GEAR DESIGN AND
MANUFACTURING

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria,
Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear
Manufacturers Association. (AGMA) This paper was presented November 2021 at the AGMA Fall Technical Meeting. 21FTM13

26     gearsolutions.com
The integration, optimization, design, and
manufacturing of gears using state-of-the-art
software allows cutting tools to be harmonized.
By MASSIMILIANO TURCI

T
he word “optimization” is becoming fashionable, niques adopted in different companies, the focus of
also with regard to gear design. It is applied to the article shifts to some business scenarios where
both macro-geometry and micro-geometry. The manufacturing has been equipped with a software for
approach can be of various types: analytical pre- a semi-automatic selection of hobbing- and pinion-type
optimization with different objectives, bulk genera- tools starting from the macro-geometry of the gear.
tion of variants, multi-objective and multi-disciplinary In particular, it will look at the case where a paper
commercial optimizers, generative optimization, and database of more than 10,000 hobs, with different
even artificial intelligence. Sometimes, the best solu- dimensioning modes, has requested to be harmonized
tion is presented directly; other times, the choice is into a single computer database. The software allows
left to the user according to multiple criteria. However, the search for a hob even with “modified rolling,” a
these are all scenarios that assume the manufacturer method very widespread in the automotive industry,
will accept any geometry indicated by the designer. practically “unknown” for industrial gearboxes.
This is certainly not the case with the industrial gear- Finally, for companies that have both design and
boxes on catalog for which standard cutting tools manufacturing departments, a design optimization
are used to reduce cost and keep available the inter- with a list of cutting tools as a main boundary will
change of suppliers, nor with special gearboxes, “goods be presented.
to order,” in which the producers try to use cutting
tools already in the tool room. Even in the automotive 1 INTRODUCTION
industry, manufacturers try to use existing cutting The key issues of this article are design and manu-
tools as much as possible, at least during prototyping facturing. So, our starting point will be the opening
and for small batches. words of two classic university books focusing on these
After presenting some design optimization tech- issues:

Number Title
ISO 6336-1:2019 Calculation of load capacity of spur and helical gears – Part 1: Basic principles, introduction and
general influence factors
ISO 6336-2:2019 Calculation of load capacity of spur and helical gears – Part 2: Calculation of surface durability
(pitting)
ISO 6336-3:2019 Calculation of load capacity of spur and helical gears – Part 3: Calculation of tooth bending
strength
ISO/TS 6336-4:2019 Calculation of load capacity of spur and helical gears – Part 4: Calculation of tooth flank fracture
load capacity
ISO 6336-5:2016 Calculation of load capacity of spur and helical gears – Part 5: Strength and quality of materials
ISO 6336-6:2019 Calculation of load capacity of spur and helical gears – Part 6: Calculation of service life under
variable load
ISO/TS 6336-20:2017 Calculation of load capacity of spur and helical gears – Part 20: Calculation of scuffing load
capacity (also applicable to bevel and hypoid gears) – Flash temperature method
ISO/TS 6336-21:2017 Calculation of load capacity of spur and helical gears – Part 21: Calculation of scuffing load
capacity (also applicable to bevel and hypoid gears) – Integral temperature method
ISO/TS 6336-22:2018 Calculation of load capacity of spur and helical gears – Part 22: Calculation of micropitting
load capacity
ISO/TR 6336-31:2018 Calculation of load capacity of spur and helical gears – Part 31: Calculation examples of
micropitting load capacity
ISO/TR 6336-30:2017 Calculation of load capacity of spur and helical gears – Part 30: Calculation examples for the
application of ISO 6336 parts 1,2,3,5
Table 1: ISO standards, technical specifications, and technical reports for cylindrical gear design.

February 2022     27
Number Title
ANSI/AGMA 2001-D04 Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth
ANSI/AGMA 2101-D04 Fundamental Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth (Metric Edition)
ANSI/AGMA 6014-B15 Gear Power Rating for Cylindrical Shell and Trunnion Supported Equipment
ANSI/AGMA 6015-A13 Power Rating of Single and Double Helical Gearing for Rolling Mill Service
ANSI/AGMA 6032-B13 Standard for Marine Gear Units: Rating and Application for Spur and Helical Gear Teeth
ANSI/AGMA 6035-A02 Design, Rating and Application of Industrial Globoidal Wormgearing
ANSI/AGMA 6114-B15 Gear Power Rating for Cylindrical Shell and Trunnion Supported Equipment (Metric Edition)
ANSI/AGMA 6115-A13 Power Rating of Single and Double Helical Gearing for Rolling Mill Service – Metric Edition
ANSI/AGMA 6132-B13 Standard for Marine Gear Units: Rating and Application for Spur and Helical Gear Teeth (Metric Edition)
ANSI/AGMA 6135-A02 Design, Rating and Application of Industrial Globoidal Wormgearing (Metric Edition)
AGMA 932-A05 Rating the Pitting Resistance and Bending Strength of Hypoid Gears
Table 2: AGMA standards for cylindrical gear design.

 “The main task of engineers is to apply

their scientific and engineering knowledge
to the solution of technical problems, and
then to optimize those solutions within the
requirements and constraints set by material,
technological, economic, legal, environmen-
tal and human-related considerations.” [1]
 “Machine tools are used for the purpose
of manufacturing parts, which meet design
requirements concerning shape, size toler-
ance, and surface characteristics from both
a technical and economic viewpoint.” [2]
It is clear how the three requisites — mate-
rial, technological, and economic — listed in
the work focusing on design are linked to
manufacturing, and, reciprocally, manufac-
turing refers to design requirements.
The need for increasing integration of
these two phases is also pursued by CAD/
CAM system developers to the extent
that books such as “Integrated Design-to-
Manufacturing Solutions: Lower Costs and
Improve Quality” [3] are distributed online
by these types of companies.
Moreover, the term “optimization” is
becoming increasingly popular, especially
in papers presented at various conferences,
such as AGMA’s Fall Technical Meeting.
So, firstly, we have to focus individually
on the four terms found in the title of this
article (integration, optimization, design,
and manufacturing), clearly restricting our-
selves to the field of gears. We will look at
them in “chronological” order:
 Firstly design, because man is above all
homo sapiens, a thinker, able to plan and
project.
 Followed by manufacturing, in other
words, the ability to construct, which is a
hallmark of homo faber, a Latin expression
that became popular once more during the
Renaissance.
 Lastly, optimization and integration, Figure 1: “Historical” manual calculation sheet.

28     gearsolutions.com
 which are new words.
We will limit ourselves to cylindrical
gears, which are the most common. We
will put to one side wormgears, which I
have already covered in other publications
[4] [5], and bevel gears, which are highly
branded [6].

2 DESIGN
Generally speaking, gear design is lifetime-
based: The aim is to transmit a specific load
for a set period of time. The ways in which
tooth failure occurs are taken into account
in order to satisfy this requisite.
Recent updating of document numbers
ISO 6336 allows for an easy overview of the
main ones (bending, pitting, micropitting,
scuffing, TFF) and stresses the importance
Figure 2: Example of modern software for gear calculation. of focus on the type of failure in order to
achieve correct sizing.
The terms used in the title of the standards (Table 1 and Table 2)
play on the nuances that can be given to design goals: calculation or
rating, strength, load capacity, durability, resistance.
From a historical viewpoint, the geometrical principles of tooth-
ing were established first of all, especially involute toothing, and
then rating criteria, above all for bending and surface fatigue [7, 8].
The formulas contained in the various standards and bibliographi-
cal references were then implemented in manual calculation sheets
(Figure 1) and subsequently in electronic spreadsheets and software
(Figure 2) to simplify the work of designers.
Figure 3: Gear data in the drawing. One of the first areas of focus in all publications dating from the

Figure 4: Different hobs with the same module and pressure angle of gear in the previous figure.

February 2022     29
last century was the definition of the pro-
portions to be given to gears following the
rules cited at the beginning of this article, in
other words “within the requirements and
constraints set by material, technological,
economic considerations.” Here are just a
few examples:
 Dudley, in his book unmistakably
titled “Practical Gear Design,” later re-titled
“Handbook of Practical Gear Design” [9].
 Niemann [10] with his formulas to split
the transmission ratios of a parallel-axis
reducer so as to minimize the costs of gear
materials and housing (a concept further
developed by Schlecht [11] at a later date).
 Severin [12] with his translation of the
Russian work titled “Increasing the load on
gearing and decreasing its weight.”
From a standardization viewpoint, the ISO
documents listed in Table 1 provide methods
to verify gears whose geometry is known.
In some of the AGMA documents listed in
Table 2, design suggestions depending on
the application are also provided. There are
no universal criteria. While in the automotive
field small b/d ratios are common, in rolling
plants, b/d ratios are often greater than 1.

3 MANUFACTURING
We will limit ourselves to looking at metal
cylindrical gears, cut mostly using hobs,
pinion-type cutters or power skiving, with
possible grinding for finishing, to correct
distortion error caused by any thermal or
surface treatments or to define micro-geo- Figure 5: Nonstandard
metric modifications [13]. dimensioning for hobs.
For obvious reasons of space, we will put
to one side gears boasting a “free” geometry:
plastic, sintered, obtained by additive manu-
facturing, 5-axis milling, or form cutting.
Therefore, the main job of the person who
receives the gear drawing, such as the one in
Figure 3, is to define the dimensions of the most suitable tool, in this aim is the one cited in the introduction “to manufacture parts that
case a hob, trying not to buy a new one, but to choose from those meet design requirements concerning shape, size tolerance, and sur-
already available (Figure 4). face characteristics from both a technical and economic viewpoint.”
Let us now try to describe some atypical situations that can occur The choice of hob, which allows for the required shape to be
in the hob’s dimensioning that may result in a difficult interpreta- obtained, can be made by entering the data of the required geometry
tion of the geometry for the reader of the drawing in Figure 5, which and the data of the hob (uniquely established, as we said) into specific
is often not even to scale. There is no standard that regulates a single calculation software (Figure 6) and superposing the calculated geom-
method of dimensioning for these tools. etry with the one produced via enveloping (Figure 7). For example, in
When there is protuberance: the case of the use of a pre-grinding tool with no protuberance, it is
 Only two out of its three dimensions are independent. easy to note the grinding notch. The grinding notch is accepted for
 If the wording “full-radius” is included for the hob’s tip radius, small-size industrial gearboxes, clearly not in the case of automotive
an iterative calculation is needed to calculate the value of the root or aerospace gears.
radius. Once the technical aim has been achieved, there is not a single
 The reference line, in relation to which the other dimensions criterion for the most economic choice. For example, it could be
such as addendum and dedendum are provided, may not be the line attempted to obtain the maximum efficiency from the hob K [14]
that divides the space thickness the same as the tooth thickness as,
instead, assumed by some calculation software. Equation 1
 Semi-topping can have a double inclination or radius not dimen-
sioned in the change of the pressure angle. where
As for design, the focus in this case is also on aim and criteria. The K is the efficiency of the hob; in m/tooth.
30     gearsolutions.com
 Figure 7: From left to right: Required tooth form, hobbing simulation, comparison
between required (black) and ground (blue) tooth form, focus on the grinding
notch.

Figure 8: Hob and gear.

Figure 6: Design and manufacturing data.

p is the number of gears (pieces).

z is the number of gear teeth. Figure 9: Profile and helix deviations generated by the hob.
l is the face width, mm.
tos is the axial pitch of the hob, mm. z0 is the number of threads.
ios is the number of hob gashes or flutes. h is the cutting depth.
b is the helix angle of the gear. As regards to cutting parameters, it must be remembered that it
b1 is the working length of the hob (Figure 8). is possible to estimate profile e1 and helix e2 deviations caused by the
The efficiency K should be between 4 and 5 m/tooth in order to be progress value (Figure 9).
assessed as good. Before calculating K, the level of wear of the hob to
be reached prior to replacement needs to be set and the cost of the Equation 3
tool and grinding taken into account.
Even if more advanced methods have been proposed [15], Equation 4
Hoffmeister’s formula can still be used to calculate the chip’s maxi-
mum thickness given a set progress for each part revolution. where
e1 is the profile deviation.
e2 is the helix deviation.
z0 is the number of hob teeth.
Equation 2 i0 is the number of hob starts.
where z is the number of gear teeth.
h1,max is the maximum chip thickness. Rp is the pitch radius of the hob; mm.
mn is the standard module. fa is the progress per part revolution; mm/rev.
b0 is the angle of the hob’s helix. b0 is the angle of the hob’s helix.
xp is the addendum modification factor. a is the pressure angle.
fa is the axial feed. Therefore, with the same reference profile of the hob, the choice
da0 is the hob head’s diameter. of hob is determined by:
i0 is the number of gaps.  Other geometric characteristics of the hob, such as the num-

February 2022     31
ber of cutters, external diameter, number of
principles, helix angle length.
 Cutting parameters, such as cutting
speed and progress/tooth, the recommended
values for which can be found in the bibliog-
raphy [14].
 Number of parts to be cut.
All these values can be used in the
Equation 2 and 1, in order to check that:
 The chip thickness is not excessive.
 Efficiency falls into the 4-5 m/tooth
interval.
But this is not the only criterion for assess-
ing the advantageousness of specific work-
ing conditions. For example, the choice of
favoring an increase in cutting speed and
hence a reduction in cutting time is com- Figure 10: Optimizer interface: goal, variables, and boundary condition for the DOE.
monplace, resulting in the waiver of a good
level of hob efficiency.
We have tried to present simple formu-
las with a deep educational value [14]. Some
other examples are in [16] and [17]. A more
precise approach can be found in [18]. For
pinion-type cutter, see [19].

4 OPTIMIZATION
We will focus on the optimization of design
and the optimization of manufacturing
as separate, independent activities: The for-
mer to be adopted in the technical depart-
ment and the latter in the workshop, even
in the case of two different companies, Figure 12: Optimizer interface: graphic with Pareto front.
i.e., an engineering company and a subcon-
tractor. while generating and selecting them forms part of the optimiza-
tion process. Without going into detail, the notion of optimization
4.1 OPTIMIZATION OF DESIGN is based on three concepts: objective/s, constraints, variables. Once
As stated in the introduction, design consists of a choice of variants, these three concepts have been established, a multitude of vari-

Figure 11: Optimizer interface: generated variants (list).

32     gearsolutions.com
Figure 13: Tool selection from Database in KISSsoft.
Figure 14: Hobs
database in Excel.

ants are generally obtained and the optimal solution chosen among
these, based on well- defined criteria.
Let us have a look at some cases of optimization applied solely to
gear design:

4.1.1 ANALYTICAL OPTIMIZATION

Some years ago, Schöler [20] presented an evolution, hence an opti-
mization, of the traditional proportioning and pre-dimensioning
formulas. The paper refers to beveloid gears, but it offers a clear idea
of what has also been done with regard to cylindrical gears.

4.1.2 FAST GENERATION OF VARIANTS

Kissling [21] has shown how quick the generation of macro-geometry
variants can be, using software already widely adopted in techni-
cal departments (Figure 10). The numerous variants generated
(Figure 11) are then selected by the designer with the help of filters
and graphs (Figure 12). The choice is up to the designer. The same
approach is used to generate micro-geometry variants, as presented
in a recent FTM [22].

4.1.3 MULTI-OBJECTIVE COMMERCIAL OPTIMIZERS

Bonfiglioli [23] and Noesis [24] presented the use of a multi-objective
February 2022     33
Figure 15: Hobs and pinion-type cutters database in Oracle.

Figure 16: From left to right: CAD drawing of a dresser for gear grinding wheel, comparison between the required geometry of the gear and the ground one.

optimizer interfaced with gear calculation software. ModeFrontier genetic algorithm optimizer developed by the university [26], which
and Optimus took care of the experiment design (DOE) while KISSsoft works exclusively on supercomputers.
calculated each individual variant. The variant generation criterion
performs better, and reporting is more functional in the face of lon- 4.1.5 ARTIFICIAL INTELLIGENCE
ger processing times. Schlecht [27] even decided to make use of artificial intelligence in
order to find the optimal flank modification for a pair of cylindri-
4.1.4 OPTIMIZERS FOR SUPERCOMPUTERS cal gears. Compared to all the methods described earlier, a training
UniMoRe has recently made available to some companies [25] a phase for the AI engine is needed in this case, but advanced contact
34     gearsolutions.com
 As mentioned previously, the aim could be the hob’s performance,
which falls within the values listed earlier. The constraints concern
generation of the desired profile and the maintenance of cutting
parameters within the recommended ranges. The only variable is the
hob. Software able to perform the calculations listed under point 3
is obviously required. An example of hob selection from database in
a gear software calculation is shown in Figure 13.

4.2.1 TOOL DATABASE

Before explaining the hob’s optimized selection process, let us take
a deeper look at the tool database. It is necessary to have a computer
database containing all the hobs’ characteristics. The platform used
can range from a straightforward Excel spreadsheet to PLM.
There are workshops that cut gears for medium-size reducers
(with a module from 0.5 to 7 mm), that have 400 hobs entered into an
Excel spreadsheet (Figure 14), and there are workshops working espe-
cially for the automotive industry that have 650 hobs in an Oracle
database that also lists the resharpening (Figure 15).
There are also workshops working for the automotive and agricul-
tural industries that handle more than 10,000 hobs for which only
printed information sheets are available. Therefore, the first step
is to enter data into a computer database. An Excel spreadsheet has
been prepared with some formulas in order to harmonize the various
ways of sizing the hobs mentioned previously. The enormous amount
of work involved in compiling the database can only be justified by
the savings, in economic terms, obtained by the process listed in the
paragraph below.
In any case, the hobs database must contain this information:
 Reference profile (module, pressure angle, addendum, deden-
dum, tip and root radius, protuberance, semitopping).
 Geometric characteristics (hob diameter, cutting edge length,
helix angle and hand, number of gashes, number of starts, mate-
rial, coating).
 Working conditions (recommended stock).
Sometimes, the database also includes data [28] or drawings of
dressers (Figure 16). So, this method is also used to determine the
choice of roll in order to dress the grinder wheels and obtain the
tip-relief listed in the drawing.

Figure 17: Workflow to generate a list of hobs (variants). 4.2.2 WORKFLOW

The process to be followed in order to generate a list of hobs used
to cut the required toothing is shown in the flowchart in Figure 17,
taking into account also the stock allowance.
Among the proposed variants, the optimal solution is the one that
best meets the set criteria. Similarly to what we saw in Point 4.1.2,
the Pareto front must also be adopted in this case.
The process can be more advanced and taken into account “modi-
fied rolling” or “short pitch tool” [29]. In this case, the hobs will not
be strictly filtered on the basis of module and pressure angle initially,
but also by the base pitch, optionally inside a tolerance range.
Figure 18: Gear hobbed and ground completely. Hob with same base pitch of the The short pitch tool usually is selected to reduce undercut when
gear (A), hob with different base pitch of the gear (B). there is the protuberance, to achieve smaller root form circle after
grinding and increase the lifetime of the hob. The tooth form chang-
analysis software can be done away with. es only in the root, and this change should be considered in the
strength calculation. In this case, both the tool and gear have the
4.2 OPTIMIZATION OF MANUFACTURING same base pitch.
The same concepts seen for the optimization of design can be applied In another case, the tool can have a base pitch different from the
to manufacturing. gear. Checking of the geometry obtained via enveloping will not be
In this case, too, optimization involves the choice of the best vari- solely of the tip and root diameters, but also of the profile deviation,
ant, in other words, the choice of the hob that “copies” the geometry which must remain within values that can be removed by grinding.
of the gear under design at the lowest cost, also taking into account This operation can be performed only if the first selection failed to
the stock allowance. result in a solution or if the workshop normally adopts modified roll-
February 2022     35
ing for cutting or if a prototype or small batch is being manufactured.
In (Figure 18), there is the same gear with m = 2.5 mm and a =
20°, hobbed and ground completely (flank and root). The hob in (A)
has the same base pitch of the gear (m = 2.4701 mm, a = 18°); the hob
in (B) has a different base pitch (m = 2.5 mm, a = 18°); the grinding
allowance is not constant, but it’s acceptable for a prototype.

5 INTEGRATION
The meaning of the term “integration” in this article goes beyond the
one adopted by Norton in the title of his book “Machine Design: An
Integrated Approach” [30] where, instead, he refers to the educational
approach. The approach tackles numerous machine parts within the
same whole that are often mutually dependent.
As mentioned in the introduction, the integration we are focusing
on is that of design for manufacturing; this has become a must, or
at least a leitmotif for many companies.
Indeed, design decisions have a significant impact on manufactur-
ing costs and product quality; 70 to 80 percent of the end manufac- Figure 19: Up to 80 percent of product costs locked in at design (Source:
turing costs and 80 percent of the work that affects product quality Dowlatshani in [3]).
are established by the end of the design phase (Figure 19). Moreover,
the further along you are in the development phase, the more expen-
sive it becomes to make modifications (Figure 20). For example, once
the hob has been ordered, any geometric modifications to the design
have an extremely costly impact.

6 INTEGRATED OPTIMIZATION
We do not need to go deeper into the importance of integration. We
have reached the apex of this ascent of the four terms listed in the
article’s title. It is just a small step to achieve integrated optimization
of design and manufacturing. The following are necessary:
 Adoption of a single gear calculation software in the technical
department and in the workshop. Usually, it is first chosen by the
technical office and then adopted by workshop.
 Sharing of the same hobs database by the design and manufac-
turing divisions. If, as listed earlier, the first step is taken by the tech-
nical office, then it is the workshop that must share its information.
 In the design software, the DOE of the optimizer searches for Figure 20: Closing window of opportunity for changes (Source: Tech-Clarity in [3]).
solutions limited to those obtained by the
hobs available in the database (Figure 21)
[21]. For each found variants (Figure 11),
the efficiency of the hob could be added as
a result to help the designer in the selection
of the best solution — “best” for the designer
and “best” for the workshop.
The advantages are for the whole com-
pany:
 Saving money in the purchase of new
hobs and time in supplying, because the
designer tries to limit himself to proposing
geometries generated using just the hobs
available in the workshop, rather than com-
ing up with geometric variables at a math-
ematical level only (e.g. pressure angle, mod-
ule, addendum, dedendum).
 The designer has a greater awareness of
what will be produced, even at the level of
efficiency of the hob, pre-grinding quality
and grinding twist, especially if the software
used conveys the skills of gear designers and
machine tool manufacturers [21].
 The workshop already has the files with
toothing and hob data; it does not have to Figure 21: Example of DOE where the hobs database is a boundary.

36     gearsolutions.com
 [11] Schlecht, B., 2009, Maschinenelemente 2: Getriebe, Verzahnungen und
interpret the drawing or enter data related to the hob, if chosen from
Lagerungen, Pearson Studium, München.
the database. Therefore, it can focus exclusively on the technologi-
cal aspects. [12] Saverin, M. M., tran., 1961, Increasing the Loading on Gearing and
Decreasing Its Weight (Original Work: Povysheniye Nagruzochnoy
7 CONCLUSIONS Sposobnosti Zubchatykh Peredach i Snizheniye Vesa), Pergamon Press,
The sharing of information and the desire to network, which is the New York.
same as the goal of AGMA, and especially of the FTM, is the spirit
[13] Turci, M., 2018, “Design and Optimization of a Hybrid Vehicle Transmission,”
that lies behind the drafting of this article. No new formulas or
Fall Technical Meeting (FTM), AGMA, Chicago.
technologies are presented in this article. The state-of-the-art, good
practices, and some real cases encountered in various situations and [14] Bianco, G., 2004, La Dentatura Con Creatore, Samp Utensili, Bologna.
inside companies are presented in order for us to draw from them.
[15] Brecher, C., Brumm, M., and Krömer, M., 2015, “Design of Gear Hobbing
“Uncomplicated” instruments that are already on hand have been
Processes Using Simulations and Empirical Data,” Procedia CIRP, 33, pp.
described:
484–489.
 To some designers in order to see whether there is already a tool
to manufacture the gear wheel they have in mind. [16] Momper, F., 2017, “Un Approccio Moderno Alla Scelta Del Creatore,”
 To the relative workshops in order to avoid having to spend time Gleason Technology Days, AGMA, Rezzato BS.
re-interpreting designs and to speed up the search for the ideal tool.
[17] Zhou, J., and Sari, D., 2020, “Selecting Correct Size of Hob/Gashing Cutter
If a drawing is a way to encode design information and reading of
the drawing represents decoding, an example of CODEC (an IT term (Ask the Expert),” GEAR TECHNOLOGY.
used in relation to audio and video meaning COde-DECode) involving [18] Radzevich, S. P., 2010, Gear Cutting Tools: Science and Engineering, CRC
design and manufacturing is shown. Press, Boca Raton.

[19] 1980, Gear Cutting Tools, Manual for Design and Manufacturing,
8 ACKNOWLEDGEMENTS
The author wishes to thank KISSsoft (a Gleason company) for the Verzahntechnik Lorenz GmbH & Co, Ettlingen.
software. Thanks also to the companies Varvel — Mechnology, CIMA [20] Schöler, T., Binz, H., and Bachmann, M., 2017, “Method for the Pre-
(Coesia group), Graziano (now parts of Dana group), and CEI, that Dimensioning of Beveloid Gears – Efficient Design of Main Gearing Data,”
provided some pictures for this article and, over the years, have dedi- International Conference on Gears, VDI Verlag GmbH, Munich.
cated resources for the integrated optimization of design and manu-
[21] Kissling, U., Stolz, U., and Turich, A., 2017, “Combining Gear Design with
facturing. They have shared among themselves the same software
and same database of hobs and pinion-type cutters in design and Manufacturing Process Decisions, VDI International Conference on Gears,”
manufacturing, not without some initial problems. International Conference on Gears, VDI Verlag GmbH, Munich.

[22] Kissling, U., 2019, “Sizing of Profile Modifications for Asymmetric Gears,”
BIBLIOGRAPHY Fall Technical Meeting (FTM), AGMA, Detroit.
[1] Pahl, G., and Beitz, W., 1988, Engineering Design: A Systematic Approach,
Springer Verlag, London. [23] Franchini, M., 2016, “Multi-Objective Optimization of a Transmission System
for an Electric Counterbalance Forklift,” International CAE Conference,
[2] Zurla, O., 1984, Appunti di macchine utensili, CLUEB.
Parma.
[3] 2007, Integrated Design to Manufacturing Solutions: Lower Costs and
Improve Quality, Dessault Système, Waltham MA. [24] Olson, M., 2018, “Optimierung Eines Stirnradpaares in Einer
Kontaktanalyse,” Schweizer Maschinenelemente Kolloquium (SMK).
[4] Turci, M., and Giacomozzi, G., 2016, “The Whirling Process in a Company
That Produces Worm Gear Drives,” Fall Technical Meeting (FTM), AGMA, [25] Pellicano, F., 2018, “Overview,” The Gear Day, Modena.
Pittsburgh.
[26] Bonori, G., Barbieri, M., and Pellicano, F., 2008, “Optimum Profile
[5] Turci, M., Ferramola, E., Bisanti, F., and Giacomozzi, G., 2015, “Worm
Modifications of Spur Gears by Means of Genetic Algorithms,” Journal of
Gear Efficiency Estimation and Optimization,” Fall Technical Meeting (FTM),
AGMA, Detroit. Sound and Vibration, 313(3), pp. 603–616.

[6] Stadtfeld, H. J., 2019, Practical Gear Engineering, The Gleason Works, [27] Schlecht, B., and Schulze, T., 2019, “Improved Tooth Contact Analysis by
Rochester, N.Y. Using Virtual Gear Twins. How Helpful Is AI for Finding Best Gear Design?,”
[7] Buckingham, E., 1928, Spur Gears: Design, Operation, and Production, International Conference on Gears, VDI Verlag GmbH, Munich.
McGraw-Hill, New York.
[28] Stangl, M. F., Kissling, U., and Pogacnik, A., 2017, “A Procedure to Find
[8] Soria, L., 1948, Tecnica degli Ingranaggi, Viglongo, Torino. Best Fitting Dresser with Grinding Worm for a New Design,” International
[9] Radzevich, S. P., ed., 2012, Dudley’s Handbook of Practical Gear Design Conference on Gears, VDI Verlag GmbH, Munich.
and Manufacture, CRC Press, Boca Raton.
[29] Liston, K., 1993, “Hob Basics - Part II,” Gear Technology.
[10] Niemann, G., and Winter, H., 1983, Maschinenelemente: Band 2: Getriebe
allgemein, Zahnradgetriebe - Grundlagen, Stirnradgetriebe, Springer Nature, [30] Norton, R. L., 2013, Machine Design: An Integrated Approach, Pearson
Berlin Heidelberg. College Div, Boston.

ABOUT THE AUTHORS

Massimiliano Turci is a gear design consultant. His professional experience is primarily in the development of computational models for enclosed
gearboxes and automotive transmissions. He is a member of the AGMA worm gear committee, the UNI (Italian national body) gears committee,
and the ISO workgroups for gear calculations.

February 2022     37
 MODELING
TOOLS FOR
GEAR DESIGN
AND FAILURE
PREVENTION

38     gearsolutions.com
Techniques to prevent, predict, and understand gear
failure have improved in part due to advances in
computing power and simpler approaches.
By BERLY MCCOY

E
vidence for the production of toothed wheels, is referred to as macropitting and can lead to a cata-
better known as gears, can be traced back as strophic gear failure, potentially causing disruptions
early as the third century BCE [1]. Over time, in goods or services production as well as high repair
through both mathematical modeling and costs. Another source of macropitting is inclusions in
trial and error, the complexity and sophistication of the gear-tooth material where stress can concentrate.
gear systems have increased, leading to innovations The presence or absence of these inclusions are dic-
in complex machinery, astronomy, and computing. tated by the metallurgy and processing of the gear
Today, gears are used in numerous applications, from material.
the small planetary gearboxes in hand drills to the The portion of the tooth below the midpoint, called
meter-wide gears in wind turbines to vehicle transmis- the dedendum, as well as the pitch line of the tooth,
sions and, more recently, engine gearboxes. are at risk for micropitting. Two points that are par-
Contacting gear teeth represent one of the most ticularly vulnerable are the start of the active profile
complicated areas of tribology. As a result, there are and the lowest point of single tooth contact (LPSTC),
many ways gears can fail. Methods to prevent, predict, but micropitting can occur anywhere on active flanks.
and understand gear failure have improved in part due
to advances in computing power, but simpler, more WEAR
accessible approaches also are available. Identifying “If you don’t fail that gear by the tooth fracture, the
the best tools to assess performance problems in gears next mode of failure is going to be tooth surface deteri-
requires an understanding of the functional require- oration,” says STLE Life Member Vern Wedeven, found-
ments of a given application as well as the ways in er of Wedeven Associates. Gears and gear systems are
which gears can fail. expected to last for thousands of hours, so manufac-
turers design and fabricate gears to resist wear and
WHY DO GEARS FAIL? other forms of surface deterioration. But depending
From a tribology standpoint, gears have a number of on the operating conditions, surface deterioration can
major modes of failure that can result from lubrication be accelerated. Wear can be caused by surface fatigue,
inadequacy, flash temperatures, and contact stresses. as well as adhesion, abrasion, and corrosion. Failure
Understanding the factors that contribute to each analysis frequently reveals that surface deterioration
kind of failure provides end-users with a path toward occurs through a combination of processes involving
predicting and avoiding these failures. wear, adhesion, and fatigue mechanisms. While the
final failure mechanism frequently takes the blame,
SURFACE PITTING the preceding events are usually the root cause.
Even the smoothest materials have rough surfaces
at the microscopic level, including gear teeth. If the SCUFFING
lubricating film doesn’t maintain sufficient thickness Scuffing is an extreme mode of gear failure in which
between gear teeth, points of stress can concentrate high temperatures and excessive sliding cause the gear
at these protruding microscopic surface irregularities, tooth surface to pierce through the lubrication layer
called asperities, or on surface material defects, which and make direct contact with each other (see Figure
may result in the formation of fatigue cracks along 1). When gear teeth mesh without the protection of a
and just below the surface of the teeth. This crack- surface film, asperities can deform, smear, or locally
ing, which can propagate along the tooth surface, weld together.
can cause the formation of micrometer-sized pits, a “When you get metal-to-metal contact, you’re going
process called micropitting. The use of low-quality to mechanically alter the profile of the tooth surface
material or contaminated lubricant can increase the and modify it in a way that you don’t want,” said
likelihood of micropitting, also sometimes referred Christopher Cooley, assistant professor in the School
to as gray staining or frosting because of the altered of Engineering and Computer Science at Oakland
tooth surface appearance. University. “You want an involute tooth surface.”
Areas of micropitting frequently accelerate wear, Because the involute shape of gear teeth is essential
which leads to a loss of the tooth profile and stress to their operation, scuffing can accelerate tooth wear
concentrations at the edge of the wear areas. When a and lead to seizing of the sliding pair.
micropit grows large enough or several pits combine, a Scuffing tends to occur more often in gears that
more severe pit known as a spall can form. This process run at high speeds and temperatures, generally near
February 2022     39
the tip or the root of the tooth where the slide-to-roll ratio is usually
the highest.

BENEFITS OF MODELING
Gear designers implement modeling tools to increase productivity,
decrease costs, and predict failure modes as well as reduce the need
for extensive testing.
“The models are really there to help optimize the design and the
design process, so that you end up with minimal testing and minimal
design risk,” Wedeven said.
He outlines four main areas where modeling can help end-users
predict performance:
The first is focused on noise, vibration, and harshness (NVH), par-
ticularly in cars and trucks. These characteristics are related to gear-
tooth dynamics. Modeling and other tools can help reduce NVH for
better consumer experiences and to reduce external or drive-by noise.
The second area modeling tools can aid in gear design is in under-
Figure 1: In high-speed spur gears subjected to a loss of lubrication, the
standing tooth bending. When gear teeth transmit power, they
temperature measured just outside of the mesh point of the gears reveals
repeatedly bend, which can cause fatigue and cracking. different stages of failure from starved liquid lubrication, through scuffing, to
large-scale thermal runaway. (Courtesy: Stephen Berkebile)
UNDERSTANDING THE BEHAVIOR
Wedeven referred to the third area as gear mesh contact or gear contact each other as well as their relative motion. Wang said gear
mesh interfacing. lubrication is, therefore, subjected to dynamic loading and transient
“This includes a combination of very complex rolling and sliding speeds, oil churning or spray, system heat transfer, contact distribu-
motion,” he said. “How that gear tooth profile is designed, along tion, surface topographic conditions, tooth wear, and flash heating.
with the number of teeth selected, makes an enormous amount of With such a complicated system, modeling offers a way to choose
difference.” the best lubrication method, gear geometry design, and condition
Wedeven said these design factors will define the motions, stress- monitoring, as well as to determine if the gear materials or surface
es, and temperatures of the operating interface, which ultimately finishing need to be modified for better performance.
will determine the life, durability, and efficiency of the gear sys-
tem. Controlling these features requires tribology engineering of the GEAR LUBRICATION MODELING
interface by taking into consideration and balancing the inherent Understanding the behavior of lubrication between tooth pairs with
rheology and chemistry of the lubricant; the strength and thermal- elastic contacts is essential in predicting gear tooth performance.
mechanical properties of the bounding surfaces; the surface films End-users can use gear lubrication modeling tools to help prevent
created during operation from reactions between the oil chemistry overheating and failure; reduce noise, vibration, and losses due to
and surface chemistry; and the surface geometry, roughness, and friction and wear in the design stage; as well as optimize the system
texture, collectively known as the surface topography. for light weight, prolonged life, and improved reliability.
“The designer has an enormous challenge accommodating One important tool specialists use for predicting lubrication
extreme interface operating conditions found in high-performance behavior between gear teeth is mixed elastohydrodynamic lubrica-
mechanical systems,” Wedeven said. tion (EHL) models. Under high-temperature conditions or with suf-
Modeling here can help designers better understand how the two ficiently high loads, or in low speed, such as during initial start-ups
gear surfaces will interact. or shutdowns, the lubrication films can be thin, which may result
The fourth area encompasses the supply and distribution of the in metal-to-metal contact of gear asperities. Mixed EHL models offer
lubricant. Oil losses due to viscous churning of the lubricant lead a way to predict the microscopic aspects of gear-tooth lubrication
to lower efficiency and increased heat generation. Because of this, under these conditions.
thermal analyses are a key part of modeling. “The mixed EHL program should be capable of taking the oper-
“There is a delicate balance and also conflicting requirements ating conditions from system analyses and output distributions of
associated with oil supply and distribution for lubrication and cool- lubricant film thickness, contact pressure, flash temperature and
ing functions,” Wedeven said. “Modeling tools for viscous losses and near surface stresses, and it would be better if wear also is predicted,”
thermal management are essential.” Wang said.
Tools to predict oil churning losses, frictional heat generation at The information obtained can be used for gear-material modi-
the contact interfaces, and thermal dissipation for controlling tem- fication, surface-finish control, gear-geometry design, lubrication-
perature are essential. method selection, and condition-based monitoring. Wang suggested
STLE Life Member Q. Jane Wang, professor of mechanical engi- finite element method software for analyzing gearbox structures
neering in the McCormick School of Engineering at Northwestern and computational fluid dynamics software for understanding fluid
University, said that because gears are supported by shafts and bear- motion and heat transfer. Mixed EHL integrated fluid dynamics and
ings and are often mounted to larger machines or vehicles, gears are contact-mechanic models can be used for different gear materials
subjected to dynamic loading and impact, as well as a wide range and surfaces to both consider material elastoplasticity and wear and
of operating conditions and work environments. System dynamics to understand the influences of a wide range of load-speed changes
(e.g. dynamic loading due to shaft deflection or the behavior of the and frictional heat transfer. The integration of multiscale models
bearings) influence the tribological interfaces of the interacting can help simulate realistic operating conditions.
gear teeth, since their lubrication is dependent on how the gears To effectively implement lubrication modeling as a way to under-
40     gearsolutions.com
Contacting gear teeth represent one of the most complicated areas of tribology. (Courtesy: Stephen Berkebile)

“Because they have so much fidelity, ity to calculate the actual motion, stresses, and temperatures for a
given application.
computational models often require Outside of or coupled with modeling, a user also can employ phys-
ical simulation testing to understand gear performance, which is
more solution time than some often outsourced. For testing, engineers extract the operating param-
eters for a given application — for example, velocity, load, lubrication
of these other design tools and type, and temperature — and duplicate them on machines in a labora-

analytical models, which might limit tory setting. The testing, which may be performed on dimensionally
modified machines, aims to recreate the gear contacts and wear.
the number of analyses that you Modeling and simulation testing can be applied to a system for
design or performance monitoring, but there also is utility in under-
choose to do.” standing how a gear has failed. In this case, an end-user can per-
form a surface or failure analysis, which also can be combined with
analyses with software, such as a finite element modeling tool. The
stand gear-performance issues, Wang said there are a number of failure analysis can include material characterization, such as chemi-
important parameters an end-user can input into a model. These cal analysis and hardness measurements, microscopic and naked eye
include properties of the lubricant itself — its viscosity and density fracture examination, stress analyses, and fatigue crack growth rate
as functions of temperature and pressure, rheology, and degradation determination, among others. Wedeven said that although this tech-
behavior — the tooth surface roughness and topography and charac- nique is not technically a form of modeling, it is an important way
teristics of gear materials such as elastoplasticity, creep (for polymer to characterize information relevant to future gear performance.
gears), and fatigue strength, as well as gear-tooth heat-treatment
results, coatings, and defect type and distribution. GEAR DYNAMICS MODELING
Wang said the information users choose to input into a model To predict and monitor gear dynamic health, Cooley said a range
will vary depending on if their interest lies in modeling a snapshot of tools exist, from analytical models, which are representations of
or an operation process. For example, in analyzing a snapshot of gears as rigid bodies with lumped inertial properties, to computa-
the worst condition — which is often at the LPSTC and the area of tional models developed using software packages.
highest sliding speed — the necessary information would include the “There are even specialized design tools that bring some elements
load and its distribution, the speeds of both surfaces, the meshing of both of these into a package for engineers,” he said.
geometry, properties of the materials, lubricant, and surface rough- The tools are largely used to determine two important areas that
ness, in return for microscopic stress cycles in the contact area, the affect gear performance: mesh stiffness variation and the static
minimum film thickness, friction, and the flash temperature. In transmission error. Mesh stiffness variation refers to the change in
contrast, analyzing the process in which the gear transitions to stiffness between gear teeth contacts.
the worst lubrication state would involve system dynamics and oil- “In spur gears, you can have two pairs of teeth in contact,” Cooley
churning analysis. said. In a hypothetical case, two pairs of teeth are a less compliant,
Users can acquire many input parameters for various models by or stiff, connection between mating gears. “Later, one pair of teeth
using bearing and gear codes, Wedeven said, which offer the abil- will leave contact, and only one pair of teeth will be in contact, which
February 2022     41
is a more compliant connection between the two gears. When the straints that limit the overall size of the gearbox.”
connection between two gears fluctuates in stiffness, that gives rise After those parameters are met, designers are less restricted and
to dynamic excitation in these systems and makes them vibrate.” can determine how the number, thickness, height, and lubrication
Static transmission error is another excitation source in gearboxes of gear teeth will affect properties such as the bending contact
and occurs as a result of the difference in the actual position of the strengths, the flash temperature, and the fatigue life of a gearbox.
output gear compared to its theoretical position. The two are not After designing the basics, Cooley said designers can employ com-
equal because gears are elastic, not completely rigid bodies, so when putational modeling software packages to optimize performance
torque is placed on a gear tooth, it leads to slight deformation locally. and monitor operations. A number of software packages are available
“All this creates some deviation from its nominal position,” that can simulate a range of gear dynamic properties. For example,
Cooley said. computational models can accurately represent the complex geom-
To understand these parameters, engineers can create an analyti- etry of the tooth surface down to the micrometer size range, an essen-
cal model by combining representations of each gear in a gearbox. tial element for dynamic analysis. Some software packages can cal-
“Through the analytical modeling process, you take idealized culate the contact distribution on all the teeth throughout a gearbox
by taking into account elastic deformations,
including localized deformations, due to the
contact on the tooth surfaces.

LIMITATIONS AND RESOURCES

But gear dynamic computational software
has its limitations.
“Because they have so much fidelity, com-
putational models often require more solu-
tion time than some of these other design
tools and analytical models, which might
limit the number of analyses that you choose
to do,” Cooley said.
Gear design and performance monitoring
require a mix of simple and complex tools in
combination.
As with gear dynamics, the computa-
tional time for gear lubrication models
increases as the mesh size decreases, requir-
ing a tradeoff between calculation efficiency
and accuracy. Wang also highlighted a need
for multiscale model integration between
gear lubrication models and gearbox system
dynamic models, which are currently largely
A number of software packages are available that can simulate a range of gear dynamic properties. (Courtesy: detached.
Shutterstock) The American Gear Manufacturers
Association provides engineers information
representations, like inertial elements and stiffness elements, and about the calculations of loose gears and gearbox components as well
through some mechanical laws, you turn those into ordinary dif- as online training videos. A handful of university-based research
ferential equations, which are equations that engineers can solve laboratories and institutes offers gear design and testing support
in order to analyze particular outputs,” Cooley said. such as the Gear Research Laboratory at the Rochester Institute of
For example, outputs may include the extent to which a gear will Technology and the Gear Research Institute at Penn State University.
vibrate or how much force will be applied on the gear. The Gear and Power Transmission Research Laboratory, a research
One benefit of using analytical models to understand gear dynam- group at The Ohio State University, performs power transmission
ics is that they are non-proprietary and can be solved relatively easily and gearing research, develops and supports gear design and analysis
because they require few inputs, like the masses and moments of software programs and offers gear training.
inertia of gears. But an end-user also can increase the complexity of
the model to suit their goals. REFERENCE
A designer, then, needs to start general and add complexity. [1] Lewis, M.J.T. (1993), “Gearing in the ancient world,” Endeavour, 17 (3),
“You normally start with a very small list of requirements,” pp. 110-115. Available at www.sciencedirect.com/science/article/abs/
Cooley said. “You will know the power to be transferred and con- pii/016093279390099O.

ABOUT THE AUTHOR

Berly McCoy is a freelance science writer and producer based in Northwest Montana. You can reach her at [email protected].
Reprinted with permission from the December 2021 issue of TLT, the official monthly magazine of the Society of Tribologists and Lubrication
Engineers, an international not-for-profit professional society headquartered in Park Ridge, Illinois, www.stle.org. Available at www.stle.org/files/
TLTArchives/2021/12_December/Feature.aspx.

42     gearsolutions.com
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February 2022     43
 IN GEAR WITH
METROLOGY

New advancements in Vision

Systems streamline gear inspection.
(Courtesy: The L.S. Starrett Company)

44     gearsolutions.com
As gear production demands increase, lead times
need to be decreased without compromising quality;
therefore, the ability to confidently perform everything
ranging from quick checks to in-depth QC inspections
in seconds has never been more important.
By CW MORAN

T
he gear is one of the most widely used manufac- must have the appropriate pin sizes for all of the gears
turing parts in the world. The number of real- in production. Gears with an odd number of teeth
world applications of gears is nearly limitless: will also require additional calculation to account
from time keeping, to automotive, to medical for being offset from center. When using tools such
and aerospace, to helping humans gain a mechanical as Vernier calipers, there is a certain amount of time
advantage in labor. As a result, there is hardly an indus- and training required to learn how to properly use
try that doesn’t use gears in some capacity, whether it the scales and read them in order to obtain accurate
be in their manufacturing process, in their finished results. With the gear tester, on the other hand, issues
products, or both. Because of this wide array of applica- such as master gear wear over time become a factor.
tions, gears themselves come in a wide range of sizes With all of these tools, the issue of time also becomes
and types. Spur, spline, bevel, and timing are just a few a factor. These methods require measurements to be
examples, and within these categories
there are many unique features such as
tooth count, size, and face width. All of
these options can also come in a broad
range of materials and finishes. As a
result, the need to have quality control
(QC) processes that are accurate, flexible,
reliable, and fast are crucial to keeping
production on schedule.

INSPECTION WITH
PRECISION TOOLS
There are a number of gear-inspection
methods that have been available for
many years. When measuring over pins
with a micrometer, the appropriate size
pins for a selected gear are placed with-
in the width of space between teeth on The Starrett AVR-FOV Vision System can accurately inspect a wide range of
opposing sides of the gear. A micrometer features on large or complex parts, as well as on multiple small parts. (Courtesy:
is then used to take measurements over The L.S. Starrett Company)
the pins and compared to a theoretical
dimensional value for features such as tooth thickness. taken piece-by-piece manually, which can slow down
Gear tooth inspection Vernier calipers are devices a busy QC department. On top of this, when making
with sliders that can be used to measure features such hand measurements, the opportunity for human error
as tooth depth, tooth height, and addendum height is introduced, especially if there are multiple individu-
with a combination of scales on the device that are als in a given QC department taking readings.
line-based, with each line corresponding to a certain
value. Handheld or tabletop gear testers, on the other MERITS OF VISION SYSTEMS
hand, are devices where a sample gear from produc- Due to faster measurement, increased throughput,
tion is placed into a device mating it to a master gear and greater accuracy by removing operator subjectiv-
for testing. The sample and the master are then run ity, the latest metrology inspection systems offer more
through rotation and runout on the gear and can be efficient gear inspection, especially on a production
measured via a dial gauge on the system. level. A vision system, which is essentially an upgrade
While these are all affordable, time-tested options, to the traditional optical comparator, uses high-defini-
it is important to factor in the following consider- tion video cameras with customizable lighting rather
ations: When using a micrometer over pins, the user than using lenses and mirrors, to create an image on a
February 2022     45
touchscreen PC monitor. This advancement enables a feature called accurate and dependable results can be obtained time and time again
video edge detection (VED), which automatically detects the differ- regardless of who is using the system or their level of experience. This
ence between light and dark, eliminating the human error usually feature virtually eliminates error due to user-to-user subjectivity.
seen in operator-to-operator subjectivity. Customizable lighting can As production demands increase, lead times need to be decreased
also be adjusted in real time, depending on the surface finish of a without compromising quality. The ability to confidently perform
gear, to ensure the image is not washed out or distorted. everything ranging from quick checks to in-depth QC inspections
An advanced vision system is combined with equally capable soft- in seconds has never been more important. The Starrett AVR-FOV
ware. Systems such as the Starrett AVR-FOV benchtop vision system allows for multiple small gears, or more features of a larger gear,
have integrated software to make the inspection process intuitive to be placed in the field of view. When combined with Super Image
and user friendly. CAD files can be imported as DXF files to instantly technology, where a master image of the entire stage is created from
compare a feature such as gear tooth thickness or slot width to a multiple smaller images, entire batches of gears can be inspected
master overlay for quick checks. Optional touch probe capability simultaneously.
also provides CMM (coordinate measurement machine) functional- This process is scalable as well. Starrett vision systems come in
ity by allowing data points to be taken from discreet, hard-to-reach a variety of sizes — from small, benchtop inspection microscopes
areas including bore holes that might also be a precision feature on to benchtop vision systems, to floor standing systems with large
a given gear. A touchscreen monitor allows the user to simply touch stages, all capable of being equipped with multiple lenses. Once the
features of the part to record desired features such as points, lines, results are obtained and presented to the user as a report, they can
arcs, angles, and more. Once the desired features are collected, they be instantly saved and exported in a number of different formats,
can be compiled into a part program that can be stored for future use. depending on the application requirements.
Variable lighting control can also be built in as programmable steps. When it comes to inspecting the numerous features of a gear,
there are many paths to success and all of them have their merits.
EASE OF USE In a modern manufacturing world, however, where speed and accu-
At this point, a user can walk up, place a gear or multiple gears in racy are paramount, the speed, accuracy, and ease-of-use of a vision
the view of the camera and initiate the program. In a few seconds, system is invaluable.

ABOUT THE AUTHOR

CW Moran is Marketing Specialist for the Metrology Division of The L.S. Starrett Co. His first role at Starrett was in the production department. For
more information, go to www.starrettmetrology.com.

No Money for Capital Equipment Purchases? NO PROBLEM!

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46     gearsolutions.com
YOU’VE GOT THE PRODUCTS.
YOU’VE GOT THE SERVICES.
NOW, LET US SHARE YOUR STORY.
Gear Solutions wants to make sure the best
possible audience knows your company.
Through our print, online, and social media
presence, our experienced staff can get your
message to an industry that wants to know
what you can do.

To learn more, contact national sales manager

Dave Gomez at [email protected]
or call 800.366.2185 ext. 207

February 2022     47
COMPANY AVERS MACHINE AND GEAR
PROFILE

QUALITY
BUILT INTO
EVERY PART

A helical pinion being inspected after

running in new HERA 90 CNC hobber.
(Courtesy: Avers Machine and Gear)

48     gearsolutions.com
Avers Machine and Gear provides its customers
with a variety of precision machined components
and gearing in materials including aluminum, tool
steel, plastics, high-alloy steels, stainless steels,
brass, and bronze with an emphasis on quality
of product made to customers’ specifications.
By KENNETH CARTER, Gear Solutions editor

D
on’t let Avers Machine and Gear’s short history
fool you. Despite its young age, the company’s
expertise spans decades — performing tasks
from machining existing parts to designing
and creating the gears themselves.
“Originally, we were a CNC turning and mill-
ing shop, and we had relationships with other gear
companies, and we would turn a lot of their blanks
and machine a lot of their components,” said Chris
Wellman, president of Avers Machine and Gear. “That
was our beginning relationship, but a short time later,
we bought a small gear company and started making
our own gear product.”
That gear product range includes spur gears, helical
gears, ground-thread worms and worm gears, splines,
and straight bevel gears, according to Wellman. The
company produces these products competitively to
customer-required delivery.

QUALITY PRODUCTS,
COMPETITIVE PRICING
“On the gear side, what we try to do is offer quality
products at competitive pricing,” said Ivan Torres, vice
president of Avers. “Most of our employees are all very
efficient and run multiple machines, so we’re able to
basically provide a better price and product than some The new Zeiss CMM system inspecting parts for 100 percent size
of our competitors based on their size. In addition, we and cylindricity. (Courtesy: Avers Machine and Gear)
try to run minimal overhead here. So, you’re getting
the benefits of a big company at the price of a smaller, be successful, according to Wellman.
tighter-run company.” “You have to have stuff in place, right? You have
In constructing Avers, both Wellman and Torres to be ISO certified; you can’t just do a part of it and
— having worked for a large corporation in the past — have the other stuff be done outside; it doesn’t work,”
were able to look at what worked and what didn’t and he said. “You have to have all your core competencies
adapt it for Avers. controlled. You have to do the work in-house. You have
“The company at the time when we were working to inspect everything that you do. And so, with all
for them was over $125 million in revenues,” Wellman of that knowledge, we just started chipping away at
said. “We were able to look at all the systems and all the bringing new equipment in and training new and
different things they had in place from ISO to company existing people and adding new processes and new
policies, shop efficiencies, and ERP systems. And what inspection equipment to be able to check everything
we tried to do was pick the best of all of those things that we manufacture. We just kept expanding, not
that worked and implement them at our company. So, only our size ranges and amount of product that we
we have this experience from the larger side of things, can make, but our capabilities as well.”
where some small businesses may not have that expo-
sure, and we were able to adapt best practices.” EXPANSION PLANS
Those challenges have to be addressed in order to Not content with resting on its current success,
February 2022     49
Wellman said Avers is constantly looking to
expand and evolve.
“We’re always testing new tools to be running on
“We’re always testing new tools to be run-
ning on our equipment; we’re always trying
our equipment; we’re always trying to improve
to improve our process,” he said. “But more our process. But more importantly, everything
importantly, everything that we do now as
far as equipment and capital expenditures, that we do now as far as equipment and capital
we’re doing more and more automation.”
To that end, Avers has purchased a new
expenditures, we’re doing more and more
HERA with auto load-unload capabilities, and
the company recently added an eight-pallet
automation.”
changer to its Doosan DVF 5000, which is a
5-axis CNC milling machine.
Avers is also setting up an intranet
where all its machines will be connected to
each other, allowing for quick program-
ming using Mastercam across all the dif-
ferent machine platforms, according to
Wellman.
“We’re doing a tool management system
where, similar to where we have our hobs all
organized on an Excel spreadsheet, we can
just go grab the tool that’s needed right away
because they’re all organized on a grid sys-
tem,” he said. “We’re doing the same thing
for all of our CAT40 and CAT50 holders. By
organizing and laser etching each one and
putting together a system so when we go
make our Mastercam programs, we have a
whole tool library that’s already designed,
built, and on-hand. And then, if there’s no
tool available, we know we have to purchase
something.”

CUSTOMER SATISFACTION
That communication goes beyond the
machines and equipment and is very much
an integral part of how Avers deals with its
customers.
“I think one of the benefits that we have
is we’re very hands-on in the business, so
we’re always accessible when it comes to
communication and if someone has a proj-
ect,” Torres said.
“For the most part, I’ve tried to remove
myself as much as possible from sales to
handle other things, but we still have a lot
of customers who would just rather deal
with me directly. So, they’ll give me a call
and bounce ideas and then we have that
communication where we’re able to throw
back other ideas to see if this might be eas-
HERA 90 CNC gear hobber with auto load/unload system. (Courtesy: Avers Machine and Gear)
ier or save some money. And they take that.
It’s well received.”
Part of that ease of customer communication stems from all of CHICAGO ROOTS
Avers’ staff having an operations/engineering background, accord- Avers Machine and Gear began life shortly after Wellman left
ing to Wellman. Chicago Gear when he bought a vendor, Avers Machine. During a
“We don’t have just a typical sales guy here,” he said. “Everybody two-year, non-compete phase, Wellman spent that time growing the
has shop-floor experience. They’ve managed, run, done everything business and, at the end of those two years, Wellman bought a small
you can imagine on the shop floor. And so, everybody has a lot of gear company and brought it into the fold.
experience. When someone does call and they have questions, our Since that acquisition, Avers has only continued to grow, accord-
staff knows exactly what they’re talking about.” ing to Torres.
50     gearsolutions.com
 “In 2015, when we put a management team together, we were the industry may go is just part of what has made Avers a successful
doing X amount of sales per year, and we brought in the new product company that continues to grow.
line with gearing,” he said. “Since 2015, with the acquisition, we’re “Automation is the wave of the future, so we’re actively looking
pushing a quadrupling of our sales. We have become ISO certified. We into other ways of growing in those fields and getting more and more
went from a 12,000-square-foot facility to 30,000 feet. That was a lot automated in here,” Torres said. “Trying to run lights out is one of
bigger than what we had, and now, we’re wrapping up an expansion our goals. And that helps our employees as well.”
for an additional 7,000 square feet.” Wellman also emphasized that Avers will be on the lookout for
In addition to the physical growth, Avers’ employees have also that ideal acquisition that would make a good addition to the com-
grown from the 20s to almost 60, according to Torres. pany portfolio.
“And we’re not done,” he said. “We’re constantly evolving. Another “We have been very successful in acquisitions, and so, if the right
big thing for us, I think, is to create a company where our employees acquisition comes along again, we can take that other company and
are very comfortable and enjoy coming to work. We worked at other adapt our procedures and processes and systems and everything else
places where sometimes the unneeded pressure and stress that was to it and make it more efficient,” he said. “Like the last addition, our
put on you made you maybe not want to come to work or not enjoy last acquisition, we didn’t have one customer overlap, and we were
it as much. We try to keep it as fun as possible for all our employees. able to sell all of our products to all of their customers. It was really
And that’s also by investing in the facilities, in technology, equip- a great marriage. We’re looking for another one. It could be a small
ment, and also in our employees by being able to pay them very com- company; it doesn’t have to be a large company, but somebody that
petitive wages. It’s not just achievements as a company, but achieve- has some core competencies that might not be the same as us but
ments also as coworkers and employees. And it puts a smile on your might help support what we’re currently doing.”
face when you’re able to see where you’re at right now.” That ambition and expertise has enabled Avers Machine and Gear
An example of that is Avers is installing air conditioning in the to have the right expertise in place in order to take any job request
entire facility, according to Wellman. to the next level.
“A lot of guys have expressed interest in that, and we followed “Avers is new to the gear industry, but all of us here are not new to
through with it, and we have a good rapport with our employees, the gear industry, because we’ve been in it our entire lives,” Wellman
and we see a lot of advantages of it,” he said. “It certainly is a very said.
large cost, but I think it’s going to pay for itself in quality and reten-
tion of employees.”

LOOKING TO THE FUTURE MORE INFO www.aversmachine.com

Attention to what keeps employees around to where the future of

YOUR INDUSTRY NEWS SOURCE COMPACT. CONSISTENT. COMPETITIVE.

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February 2022     51
 PRODUCT
SHOWCASE NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS

Olympus’ new PRECiV™ software enables microscope users to easily capture precise, repetitive 2D images and measurements. (Courtesy: Olympus)

Olympus software guides tional darkfield), polarization and differ- the distance between two points, auxiliary

users to make precise

ential interference contrast (DIC) imaging lines (available in PRECiV Pro and PRECiV
for flexibility and offers robust color ren- Desktop) to make complex geometric mea-
2D measurements dering and high resolution to provide high-
clarity images.
surements and a magic wand for automatic
area detection enable inspectors to be confi-
PRECiV™ software enables users in pro- The software’s intuitive interface is sim- dent in their data.
duction, quality control, and inspection to ple to use with a navigation tab that clearly Acquiring all-in-focus images that extend
make precise, repetitive 2D measurements groups the software’s functions — such as beyond the microscope’s field of view is also
and obtain results that comply with the lat- observation, acquisition, and measure- easy. The extended focal imaging (EFI) func-
est industrial standards. With robust data ment — using large, clearly labeled buttons. tion serially acquires multiple images in dif-
sharing and security features, PRECiV soft- For newer users, advanced settings remain ferent focal planes while the panorama func-
ware makes microscopy workflows faster hidden while experienced users can easily tion enables users to move the stage across
and more efficient. access all the available features and func- the sample and then stitch those images
PRECiV software turns any manual tions. The home screen can be customized together into one large image. Using PRECiV
microscope into a comprehensive imag- so that the features and functions used most software, users can now combine instant EFI
ing and measurement platform. The soft- often can be readily accessed. and panorama images while keeping both
ware can control all Olympus conventional PRECiV software enables precise, repeti- hands on the microscope.
industrial microscopes, their coded func- tive two-dimensional measurements on a For advanced applications like grain
tions, Olympus motorized nosepieces, and live or recorded image. Powerful functions sizing or non-metallic inclusions, optional
Olympus digital microscope cameras. It like auto edge detection (available in PRECiV Materials Solutions guide users through the
supports brightfield, darkfield, MIX (direc- Pro and PRECiV Desktop) to reliably measure steps required to acquire measurements that
52     gearsolutions.com
comply with the latest standards, including tion/cleaning, finishing, and polishing. A
ISO, ASTM and JIS. “best product” solution is referenced for
PRECiV software has robust data shar- each application. In addition, an applica-
ing and security features (Olympus can tion matrix provides a product selection
provide a manufacturer disclosure state- guide divided by material and cost require-
ment for medical device security [MDS] ment, whether by performance or economy
that focuses on the NIST framework for criteria.
cybersecurity). With a connected work- The guide also has a grit application
station, users can easily save images and table which shows the grit overlap for each
configuration files to the cloud or a net- product type and every stage of the appli-
work drive, receive automatic software cation process. Process-to-product recom-
updates and security patches, use a floating mendations are provided based on material
license, and upgrade to new versions. Images including mild steel, stainless steel, and
can be saved and loaded in multiple formats aluminum.
or saved as a JPEG with the accompanying Fourteen pages of the product guide
calibration information for traceability. detail technical tips for application steps
Sharing methods and configuration files — and recommended products. Application
including measurements, image processing steps for various materials include weld
settings, and materials solutions settings preparation and removal in carbon steel,
— between connected workstations makes cut-off to commercial finish in stainless
it possible to get the right information steel, weld removal to a bright finish in
in front of the right person quickly and stainless steel, aluminum and non-ferrous
easily. metal preparation for paint/coatings, paint
For more information about PRECiV soft- coating and corrosion removal, scale remov-
ware, visit www.olympus-ims.com. al/cleaning, sharp edge removal after laser
cutting in carbon steel, and final finish pol- The Norton product guide for abrasive products for
ABOUT OLYMPUS ishing in carbon steel and stainless steel. right angle grinding is designed to guide users in
Olympus is passionate about the solutions selecting the best product for their needs. (Courtesy:
it creates for the medical, life sciences and MORE INFO www.nortonabrasives.com Norton Abrasives)
industrial equipment industries. For more
than 100 years, Olympus has focused on
making people’s lives healthier, safer and

CUSTOM ENGINEERING,
more fulfilling by helping detect, prevent,
and treat disease, furthering scientific
research, ensuring public safety and captur-
PROTOTYPE WORK, PRECISION
MACHINING, ASSEMBLIES AND
ing images of the world.

MORE INFO www.olympus-ims.com

STANDARD COMPONENTS
Norton product guide Gears, pulleys, shafts,
bearings, couplings,
simplifies making fasteners, custom
abrasives selection gear boxes
Norton | Saint-Gobain Abrasives, one of the
world’s largest abrasives manufacturers, has
introduced a new comprehensive 24-page
product guide for right angle grinding. The
new guide simplifies proper abrasives selec-
tion for varying process steps and materials,
including the most complex and challenging
right angle grinding applications. ISO9001:2015 & AS9100D,
Explained in the guide, Norton abra- ITAR Registered, NIST.SP800-171R1,
sives are classified in Best, Better, and Trace Certified,
Good Performance/price tiers to help users Class 100 clean room
choose the right product for a specific appli-
cation. The product guide is color-coded for
the eight key application processes found
in metal fabrication including cutting, Nordex.com I [email protected] I [email protected]
heavy-duty grinding, stock removal, blend- 800-243-0986 I 203-775-4877
ing/refining, deburring, surface prepara-
February 2022     53
 MARKET Manufacturing excellence through quality, integration,

PLACE materials, maintenance, education, and speed.

Contact Gear Solutions at 800-366-2185 to feature your business in the Marketplace!

WE’RE
CERTIFIABLE
Our ISO 17025 A2LA Laboratory is available
to certify or recertify your Master Gears and
SERVICING
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FELLOWSGEAR SHAPERS Spline Gauges or Contract
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Site Service:
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The Voice of Manufacturing Inspection of your gears.

Training:
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Via Telephone (Electrical
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Preventive Maintence Plan: Customized to Your Needs
& Mechanical) www.mfgtalkradio.com “out of service” time.
Parts: New and/or
Preventive Used Plan: Customized to Your
Maintenance
Retrofi
Needsts - Counters, Servo Controllers, or Single and
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Parts: Axis
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Multiple
Allen Axis CNC
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Tim Grady
174 InnovationADAMS
ALLEN Drive N. SHAPER SERVICES, INC.
Clarendon, VT 05759
174 Innovation Drive • North Clarendon, VT 05759 6161 Webster Street, Dayton, Ohio 45414
Telephone:
Telephone:802-226-7891
802-226-7891
E-mail: [email protected]
E-mail: [email protected]
937-660-8182 [email protected]
Website: www.sharperservices.com
Website: www.shaperservices.com www.gearinspection.com

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54     gearsolutions.com
ADVERTISER
INDEX
CONTENTS PAGE NO.

All Metals & Forge Group................................................................ 11, 54

Allen Adams Shaper Services Inc...........................................................54

AVAILABLE SIZE
Amorphology........................................................................................IFC RANGES 0 – 18”
INTERNAL
MODELS
Avers Machine and Gear........................................................................54 AVAILABLE

B&R Machine and Gear.........................................................................12

Forest City Gear....................................................................................19

Involute Gear & Machine.......................................................................14

Liebherr..................................................................................................2

KAPP Technologies................................................................................51

KISSsoft USA LLC................................................................................25

Machinist Inc........................................................................................13

MicroGear.............................................................................................54

Nidec Machine Tool America................................................................. BC

GEARING AHEAD TO MEET INDUSTRY’S
New England Gear...................................................................................7 DEMAND FOR PRECISION
Nordex.................................................................................................53
– SERVING –
Aircraft • Aerospace • Actuation
Piselli Enterprises Inc.......................................................................... IBC Instrumentation • Optic
Robotics • Radar • Medical
Penta Gear Metrology LLC ............................................................. 46, 54 Marine • Defense • Experimental
Prototype • Production
RHH Inc...............................................................................................25 Hi-Performance Automotive
Precision Gear Products (up to AGMA Q14):
SMT.....................................................................................................10 Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, Clutch Gears,
Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, Bevel Gears, Miter Gears,
Solar Atmospheres................................................................................43 Metric Gears, Internal Gears, Idler Gears, Gear Rack & Pinion, Worms, Wormshafts,
Splines, Spline Shafts, Serrated Shafts.
Southern Gear & Machine........................................................................9
CNC Thread Grinding
STD Precision Gears..............................................................................55
Nadcap Accredited: Heat Treatment, Induction Hardening, Passivation

STD Precision Gear & Instrument, Inc.

Toolink Engineering Inc...........................................................................1 318 Manley St. • W. Bridgewater, MA 02379
(888) STD-GEAR or (508) 580-0035
United Tool Supply................................................................................55 Fax (888) FAX-4STD or (508) 580-0071
E-mail [email protected] • Web site: www.stdgear.com
Wenzel America......................................................................................4

February 2022     55
 Q& A GLENN GARRETT
CHIEF TECHNOLOGY OFFICER 
INTERVIEW WITH AN AMORPHOLOGY, INC.
INDUSTRY INSIDER

“Precision BMG gears that do not require heaters allow

for lighter weight structures and systems.”
Amorphology has made strides in the advancement of Bulk and also for efficient processing where there’s going to be interest-
Metallic Glass (BMG) for gears. What makes BMG an industry ing applications.
material to watch? Robots require extremely precise and difficult-to-make gears —
BMG is a relatively new class of metallic alloys that is now transition- especially if they’re working side-by-side with humans. You need the
ing out of academia and into industry. NASA is responsible for pulling confidence that these machines will behave and move as advertised,
BMG into the world of gears as they faced a pretty unique challenge and the gears required have very small-shaped teeth.
for long-life precision motion at the cold temperatures of space. As Our strategy is to mold these difficult, expensive gear compo-
temperatures drop, wet lubricants increase in viscosity, requiring nents. If we cut and inspect the cavity very carefully, we remove
powered heaters to make sure the steel gears are adequately lubri- some of the quality burden by making sure you have a really good
cated. For NASA, not every situation where they would like precision permanent mold then reproducing that precision across large num-
motion has an abundance of available power. bers of parts.
Through testing and validation at low temperatures, they found
that gears made out of BMG last significantly longer than steel under How does quality assurance factor into the material quality as
these demanding conditions. Even though the steel is coated with well as the molds and the final parts?
a dry lubricant, it wears off, and the stiffness of the steel results in It’s extremely critical. My background is in the science and manu-
high contact stresses that accelerate wear to unacceptable levels and facturing of BMG, but I am a recent arrival to the world of precision
give poor gearbox performance. Precision BMG gears that do not gearing. It has been incredibly challenging, yet fun, to bring BMG
require heaters allow for lighter weight structures and systems that into such a demanding field. The tooth widths range from a half
can expand the capabilities of satellites and rovers. millimeter to several millimeters with micron requirements for the
The gears we make with BMG may be quite small for some read- tooth profiles. It is exciting to push the boundaries of BMG technol-
ers of Gear Solutions. To obtain the amorphous character of BMG, we ogy and alloy innovation in this space. The dimensional tolerances
must cool the molten liquid quickly enough to bypass crystallization of the gears we are making demand extreme accuracy in the mold,
altogether. and the desired performance levels require stringent material qual-
While this does limit the size and thickness of gears that we mold, ity standards.
it is also a key manufacturing advantage. Because the liquid does Amorphology has invested in its own machining and inspection
not crystallize, it doesn’t shrink dramatically, and small low-module center to verify the dimensions of the molds and resulting parts.
gears can be molded with high precision in permanent metal molds Having this capability in-house allows us to rapidly inspect, machine,
with smooth surface finish thus eliminating traditional expensive and iterate on molds or parts as necessary.
post-processing steps. We also have our own full metallurgical characterization labo-
In essence, this is an exciting new material that offers different ratory so we can ensure high-material quality and correlate it with
properties to complement existing gear technologies. They address the full gearbox performance, which is measured on our gearbox
challenges in areas such as space where lubrication or relubrication test bench.
is difficult. They also enable the manufacture of gears with very fine Because the material is different from steel, we are exploring the
teeth with minimal steps — eliminating some of the more expensive broad number of gear-design parameters that can be adjusted. Our
processes. BMG alloys have a modulus about half that of steel; they are lower
density and still relatively hard. We have a unique opportunity to
What Earth-bound applications do you see this being used in? take advantage of those properties to innovate in the gear space.
Terrestrial use cases include small precision gears for motion con-
trol, strainwave gears in robot and cobot arms, and other small What should we stay tuned for coming out of Amorphology’s lab?
complex precision components. There are also many unusual envi- Just directly, NASA is responsible for pulling BMG into the world of
ronments on Earth that could benefit from the material properties gears and doing the initial validation. Their work gave other custom-
of BMG including corrosive environments, food handling, medical ers the confidence to approach us and try it for themselves.
applications, vacuum environments, and extremely cold environ- And while we will absolutely continue working in the space sector,
ments. we are also in the process of developing the first commercial Bulk
We also see a gap to address in applications where the raw Metallic Glass strainwave and planetary gearboxes to validate with
strength of steel is not required, but the strength of aluminum and industry leading partners here on Earth.
plastic is not enough. These use cases may also leverage the unique
manufacturing techniques allowing for efficient production of small,
low-module gears.
MORE INFO www.amorphology.com
I believe we’re in the sweet spot of properties for the material
56     gearsolutions.com
 2005 Bourn & Koch model 100H CNC horizontal Hobbing Machine, 5” max diameter part

Fellows Model 10-4 CNC 3-axis Gear Shaper

with Fanuc Controls, Motors & Drives

2012 Gleason Model 150 SPH CNC Power Honing machine

2020 Mitsubishi Model ST-40A CNC guideless

Gleason Model 350 GMM CNC Gear Testers, Fellows Model 36-8 12” Riser Cutter
Gear Shaper, 18” max diameter capacity option updated software 2016 & Renishaw probes Elevating Gear Shapers

1997 Gleason Model Tag 400 CNC Generating 1997 Gleason Model GTR-250VG CNC 2005 Gleason Model Phoenix 125GH CNC 2006 Mitsubishi Model SE25A CNC
Style Gear Grinder 400mm capacity chamfering, pointing and rounding 6-axis Gear Hobber, 180-position loaders Gear Shaper with autoloading

820 Cochran Street Statesville, NC 28677

704.609.0766 • [email protected]
THE #1 SOURCE FOR USED GEAR MEMBER

www.pisellient.com
MACHINERY — AND MORE! MEMBER
Contact us to add your surplus machinery
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