Materials Mattertooth tips

hot seataGMa UpDate

Q&a: tony WerschkyDelta ReseaRch/Delta GeaR

coMpany profile: DRake ManufactuRinG

seRvices co.

gearsolutions.comJUNE 2013

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agazine

June 2013

HandlingTWiST

CaSe STudy: VieWpoinT SySTemS/gleaSon WorkS

alCrn-BaSed Hard CoaTingS

on modern CarBide ToolS

energy effiCienT induSTrial

gear luBriCanTS

kapp-niles.com 2870 Wilderness Place | Boulder, CO 80301 p: 303.447.1130 | f: 303.447.1131 | info@kapp-niles.com

BOOTH 611

Capital Gain.

Invest in your future. You can’t put a price on the value of a Kapp Niles machine. Our machines are

built for the long haul, so you can pass them down from generation to generation – with 97% of our finishing

machines still in operation since 1984. Plus, our quality service and retrofitting capabilities allow you to stay current

with changing technologies. Invest in Kapp-Niles and invest in the future of your business.

The ZP 20 is designed to grind external and internal gears, up to 2,000 mm using dressable or non-dressable

CBN tools. Automatic measuring and balancingfurther increase ZP’s productivity.

Indiana Technology & Manufacturing Companies, Inc. (ITAMCO), left to right: Joel D. Neidig - Technology Manager Gary Neidig - Vice PresidentNobel Neidig - President

Booth#723

Precise and productive.With the LCS product line a series of machines is now available that is characterized by their productivity and versatility.

Generating or profile grinding on one machine Dressable corundum and CBN tools Galvanic CBN tools Most economical grinding worm dimensions Short floor-to-floor times through automation Fast set-up for flexible gear finishing

Generating and profile grinding machines from Liebherr.

Liebherr Gear Technology, Inc.1465 Woodland DriveSaline, Michigan 48176-1259Phone.: +1 734 429 72 25E-mail: info.lgt@liebherr.comwww.liebherr.com The Group

With the LCS product line a series of machines is now available that is characterized

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JUNE 2013 3

Features

Company Profile: Drake ManufacturingBy Tim Byrd

Jim Vosmik, president of Drake Manufacturing, explains that his customers don’t want machine tools; they want quality parts.

AlCrN-Based Hard Coatings on Modern Carbide ToolsBy Sergio Lopez

The refinement of coatings delivers decisive advances with respect to cost-effectiveness and manufacturing reliability.

Case Study: Viewpoint Systems/Gleason WorksBy Jim Campbell and Viewpoint Systems

The Gleason Works sought to create a dynamic, torque-controlled lapping solution with responsive, real-time feedback to create better quality gears.

Energy Efficient Industrial Gear LubricantsBy David Blain, Angela Galiano-Roth, Rick Russo, and Kevin Harrington

We can help the industrial sector manage the projected demand through the use of energy efficient synthetic gear lubricants, which would maximize the energy available to meet demand.

28

32

48

38

42Handling Twist

By Thomas Weber

There is a lot to be said for the precise measuring methods that

can be achieved right on the production machine, specifically

on the 5-axes LFG.

BroachmasterFP.indd 4 12/20/11 2:36:20 PM

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JUNE 2013 5

Departments

Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates: $72.00 per year. Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: Send address changes to Gear Solutions magazine, P.O. Box 1210 Pelham AL 35124. Publications mail agreement No. 41395015 return undeliverable Canadian addresses to P.O. Box 503 RPO West Beaver Creek Richmond Hill, ON L4B4R6. Copyright 2006 by Media Solutions, Inc. All rights reserved.

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

8Trends, data, and developments to keep you aware of what’s happening with your colleagues in the gear-manufacturing industry around the

country and world.

Industry News

59News of products, equipment, and resources from across the manufacturing spectrum that will help propel your

company toward success.

Product Showcase

24In this final “Materials Matter” column on Powder Metal Gears, some new tests that we have conducted will be presented, and

some loose ends from past columns are tied up.

Materials MatterAnders Flodin

27One of the requirements depending on a gear’s mass when HPGQ is considered is the hardenability of the steel.

Hot SeatJack Titus

26When a gear is produced by machining, it must begin with a blank that is properly designed and produced in full accordance

with the specifications.

Tooth TipsWilliam P. Crosher

57MACHINERY

65MARKETPLACE

67ADVERTISER

INDEX

American Gear ManufacturersAssociation

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

Resources

JUNE 2013 | VOLUME 11 / NO. 06

Tony WerschkySaLeS/PrOJecT MaNaGer

Delta research/Delta Gear68Q&A

Cover Photo: Liebherr-Verzahntechnik GmbH

19

Recently I've enjoyed scanning the titles of the technical papers for this fall’s AGMA technical meeting (you can find information in our AGMA update section). Here are a few samples:

“Striving for High Load Capacity and Low Noise Excitation in Gear Design” “Metallurgical Investigation of Tiger Stripes” “Precision Shaped Grains Turn the Concept of Gear Grinding Upside Down”

It's clear there are minds across the country hard at work on turning the whole industry “upside down” in the quest to make the perfect gear. And Gear Solutions has a front row seat for the whole show; it’s why we’re the most read publication in the gear industry.

Our editorial focus is on coatings and finishing this month, and a fine example of the finishing process is evident in the results of an exciting case study involving The Gleason Corporation. To prevent noise and vibration often present their applications, gears are lapped or ground to smooth their teeth surfaces and improve operational characteristics, as well as reduce surface and tooth spacing deviations that may produce noisy gear sets. Jim Campbell describes how Gleason turned to his company, Viewpoint Systems, to help develop and implement an embed-ded control system to measure these deviations in real-time and apply dynamic corrective torque.

The folks at Liebherr were also kind enough to give us a play-by-play of how specific and con-trolled handling of twist in profile grinding can solve production-related problems, opening new gear manufacturing doors, in their article “Handling Twist.”

Coatings, on the other hand, are Star SU's specialty, and we'll hear about their potential for a significant reduction of costs in mechanical machining through increased performance of the deployed tools.

Of course, none of this will remain possible without a continual focus on sustainability, which ExxonMobil Corporation defines as "Balancing economic growth, social development, and envi-ronmental protection so that future generations are not compromised by actions taken today." For our part, how will we as an industry address the question of sustainability in the coming years? ExxonMobil's own David Blain et. al suggest the answer lies, at least in part, in energy-efficient synthetic gear lubricants. Learn how these lubricants would maximize the energy avail-able to meet demand in their article, “Energy Efficient Industrial Gear Lubricants.”

Drake Manufacturing is this month’s company profile. I got a chance to sit down with company president Jim Vosmik to discuss the retirement of highly skilled post-war machinists, the exper-tise they’re taking with them, and how the next generation of machine operators is changing the whole game. Similarly, our Q&A subject, Delta Research/Delta Gear’s Tony Werschky, talks about finding capable individuals to help your company grow. As he puts it, “Good gear people don’t grow on trees.”

Our three columnists once again provide valuable insight into their respective fields. Jack Titus examines the influence of heat treated gears on motor-in-wheel locomotion in his "Hot Seat" column, and Bill Crosher begins a new study on based on his knowledge of gear blanks in "Tooth Tips."

Finally, I’d like to extend a personal “Thank You” to Anders Flodin, our “Materials Matter” columnist, for his contribution over the last year. June will mark the conclusion of Dr. Flodin’s series of discussions on powder metal technology, and on behalf of the entire Gear Solutions staff, we thank you for sharing your expertise with our readership. We wish you the best, Anders!

Tim Byrd managing editor

Gear Solutions magazineeditor@gearsolutions.com

(800) 366-2185 x205

6 gearsolutions.com

Published by Media solutions, inc.P. O. BOx 1987 • Pelham, al 35124

(800) 366-2185 • (205) 380-1580 fax

David C. CooperPuBlisher

Chad MorrisonassOciate PuBlisher

eDITOrLETTERFROM THE

Dav id C . C o operPresident

C had Mor r i s on Vice President

Ter e sa C o operOPeratiOns

Contributing writersdaVid Blain

Jim camPBellWilliam P. crOsher

anders flOdinkeVin harringtOn

angela galianO-rOthsergiO lOPezrick russOJack titus

thOmas WeBer

eDitoriALStephen Sisk

editOr

Tim Byrdmanaging editOr

sALesChad Morrison

assOciate PuBlisher

Michael SellaroliregiOnal sales manager

CirCuLAtionTeresa Cooper

manager

Kassie HugheycOOrdinatOr

Jamie Willettassistant

ArtJeremy Allen

creatiVe directOr

Rebecca AllengraPhic designer

Michele HallgraPhic designer

Coop wants to use this one for the website

Vertical Logo Horizontal Logo

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INDUSTRYNEWS

DMG/MORI SEIKI USA, a leading manu-facturer of machine tools, has announced record attendance at its Innovation Days 2013. The event, which ran May 7-10, welcomed 3,208 visitors from more than 10 countries. The attendance represents a 45 percent increase from 2012. This is the ninth year DMG/MORI SEIKI has

hosted employees, partners, customers, and potential customers at its U.S. head-quarters.

Randy Harland, executive vice president of sales, attributes the event’s success to both substance and consistency.

“People know they can come here and see changes in manufacturing processes

from each year to the next, so we get a lot of repeat customers spreading the word that this is the place to be,” said Harland.

Highlights and hot topics at Innovation Days 2013 included:

• Five U.S. machine premieres: While Innovation Days boasts 45 machines

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

New Products, Trends, Services, and Developments

DMG/MORI SEIKI Experiences Record Attendance at Innovation Days 2013

JUNE 2013 9

under power, five made their U.S. debut at Innovation Days. Those machines include the DMC 85 monoBLOCK®, the Vertical Mate 125, the NVX7000/50, the NLX1500SY/500, and the NLX2000SY/700. Attendees experienced dynamic demonstra-tions on all machines.

• Presentation of NIMS accreditation: The National Institute for Metalworking Skills (NIMS) was on hand to present DMG/MORI SEIKI University (DMSU) with its official accreditation for its CNC machining and maintenance training programs.

• Gear milling technology advancements: DMG/MORI SEIKI manager of gear produc-tion Nitin Chaphalkar, and Nicklas Byland, InvoMilling Project Manager at Sandvik Coromant, presented the InvoMilling™ pro-cess, a new machining technique that allows faster, more efficient production of spur and helical gears in multitask machines and machining centers. The new technology was a highlight for many attendees as the need for flexible manufacturing increases.

DMSU welcomed more than 200 Chicago-area high school students to increase awareness of and enthusiasm for the machine tool industry. To fur-ther students’ interest in manufactur-ing, 18-year-old Andretti Autosports INDY Lights driver Zach Veach spoke to stu-dents about the importance of machining and manufacturing in the racing industry.

Ronda Turner Peterson, CEO with Peterson Machining located in Boulder, Colorado attends Innovation Days to help her company forecast new offerings.

“We’re a job shop, so our product changes all the time. We like to see what’s up and coming and what areas we might want to move into for our next (machine) purchase,” Peterson said.

DMG/MORI SEIKI looks forward to hosting future successful Innovation Days events as well as sharing more groundbreaking technologies at EMO 2013 in Hannover, Germany September 16-21.For more information, visit www.dmgmoriseikiusa.com.

Precision Technology Group Acquires SP GearsThe Precision Technology Group has acquired Orpington-based SP Gears,

which provides products for clients across the valve, nuclear, rail, marine, and automotive industries. The company has nuclear accreditation, enabling it to service customers in the nuclear new build and refurbishment sectors.

The Precision Technology Group (PT Group) specializes in creating innovative technology for motion with manufactur-

ing, service, and supply businesses located in the USA, Great Britain, and Australia. With the acquisition of SP Gears, the PT Group now comprises four companies: Precision Technology USA Inc, manufacturer and supplier of indus-trial and defense high performance elec-tro-mechanical actuators; Hypac Pty Ltd, an Australian manufacturer of hydrau-

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lics systems used in marine applications, including a unique range of lightweight deck machinery for fast commercial and leisure vessels, and of presses used in wine production and other commercial applica-tions; and Seaway Powell Marine Ltd, the British-based designer and manufacturer of hydraulic equipment and deck gear for sailboats, powerboats, super-yachts, and commercial craft.

Commenting on the acquisition, Chris Oswald, who heads up the PT Group, said: “We are delighted that we have concluded the successful purchase of SP Gears as this brings outstanding high quality gear manu-facturing expertise into the PT Group. SP Gears’ products and services will comple-ment the specialist and innovative skills available from our other Group compa-nies, enabling the sharing of engineering, design, manufacturing, supply, and service to enhance our customer offering across our core markets in marine and automation.”

SP Gears has significant growth poten-tial in several rapidly expanding markets. All existing staff are staying on with the business, including managing director Greg Jenkins, who will be a leading figure in our growth plans over the next few years. The PT Group is achieving growth of around 40% a year and SP Gears will be a key contribu-tor to the future. For more information, visit www.pt-usa.net.

Seco/Warwick Set to Deliver Second 12 Bar Vacuum Furnace to IBC Coating Technologies

Seco/Warwick will deliver a 12 Bar Universal HPQ™ (High Pressure Quench) vacuum fur-nace to IBC Coating Technologies, Inc. in Lebanon, IN this spring. This low-pressure vacuum carburizing furnace with high tem-perature convection heating is intended for hardening and carburizing bearing steel and aerospace components. The furnace will

be designed with a hot zone of 24” x 24” x 36” and a maximum temperature rating of 2400ºF and 1300-lb gross load capacity. It will also have 12-bar pressure quench-ing. Additional features include isothermal quenching and modifications to address low-distortion and demands of high-performance bearings and gear markets. This is the sec-ond vacuum furnace that IBC has purchased from Seco/Warwick.

The Seco/Warwick Group and its five business segments produce vacuum fur-naces (VAC), atmosphere furnaces (ATM), controlled atmosphere aluminum brazing furnaces (CAB), aluminum process furnac-es (AP) and vacuum metallurgy equipment Retech (VME) in its manufacturing sites in Poland (Seco/Warwick Europe), the United States (Seco/Warwick Corp. + RETECH Systems LLC), India (Seco/Warwick Allied Ltd.) and China (Seco/Warwick RETECH Mfg. (Tianjin) Co., Ltd.). Sales, service, and spare parts offices in Germany (SECO/WARWICK Services GmbH) and Russia (Seco/Warwick Russia) complete the world-wide customer care network. The Seco/Warwick Vacuum Team offers vacuum heat treating furnaces for hardening, tem-pering, annealing, solution heat treating, brazing, sintering, carburizing, carbonitrid-ing, high vacuum, CVD–graphitizing and degassing. Seco/Warwick has built some of the largest and technically advanced vacuum furnaces in operation today, devel-oping advanced technologies like Universal HPQ™ (High Pressure Quench), PreNit® and FineCarb® LPC vacuum carburizing, fully automated control systems, and mod-eling software. Vacuum furnace configura-tions are available for vertical, horizontal, and elevator style furnaces. Both cylindrical and rectangular hot zones with metallic or graphite heating elements are available for both new and used equipment. Retech LLC provides vacuum melting equipment. Visit www.secowarwick.com for more infor-mation.

IBC develops diffusion surface treatment technologies for anti-wear and anti-corro-sion applications. IBC innovative surface treatments, based on plasma-chemical and diffusion reactions—boriding, nitrocarburiz-ing, chrome carbide, vanadium carbide, etc.—are used in different applications with very good results.

JUNE 2013 11

IBC Coating Technologies, Inc. is a privately-owned company located in Lebanon, IN. The company started its activities in July of 1996 as a research and development project, based on the know-how and experience of its found-ers. The company has expanded the array of its services in material treatments. Learn more at www.ibccoatings.com.

Solar Manufacturing Launches Podcast SeriesSolar Manufacturing recently launched a new bimonthly podcast series in cooperation with Industrial Heating called “Vacuum Heat Treat Minute.” The topics will concentrate on provid-ing helpful tips and new knowledge to vacuum furnace owners and users.

The podcasts feature Solar Atmospheres CEO William R. Jones and Solar Manufacturing president Jim Nagy. Mr. Nagy explains, “Solar Manufacturing is dedicated to educating own-ers on how to best care for their vacuum furnace and keep it running smoothly for years to come. Between our engineering expertise and the feedback we receive from our sis-ter company, commercial heat treater Solar Atmospheres, we are intimately familiar with the challenges and best practices for getting the most out of your furnace investment. We are excited to have this new venue for sharing these lessons learned.”

The debut edition covers “The Advantages of Processing Titanium in Vacuum Furnaces” and the second explores “Responding Effectively to Utility Loss: Power/Gas/Water.”

The podcasts are available free of charge and can be accessed through the Industrial Heating website at www.industrialheating.com or the Solar Manufacturing website at www.solarmfg.com. If you would like to be alerted when the next podcast is posted, please email your request to info@solarmfg.com.

Gilman Precision Begins Work with New England ToolingEffective immediately, Gilman Precision will begin working with New England Tooling. They are headquartered in the city of North Hampton, New Hampshire and have eight technical representatives covering New York and New England. New England Tooling will serve as a representative for Gilman products and services.

This partnership allows companies within New York to easily communicate with Gilman

for sales quotes and provides product lit-erature and comprehensive in-field technical knowledge and support.

The counties within New York that have been assigned to New England Tooling for outreach predominantly include the western half of the state. New England Tooling represents vari-ous manufacturers of cutting tools, machine components, work-holding, and gauging. New

England Tooling has a technical representative within 90 minutes of 90% of the manufacturing in the areas that they cover. For more infor-mation on the services that they offer or for product support, contact Jeff Springer at jeff.springer@newenglandtooling.com.

Springer, owner of New England Tooling, stated, “We are happy to add Gilman to our product group. It allows us to offer additional

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solutions to our existing customer base as well as help Gilman grow their market share. Please contact us for your spindle reconditioning needs, new spindle or slide applications. We can also provide spindle/slide combinations for new machine builds.”

Gilman USA develops customized slides and spindles for value-minded engineers with exacting needs and stan-

dards, and provides expert service for virtually any manufacturer’s equipment. Serving a variety of industries and appli-cations, these engineered solutions are advanced by a highly skilled, knowledge-able, experienced team that delivers on-time and within budget. For more information, visit www.gilmanprecision.com, or call 800-445-6267.

Engis Corporation Celebrates Anniversaries Around the World

Engis Corporation, an early pioneer in the use of diamonds for lapping, hon-ing, grinding, and polishing applications, celebrates its 75th anniversary in 2013. Engis manufactures superabrasive fin-ishing systems consisting of machines, tooling, and consumable products. The group prides itself in not only supplying systems for fine finishing, but also the technical know-how through their Process Development Laboratories in the U.S. and Japan.

“Engis would like to thank its custom-ers, employees, affiliates, and distri-bution partners for working with us to establish the company as the leaders in superabrasives finishing systems,” says Stephen Griffin, president of Engis Corporation. “We earned this position by solving problems and developing custom solutions, and we will build upon this success by continuing to advance our diamond expertise and working hand-in-hand with end-users.”

Industries served include oil and gas, electronics, semi-conductor, medi-cal devices, aerospace, automotive, defense, ceramics, mechanical valves and seals, foundries, and mold and die. Engis employs approximately 220 people worldwide and remains privately held by the original founding family. Facilities include its headquarters in Wheeling, IL, (a Chicago suburb) and affiliate compa-nies in Japan, Singapore, Hong Kong, Korea, Canada, and the U.K.

Engis Corporation founded Engis Japan in partnership with Mr. Leslie Carter in April 1983 in Yokohama, Japan. It was Engis Corporation’s first entry into the Asian market. Since that time, Engis Japan has grown into a significant con-

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JUNE 2013 13

tributor to the Engis Group of Companies in Asia with its design, manufactur-ing, and customer support capabilities. Notably, it has expanded the Engis Corporation’s presence into precision lapping equipment and consumables for the LED, semi-conductor, and optical markets.

Engis Asia Pacific, based in Singapore, will celebrate its 20th anniversary in 2013. Engis Asia Pacific (EAP) was established in 1993 to support cus-tomers that were migrating from the U.S. to Southeast Asia to set-up their manufacturing facilities. EAP has been particularly active supplying high qual-ity finishing products and systems to the hard disk drive, optical, and auto-motive markets in the ASEAN coun-tries (Indonesia, Malaysia, Thailand, Singapore, Philippines).

Originally established in Chicago in 1938 as a trading company for qual-ity assurance instrumentation, Engis developed the industry’s first industrial diamond compound and established it under the HYPREZ trade name. Notable accomplishments include developing a diamond lapping compound, believed to have improved the accuracy of military aircraft guidance systems during WWII, and the micronization of diamond and CBN (cubic boron nitride) powders used in the synthesis of PDC (polycrystalline diamond compact) tooling for oiling and gas drilling. Anyone who has used a por-table hard drive or supermarket bar code scanner with lapped optical components has touched products shaped by Engis submicron diamond particles. For more information, visit Engis’ website at www.Engis.com or call (800) 993-6447.

Sumitomo Drive Technologies Launches New Version of PT UnitsSumitomo Machinery Corporation of America (SMA), U.S. headquarters for Sumitomo Drive Technologies, has now released Version 1.2 of its popular PT Units mobile app. This popular power-transmission industry mobile app has a newly-updated user interface and is now optimized for the latest versions of the Apple iOS and Google Android operating systems and displays. Originally launched in 2012,

PT Units offers three main functions: con-verting units, contacting Sumitomo Drive Technologies’ sales representatives, and connecting to Sumitomo’s web resources. Version 1.2 expands the features available in all three of those functions.

The unit converter quickly and accurately con-verts between commonly used units of power, torque, force, temperature, fluid volume, mass,

length, and newly added units: linear velocity, pressure and stress, and moment of inertia. Additional options available in this function include copying the resulting conversion text and pasting it into other applications, as well as setting the default units upon launching PT Units.

The contact function enables users to locate a Sumitomo Drive Technologies’ sales rep-

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resentative by navigating to find their location, or using their device’s built in “current location” feature to obtain the nearest representative’s contact information. PT Units Version 1.2 has expanded the contact search area. Now users can search globally for a representative in six continents (excluding Antarctica). This function also enables users with a smart phone to contact representatives in customer service via phone or email and tablet users via email.

The web function for Version 1.2 allows users with a data-network con-nection to navigate through Sumitomo Drive Technologies’ new global website, which is now optimized for mobile devices, for product data, industry-specific information, and white papers. Users may also use the provided links to visit the company’s Facebook, Twitter, and YouTube pages.

Designed to assist the power transmission and controls industry, PT Units is available in English, Spanish, Portuguese, French, Japanese, and now Korean and Chinese. Visit www.sumitomodrive.com for more information.

Walter’s New Website Simplifies Ordering, Delivers Array of Information Walter has unveiled a redesigned website featuring an expanded range of information and services. The new site, www.walter-tools.com, with its clear page layout and easy to use graphics, embodies Walter’s integrated TOOLSHOP concept, and is designed to simplify and speed-up the ordering of Walter products. Information can be

quickly accessed on the complete range of Walter Valenite, Walter Titex, and Walter Prototyp products, and features like TOOLSHOP’s “my product check” function gives users up-to-the-minute availability and pricing information. In addition, customers who work with the Walter GPS (Global Productivity System) catalog can add selected products to a personal wish list, which can then be transferred directly into the fast entry screen of TOOLSHOP, thereby speeding and simplifying the ordering process even further.

The new site provides convenient access to a wide range of information sources, including videos, downloadable apps and soft-

NEW RELEASE 03/2012

KISSsoft SoftwareThe Industry Benchmark for

● Gearbox Design● Gear Optimization● Contact Analysis● Shaft Design & Analysis● Bearing Design & Analysis● Industrial Gears, Heavy Machinery, Wind, Automotive, Medical

Download your free evaluationcopy from www.KISSsoft.com

KISSsoft USA, LLC3719 N. Spring Grove Road

Johnsburg, Illinois 60051Phone (815) 363 8823

dan.kondritz@KISSsoft.com

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

CIRCLE GEAR and MACHINESTRAIGHT BEVEL GEARS

SPIRAL BEVEL GEARS

.25” to 34 ½” diameter

32 dp to 1.5 dp

.5 module to 16 module

.25” to 33” diameter

32 dp to 2 dp

.5 module to 12 module

JUNE 2013 15

ware, and an array of free and download-able printed material including technical handbooks, brochures, and catalogs. In addition, the site’s social media facilities allow users to share tips and experienc-es with their peers, providing timely real-world information and best practices.

Importantly, the new website also makes it easy for customers to contact the service experts at Walter Multiply directly. The Walter Multiply competence brand helps customers optimize the entire production and tool logistics chain, thereby increasing their productivity sus-tainably.

“We wanted to create a platform which our customers can benefit from in their everyday work,” explained Bernhard Weihermüller, Walter’s manager for e-marketing and sales support. “For our customers, being close to our services and products is essential for ensuring smooth cooperation. Therefore, our new online presence not only simplifies tool orders, but also improves access to prod-uct information and provides a broader range of services.” He added that the Walter TOOLSHOP can be accessed in 20 different languages.

Walter offers an extensive line up of cutting tools for milling, drilling, turning, boring, and specialized tooling for unique applications through its competence brands Walter Valenite, Walter Titex, and Walter Prototyp, as well as multi-level service programs through its Walter Multiply brand. Regionally headquartered in Waukesha, Wisconsin the company has a strong network of distributors and field engineers across North America.

The Walter name is synonymous with productivity, thanks to more than 80 years of developing cutting tools and inserts that set new standards in quality, innovation and production. Take a look at all these products and more on the new website, www.walter-tools.com.

EXSYS Tool, Inc. Appoints New Territory Manager for CaliforniaEXSYS Tool, Inc., a provider of high preci-sion rotary and fixed tool holder solutions for CNC turning centers, recently hired Mike Englebrecht to be its territory man-ager for California. In this newly-created

role, Englebrecht will further enhance the company’s sales and support functions as well as overall market position on the West Coast.

With more than 30 years of industry-related experience, which includes sales, product development, and applications support, Englebrecht will develop new and foster existing relationships with

regional metal working manufacturers from various market segments.According to Stewart Bachmann, president of EXSYS Tool, Inc., the West Coast is expe-riencing a surge in manufacturing, which prompted EXSYS to develop this territory manager position. “There are significant growth opportunities for our advanced tool holders on the West Coast because

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shops need comprehensive metal work-ing solutions to effectively compete in today’s challenging marketplace,” he said.

Bachman also said the company is excited to have Englebrecht on the EXSYS team. “Mike’s impressive and extensive manufacturing industry experience makes him uniquely qualified to serve this grow-

ing region. I am confident he will take EXSYS and its customers to new heights of success.”

Prior to joining EXSYS, Englebrecht worked within several manufacturing indus-try sectors, carrying out positions that ranged from consulting to large contract sales and focused on high-performance machine tools, cutting tool holders, and

workholding. Visit www.exsys-tool.com or call (352) 588-4345 for more information.

Michigan Manufacturing International: New Name, New WebsiteMichigan Mechanical, a leading broad line supplier of high-quality mechanical assemblies and components, is pleased to announce the company’s new name: Michigan Manufacturing International (MMI). The new name provides a more accurate description of the company’s services and reflects its global presence.

A new website, www.michmfg.com, was recently launched in conjunction with the company’s new name. It is part of a com-plete re-branding initiative, with a contem-porary visual identity that is revealed on the site.

Visitors to the new MMI website now have increased access to information about the company’s manufacturing and engineering capabilities, as well as more details about the products that MMI offers.

Jacob Prak of MMI said, “Our new name symbolizes our global work. MMI brings together the entire world’s manufacturing capabilities and uses those resources to produce exactly what our customers need in the most efficient manner possible.” Prak continued, saying, “By locating our facilities in the most dynamic markets across the U.S., India, Mexico, China, South Korea, and Vietnam, we are well-positioned to take advantage of any shifts in the market and provide our clients with the resources they require.”

Founded in 1991, Michigan Manufacturing International (MMI) specializes in supplying manufactured to print assemblies and components to original equipment manu-facturers (OEM). Products include assem-blies, castings, stampings, machined parts, gears, bearings, and more. Services include product engineering, manufactur-ing, inventory management and stocking programs—all designed to streamline cli-ent operations and increase profitability. MMI designs the most effective, highest quality solutions from anywhere in the world.

For more information, visit Michigan Manufacturing International on the web or call (800) 677-0504.

JUNE 2013 17

PECo Wins 2013 Better Business Bureau Eclipse Integrity AwardPECo was announced as the winner of the Better Business Bureau’s Eclipse Integrity Award in the 100+ employees category. These awards honor businesses and non-profits for their management practices, busi-ness relationships, promotional efforts and reputation. PECo was the only heavy manu-facturing company among all of the award finalists and winners.

“We are truly honored to receive this award,” said PECo CEO, Bill Rosenberg. “PECo is a company entrenched in good values, with great people who work hard and respect the environment and community around us.”

Nominations are taken each spring for businesses who demonstrate continuous commitment to customer service, trust, and fair play. Nominees present evidence of this commitment to the judges through a binder they comprise to tell their story of integrity. Out of the 240 binders received, the judges narrow down the focus to a group of final-ists. An onsite visit from the judges is then conducted at the finalists’ facility.

Albert Naggar, PECo’s owner, stated: “PECo has a culture of honor and individual accountability that permeates our organiza-tion.” He added: “Our average employee tenure is 25 years. With that longevity comes commitment, experience, knowledge, and loyalty.”

“We delegate responsibilities for ethical behavior to the lowest levels of the com-pany, and our ‘opinion leaders’ throughout the organization provide for a self-reinforcing adherence to honesty and protection of the company’s assets and sterling performance record,” Rosenberg said. “This award is a direct reflection on the exceptional work of the many generations of employees who have made PECo their ‘home away from home’ over the last 67 years.”

Earlier in 2013, PECo was also the only U.S. manufacturing company selected as a Dayton Daily News and Springfield News-Sun 2013 Top Workplace and was hon-ored by the Ohio Senate for outstanding achievement. The Top Workplace honor was bestowed upon the company from its own employees via an independent third party survey—an award that was highly dependent upon PECo’s strong communications pro-

gram, management practices, and culture of integrity.

PECo serves the machining, welding, turn-key manufacturing system, marking/trace-ability, assembly, gear/CMM inspection, and automation tooling needs of the alternative energy, automotive, defense, power trans-mission, aerospace, and commercial and industrial products manufacturing industries.

PECo provides customers with both customer-specific, engineered solutions and production components. Since their inception in 1946, Process Equipment Company (PECo) has prid-ed itself on its innovative machines, systems, products, and services—all designed to meet the unique needs of the markets and custom-ers they serve. Log on to www.peco-us.com for more details.

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Charlie FischerAGMA VP Technical (703) 684-0211fischer@agma.orgwww.agma.org

American Gear ManufacturersAssociation

The Fall Technical Meeting Heads to Indy

Each year the latest gear research is on display at AGMA’s Fall Technical Meeting, and for 2013 the FTM once again brings the best experts in gear-ing from around the world to present their latest findings to the industry. This year, the FTM will be held September 15–17 at the Indiana Convention Center in Indianapolis, Indiana, and I encourage you to join us.

In preparation for this FTM, we received a good number of abstracts and the Technical Division Executive Committee and others have worked diligently with the authors to select the best 25 pa-pers for presentation at the 2013 FTM. In only two and half days you will get to learn, share ideas, and network with others on design, analy-sis, manufacturing and application of gears, gear drives and related products, as well as associated processes and procedures.

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

• Gear Manufacturing• Gear Design Issues• Failure Analysis & Inspection• Gear Drive Components• Materials & Heat Treatment

A complete list of the papers that will be presented on each topic can be found on the next page.

Attending the FTM affords you with an intimate setting for learning and networking. The confer-ence is designed for attendees to take in all the presentations and take home practical informa-tion that may ultimately affect your company’s bottom line. Additionally AGMA prides itself in the opportunity offered during each FTM for the participants to have ample time to question the authors on the technical aspects of their papers

and research—which often leads to interesting and thought-provoking discussions. But the meeting is also de-signed to afford invaluable networking time between sessions and in the eve-nings to interact with colleagues and meet new experts in the industry.

While I would encourage you to take advantage of all the great papers dur-ing the Fall Technical Meeting, we un-derstand that you may not have two and a half days to attend the event. Each session is designed to cover a particular subject area, so if you only have a few hours, you can still make it for a few papers that you are particularly interested in by registering a la carte for the sessions as well. For more information on all of your registration op-tions, visit www.agma.org or www.gearexpo.com. To get the most value, make sure you register before the early bird deadline of August 16th–by planning early you can save hundreds of dollars!

Finally, while you are attending the Fall Technical Meeting, I would encourage you to take advan-tage of Gear Expo, which will be held during the Fall Technical Meeting, September 17–19. This year’s Gear Expo will bring more than 185 exhibi-tors of gear products, machinery, and suppliers to the industry together for the world’s only trade show devoted to the gear manufacturing process. More than 3,000 of your peers will be on hand at the event, making Gear Expo and the Fall Techni-cal Meeting a “can’t miss” week of education and networking. The Fall Technical Meeting is your best opportu-nity to learn the latest gear research from the best experts in the industry. I look forward to seeing you there.

AGMA’s 2013 Fall Technical MeetingDates: September 15-17Location: Indiana Conven-tion Center, Indianapolis, IN

Registration Fees:

Early Bird (must register by August 16th):$835 AGMA Member $1,185 Nonmember

After August 16th:

$935 AGMA Member$1,285 Nonmember

To Register:Visit www.agma.org or www.gearexpo.com

20 gearsolutions.com

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

**Event open to AGMA members only. Not a member? Send e-mail to membership@agma.org.

Spline Committee Meeting – June 4-5, 2013 WebEx

Lubrication Committee Meeting – June 6, 2013 WebEx

Gear Failure Analysis Seminar – June 10-12, 2013 Big Sky, MT

Plastics Gearing Committee Meeting – June 11-12, 2013 Columbus, OH

Metallurgy & Materials Committee Meeting – June 13, 2013 WebEx

Computer Programming Committee Meeting – June 17-18, 2013 WebEx

Detailed Gear Design - Beyond Simple Service Factors – June 18-20, 2013 Las Vegas, NV

Mill Gearing Committee Meeting – subcommittee 6014 – June 19-20, 2013 Alexandria, VA

Cutting Tools Committee Meeting – June 20-21, 2013 Schamburg, IL

Vehicle Gearing Committee Meeting – June 26, 2013 WebEx

Worming Committee Meeting – July 9, 2013 WebEx

Enclosed Drives for Industrial Applications Committee Meeting – July 10, 2013 WebEx

Powder Metallurgy Committee Meeting – July 10-11, 2013 Detroit, MI

Helical Enclosed Drives High Speed Units Committee Meeting – July 11-12, 2013 Hartford, CT

Helical Enclosed Drives Marine Units Committee Meeting – July 15, 2013 WebEx

Wind Turbine Committee Meeting – July 16-17, 2013 Denver, CO

Helical Gear Rating Committee Meeting – July 30, 2013 WebEx

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FAll TeCHnICAl MeeTInG ProGrAM InForMATIonThe FTM is the best educational opportunity available to you today, as you learn from the best experts in the business as they present the latest gear research. In addition to the presentations, there are many opportunities for networking and interacting with the presenters.

The 2013 FTM will host 25 papers over two and half days, and are conveniently divided into five sessions so that registrants can attend the whole event, or just an individual session.

The presentations for the 2013 Fall Technical Meeting are:

sessIon I – GeAr MAnUFACTUrInGPower Skiving of Cylindrical Gears with Bevel Gear Cutting MachinesDr. Hermann Stadtfeld, Gleason Corporation

Performance and Technological Potential of Gears Ground by Dressable CBN Tools Dr. Klaus Finkenwirth and Dr. Andreas Mehr, Liebherr-Verzahntechnik GmbH, and Dr. Fritz Klocke and Jan Reimann, RWTH Aachen University

Analysis of Gear Root Forms: A Review of Designs, Standards, and Manufacturing Methods for Root Forms in GearsDr. Gregory Hyatt, Nitin Chaphalkar, Orrin Kleinhenz DMG/Mori Seiki USA Inc.

JUNE 2013 21

Best Practices for Gearbox Assembly and Dis Assembly Jodi Bello, Chief Engineer, David Brown USA Inc

Precision Shaped Grains Turn the Concept of Gear Grinding Upside Down Walter Graf, 3M

sessIon II – GeAr desIGn IssUes High Gear Ratio Differential Planetary Drives’ Analysis and Design Alexander L. Kapelevich, AKGears, LLC

Finite Element Analysis of a Floating Planetary Ring Gear with External Splines Dr. Vanyo Kirov and Dr. Yun Wang, Caterpillar Global Mining, LLC

Application and Improvement of Face Load Factor Determination Based on AGMA 927 (Accurate and Fast Algorithm for Load Distribution Calculation, for Gear Pair and Planetary Systems, Including Duty Cycle Analysis)Dr. Ulrich Kissling, KISSsoft AG

Investigations on Tooth Root Bending Stress of Case Hardened Gears in the Range of High Cycle Fatigue Dr. B. R. Höhn, Dr. K. Stahl, Dr. T. Tobie, Dr. N. Bretl, and S. Schurer, Gear Research Centre (FZG)

Calculation of the Tooth Root Load Carrying Capacity of Beveloid GearsDr. Jannik Henser, Dr. Christian Brecher and Dr. Markus Brumm, RWTH Aachen University (WZL)

Striving for High Load Capacity and Low Noise Excitation in Gear Design Dr. K. Stahl, Dr. M. Otto, and M. Zimmer, Gear Research Centre (FZG)

sessIon III – FAIlUre AnAlYsIs & InsPeCTIon Practical Considerations for the Use of Double Flank Testing for the Manufacturing Control of Gearing Ernie Reiter, Web Gear Services Ltd. and Fred Eberle, Hi Lex Automotive Center

Gear Failure Analysis and Lessons Learned in Aircraft High-Lift Actuation Anngwo Wang, Seth Gitnes, Lotfi El-Bayoumy, and Jonathan Davies, MOOG Inc. Aircraft Group

Metallurgical Investigation of “Tiger Stripes” on a Carburized High Speed PinionM. Li, Lufkin Industries, Inc., P. Terry, P. Terry & Associates, and R. Eckert, Northwest Laboratories, Inc.

White Structure Flaking in Rolling Bearings for Wind Turbine Gearboxes Hideyuki Uyama and Hiroki Yamada, NSK Ltd.

The Anatomy of a Lubrication Erosion Failure: Causation, Initiation, Progression, and PreventionRaymond J. Drago and Roy J. Cunningham, Drive Systems Technology, Inc. and Chad Smith, Chalmers & Kubeck

sessIon Iv – GeAr drIve CoMPonenTs Dynamic Simulations of Radial Lip Seals Followability in an Industrial Gearbox Michel Organisciak, Rossana Iervolino, Mickael Sansalone, Stellario Barbera, SKF Engineering and Research Centre, and Alex Paykin, SKF Sealing Solutions

Gear Lubrication – Long Term Protection for Wind Turbines Steve Mazzola, Kluber Lubrication North America LP, Dr. Michael Hochmann, and Juian Wald, Kluber Lubrication Munchen SE & Co.

Gear Resonance Analysis and Experimental Verification Using Rapid Prototyped Gears Scott R. Davidson and Jeffrey D. Hayes, The Boeing Company Philadelphia

Influence of Gear Loads on Spline Couplings Dr. Carlos H. Wink and Marcelo Nakandakari, Eaton Corporation – Vehicle Group

How to Spec a Mill Gear Frank C Uherek, Rexnord Industries LLC

Investigations of Bearing Failures Associated with White Etching Areas (Weas) in Wind Turbine Gearboxes Robert Budny, Clipper Windpower, Robert Errichello, GEARTECH, and Rainer Eckert, Northwest Laboratories

sessIon v – MATerIAls & HeAT TreATMenTHeat Treatment of Big Gear Components Gerhard Reese, Härterei Reese Bochum GmbH

Ductile Iron for Open Gearing: A Current Perspective Fabrice Wavelet, Ferry Capitain and Michel Pasquier, CMD

Innovative Induction Hardening Process for Improved Fatigue Performance of External Spur Gear Dr. Zhichao (Charlie) Li, Deformation Control Technology, Inc.

Controlling Distortion in Heat Treatment through Press QuenchingArt Reardon, Gleason Corporation

Vacuum Carburizing Large Gears Nels Plough, Stack Metallurgical Services, Inc.

The 2013 AGMA Fall Technical Meeting will take place immediately before the Gear Expo. For more detailed presentation abstracts and to register, visit www.agma.org or www.gearexpo.com.

22 gearsolutions.com

John Cross: President, ASI Technologies

Sulaiman Jamal: Managing Director, Bevel Gears India

Steve Janke: President, Brelie Gear Company, Inc.

Jan Klingelnberg: CEO/CFO, Klingelnberg

Justin McCarthy: VP, Sales, Scot Forge Company

Mark Michaud: President, REM Surface Engineering

Bob Sakuta:President, Delta Gear

Dylan Smith: President, VanGear

Michael Smith: VP, Sales & Marketing, Capstan Atlantic

Mike Suter: VP, Marketing, Emerson Industrial Automation

Wendy Young: President, Forest City Gear Company

Instructor: Robert Errichello, GEARTECH

AGMA leAdersHIP

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Lou Ertel: ChairmanPresident & CEO, Overton Chicago Gear Corporation

Matt Mondek: Chairman EmeritusPresident/CEO, Reliance Gear Corporation

Dean Burrows: TreasurerPresident,Nixon Gear

John Strickland, Jr.: Chairman, BMECFairfield Manufacturing Co.

Buzz Maiuri: Chairman, TDECSenior Product Manager, The Gleason Workse

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Joe T. Franklin, Jr.: President

Charles Fischer: Vice President Technical Division

Jill Johnson: Director, Member Services

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1001 N. Fairfax Street | Suite 500 Alexandria, VA 22314

(703) 684-0211 | www.agma.org

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

American Gear ManufacturersAssociation

moVing BuSineSS forWard oCToBer 1-3, 2013

Making Websites and Social Media Work for Your CompanyMary Ellen Doran: Web Communications Manager, AGMA

Seven Key Numbers that Drive SuccessStan Blenke: Executive Vice President, Schafer Gear Works, Inc.

Steel Consumption UpdateCengiz S. Kurkcu: President, Industrial Engineered Steel Solutions, Timken Steel Company

Update on AGMA for Your Company, Your Profession, and Your EmployeesJoe Franklin: President, AGMA

The Strategic Resources Network (SRN) is a group of up-and-coming professionals who are employed in the AGMA member companies, and this event is open to all AGMA members. The goal of the SRN is to perpetuate long-term viability of the industry and grow as future leaders of the association. For more information and to register, visit www.agma.org.

In this world of tweets, new federal tax laws, trending, economic indicators, and forecasting, what is right for your company? Let the AGMA Strategic Resources Network (SRN) provide some clarity at the 2013 event this October in Asheville, NC.

The AGMA SRN events are designed with three things in mind: relevant presentations with take-home benefits, plant tours, and great networking opportunities. The 2013 event will not disappoint. Start your meeting on the golf course getting to know your peers. Then spend two days interspersed with two plant visits to Linamar and Meritor, and quality presenters on topics hand-picked by the leaders of the SRN for their relevancy to those in the gear industry.

THe preSenTaTionS inClude:

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24 gearsolutions.com

damping of vibrations have been measured as a function of material.

Three gears with the same geometry have been tested:

•Solid steel FZG gear made by ZF•PM gear 7.2 g/cc Astoloy 85Mo • Multi density gear as reported in the second

column a few months ago.

The result showed that the multi density gear had 50% higher damping of the critical frequency compared to the solid steel gear. The experimental setup can be seen in Figure 3. The low-density web section can be seen since the reflection is different and appears as darker. Hanging in the front is the 7.2 PM gear.

The sound clips from the testing can be listened to from the Gear Solutions website—the difference is quite audible.

Heat treatment work has also progressed, and my teammates have been working hard trying to increase pitting durability by optimizing the hardness curve shape near the surface as well as hitting the sweet spot of 350-400Hv0.1 in the center of the tooth. By doing this, pitting performance went up

IN COLUMN #4, MACRO DESIGN was discussed and a corrugated web was presented. The idea of the corrugated web came from several directions and sprung from a design with spokes. For some reason, on certain gears we looked at, especially older cast gears, some spokes were not straight, but spiraled.

What is the reason for that? My colleague Dr. Andersson (who enjoys math rather than struggle with it like I do) got interested and, by setting up and solving the equations, he quickly came to the conclusion that it enhances stiffness in

j -direction. By taking this into the computer and making the necessary FEA’s, he could design and optimize the gear body, all in a days work.

The point: Math is still, and will continue to be, very important. Using the CAD model, the CNC machine was programmed (CAM) and the gear body was machined into a prototype. So the progress for the corrugated web is depicted in Figure 1. This was all done for two reasons: weight reduction and stiffness increase. The prototyped gear can be seen in Figure 2.

We are working with tooling for this and for the holed gear in Figure 2 to be able to compact net shape gears with these designs, which is quite a challenge since tool robustness is a must and service life of tooling should be 200,000 gears minimum.

The work has also progressed regarding NVH of PM gears. Acoustic tests have been made at the Royal Institute of Technology in Stockholm were the

abOuT THe auTHOr: Anders Flodin earned his PhD on gear wear and failure modelling at the Royal Institute of Technology, Stockholm, Sweden, and continues to work in powder metal gear technology as a Höganäs AB employee in Sweden. Contact him at

anders.flodin@hoganas.com, or call +46 42 338906.

MATERIALSMATTER

In this final “Materials Matter” column on Powder Metal Gears, some new tests that we have conducted will be presented, and some loose ends from past columns are tied up.

andersFLoDin Powder metal gear processes, Höganäs AB

Figure 1

Twisted Corrugated CorrugatedWeight

reducing holes

Originaldesign

Figure 2: Machined prototype of PM gear.

“A lot of work has been done in order to find the right parameters for the heat treatment so that it

suits the alloying contents and base graphite level of

the material.”

JUNE 2013 25

around 10% and is pushing 1250MPa at 50e6 cycles and 99% survival, which is very good (see Figure 4).

Hardness profile after case hardening tempering and grinding on FZG gears, same geometry as in Figure 4. Note the plateau at the surface of series C compared to a sharp drop in in series A.

A lot of work has been one in on order to find the right parameters for the heat treatment so that it suits the alloying

contents and base graphite level of the material. Process control of material, compaction, sintering, and case hardening is essential with PM. The material has, depending on porosity, faster carbon diffusion rate and the heat-treater needs to know how his equipment works and have the experience with PM, or get experienced by doing trials and investigations.

With that I conclude this series of short articles about PM gears. If you have any questions, don’t hesitate to contact us: anders.flodin@hoganas.com.

Figure 3: Experimental setup with multi density gear in rear denoted.

Figure 4. Hardness profile after case hardening tempering and grinding on FZG gears.

Bobbers, bucktails, and shumway, seem the same, but an avid angler knows the slightest difference to entice the cleverest musky. The same is true in recontrolling. Under-standing what components are kept and replaced is the difference of fifteen reliable years in production versus a broken down machine. When you’re bobbing for facts, talk to the gear experts at MTB.

BOBBING FOR BYTES OF INFO to improve your aging controls system?

Call MTB: 815.636.7502 or visit www.machinetoolbuilders.com

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26 gearsolutions.com

WhEN A GEAR IS pRODUCED by MAChINING it must begin with a blank that is properly designed and produced in full accordance with the specifications. The blank is subject to tangential, separating, and axial forces during the manufacturing process, and must therefore be resistant to distortion from these stresses. To avoid distortion the blank design must avoid thin cross sectional areas.

Gear calculations currently do not determine the critical fatigue stress for gears that are thin rimmed or have special blank geometry. Rim thickness is defined as the shortest distance from the root of the tooth to the bore surface. Keyways are taken into consideration as they reduce the section. If the rim thickness is undersized distortion will occur with or without the keyway. The section of material under the root should be no less than the tooth height and, preferably, one and a half times this height.

The recommended minimum rim thickness for gears with a larger outside diameter than fifty inches = 0.03in × OD. As further insurance against the development of a crack through the rim a minimum thickness based on tooth size is established as:

Rim Thickness = 3 inches DP

Inferior gear quality frequently results from poorly designed, and/or inaccurately produced blanks. When the blanks are stacked together and the bores are not perpendicular to the sides, problems increase. A Chicago manufacturer purchased their blanks with one face ground allowing them to be stacked together during the hobbing process. The outsourced blanks were inconsistent in bore quality and face parallelism. When the teeth were cut all the gears were scrapped at a financial loss to the manufacturer. Many gears are produced on blanks that are located by their bore on the cutting arbor. When the bores are not a tight fit,

TOOTHTIPS

When a gear is produced by machining, it must begin with a blank that is properly designed and produced in full accordance with the specifications.

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

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

book Design and Application of the Worm Gear.

abOuT THe auTHOr:

eccentricities are inevitable. Should the blank run eccentric to the operating centerline the teeth will not be of the required geometry. Throughout the gear’s production the blank provides the centerline and locating surfaces. The blank must permit the work piece to be supported just inside the gear's root diameter during the tooth cutting. Normal practice is to finish the blank in a lathe prior to the cutting of the teeth. The locating face or faces must be finished with the final bore perpendicular to the face and concentric to the outside diameter.

The gear blank design is frequently influenced by the cost. The ideal blank is solid, machined and capable of being through hardened or surface hardened. This design reduces the centrifugal stress limitations present with fabricated blanks. The method of preparing the blank is influenced by the quantities. Low volume gears can be produced from bar stock, medium size runs by forgings or welded blanks, high volume runs by forging, casting, extrusion or powder metallurgy. Cold extrusion is the most popular method used for high volume automotive gears.

Many gear blanks with an integral hub are produced from a cost effective open-die forging. It is a fairly simple matter to provide changes in the dimensions of the forged blanks to reduce the amount of surplus material to be removed. Frequently die-forging is the best way to produce quantities of gear blanks with an integral hub. A wide variety of other methods are also available for the production of blanks such as machining from bar stock, castings, extrusions and cold forming.

North American practice is for blanks larger than fifty inches to be of welded construction. Improved welding methods, such as buttering, make the welding of gear steels such as 4140 and 4340 practical. Rim hardness’s of 300 to 340 BHN are usual. When the tooth hardness exceeds the range 300-340HB, additional material and strengthening is required. The rim may be an alloy steel rolled ring, heat treated to the required tooth hardness, while a lower cost steel provides the strength and rigidity in the ribs. The two main full penetration welds joining the ring to the center. To ensure the soundness of the weld after the first and final weld pass magna-fluxing is necessary. Welded blanks are generally limited to pitch line velocities of 25,000/fpm. Every welded gear blank should be stress relieved.

JUNE 2013 27

WhAt DO MAx thE StONE-AGE ENtREpRENEUR, Ben Franklin, and your daughter’s hamster have in common? All have contributed indirectly to the latest development in [EV] electric vehicles: Motor-in-wheel locomotion. This ongoing development was recently announced by Ford to advance their EV effort where the (stator and rotor) windings of an electric motor are integrated into the center of the wheel, on all four wheels.

The concept of a wheel-motor is not new, having its beginnings in the late 1880s with dozens of variations over time as enabling technologies improved. Presently, Ford is offering a twist by designing the independently controlled wheels to rotate almost 90 degrees, providing a unique parallel parking assist. The primary difference between motor-in-wheel technology and existing systems is the lack of a transmission and drivetrain, resulting in a drive-by-wire transportation system that provides for enhanced drivability and safety, not to mention more usable space.

GM (and others, no doubt) are working on their particular drive-by-wire variations to help them conform to 2025 CAFE standards. Hybrids are the most common version of EV with a small internal combustion engine that powers a generator. The generator then, in turn, powers the electric motor and/or charges the battery and provides power after it has lost its initial charge. Until batteries for a non-hybrid EV can hold a charge for at least 200–300 everyday, stop-and-go miles, they will always be a minor player.

It’s no surprise that the most direct and cost effective route to improved fuel mileage is the continued refinement of existing automobile technology, namely the internal combustion engine and associated drivelines. As the number of speeds in an automatic transmission increase, the horsepower required to move a car from zero to 70 mph is reduced. The advantage of multiple speeds in a transmission can be immediately felt when skipping a gear in a manual transmission, especially when driving a four-cylinder car. It’s then very easy to see how a smaller engine can be made more effective with a transmission with 10 or more speeds.

I mentioned several columns ago that gas nitriding has been the recipient of considerable interest by automotive transmission suppliers, either OEM or tier one providers. So much has distortion become an issue that the added material cost for nitride capable steels is becoming a common denominator for many. And with the advancement of hard turning technology, gears

HOTSEAT

One of the requirements depending on a gear's mass when HPGQ is considered is the hardenability of the

steel.

jacktitusDirector of process and developmental

engineering, AFC-Holcroft

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

abOuT THe auTHOr:

can be fully machined after heat/quench and temper, because the 26 to 32 HRC is easily machined even with conventional tools. To duplicate the tooth root-to-root core hardness values to that of carburized and quenched lower alloy steels, grades such as 4140 are tempered 50°F to 100°F (10°C to 37°C) above the nitriding temperature so the core hardness can be preserved with the sometimes long nitriding soak times. Nitriding in the traditional sense has been perceived as a very long process with 40 to 60 hours not uncommon. However, for multi-speed automobile transmissions, especially the higher speed gears, long processing times are not required. As automatic transmissions move to double-digit speeds the load that any one gear is expected to endure is that much less, thus shallower nitrided case depths will suffice. Tooth wear, however, is still a requirement and nitriding can easily provide that parameter.

Moving a car from a standing start per unit of time requires substantially more energy than is required to keep it moving, thus lower speed gears will require higher strength and deeper case depths so carburizing is likely to still be in the program.

Due to the sheer number of gears needed per year for the quantity of cars produced even for one manufacturer, continuous endo carburizing furnaces have been the standard for production, and for critical gears, special quench processing is required for distortion control. That presents two options: oil press quenching and HPGQ (high pressure gas quenching). Press quenching except for unique considerations can only be practically done with continuous furnaces mainly pushers, whereas HPGQ is a batch process. That’s not to say HPGQ couldn’t be employed from pushers—it’s been done, by AFC-Holcroft. That leaves the OEM and tier one supplier with a decision: Which are the most cost effective when capital equipment and operating cost are the metric?

One of the requirements depending on a gear’s mass when HPGQ is considered is the hardenability of the steel. This also happens to be the same constraint with nitriding, because the steel must have sufficient alloy to not only achieve the core hardness but retain that hardness during hours of process time. Since nitriding is also a batch process, the determining factor becomes how many parts can be processed per hour in one batch to meet the high volume needs of the auto industry.

In HPGQ, the overall load and an individual gear’s mass are critical considerations when quenching for hardness uniformly. However, size is not an issue in gas nitriding, because a fast quench speed is not required.

28 gearsolutions.com

By Tim Byrd

COMPANYPROFILE

“Customers don’t want machine tools. They want quality parts out the door, from day one.”

Drake Manufacturing Services Co.

JUNE 2013 29

DDrake Manufacturing Services Co., a process-driven manufacturer of precision CNC Manufacturing Systems for producing threads and gears, is located in Warren, Ohio. “We apply our threaded part making experience to specific manufacturing applications around the world,” says president Jim Vosmik. “Our machines are designed and built with the idea that our customers want finished parts that meet relevant specifications, not machine tools.”

Vosmik started as a Drake customer back in 1996. “I had a cutting tools company, and I got to know the people and engineers at Drake,” he recalls. “They were a machine tool company who understood that their cus-tomers did not want machine tools. That was really at-tractive to me. If I could have a product made to my specifications, of high quality, without any capital in-vestment, I would do that. Customers don’t want ma-chine tools. They want quality parts out the door, from day one. They are buying the ability to make however many parts per hour they need to make in an inexpen-sive way.”

Over the years, the research and development team at Drake Manufacturing has invested a substantial amount of capital in making the thread grinding software simple and user-friendly. A machine operator who understands the grinding process but is not skilled in computer code can, with a few simple menu screens, grind a thread, a

worm, or a gear. Every Drake machine comes equipped with this PartSmart™ programming. Its thread and worm software is state-of-the-art, with simple menus for all thread forms as well as ZA, ZN, ZK, and ZI worms. With feedback from early customers of its profile gear grind-ers, it is applying the same principles and working to simplify the form definition and modification interfaces. Vosmik explains the rationale behind it:

“Over the last 30 years, a great number of highly skilled post-war machinists retired,” he says. “That

30 gearsolutions.com

breed of expertise is going away. The new people are used to computers running machines. They are not going through machinist apprenticeship programs like the previous genera-tion. They’re coming at it from more of a machine operator standpoint rather than a machinist standpoint. The differ-ence is that machine operators are more adept at respond-ing to the output of gear analyzer, and adjusting the program appropriately. Our user interface has to be a part of this closed loop machine feedback system to make it easy for the operator to respond to the measurement feedback.” To-day, Vosmik and Drake Manufacturing are adjusting to a new generation of operators by simplifying and automating the process.

Drake started out as retrofitters. Now, however, many of the old machines they retrofitted are outdated and no lon-ger, in many cases, capable of getting the part tolerances. “The customers’ geometric tolerances have tightened, but you also have this whole world of fastening, rippling, noise, harshness, and vibration. Customers are interested in as-pects of the part, at a level we could hardly measure ten years ago,” Vosmik explains. Because of this technology, part quality has been driven so far that when combined with advances in the capabilities of the tooling now in the milling, cutting, and grinding worlds, the entire process has made an unbelievable leap forward. “Now we’re required to control waveforms on parts down into the sub-micron range. Some-times it’s hard to do that with the older machines.”

In general, that’s what has driven Drake towards new, carefully engineered machines, and has made retrofitting a smaller part of its business. At this point, Drake only pro-vides retrofits for existing customers, and that’s after trying

to convince them they’re better off getting a new machine. “For not that much more money, we can get the customer a thermally-stable new machine with high dynamic stiffness with temperature-controlled, motorized dressing and grind-ing spindles, temperature-controlled slides that hold and re-peat position all day long—almost regardless of the environ-ment,” Vosmik says. “Greater performance overcomes any cost difference over the life of the machine in many cases.

“There are no compromises in process, performance, or quality,” Vosmik says. “Maximum dynamic stiffness, rigidity, and precision are designed in. And Drake takes responsi-bility for complete process development: wheels, dressing, and process on your parts. All aspects of the process are programmed: in-grinding, dressing, loading/unloading, gag-ing—whatever is required for the entire family of parts. Con-trol set-up is completed through a few simple menu entries, to provide the customer with quality parts from day one.”

Drake’s thread and gear manufacturing solutions include rack mills, profile gear grinders, worm and thread grinders, internal thread grinders, and ball nut and ballscrew grinders.

Its machines help maximize productivity, improve quality, and reduce production costs for a wide variety of demanding applications in the steering systems, power transmission, speed reducer, cutting tool, ball screw, linear motion, and aerospace industries.

Drake Manufacturing Services is inviting customers and friends to visit booth #311 at Gear Expo, September 15-17 at the Indianapolis Convention Center, where they are exhibiting with their gear systems reps, Koepfer America. Manufacturers are encouraged to discuss their unique gear production challenges with Drake Manufacturing application engineers who will be on hand to offer solutions using a vari-ety of Drake machines and automation systems.

TO LearN MOre: Visit www.drakemfg.com or call (330) 847-7291.

“Because of this technology, part quality has been driven so

far that, when combined with advances in the capabilities of the tooling now in the milling, cutting, and grinding worlds,

the entire process has made an unbelievable leap forward.”

TOOLING SOLUTIONS FOR ALL CYLINDRICAL AND BEVEL GEAR PROCESSES,

ANY SIZE AND TYPE

For worldwide sales locations and additional information, visit:

www.gleason.com • sales@gleason.com

Whether you’re cutting spiral bevel gears by the

thousands, or just a few large cylindrical gears

each day, Gleason has a cutting tool solution

to make your processes more productive. Our

investment in advanced production technology

and lean manufacturing has cut delivery times

to the shortest in the industry for our bevel

gear cutters, and coarse pitch hobs. Even

better, these products now deliver superior

accuracies and productivity.

Unlock your full potential, with a visit to:

www.gleason.com/cuttingtools.

we’ve UNLOCKed

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Advanced new Gleason Pentac®Plus and Coniflex®Plus cutter systems deliver unprecedented productivity improvements for spiral and straight bevel gears, respectively. Gleason Opti-Cut® hobs, gear gashers, and shaper cutters offer all the performance benefits of the latest replaceable, indexable carbide insert technology.

Booth#423

Viewpoint Systems Improves Gear Finishing Using Real-Time Embedded Control System With NI RIO Hardware

By Jim Campbell and Viewpoint Systems

CASESTUDY

ComPAny: CusTomer:

Viewpoint SystemsThe Gleason Works

THE GLEASON WORKS SOUGHT TO CREATE A DYNAMIC, TORQUE-CONTROLLED LAPPING

SOLUTION WITH RESPONSIVE, REAL-TIME FEEDBACK TO CREATE BETTER QUALITY GEARS

AND REDUCE CYCLE TIME FOR ITS GEAR LAPPING MACHINES.

Gleason Corporation and The Gleason Works create the machines, tooling, processes, and services needed to produce the bevel and cylindrical gears found virtually everywhere—from automobiles and airplanes to trucks and tractors, and from giant wind turbines that can power a thousand homes to the lawn mowers and power tools found at these homes.

Gear tooth surfaces and spacing are never perfectly machined, and consequently, noise and vibration are often present in applications where the gears are later used. Gears, after the typical heat treatment process, are commonly lapped or ground to smooth the gear teeth surfaces and improve operational characteristics. The goal of lapping is to reduce

surface and tooth spacing deviations that may produce noisy gear sets.

Gleason machines lap gears in pairs, the mating gear and pinion members rotating together at a high speed with an abrasive lapping slurry applied. After machining and heat treatment, however, the spacing deviations that need to be lapped are at unknown locations on the gears and can show themselves as run-out (i.e., an off-center axis). To further complicate finding the deviations, the run-out is actually composed of multiple orders, likely making the run-out for each order different than the others.

One conventional approach to lapping employs machines with relatively high-inertia spindles to carry the

JUNE 2013 33

gear set members. At moderate speeds, this configuration can somewhat reduce spacing errors during lapping, but is far from optimal in refining the tooth surfaces. Another approach employs at least one low-inertia spindle. This configuration can refine tooth surfaces well, but tends to increase spacing errors—especially at higher speeds. In both conventional cases, one spindle is operated in a simple constant torque command mode to control lapping force, but the critically

important dynamic torque components are left to passive physics.

To get the best of both worlds, Gleason could no longer rely on passive physics, and turned to Viewpoint Systems to help develop and implement an embedded control system that could measure deviations in real-time and apply dynamic corrective torque.

Solution: Viewpoint Systems, a member of the Control System Integrators Association (CSIA), provided system integration using NI

RIO technology and LabVIEW FPGA code for real-time measurement and control.

Gleason engaged Viewpoint Systems to implement this real-time measurement and control system because of their expertise with the leading reconfigurable I/O (RIO) hardware from National Instruments. Viewpoint used the NI RIO technology and developed LabVIEW FPGA code to create a real-time measurement and control solution for the lapping machine.

Viewpoint equipped an NI cRIO-9076 controller with an NI 9411 digital input (DI) module and an NI 9263 analog output (AO) module. The DI module monitors two digital rotational encoders, one on each spindle carrying the bevel gear set members. Innovative analysis of these angular signals can tease out subtle variations in the average rotational speed. Coupled with sophisticated order analysis, these variations are used to modify the torque applied to the gear set at the proper angular positions and with the appropriate amplitude. Thus, the high-frequency dynamic torque components experienced

“With the embedded control system that Viewpoint created using NI RIO hardware and LabVIEW FPGA, our customers can increase gear quality and save cost at the same time.”

–Mark Strang, project engineer, The Gleason Works

A COMMON SENSE APPROACH IN THE MANUFACTURING OF WORLD

CLASS GEARS

Raycar manufactures high quality smooth running gears offering competitive pricing and quick turn around.

• CNC GEAR BLANKING

• CNC GEAR SHAPING

• CNC GEAR HOBBING

• CNC GEAR GRINDING

• ANALYTICAL CHARTING EQUIPMENT

WE WANT THE OPPORTUNITY TO MAKE YOUR NEXT HIGH qUALITY GEAR SEND YOUR qUOTES TO:

Phone: 815.874.3948www.raycargear.com

sales@raycargear.com

Raycar Gear & Machine Co.6125 11th StreetRockford, IL 61109

Booth#1149

34 gearsolutions.com

by the gear set during lapping are no longer dominated by passive physics, but are actively controlled to achieve desired results.

Viewpoint created the system to manage all of the measurements, analyses, and torque corrections in the RIO FPGA with specific, efficient coding in LabVIEW FPGA using Viewpoint’s FPGA IP toolset. The cRIO controller provides data collection and even data archiving functions to support other advanced post-processing. The controller also provides an API to control the adaptive lapping process from a supervisory application.

ProDuCts useDNI LabVIEW FPGA, NI cRIO-9076 controller, NI 9411 digital input module, NI 9263 analog output module.

resuLtsWith this new, patent-pending system founded on embedded control and dynamic real-time process monitoring technologies, Gleason and Viewpoint bring exciting

new capabilities to a worldwide and well-established gear finishing process. The unprecedented ability to improve gear set quality during lapping, and to do so at higher speeds, provides a winning market proposition—one made possible by intelligent application of today’s leading-edge technologies. With its new solutions, Gleason gear manufacturing systems now

produce higher quality gears in 30 percent less time.

Throughout the process, Gleason appreciated Viewpoint’s expertise and synergy achieved when working together. More than just an implementer, Viewpoint’s experts worked alongside their own to develop new techniques and solutions in an agile and collaborative environment.

FOr MOre INFOrMaTION:

Viewpoint Systems, Inc., of Rochester, N.Y., partners with product development and manufacturing companies to enhance productivity and quality through automated measurement and control systems integration. A member of the Control System Integrators Association (CSIA), Viewpoint’s expertise includes test software and systems, custom electronics instrumentation, real-time control, and data management. For more information, visit www.viewpointusa.com

The Control System Integrators Association (CSIA) is a global non-profit professional association that seeks to advance the industry of control system integration for the success of members and their clients. For more information, visit www.controlsys.org. Jim Campbell manages the design and creation of enhanced machine automation systems. Before starting Viewpoint Systems, he was a primary developer of commercial software for automated data collection, signal processing, and numerical analysis. He has a strong interest in making machines smarter with sophisticated control schemes and remote monitoring.

Booth#829

JUNE 2013 35

CUTTER bODY haRDwaRE

hSS bLaDE SETS & SOLID bODY CUTTERS FOR SPIRaL bEvEL GEaRS

hSS STRaIGhT bEvEL GEaR CUTTInG TOOLS

SPRInG LOaDED CUTTER bODY SCREwS

CaRbIDE anD hSS STICk bLaDES

“Providers of world class gear tooling with first class service,

quality and performance.”

Engineered Tools Corporation

1307 e. Maple rd., Suite “G”, Troy, MI 48083Ph: (248) 619-1616 | FaX: (248) 619-1717

engineeredtools.com

ETC2710 West caro rd., caro, MI 48723Ph: (989) 673-8733 | FaX: (989) 673-5886

– Complete line of Bevel Gear Tooling

– Cutter Body Reconditioning to O.E.M. Specifications and Cutter Body Maintenance Program

– Precise Wire EDM Forms for Stick Blades

NEW and RECONDITIONED CUTTER BODIES for Sale.

WE PURCHASE USED CUTTER BODIES IN ANY CONDITION

Booth#504

AlCrn-Based Hard Coatings on modern Carbide ToolsThe refinement of coatings is not just a response to requirements imposed by manufacturing technologies. It also delivers decisive advances with respect to cost-effectiveness and manufacturing reliability.

By Sergio Lopez

2003 marked the birth of a totally new coating generation based on aluminum chromium nitride. It allowed the Oerlikon Balzers research team to open up new dimensions in coating performance. In comparison with TiAlN-based coatings, the AlCrN generation exhibited improvements of all key coating properties such as hot hardness, oxidation resistance, and resistance to abrasive wear. It delivered remarkable results in all typical machining industry cutting speed ranges. The products developed by Oerlikon Balzers, especially BALINIT® ALCRONA, have meanwhile established themselves on a global scale as the benchmark for cost-effective production in cutting applications. Systematic refinements have now kicked off the next big step toward enhanced application characteristics.

The evaluations of a major tool manufacturer confirm the enormous progress made in this domain since the TiN coatings developed by Oerlikon Balzers were introduced. The ongoing development of new and more durable coating systems, combined with improvements and modifications materials and tool geometries, made it possible to boost the material removal rate in roughing by a factor of 15. The norm with TiN-coated HSS mills was 7.5 cm3/min, but today, using cemented carbide mills AlCrN-coated with BALINIT® ALCRONA, it is 120 cm3/min.

In the machining industry, the reduction of tool costs and service life extensions are highly significant. An increase of the number of regrinding and recoating cycles of expensive cemented carbide tools is also one of the industry’s requirements.

The latest-generation AlCrN-based coatings are the right response to these expectations. BALINIT®-coated tools have the following convincing features:

• Excellent service lives at lower cutting speeds • High process reliability • Stripping and recoating without performance

degradations.

In cooperation with leading international research institutes, Oerlikon Balzers was able to gain an in-depth understanding of the correlations between coating properties and targeted application characteristics. Using the latest analysis methods, the staff members of the Christian Doppler laboratory for “Advanced Hard Coatings” decoded the secrets of doping elements for AlCrN-based hard coatings.

The addition of a few atoms, for instance of the yttrium, silicon, boron, or vanadium groups, produces nanocrystalline coating structures, so-called nanocomposite coatings. This is of decisive

AACCORDING TO A GENERAL RULE OF THUMB, A SIGNIFICANT REDUCTION OF COSTS IN MECHANICAL

MACHINING CAN ONLY BE ACHIEVED BY INCREASING THE PERFORMANCE OF THE DEPLOYED TOOLS.

THIS IS ILLUSTRATED BY THE FOLLOWING NUMBERS:

• A 50% INCREASE IN SERVICE LIFE REDUCES MANUFACTURING COSTS BY 1%.

• IF TOOL COSTS ARE REDUCED BY 30%, THIS ALSO RESULTS IN A 1% REDUCTION OF MANUFACTURING

COSTS.

• A 20% INCREASE OF CUTTING PARAMETERS CUTS MANUFACTURING COSTS BY 15%.

CONSISTENTLY, TENACITY PAYS OFF FOR THE DEVELOPMENT ENGINEERS AT OERLIKON BALZERS.

THEY CREATED SEVERAL ALUMINUM CHROMIUM NITRIDE-BASED COATINGS FOR TOOLS USED IN

CUTTING AND FORMING APPLICATIONS.

“In the machining industry, the reduction of tool costs and service life extensions

are highly significant. An increase of the number of regrinding and recoating

cycles of expensive cemented carbide tools is also one of the

industry’s requirements.”

JUNE 2013 39

significance for the mechanical and thermal properties of hard coatings. The addition of a small amount of boron, for example, increases hardness by about 25%, thus improving resistance to abrasive wear.

Many scientific reports focus on hardness values at room temperature. This leaves highly-stressed tools unimpressed. The coating properties under service conditions are what count. In the refinement of AlCrN-based coatings, great emphasis was therefore placed on improving hot hardness. With a suitable coating design approach and the right selection of doping elements, it proved possible to achieve a 50% gain in hardness at service temperature levels.

AlCrN-based hard coatings on modern cemented carbide tools exhibit excellent results in dry machining; longer tool life spans compared with emulsion machining are the rule rather than the exception.

Oxidation resistance and hot hardness are decisive when machining with emulsions, but so is thermal shock

40 gearsolutions.com

resistance. The coated tool is exposed to high temperatures when engaged in the stock, and emulsion cooling results in considerable temperature fluctuations that stress the cemented carbide and the coating. In simulations and numerous real-world machining tests, the researchers at Oerlikon Balzers were able to demonstrate that an optimized residual stress profile in the coating and an enhanced etching process produce decisive advantages. Thus, high material removal rates can be attained with a high level of reproductability.

whAt Are the FeAtures oF AlCrn CoAtings? To an unprecedented degree, AlCrN coating systems withstand the extraordinary stresses that occur in HSC and HPC machining applications.

With the new coatings, Oerlikon Balzers achieved two important goals: Building on the BALINIT® ALCRONA coating, the company’s engineers succeeded in developing an even tougher all-round coating with outstanding wear resistance, oxidation resistance, and hot hardness. They also designed a further coating that delivers perceptible productivity gains in milling.

BALINIT® ALCRONA PRO has the same chemical composition as BALINIT®

ALCRONA. However, thanks to optimized process parameters as well as coating structure modifications, it was possible to significantly improve the residual stress profile and the thermal shock resistance of the coating.

BALINIT® ALCRONA PRO has not only pushed the performance limits of cutting

tools to a new level. Thanks to tangibly improved protection against cold welding, abrasive wear, and thermal stresses, tools used in punching and forming as well as aluminium pressure die-casting moulds also exhibit considerably longer service lives, resulting in high-quality work.

abOuT THe auTHOr:

Sergio Lopez is manager of

marketing and communications:

Americas for Star SU. Star SU

is the go-to-market cooperative

par tnership of Star Cutter

Company of Farmington Hills,

MI, SU America, Inc., the US

sales and manufacturing unit to

Samputensili, S.p.A., and Bourn

& Koch Inc. of Rockford, IL. The

companies together represent

the world’s largest gear machine,

tool, and gear tool manufacturing

producers. For more information,

visit www.star-su.com.Drake GS:TE Worm Grinder

World Class Thread & Gear Machine Solutions from Drake• Full range of models and sizes for threads, ballscrews, steering parts, cutting

tools, gears, gages and fasteners• Equipped with latest automation packages• World class accuracy and reliability• Grinding process proved before delivery• Factory programmed on your parts

www.drakemfg.com 4371 North Leavitt Road • Warren, OH 44485 • 330-847-7291 Phone • info@drakemfg.com

JUNE 2013 41

Handling Twist

There is a lot to be said for the precise measuring methods that can be achieved right on the production machine, specifically on the 5-axes LFG.

By Thomas Weber

The LFG does not require a dressing axis, which rules out one potential source of inaccuracy. Another difference to comparable machines is the inversion of the shift and swivel axes. As a result, the mechanical limitation that results from the process of “first swivel, then shift” is overcome. This special arrangement allows for the dimensioning of shift travel to be much larger than usual.

simuLtAneous Dressing shortens CyCLe timesThe machine’s directly-driven table, featuring a highly dynamic wear-free torque motor, is a key component in allowing the machine to single- or double-flank grind precision- and custom-topographic tooth flanks.Because the machine also uses the shift and swivel axes to dress the grinding disks, the dressing axis can be eliminated.

The basic LFG model's grinding disk is dressed by a single dresser in combination with the shift and swivel axis. The Syncdress design provides two dressing rolls that dress simultaneously left and right and greatly reduce dressing time.

The LFG relies on the permanently active swivel axis for profile grinding. Traditionally, the swivel axis was a set-up axis that was pivoted and clamped for grinding purposes. The grinding head for producing internal gears is mounted over the outer grinding head. No contact is made with the outer grinding head. Only the grinding disk must be removed. The dressing process for the internal grinding disks is consecutive, with the aid of the shift axis.

twist ProbLems unDer ControLCrowning could only be performed via the X-axis in conventional grinding machines. Twist, however, occurs when this type of crowning is employed in profile-grinding. The result is an altered profile angle

over the entire face width. The problem of twist due to this crowning method has played a rather minor role in gear manufacturing development for quite some time.

grinDing resuLt: ConventionAL AnD with Five Axes movement"Minimizing twist is one thing, incorporating specific twist designs is yet another. LFG series machines can grind anything required," explains Dr. Hansjörg, Manager Development and Design Gear Cutting Machines at Liebherr-Verzahntechnik.

The axes of the LFG facilitate additional movements and generate the opportunity to create the desired degree of crowning and prevent twists, even if double-flank grinding is involved, by overlapping the axis movements.

By using the V, C and A-axes in addition to the X and Y-axes, the profile angle can be modified and the twist problem can be solved for both single- and double-flank grinding. In this way the operator can completely avoid tooth flank twist or

SSPECIFIC AND CONTROLLED HANDLING OF TWIST IN PROFILE GRINDING CAN SOLVE PRODUCTION-

RELATED PROBLEMS AND SIMULTANEOUSLY OPEN NEW GEAR MANUFACTURING DOORS. VARIOUS

SOLUTIONS HAVE BEEN AVAILABLE FOR MANAGING TWIST PROBLEMS. LIEBHERR RECENTLY

INTRODUCED THE FIVE-AXIS LFG SERIES PROFILE GRINDING MACHINES, WITH A NOVEL MACHINE

DESIGN FOR TWIST-FREE PROFILE GRINDING (INCLUDING THE MANUFACTURE OF SPECIFIC TWIST

DESIGNS) FOR SINGLE- AND DOUBLE-FLANK GRINDING.

THE MACHINE CONCEPT PERMITS HIGHLY PRODUCTIVE PROFILE GRINDING FOR LARGE WORKPIECES—

EXTERNAL AND INTERNAL GEARS TO 2,000 MILLIMETERS—FOR INDUSTRIAL GEAR UNITS, WIND

POWER, AND MARINE PROPULSION APPLICATIONS.

JUNE 2013 43

CuSTom gearBoxeSgear produCTS

gearS

Broadway gear has been dedicated to manufacturing gears for more than 40 years. We are one of the top gear makers in China, and the industry leader in fine module gears. We focus on precision in the design and manufacture of many different types of gears for markets includ-ing aviation and aerospace, automotive, ship building, textile, printing machines, electronics, and other light industries. other gear-based products we manufacture include gearboxes, gear pumps, and other finished products that are assembled to our customer’s exact specifications.

Broadway gear inc. | 4911 olson dr. | dallas, Tx 75227phone: 972-351-8737 | fax: 972-268-9920 | info@broadwaygear.com

www.broadwaygear.com

aS9100 reV. C:2009

iSo 9001:2008

iSo/TS 16949:2009

intentionally produce it in compliance with the narrowest of tolerances.

toPoLogiCAL moDiFiCAtionsCertainly the opportunities that the five axes create with respect to twist are limited by mathematics. Additional clearance allows for precision topological grinding.

The division of the topography into multiple strip -shaped areas and corresponding processing with multiple strokes provide a multitude of specific options, for example, for prototype development or academic applications. The operator no longer has to concentrate on fHα and Cα corrections, but rather can target individual points for processing.

removAL-oPtimizeD grinDing through 5 Axis inFeeDingThe figure shows how, during radial infeeding, the removed material near

the tooth head is greatest at three infeeds during the final strokes. The workpiece is subjected to unnecessarily-high loads as a result of variable grinding steps. Microstructure damage occurs frequently.

ComPArison: ConventionAL AnD with Five Axes movementFive-axis infeeding produces a (as far as possible) constant allowance distribution

Booth#914

44 gearsolutions.com

over the course of the strokes. The principal material for this wear-optimized grinding is no longer left to wear out on the tip; as a result the risk of grinder-burn is minimized, and the workpiece is protected. Number of strokes and production time can therefore be reduced, depending on application.

inFLuenCe oF removAL-oPtimizeD grinDingThe different involute gear profiles (pinion/planet/cylindrical) show the distinction between the three tested gears, which lies primarily in the

Booth#707

JUNE 2013 45

curvature in the involute gear profiles. Thus, in the case of a pinion with maximum curvature, the maximum benefit can be derived by using the 5-axis infeed method.

In this case, the number of infeed steps is reduced from 15 to 9 as a result of the 5-axis infeed. The curvature of the spur gear is small (due to the number of teeth, among other things) and, therefore, the savings in infeed steps is smaller (9 to 8).

LArge shiFt trAveL beneFits ProDuCtion quALityThe measuring sensor swivels laterally along the grinding disk. It uses the large shift travel (+/- 300 millimeters) and, like a dedicated measuring machine,

measures the gear. This leads to an additional acceleration of the process. Table rotation and radial infeed are not required for measuring, which contributes to additional precision of the measurement results.

With calibration in mind, conventional methods of measurements usually focus on a very sensitive fHα profile angle. There is additional potential for inaccuracy when a machine radially retracts and extends its stylus. The sensitivity is considerably lower and, accordingly, the results more accurate when retracting laterally (shif ting). There is a lot to be said for the precise measuring methods that can be achieved right on the production machine, and specifically this 5-axes LFG.

abOuT THe auTHOr:Thomas Weber works in marketing for Liebherr-Verzahntechnik GmbH, a

world-leading designer and builder of gear production machines and part-

handling automation. It is part of the LIEBHERR Group. The Liebherr family

business was established in 1949 by Hans Liebherr. The great success

of his first mobile, easy-to-assemble and affordable tower crane was the

foundation on which the company flourished. Today Liebherr is not only

one of the world’s leading manufacturers of construction machinery but

is also an acknowledged supplier of technically innovative user-oriented

products and services in numerous other fields. For more information visit

www.liebherr.us.

“The machine’s directly-driven table, featuring a highly dynamic wear-free torque motor, is a key

component in allowing the machine to single- or double-flank grind precision- and custom-

topographic tooth flanks.”

Booth#807

46 gearsolutions.com

• Competitively priced machines• (6) Models from 60 mm to 750 mm• Quick and easy installation• Quick delivery• • • Turn key solutions• Quality components used• Wet and dry hobbing• Trade-ins welcomed• Hera-200 in stock, Statesville NC

New Hera CNC Gear Hobber Line

820 Cochran Street • Statesville, NC 28677F: 704.872.5777 • sales@rpmachine.com • www.rpmachine.com

866.256.3708Booth#623

energy efficient Industrial Gear LubricantsAn effort to help the industrial sector manage the projected demand through the use of energy efficient synthetic gear lubricants, which would maximize the energy available to meet demand.

By David Blain, Angela Galiano-Roth, Rick Russo, and Kevin Harrington

sustAinAbiLityAdvanced synthetic lubricants can address help us address energy demand to achieve sustainability. ExxonMobil Corporation defines sustainability as balancing economic growth, social development and environmental protection so that future generations are not compromised by actions taken today [3]. See Figure 2. For example, oil that extends lubricant drain intervals may contribute to health and safety by reducing the amount of interaction between humans and the machines. The choice of proper lubricant can also help extend equipment life enhancing reliability and equipment availability leading to increased return on capital or economic growth. And longer oil life can also help reduce waste or environmental impact related to energy use.

energy Loss in inDustriAL equiPmentThe causes of efficiency loss in gearboxes generally fall into two categories, those which are speed dependent and those which are load dependent. The load dependent losses are of interest as they result from internal fluid friction and metal-to-metal contact. They may be improved upon by using a suitably formulated lubricant, with carefully selected base oils and additives to improve efficiency.

Frictional losses can occur under all three lubrication regimes: hydrodynamic, elasto-hydrodynamic (EHL) and most significantly boundary lubrication, where metal surfaces are in contact. See Figure 3.

Hydrodynamic lubrication exists in systems where the contact occurs over a relatively large area and the pressure in the contact region is not too high. A significant part of the energy losses in the hydrodynamic scheme are related to the viscosity of the oil under operating conditions. Components operating under this regime are found in a large number of industrial and automotive applications and most often include journal and thrust bearings.

Elastohydrodynamic lubrication is associated with components where the load is supported over a small area. In this system, the load is so high that the surface of the mating components elastically deforms to form a small contact patch. The lubricant film is drawn into this area and separates the surfaces. Under these high pressure conditions, the oil is sheared, with the extent of shear loss determined by how the oil behave under high pressure conditions, greater than 1 Gpa. Examples include all types of rolling element bearings, such as those found in engines and gears.

Boundary lubrication occurs as the bodies come into closer contact at their asperities; the heat developed by the local pressures causes a condition which is called stick-slip and some asperities break off. At the elevated temperature and pressure conditions chemically reactive constituents of the lubricant, commonly referred to as anti-wear additives and friction modifiers, form a chemical film on the surface and prevent direct metal-to-metal contact. This phenomena may occur in all

TTHE USE OF ENERGY HAS PROPELLED THE WORLD FROM EARLIEST CIVILIZATIONS, THROUGH THE INDUSTRIAL REVOLUTION, TO THE CURRENT TECHNOLOGY ENABLED WORLD. IT ALLOWS US TO HEAT AND COOL OUR HOMES, TRAVEL TO AND FROM WORK, AND UTILIZE THE MULTITUDE OF MANUFACTURED GOODS WE RELY ON. GLOBAL ENERGY DEMAND IS PREDICTED TO BE ABOUT 30 PERCENT HIGHER IN 2040 COMPARED TO 2010, WITH THE INDUSTRIAL SECTOR CONSUMING ALMOST 48% OF THE DEMAND [2]. SEE FIGURE 1.

THE PURPOSE OF THIS ARTICLE IS TO HELP THE INDUSTRIAL SECTOR MANAGE THE PROJECTED DEMAND THROUGH THE USE OF ENERGY EFFICIENT SYNTHETIC GEAR LUBRICANTS, WHICH WOULD MAXIMIZE THE ENERGY AVAILABLE TO MEET DEMAND.

Figure 1: Projected Energy Use by Sector (Quadrillion BTU)

Figure 2: Sustainability

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.

JUNE 2013 49

components found in engines and gears and is the most common of the lubrication regimes experienced [4].

LubriCAnt benCh AnD rig testingSynthetic lubricants may be used to improve energy efficiency, however not all synthetic lubricants provide the same benefits5. In controlled testing, three synthetic oils were tested and the results showed that Polyalphaolefin (PAO, API Group IV) -only based gear oil were superior with showed an average of 6% efficiency over an API Group III / PIB-based gear oil.6 Further testing found PIB-containing gear oils showed significant shear loss versus PAO-only based gear oil, with corresponding higher wear rates which would result in shorter equipment life.

Figure 3c: Mixed and Boundary LubricationFigure 3a: Hydrodynamic Lubrication

Figure 3b: Elastohydrodynamic Lubrication (EHL)

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Experiments to measure finished lubricant-related energy efficiency benefits are inherently challenging. A Mini Traction Machine (MTM) was used to measure the traction forces transmitted across a lubricant film under varying amounts of sliding while controlling load, speed and temperature. The actual traction coef f icient measurement over a range of slide to roll ratios shows that synthetics have much lower traction coefficient than typical mineral oil based products. See Figure 4. This leads to more energy efficient operation, reduced heat generated, and lower overall system operating temperatures.

Testing was also carried out using a conventional EHL ball on disc rig equipped with temperature mapping using infrared imaging. [7] This provides a map of lubricated contact under highly loaded EHL conditions with varying amounts of sliding, while controlling load, speed and inlet temperature. The data generated showed variation in temperature as the disk surface is heated due to shearing of the fluid in the contact zone (Figure 5). The temperature rise is a function of the heat generation per unit area, which is the product of the fluid shear stress under the contact conditions and sliding speed.

Figure 5: EHL thermal mapping.

Figure 6: EHL thermal mapping results.

Figure 4: Low traction benefit.

JUNE 2013 51

For a given sliding speed, fluids with lower shear stress will provide lower temperature rise across the EHL contact. Advanced synthetic lubricants were evaluated against conventional mineral oil based lubes and found to reduced the temperature in the contact zone by >4°C, leading to lower overall system operating temperatures.

The next phase of testing was done in a highly instrumented worm gear box specifically developed by ExxonMobil to evaluate lubricant ef f iciencies. Worm gears were chosen because the worm forms elliptical contact against the wheel, where sliding motion predominants, creating a relatively inefficient energy transfer environment (70 – 80%) compared to other types of gearing.

A Modular Small Worm Gear (MSWG) test rig was used in this part of the testing. It employs two torque meters to measure torque into and out of the gearbox. The output torque is divided by input torque to provide the percent efficiency. Torque, rather than current, is measured in this test as current/voltage measurements have much higher associated error.

Figure 7 shows the efficiency of advanced synthetic technology (reference oil) and a mineral oil based gear oil. Efficiency is determined from data from the latter part of the test run, after the gearbox reaches thermal equilibrium. The gearbox is run at full speed (1800 rpm input), 100% of rated load at 20/1 reduction ratio. Each gear box is separately calibrated and run-in, and tests are bracketed by reference oil runs to take into account any consistent drift in the data.

The reproducibility of this test has been determined to be +0.25% (absolute). The results from this highly controlled testing indicate an energy efficiency improvement of 3% when comparing these two lubricants.

Thermo -graphic images (F igure 8), taken from the MSWG show that advanced synthetics run approximately 15°C (27°F) cooler than typical mineral oil based industrial gear oils. Lower operating temperatures lead to

increased equipment life, improved efficiency and reduced maintenance costs.

LubriCAnt FieLD testingField testing of advanced synthetic technology was carried out in a Falk double reduction gear box driven by an 1150 HP induction motor at a taconite mine in Minnesota. The gear box is coupled to a primary ore conveyor that is approximately one-quarter mile in length. It is supported by a series of guide rollers and standards, with the rollers positioned in a concave arrangement that cups the conveyor to

channel the taconite ore to the center of the conveyor as it being transported.

The Falk gearbox is a double reduction parallel shaft speed reducer with a ratio of 39.4:1, driven by a 4160 VAC, four pole, 3-phase 1150 HP GE induction motor. The motor is directly coupled to the high speed input shaft of the gear box providing 1792 RPM that is reduced to 45 RPM at the gear box output shaft. The maximum calculated torque output from the gear box at is 137,189 ft-lbs.

The efficiency study was undertaken using an A -B -A -B comparison methodology. The conventional gear oil representing the ‘A’ series studies and the advanced synthetic representing

Figure 8: MSWG testing confirms energy efficiency benefit.

Figure 7: Modular small worm gear test rig.

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the ‘B’ series. The premise was to determine if one gear oil type was more efficient, requiring less motor input power to generate comparable torque as a function of loss reduction in the gear box. During the study, power input to the motor was compared relative to the torque required to transfer the taconite ore over various time periods. Load curves were created for each period as function of input power to the motor versus output torque produced by the gearbox.

To obtain measurements, a Fluke 1760 three phase power analyzer was used to monitor input power to the motor. Input power was captured at the main MCC feeding the motor, where true three

phase power readings were continuously recorded along with motor RPM at 200msec intervals. The power recordings were time synchronized with the torque values taken on the output shaft of the gear box. The readings were captured using a strain gage mounted to gear box output shaft. See Figure 10.

As the conveyor belt transports batches of ore, the power consumption cycles up and down. Amidst these cycles, 10 periods of steady state operation were identified. These steady state periods were the basis of the efficiency calculations, and these periods were considered as independent samples to calculate confidence intervals on the estimates of mean efficiency.

Including both high and low load conditions, using 95% confidence intervals, the advanced synthetic lubricant was found to be 3.6% (+/- 1.3%) more efficient than the conventional mineral oil based product as shown below (Figure 11). [8]

Based on measured watt usage and assuming continuous operation, using the advanced synthetic lube can save from $8,700 to $17,400 per year using a range of $0.05 to $0.10 per kilowatt hour.

ConCLusionBased on the results presented, advanced synthetic products have the potential to significantly reduce energy consumption in gearboxes, demonstrating energy savings

Figure 10: Torque readings captured by a strain gage.Figure 9: Primary ore conveyor and gearbox.

Booth#729

54 gearsolutions.com

of up to 3.6 percent versus conventional mineral based gear oils.

Our test gear box held 330 gallons and the cost to upgrade the gear oil from mineral to advanced synthetic was approximately $6,600. Based on the test results, the increased oil expense would be recovered after 5 - 9 months of operation and any addtitonal runtime achieved on a single charge of oil, would be energy savings realized by the user.

In sustainability terms, the choice of proper advanced synthetic lubricant clearly leads to increased return on capital investment and provides economic growth. Remember, energy usage is predicted to grow substantially over the next 30 years. Using an energy efficient lubricant is one way to help meet this demand.

reFerenCes[1] ExxonMobil: 2012 The Outlook for Energy: A View to 2040[2] ExxonMobil: Fuels & Lubricants, http://exxonmobil.com/

lubes/sustainability[3] AGMA 925-A03[4] Improving Energy Efficiency Through Optimized Lubricants, F.

Guerzoni, Utilities Manager, February 2008.[5] API: "API Base Oil Interchangeability Guidelines for Passenger

Car Motor Oils and Diesel Engine Oils"[6] Improved Temperature Mapping of EHL Contacts, Reddyhoff,

T., et. al., Proc. I. Mech. E. part J: Journal of Engineering Tribology, 2008, pp 1165-1177

[7] Mobil Industrial Lubricants, "Mobil SHC Gear Next-Generation Gear Lubricants," http://www.mobilindustrial.com/IND/English/products_mobil-shc_mobil-shc-gear-series.aspx

abOuT THe auTHOrS:

Kevin Harrington has over 25 years of lubrication-related

experience and manages technology programs for the

Mobil SHCT portfolio of flagship industrial lubricants

sold under the MobilT brand. David Blain has spent

most his career developing industrial lubricants, and

is the holder of 24 US patents and author of several

industry papers and presentations. Angela Galiano-

Roth, industrial lubricant technology program leader, has

worked for ExxonMobil for more than 25 years and is an

inventor of 15 lubricant-technology patents. Rick Russo

is product technical advisor for ExxonMobil. He has

worked for ExxonMobil since 1988.

Figure 11: Energy efficiency comparison.

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IKO_OVERSEAS_AD_1_3Page.pdf 1 2013/05/01 13:31:39

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FEATUREDsUppliersMidwest Gear Corporation — REF #101Phone: 330-425-4419 • Fax: 330-425-8600Email: sales@mwgear.comWebsite: www.mwgear.com

New England Gear — REF #102Phone: 860-223-7778 • Fax #:860-223-7776Email: jeff@newenglandgear.comWebsite: www.newenglandgear.com

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GQ Machinery Inc. — REF #106Phone: 516-867-4040 • Fax: 516.223.1195Email: george@gqmachinery.comWebsite: www.gqmachinery.com

Gibbs Machinery Company — REF #107Phone: 586-755-5353 Fax: 586-755-0304Email: rj@gibbsmachinery.comWebsite: www.gibbsmachinery.com

MACHINERYContact Gear Solutions at

800-366-2185 to list your machinery.

58 gearsolutions.com

barber colman 6-10, cnc, cRt 5 axis, 6” dia, 10.5” travel, 6 dP REF#103barber colman hobber type t REF#103barber colman model #14-15 Gear hobber, horizontal heavy duty REF#103barber colman Model #16-36 Gearhobber REF#103barber colman Model #16-56, 16” dia, 56” Face, adj. air tailstock REF#103barber colman Model 2.5-2 gear hobber, 2” length Manual dresser REF#103G&e Model 5.2 cnc internal Gear gashing head REF#103Jeil Jdh-3, Gear hobber, Max dia 31.5”, 3dP, 22.8 table diameter REF#103Jeil JdP-2, Gear hobber, Max dia 26”, 4 dP, 19.5” table dia, differential and tailstock REF#103liebherr et 1802, internal Gashing head, Fanuc 16i control, 98”Max dist 17” Face REF#103liebherr l-402 Gear hobbing Machine, new 1977 REF#103liebherr lc 752, 6 axis cnc hobber, Max od 29.5”, Max Face width 23.6” REF#103Micron Model 120.01 w/bevel cutting attachment, new 1975, 1.6” dia, 25.4 dP REF#103nihon Kakai Model ntM-3000, spline hobbing Machine, Max dia 400mm, 3150mm between center REF#103Pfauter P900 Reman and Recontrolled, Max od 120” REF#103Pfauter Model Pe125 cnc Gear hobber REF#103Pfauter model Pe300 cnc, Max od 12”, Max gear face 15”, 3 dP, 6 axis REF#103Reinecker heavy duty Gear hobber REF#103scheiss Model RF10 horizontal hobber, 60” dia, 144” face, 180”cc, 8 dP REF#103G&e 96h, roughing & finishing 104” dia. REF#106tos Fo-16 single index 80” dia. yr 1980 REF#106craven spline & pinion hobber 36” x 96” REF#106G & e 48h 48” dia. diff, ob, change gears REF#106Pfauter hobber P-1800 70” dia. 29” face yr 1980 REF#106lees bradner 7Vh, 8”Pd, 10” Face, , Magnetic chip conveyor , hob shift REF#107lees bradner 7Vh, 8”Pd, 4Pd, Magnetic chip conveyor, hob shift REF#107Mitsubishi Model Gh300, 15.7”, 3 dP, differential, 2 cut REF#107tos 32a, 320mm Gear dia.,3.6 dP, differential, 2 cut REF#107Gleason 775 8”Pd, high helix head, infeed, Very light use REF#107barber c. 16-15, 7 ½” hob, crowning, differential, 2 cut REF#107barber colman 14-15, 2 cut, Fast approach, 4” bore REF#107barber colman 16-36, type a – Very Good, double thread index REF#107G & e Model 48hs 48”Pd, 18” Face, 2.5 dP REF#107

GEAR SHAPERSFelloWs #10-2, (10” dia), 2” Face REF#102FelloWs #10-4, (10” dia), 4” Face REF#102FelloWs (200) 10-4 / 10-2 shapers REF#102FelloWs (1) 50-8 hydrostroke shaper s/n 36607 w/ 6 axis 16iMb Fanuc (2009) REF#102FelloWs (1) 20-8 hydrostroke shaper s/n 35932 w/ 6 axis 16iMb Fanuc (2009 REF#102 FelloWs (1) #7 125a Face Gear Machine REF#102FelloWs (2) #3 Face Gear Machine REF#102(1) 4ags with adjustable helical Guide s/n 30634 REF#102(1) #7 125a adjustable helical Guide REF#102FelloWs (1) Fs630-200 hydrostroke shaper s/n 36943 w/ 6 axis 16iMb Fanuc (2009) REF#102FelloWs (3) tilt table 10-4 / 10-2 w/ 4 axis 21i Fanuc controller (2009) REF#102FelloWs (2) swing-away center support for 10-2 / 10-4 REF#102FelloWs (1) Fs630-170 hydrostroke shaper s/n 36732 w/ 6 axis 16iMb Fanuc (2009) REF#102FelloWs (2) Fs400-170 hydrostroke shaper w/ 6 axis 16iMb Fanuc (2009) REF#102FelloWs (4) Fs400-125 hydrostroke shaper w/ 6 axis 16iMb Fanuc (2009) REF#102FelloWs (1) 20-4 shaper s/n 35687 w/ 4 axis 21i Fanuc controller (2009) REF#102FelloWs (1) 48-8Z shaper w/ 14” throated riser (53” of swing) REF#102FelloWs (1) horizontal Z shaper s/n 21261 REF#102FelloWs (1) 4-b steering sector Gear shaper w/ 18iMb 4 axis Fanuc controller s/n 34326 REF#102FelloWs (1) 36-10 Gear shaper REF#102FelloWs (1) 10x6 horizontal Z shaper REF#102FelloWs (1) 36-6 Gear shaper w/ 13” riser s/n 27364 REF#102FelloWs (1) 10-4 shaper w/ 3” riser w/ 4 axis 21i Fanuc controller (2009) REF#102all Parts for 10-4/10-2 Fellows Gear shapers REF#102FelloWs #36-8, 36” dia, 8” Face REF#103FelloWs #100-8 100” dia, 8” Face REF#103FelloWs #612a, 615a, #645a REF#103FelloWs #10-4, 10” dia, 4” Face, 4 dP REF#103FelloWs #4a Versa, 10” dia, 3” Face, 4 dP, new ‘70’s REF#103FelloWs #10-2, 10” dia, 4” Face, 4 dP REF#103FelloWs #20-4, 20” dia, 4” Face, 4 dP, ‘70’s REF#103FelloWs #3-1,/3Gs, 3” Max dia, 1” Face, Pinion supp, high Precision REF#103FelloWs #48-6 inteRnal GeaR shaPeR only,0-72"od,6" Face REF#103MaaG #sh-150, 57" dia.12.6" Face REF#103PFauteR #sh-180 shobber 7" capacity hobbing, 9.45" cap REF#103

FelloWs #36-6 Max dia 36” 6” Face, 3 dP REF#103FelloWs #hoRZ Z shaPeR, 10 x 6 dia 27.6 Face 8.5” REF#103FelloWs #4Gs & 4aGs, 6” dia, 2” Face, 4dP, ’68, Ref.# several REF#103FelloWs #624a, 18” Max dia, 5” Face REF#103FelloWs #7, #7a, #715,# 75a, #715, #725a, 7” dia, 0-12” Risers,

several avail REF#103MichiGan #18106 sheaR-sPeed GeaR shaPeR,14" dia, 6"Face REF#103FelloWs Model Z shaper, 5" stroke, ‘50’s REF#103staehely shs-605, Gear shaper REF#103FelloWs #6, #6a, #61s, From 18”-35” dia, 0-12” Risers REF#103FelloWs #8aGs Vertical Gear shaper, 8” dia, 2” Face, 6-7 dP REF#103tos oha50 cnc 5 20” dia 5” Face REF#105Fellows 36-6 shaper (2) 12.5" Risers 6" stroke Mint yR 1969 id 3616 REF#106Fellows 36-6, shaper W/6” riser, change gears REF#106Magg shaper sh4580-500s, 206”dia. 26” face REF#106Magg shaper sh250, 98” dia. 26” face REF#106Fellows #10-4,7” riser yr 1980 REF#106Fellows 3”, 6”, 7”, 10”, 18”, 42”, 100, some cnc REF#107

GEAR DEBURRING/CHAMFERING/POINTING

cRoss #50 Gear tooth chamferer, 18” dia, single spindle REF#103Redin #20d, 20” dia, twin spindle, deburrer/chamfer REF#103saMPutensili #sct-3, chamf/deburrer, 14” dia, 5” Face, ‘82 REF#103saMPutensili #sM2ta Gear chamfering Mach, 10” Max dia, (3) new ‘96 REF#103Redin #24 cnc dia 4” setup Gear deburring REF#103

cRoss #60 Gear tooth chamferer, 10” dia, single spindle REF#103FelloWs #100-180/60 cnc Max dia 180”, single spindle REF#103ciMtec #50 Finisher REF#103cRoss #54 Gear deburrer, 30” dia, 18” Face REF#103Red RinG #24 twin spindle dia 4” REF#103Gleason GtR-250 VG cnc 5-axis REF#103Gleason- hurth Model Zea 4, Max dia 250mm, Max Module 5mm REF#103Redin Model 36 universal chamfering and deburring Machine, Max od 36”, twin spindle,

tilt table REF#103samputensili sct3 13.7”, sM2ta 10”, (5), 2003 REF#107Mitsubishi Ma30 cnc, 11”Pd, Fanuc, Powermate, 1999 (2) REF#107

GEAR HONERS

Kapp #cX120 coroning 4.7” dia REF#103Red Ring Ghd-12, 12” dia, 5.5 stroke REF#103Red Ring GhG, 12” dia, 5.5 stroke REF#103Kapp #Vac65 coroning 10” dia REF#103

GEAR SHAVERS

Red Ring #GcX-24" shaver, 24” dia, 33” stroke REF#103Red Ring #Gcu-12, 12” dia, 5” stroke REF#103

Red Ring #Gcy-12, 12” dia, 5” stroke REF#103Red Ring Gci 24, 12.75” dia, 5” stroke REF#103Kanzaki model GsP 320 Gear shaver REF#103Red Ring Gcu 12 crowning, 1956 to 1988 (6) REF#107Mitsubishi Fb30, 12.2 cnc Fanuc, 1997 REF#107sicmat Raso 100, cnc Fanuc 16M, new, Guarantee REF#107

GEAR GENERATORS

Gleason #37 str. bevel Planer, 6” dia REF#103Gleason #496 straight.& spiral. 7.5” dia REF#103Gleason 725-Revacycle, 6” dia REF#103Gleason 726-Revacycle, 5” dia REF#103Farrel sykes Model 12c herringbone max dia 264”, max face width 60” REF#103Farrel Model 5b herringbone gear generator. REF#103Gleason 529 gear quench press, auto cycle 16” diam, new 1980 REF#103Gleason 614 hypoid finishing machine, 10.5” pitch, dia 5.25” Max cone dist REF#103oerlikon/klingelnburg Model c28, Max dia 320 mm, Max Module 7.5 mm REF#103Gleason Model 26 Quench press and hypoid Generator Max od 16”, Max face Width air cylinder

REF#103Gleason Model 36 Gear Quenching Press, Max Ring 28” od, 8” Face, universal REF#103 Gleason Model 450 hc cnc hypoid cutter, Face width 2.6”, fanuc 150 controls REF#103Gleason 24 Rougher, Gears, Finishing tool holder REF#10712” Gleason, Gears, Gauges tool blocks REF#107Gleason 116 Rougher & Finisher (6) REF#107Gleason Phoenix 175hc cnc – 1994 REF#107Gleason 22 Rougher & Finisher (8) REF#107Gleason 610 combination Rougher & Finisher, 1988 REF#107

Gleason 608 & 609 Rougher & Finisher REF#107Gleason 7a, 7”Pd helical Motion, Gears & cams REF#107Gleason cutters, 3” to 25” in stock, 1000 REF#107

GEAR GRINDERS#27, #137, and #463 Gleason hypoid spiral bevel gear grinder generating cams (2 full sets) REF#102springfield Vertical Grinder, 62" table, #62aR/2cs, 3.5a Rail type, 70" swing REF#102ReishaueR Za, Gear Grinder, 13" dia, 6" Face, strait & helix REF#103Gleason #463, 15” dia REF#103hofler model Rapid 2000l, cnc Grinder, Max od 78”, cnc dressing REF#103Matrix model 78, Reman cnc thread grinder, 24” dia, 86” grind length, 106 between centers REF#103Mitsu seiki Model GsW-1000 Gear Grinder REF#103Reishauer RZ 362 as, cnc Grinder, Max dia 360mm REF#103sundstrand/arter Model d12 Grinder REF#103teledyne-landis Gear Roll Finishing Machine, 5” diam, 42k lbs Rolling Force REF#103Reishauer RZ301as cnc, 13” Measuring system (3) REF#107Reishauer Zb, 27.5” Pd Gears, coolant REF#107

GEAR RACK MILLERS/SHAPERSMiKRon #134 Rack shaper, 17.4" length, 1.1" Width, 16.9 dP REF#103syKes VR-72 Vert Rack shaper, 72" cut length, 4dP, 4" stroke, ‘80 REF#103Fellows 4 – 60 Rapid traverse, 2 cut REF#107

GEAR THREAD & WORM, MILLERS/GRINDERSbaRbeR-colMan #10-40, 10" dia., 40" length, 4 dP REF#103eXcello #31l, external thread Grinder, 5" od, 20" Grind length REF#103eXcello #33 thread Grinder 6” dia 18” length REF#103huRth #KF-33a Multi-Purpose auto-Milling Machine 88” REF#103lees bRadneR #ht12x102, extra large capacity REF#103lees bRadneR #ht 12"x 144" thread Mill, 12" dia, REF#103 lees bRadneR # lt 8” x 24” 8” dia REF#103 holRoyd 5a 24.8 “ dia REF#103 lees bRadbeR WoRM MilleR REF#103 dranke cnc internal ball nut Grinder REF#107

GEAR TESTERS/CHECKERS (incl CNC)FelloWs (1) Rl-600 Roll tester s/n 35814 REF#102FelloWs (1) 24h lead checker s/n 32289 REF#102Gleason (1) #14 tester s/n 31907 REF#102Gleason (1) #6 tester s/n 19316 REF#102FelloWs (1) 20 M Roller checker REF#102FelloWs (1) 20 M w/ 30” swing Roller checker REF#102FelloWs (1) #8 Micaodex s/n 36279 REF#102david brown #24 Worm tester REF#103Gleason #4, #6, #13 and #17 testers REF#103hofler eMZ-2602 int/ext Gear tester 102” REF#103Klingelnberg #PFsu-1600 Gear tester-2001 REF#103Kapp hob checker WM 410 REF#103Maag #es-430 Gear tester REF#103Maag #sP-130 lead and involute tester REF#103national broach Gear tester GsJ-12 REF#103oerlikon #st2-004 soft tester REF#103Maag #sP-60- electronic tester REF#103Parkson #42n Worm Gear tester REF#103Vinco dividing head optical inspection REF#103Gleason model 511 hypoid tester Max dia 20”, max spindle centerline 3.5” REF#103Klingelnberg Model PFsu-1600 63” dia, 1.02 dP, Rebuilt REF#103MaaG es401 Pitch tester With Process computer REF#103Fellows 12 & 24M involute, 12 & 24 lead REF#107Fellows 36” space tester, hot Pen Guaranteed REF#107Gleason 17a Running or Rebuilt Guaranteed REF#107Gleason 511, 20” Reconditioned in 2010 Guaranteed REF#107Gleason 27, 26”, Guaranteed REF#107Gleason 515, 24” REF#107Gleason 523, 20” Reconditioned, 2010 REF#107

MISCELLANEOUSWaRneR & sWaysey #4a M-3580 turret lathe, 28 1/4 swing, 80” centers, 12” spindle hole 50/25 Motors, 480/3 Phase, year 1965 REF#101springfield Vertical Grinder, 62" table, #62aR/2cs, 3.5a Rail type, 70" swing REF#102Gleason #529 Quench, 16" diameter REF#103Klingelnberg Model lRK-631 Gear lapper REF#103VeRtical tuRninG lathes and MoRe - Please check our Website to View our entire inventory REF#103tos su & sus series conv lathes REF#105tos sua series cnc Flat-bed lathes REF#105change gears for G & e hobber REF#106

JUNE 2013 59

PRODUCTSHOWCASE

New products, equipment, and resources

New Dimensions for the Measurement of Gears

The new WGT 280 Wenzel offers a gear measuring machine for the fast and efficient analysis of small gears up to a maximum diameter of 280 mm. Because of its compact construction and small footprint, it can be easily integrated into existing processes. The easy-to-access measuring volume allows a simple loading and operation

of the measuring system, making the WGT 280 ideal for the use of automated loading systems.

The highly-precise rotary table can be loaded with parts weighing up to 110 lbs. The WGT 280 is equipped with the Renishaw scanning probe SP 600 and allows the measurement of gears starting with a module of 0.5 as standard. For the accurate measurement of shafts, the gear measuring machine can be equipped additionally with a tail stock. The WGT 280 allows mea-surements in a Z range of 500 mm.

"The developments in drive technology make precise and reliable measurements of gear components (espe-cially gears) mandatory. Drives of any kind have to be as efficient as possible. In the future, gears will still be of great importance,” explains Heinrich Brüderle, responsible for the product series gear measurement at Wenzel Group. The decision was made to extend the WGT series by a smaller gear measuring machine, espe-cially for the requirements of the automotive industry.

With the new gear measuring machine, Wenzel com-bines innovative technology and modern industrial design. “The main focus was on the consequent real-ization of the intention to create an explicit recognition value combined with an existing line character. The new image of Wenzel reflects a precise and highly dynamic

layout of the line that extends to material and color combination,” explains Tim R. Wichmann, managing and mar-keting director of the Kaikai Company, Wenzel´s design partner. “Also a new approach is the 360°Design. This concept ensures that the machine looks designed from every side and overall harmonious. There is no back side that needs to be hidden,” adds Christian Jaeger, managing and creative director of the Kaikai company.

During the development of the WGT 280, Wenzel focused on one of its core competencies. The base plate and linear guides are made of massive hard stone and finished by hand. The combination of granite technology and pre-cise air suspension makes a gear measuring machine a durable and highly accurate measuring system, according to VDI/VDE 2612/13 group 1. Furthermore, the specially developed controller for gear metrology provides optimal 4-axes-control and high measuring performance.

The WGT gear measuring machines are equipped with a modular software package. The user is led intuitively through different input masks to enter parameters for part, measurement, and analysis. Additionally, the user is supported by different graphics. The basic package TGear can be individually extended by different modules for the measurement and analysis of different types of gears and shafts. This allows to set up the software optimally for every application.

Visit www.wenzel-group.com for more information.

60 gearsolutions.com

ZEOZORB: Innovative Desiccant Breathers for Gearbox ProtectionDrytech Inc., a manufacturer of moisture control systems for the aerospace and defense industry, is proud to announce the launch of its ZEOZORB desiccant breathers for long-term protection from oil contamination and harmful effects of moisture.

Contaminant prevention has always been a concern within the fluid system industry. Contaminants will enter industrial equip-ment as pressure, temperature, or fluid level changes occur. To prevent harmful contaminants from entering equipment a desic-cant breather should be used. Many industrial applications today use a breather cap or air filter to prevent contaminants from entering their system, but nothing to filter out moisture.

Maintaining industrial equipment can be a daunting task, but with proper operations and maintenance procedures maximizing your equipments potential is easier than ever. As with any fluid system, maintaining the condition of the lubricating oil is vital to prolonging optimal performance and life. ZEOZORB desiccant breathers ensure maximum protection of industrial equipment and fluid systems by preventing the entry of moisture and particulate contamination. The desiccant breathers are designed to replace breather caps or air filters on: fluid storage tanks; gearboxes; transformers; hydraulic fluid reservoirs, oil drums; and industrial equipment.

Desiccant breathers are one of the most cost-effective ways to prevent contamination. ZEOZORB desiccant breathers can be a powerful preventive maintenance tool to maximize equipment and lubricant life while minimizing operations and maintenance costs. It costs ten times more to remove contamination than to prevent it. Choose from a variety of different sizes and applica-tions to meet your needs.

ZEOZORB desiccant breathers were showcased at booth 3320 at WINDPOWER 2013 in Chicago, IL. For further information, please contact Cliff Jones, via email at jonesc@drytechinc.com or call 609-758-1794.

CNC MaChiNery SaleS iS a full ServiCe uSed aNd reMaNufaCture/retrofit MaChiNe tool Supplier

SpeCializiNg iN gear griNdiNg MaChiNeS. upgradiNg the MaNual gleaSoN 19/29/120/130 to CNC iS our SpeCialty.

CNC Machinery Sales, Inc.

Gleason 19/29/120/130 Curvic® Coupling Grinder

2 4 3 0 E A S T M O N R O E , P H O E N I x , A Z 8 5 0 3 4P H O N E (602)244-1507 • F A x 6 0 2 / 2 4 4 - 1 5 6 7WWW.CNCMACH.COM • SALES@CNCMACH.COM

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We use fanuc controls of the latest technology and our program is said to be the most user-friendly. We now boast over 25 fully functioning

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JUNE 2013 61

If there ever was a process taken for granted, it is Keyseating. This fundamental and traditional method to cut key-ways in bores has been stagnant and without development for many decades. Yet the quality and sophistication of the components with keyways have greatly improved through smaller tolerances, more exotic materials, and greater load carrying abilities. Keyways in high-dollar-value hubs or gears, processed to near-completion using CNC turning and grinding operations, are often trusted with an antique keyseater for one of the final steps of production. Or worse yet, they are manually broached by hand in a press using shims to control the final depth!

Leistritz, a German machine tool builder has a line of Keyseaters to match the control and flexibility needed by today’s manufacturers to produce a straight and accurate keyway. Their CNC keyseaters are very well-suited for cutting small keys yet heavy duty enough for huge keyways, up to 7" wide, as well. The CNC control is a valuable time saving device and can optimize the cutting parameters through fully flexible programming of feedrates and cutting speeds, as well as variable depths, if required. The CNC also allows the addition of a rotary table to produce helical grooves for special applications or multiple grooves within a single bore.

Leistritz has also developed keyseaters with linear motors to make full use of modern cutting tool materials, includ-ing carbide to cut keyways in already hardened workpieces. The linear motor systems produce the high cutting speeds required to match those needed by the tooling, and shorten the cycle times for a production environment.

With machine strokes up to 60” these machines can cut a wide variety of grooves in steels previously un-thought of with little investment in both tooling and capital.

Contact Leistritz at (201) 934-8262 to discuss your particular application and learn about the newest technology available to cut precision grooves or splines in bores. Visit them online at www.leistritzcorp.com.

Leistritz Offers Quality Line of Keyseaters for Producing Straight and Accurate Keyways

62 gearsolutions.com

MTI Systems Releases Costimator Software Version 12

New HU63Ex HMC from Mitsui Seiki USA Offers Precision, Power, and Torque

MTI Systems, Inc., a worldwide provider of cost estimating software and should cost estimating services, recently announced the release of Costimator® version 12. For decades, this dynamic cost estimating software has provided manufacturers a better way to estimate and quote parts more competitively. Version 12 is packed with upgrades and features that further enhance the speed, accuracy, and consistency for estimators, as well as a new layer of specialized and unique features for machining and fabrication.

“Costimator V12 is now easier to use and more accessible for estimators than ever before,” commented David LaJoie, vice presi-dent of sales at MTI Systems. “Now, the learning curve is significantly shorter, meaning not only will estimators get accustomed to how to use the software quicker, but they’ll be able to reap the benefits of faster, more accurate estimates. When combined with our enhanced customizable cost model building tool, users have even more options to estimate parts ‘their’ way—a benefit that’s hard to find in the cost estimating software industry.”

Costimator is cost estimating software designed for manufacturers of all sizes, who make or buy parts. This includes single-man job shops, large contract manufacturers, precision machining and fabrication shops, as well as full-service OEMs (original equipment manufacturers). While annual updates to the software add information to the extensive manufacturing data library, new features also offer estimators more flexibility to estimate and quote parts, products, and manufacturing processes “their way,” making it one of the most unique and customizable cost estimating software products for the manufacturing industry. MTI Systems has leveraged real-world manufacturing experience to deliver a comprehensive range of cost estimating solutions to the industry. By using MTI's solutions, organizations of all sizes, including small to mid-sized companies, can reduce costs and increase profits.

Sign up for a free demonstration to learn more: (800) 644-4318 or (413) 733-1972.

The new HU63EX horizontal machining center from Mitsui Seiki USA, Inc. is engineered to boost metalworking productivity through a combination of preci-sion, power, and torque. The 17,000kg (37,400lb) machine has a footprint of 2,900mm (116") x 3,180mm (127"), with X, Y and Z axes travels of 900mm, 800mm and 800mm (36", 32" and 32") respectively.

The machine’s structure maximizes rigidity and accuracy. The bed is a single casting supported at three points, which minimizes the effect of foundation fluctuations on accuracy. A thickened structure and specifically-developed rib configuration generate high rigidity. The mating surface of each axis box way, as well as other important areas such as rotary axis mounting, ball screw mounting points and spindle attachment surfaces are carefully hand-scraped, establishing extremely precise geometric characteristics such as parallelism, squareness, and straightness. This ensures consistent accuracy over an extended period of time. Air cavities between the ways and the column mat-ing surfaces are charged with low-pressure air, reducing the load on the way surface and enabling smooth movement without compromising rigidity. Ball screws located at the center of each guide way also assure stable movement.

Mitsui Seiki says the machine offers X, Y and Z axis positioning and repeatability accuracy of +/- 0.001mm (+/- 0.00004" or one micron), and B axis (rotating the 630mm [25.2"]-sq pallet) accuracy of +/- 2 sec with repeatability +/- 1 second.

The focus on accuracy and rigidity produces repeatable precision performance. According to Mitsui Seiki, in turn-boring opera-tions on 10 consecutive workpieces the HU63EX achieves concentricity within three microns.

In addition to precision, the HU63EX offers substantial power and torque. The machine’s standard 50-taper, 6,000 rpm spindle offers 18.5/15kw (30 min/continuous, 24.7/20hp) power with 601nm (443 ft-lb) torque, delivered through a two-step gearbox. Optional spindles include a 6,000 rpm, 26kw/22kw (34.8/29.4 hp) unit with 1,081nm (797 ft-lb) torque and a three-step gearbox, and a 12,000 rpm, 30kw/25kw (40/33.5 hp) version with 420 nm (309 ft-lb) torque driven by an integral, built-in motor.

For more information, contact Mitsui Seiki USA, Inc., (201) 337-1300, on the web at www.mitsuiseiki.com.

JUNE 2013 63

Methods Machine Tools, Inc. is introducing Version 6.0 of its CAMplete TurnMill software for Nakamura-Tome

Multitasking Turning Centers. The new version includes several upgrades for greater macro language support, improved

error handling, increased post processing capabilities, and more. CAMplete TurnMill software is an integrated suite of

G-Code editing, optimization, analysis, and verification tools, enabling a full range of turn/mill functions, and comes

standard on the full line of Nakamura Multitasking Turning Centers. CAMplete TurnMill Version 6.0 offers added sup-

port for Fanuc Macro B language including G# and M# calls; G65 macro calls; local, common, system, and shared

variables; variable math; IF/GOTO statements; and sub program calls. Users now have the ability to create custom

macros that can be easily inserted into any G-Code or formatted program.

Upgrades also include improved error handling, reporting and navigation, and an enhanced simulation progress dis-

play that now shows nested program calls. Newly designed regeneration controls have been added to show the active

program and current location, including line number, within the program.

Post processing support has been broadened in CAMplete TurnMill Version 6.0 to be compatible with Delcam’s

PowerMILL CAM software for milling from CUT files for 3+2 milling, 5-Axis milling, and canned cycles; Mastercam®

CAD/CAM software support from NCI files as well as OPEN MIND’s hyperMILL® post processing from POF files.

Mastercam and HyperMill post processing works with ATC and WT-Series machines, turning, milling, and 5-Axis milling.

“CAMplete TurnMill Version 6.0 features upgrades that will further enhance our Nakamura multitasking solution.

Users now have a number of new functions which will result in greater productivity,” said Mr. Richard Parenteau, direc-

tor of applications development at Methods Machine Tools, Inc. CAMplete TurnMill software was originally developed to

create a program that could combine G-Code from CAM systems and hand-coded G-Code into a set of programs that

could be simulated, fine-tuned, and optimized using detailed 3-D Nakamura machine models.

For more information, call (978) 443-5388, email sales@methodsmachine.com or visit www.methodsmachine.com.

Methods Machine Tools Announces Upgrades for CAMplete TurnMill Software

64 gearsolutions.com

Continued on page 66 >

Ingersoll Announces Gold-Max4 Super-Finishing Face Mill

Ingersoll is pleased to announce the arrival of their newest Super-finishing face mill, Gold-Max4 FFin. The generous .300" wide crowned wiper provides high quality finishes with superior flatness, eliminating the need for finish grinding opera-tions. While most MicroMill finishing inserts are designed for depths of cut less than .010", the Gold-Max4 FFin easily handles depths of cut up to .038”. Features include:

• Cutter diameters from Ø3.00" thru Ø8.00"

• High precision cutter bodies with tangentially mounted inserts offer-ing four insert indexes.

• Microfinishing possible at four times the typical axial depth of cut.

• Large elliptical radius that aligns itself to the surface.

• Multiple carbide grades for all material types.

Ingersoll Cutting Tool Company is a world leader in the design and manufacture of both standard and special indexable cutting tools for a complete range of metal removal applications. In addition to innova-tive solutions for high-performance milling and the project-focused engi-neering of special cutting tool solu-tions, Ingersoll offers a full range of metal removal technology for all industries.

For more information on Ingersoll's new finishing face mill family, con-tact an Ingersoll Cutting Tools' rep-resentative today. Visit www.inger-soll-imc.com for more information.

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JUNE 2013 65

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

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· Custom gear racks in AMERICAN and METRIC standards, STRAIGHT and HELICAL, VARIOUS materials, FINE and COARSE pitch (254 D.P. – 0.5 D.P.; 0.10 Module – 50 Module); hard-cut (up to 60 Rc) and soft-cut (up to 40 Rc); 32” face width; Up to 82” lengths – longer lengths through resetting

· Custom gears in AMERICAN and METRIC standards (3 D.P. – 72 D.P., 10” Diameter)

· Precision Quality up to AGMA 12· Prototype & Production quantities· Breakdown Service Available· Reverse Engineering · Unique Tooth Configurations· Heat Treating· Complete CNC Machining

Booth#606

LAWLER GEAR CORP.L E E ’ S S U M M I T , M I S S O U R I

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

SPUR - HELICAL - SPLINE - WORM - BEVEL - RACK

Gear Hobbing • Gear Shaping • Gear rack • Sprocketsbroaching • cNc Turning • cNc Milling • automatic Sawing

A HANDFUL OR A TRUCKLOAD!

LAWLER GEAR CORP.1320 S.e. Hamblen road • Lee’s Summit, MO 64081

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

SHARP HOBSChange Downtime To Productivity

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

• Stripping & Re-Coating

• Gear Shaper Sharpening

• Milling Cutter Sharpening

• Gear Tool Certifications

Tel: 216-642-5900 • Fax: 216-642-8837 • 5755 Canal Road • Valley View, OH 44125Email: gallen@gallenco.com WWW.GALLENCO.COM

66 gearsolutions.com66 gearsolutions.com

< Continued from page 64

DMG / MORI SEIKI Offers MTConnect V1.1 Adapters on New Machine Shipments

As of June 1st, 2013, all new DMG/MORI SEIKI machines equipped with MAPPS con-trol come installed with an MTConnect Standard V1.1 compliant MTConnect Adapter. With pre-installed MTConnect Adapters, DMG/MORI SEIKI customers will have a plug-and-play solution that allows easy, real-time monitoring of their machines—from anywhere, at any time. This remote-monitor-ing capability is enabled with MTConnect—a standard, open Web protocol that allows inter-connectivity between manufac-turing equipment, peripherals and software. For data collec-tion, archiving and reporting, customers have the option of choosing DMG/MORI SEIKI as their single-source remote moni-toring vendor, or a third-party vendor.

DMG/MORI SEIKI is very excit-ed to provide MTConnect V1.1 Adapters to empower custom-ers to achieve their next level of agility and competitiveness through remote monitoring of their machines. According to the

management adage “You cannot manage what you cannot measure”, one would need tools to monitor the historical and ongoing production activities to be able to improve and realize full utility of their capital investments. For small job shops to large manufacturing corporations, the insight into detailed shop-floor activities that allows one to find ways to improve productivity goes a long way.

DMG/MORI SEIKI is uniquely positioned to provide a complete solution on the market, offering a single source for all necessary remote-monitoring elements. This solution set based on MTConnect standard; comprises of the MTConnect Adapter, Agent and web services to let customers monitor productivity and status of machine tools. The Adapter and Agent collect the data from the machine and output the MTConnect XML protocol for the downstream software applications (web services or desktop) to collect, analyze and report.

MTConnect is an open, royalty-free and an evolving standard; thanks to the continued support and contribution of AMT, MTConnect Institute, software companies and major machine tool vendors, including DMG/MORI SEIKI. The MTConnect Standard V1.1 compliant Adapter on MAPPS control provides with basic remote monitoring capabilities that includes information like current machine operating status, overrides, alarm conditions and work count with exact time stamp in real-time. For more information on MTConnect Standard please visit www.mtconnect.org.

JUNE 2013 67

aDVerTISerINDEX

COMPANY NAME .............. PAGE NO.All Metals & Forge Group ........................................................... 51

Allen Adams Shaper Services .................................................... 65

Apollo Broach ............................................................................ 65

AWEA Offshore 2013 ................................................................. 64

Bourn & Koch ............................................................................ 67

Broadway Gear .......................................................................... 44

Carbide Tool Services Inc ........................................................... 16

Cincinnati Gearing Systems ....................................................... 35

Circle Gear & Machine Co. Inc ................................................... 14

CNC Machinery Sales Inc .......................................................... 60

Delta Inspection ......................................................................... 23

Drake Manufacturing Services Co. ............................................. 41

DT Technologies ........................................................................ 34

Encoder Products Company ...................................................... 40

Engineered Tools Corporation ...............................................36-37

Gear Expo 2013 ........................................................................ 53

Gleason Corporation .................................................................. 31

Hanik Corporation ...................................................................... 67

IKO Nippon Thompson .............................................................. 55

Index Technologies .................................................................... 65

Ingersoll Cutting Tools ................................................... 9,11,13,15

Innovative Rack & Gear .............................................................. 65

IOSSO Metal Processes ............................................................. 44

Ipsen International.................................................................... IBC

KAPP Technologies ................................................................... IFC

KISSsoft USA LLC ..................................................................... 14

Koro Sharpening Service ........................................................... 65

Lawler Gear Corp ...................................................................... 65

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

Machine Tool Builders ................................................................ 25

McInnes Rolled Rings ................................................................ 10

MicroGear .................................................................................. 40

Mitsubishi Heavy Industries America Inc .................................... BC

New England Gear ....................................................................... 7

Process Equipment Company .................................................... 54

Proto Manufacturing Ltd ............................................................ 12

R&P Metrology/KAPP Technologies............................................ 17

R P Machine Enterprises Inc ................................................. 47,56

Raycar Gear & Machine Co ........................................................ 34

Repair Parts Inc ......................................................................... 25

Russell Holbrook & Henderson ................................................... 45

STD Precision Gear ................................................................... 50

Stor-Loc .................................................................................... 60

The Broach Masters Inc ............................................................... 4

The Company Corporation ......................................................... 65

TMFM LLC ................................................................................ 50

Toolink Engineering Inc ................................................................ 1

TTI-Tokyo Technical Instruments USA ........................................ 46

WD-40 .................................................................................. 18,47

500 E. Higgins Road-stE 203PHonE 847-364-4800 FaX 847-364-4840

Elk gRovE villagE, il 60007

Booth#305

Booth#901

68 gearsolutions.com

GS: So “Delta” really describes more than one company, right?TW: We’re lumped into two different companies: Delta Research and Delta Gear, Inc. Delta Gear produces gears for the aerospace industry, while Delta Research does more automotive proto-types and off-highway, defense-type gears: heavy trucks, moving equipment, mining, and drilling. Delta Gear specializes in precision gears, preci-sion shafts, splines, collets, internal ground ring gears, pump gears, prototype gears, master gears, exotic gears, and gear assemblies. Our work is used by NASA and powers the fuel pumps on many aircraft, as well as with the Navy. We provide world-class solutions to the most demanding applications, tapping the expertise that only comes from decades of proven per-formance.

GS: How long have you been with Delta? TW: I’ve been here for six years—pretty short in the long scheme. We are a third-generation com-pany, started in 1952 by Alex Sakuta. He started it as a prototype design and build company for the auto industry. Alex was a mechanical engineer by trade. He was designing transmis-sions for a large auto company when he decided started his own company.

From there, his two sons Bob and Dennis expanded Delta Research into a number of different industries. Very soon after automotive came defense, then the aerospace industry. We’ve been doing work for those industries for decades, along with trucking and off-highway. And even though those came on decades ago, we still enjoy the diversity that they provide today. However, they all present their own challenges.

SaLeS/PrOJecT MaNaGer,DeLTa Gear/DeLTa reSearcH

GS: What about your facilities and equipment? I understand you’ve built some new build-ings recently.TW: Delta Gear is a fairly new facility, only two years old, and we’ve added a new building for Delta Research as well. We’ve over doubled the size and “footprint” of our company significantly in the past few years. Since I’ve started we’ve almost tripled our sales, and we have aggressive growth prospects; we’re bringing on quite a few people to help us meet that goal. It’s exciting. There’s a good chance we will double again in the next five years. That involves additional management and internal process controls—basically adding an entirely new level of support for our customers and the executive team.

The equipment that we have here is all leading edge equipment—from the two Gleason GP300ES CNC Shaping Machines to the KAPP VUS 65 and 67. The KAPP machines are truly the benchmark gear grinders for aerospace grinding. They have the ability to do stock division, in which you can actually calculate the amount of material you’ll be removing on each blank, which ensures that you’re not removing too much case off of any single gear tooth. This is critical when grinding gears that go to a critical component. It’s highly controlled.

GS: I hear people talk a lot about their “aggressive growth prospects,” but what is Delta Gear actively doing to grow?TW: We’re tier one to a lot of customers in different industries. As you continue to grow, you get more hands helping stir the pot. You have to make sure everybody knows what they’re doing. The most difficult thing is finding capable individuals to help your company grow. Good gear people don’t grow on trees. So we work to provide a great environment for our employees, where there is a high level of mutual respect between management and the team—we treat them like family. We still have that family feel, even though we’re up to roughly 130 employees. We still know everybody by name.

What we’re finding is that we have to grow these workers organically. You can’t just hire someone out of the blue, off the street and expect him or her to handle the kind of CNC equipment that we have in our facility. Some of our workers are running million-dollar machines. So we’ve partnered with the area schools and worked with them to find people who have the desire, drive, and ability to be valuable part of our company. We’re currently in the process of developing a curriculum, in addition to the in-house training program that we have, so that we can develop workers for our company and for our community as well. It enhances our region’s ability to become a center for excellence in gear manufacturing. We’ve become part of an “industrial council” connected with local colleges and areas of higher learning that discusses current curriculums, how to attract the right people for their schools, and how to train them up to become the next generation’s manufacturing technicians.

GS: What sort of students do you look for?TW: We look for candidates who have the interest and ability to make a career at the Delta Companies. The schools give them the basics, and we develop them from that point. It helps us to identify individuals who have the ability to become the highly trained technicians we have in our facility.

GS: I noticed on your website that you advertise “exotic” gears…TW: : From time to time, we’re asked to produce gears or rolling elements that aren’t traditional. Much of our equipment is designed to produce these types of involute, like a particular profile on a free-form surface. That’s where the partnership between Delta Research and Delta Gear comes in: We can produce non-involute forms and exotic profiles with our 5-axis milling capabilities at Delta Research, and then we can grind many of those surfaces with our Studor S40 at Delta Gear.

tony wersChkyQ&A

TO LearN MOre:Visit www.deltaresearch.com or call (734) 261-6400.

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Booth#1529

Maximize Production and Profi ts With Mitsubishi’s Multiple Process Capabilities Machines. When you reduce steps you reduce costs. With that in mind Mitsubishi developed its Process Integration platform. It allows various operations, such as chamferring, deburring, inspection, timing and meshing, to be incorporated into our existing gear machines. The advantage is clear. It’s simply more effi cient to have one machine completing two or more processes. With numerous options and confi gurations available you can customize our shaping, grinding or hobbing machines to incorporate the additional services that precisely meet your needs—and maximize your effi ciencies, production and profi ts. To learn how you can leverage all the possibilities of Process Integration visit www.mitsubishigearcenter.com or contact sales at 248-669-6136.PROCESS+integration

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Booth#909