Opportunities of Efficiency Improvement by the Use of Hydro Lubricants

GEAR SOLUTIONS MAGAZINE

Your Resource for Machines, Services, and Tooling for the Gear Industry OPPORTUNITIES OF EFFICIENCY IMPROVEMENT BY THE USE HYDRO LUBRICANTS ISSUE FOCUS Lubrication | Broaching OPPORTUNITIES OF EFFICIENCY IMPROVEMENT BY THE USE OF HYDRO LUBRICANTS

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FCG_GearSolutionsFullPageAd_WKG.indd 1 1/15/20 3:19 PM www.toolink-eng.com 6595 Odell Place, Suite I Boulder, CO 80301 303-776-6212 ARE YOU MAXIMIZING YOUR EXPOSURE? Connect your company to the gear industry with a storefront in the Gear Solutions Community. Storefronts paint a portrait of your company with a 500-word description and include your logo, website link, phone number, email addresses, and videos. Your social media pages such as Twitter and Facebook are integrated with live updates, which may also be re-posted through our social media feeds. With a community storefront, your company also receives a premium listing in the annual Buyer’s Guide published each November. Premium listings feature graphic treatments to draw more attention to your company.

JOIN THE GEAR SOLUTIONS For information on how you can participate in the COMMUNITY GearSolutions.com community storefront, contact FOR ONLY [email protected]. $ 350 Chad Morrison – associate publisher PER YEAR 800.366.2185 x 202 FEATURES

OPPORTUNITIES OF EFFICIENCY IMPROVEMENT BY THE USE OF HYDRO LUBRICANTS While searching for a material that meets all of the general and 30 branch-specific lubrication requirements, water is a visionary, yet obvious, raw material available worldwide that’s non-toxic and non-combustible.

By MATTHIAS PFADT, ELENA VON HÖRSTEN, and BALASUBRAMANIAM VENGUDUSAMY

ADVANTAGES OF FLAT BROACHING MACHINES 38 Flat broach manufacturing is a tooling option that offers some advantages to circular broaching, but the tools need to maintain optimum sharpness in order to be effective.

By JEFF BURG

OFFERING MODULAR PLANETARY GEARBOX DESIGN 42 COMPANY PROFILE Starting out almost a century ago by making clock parts, Neugart now develops, produces, and sells planetary gearboxes and custom gearboxes all around the world to a variety of industries.

By KENNETH CARTER

March 2020 3 Manufacturers of:

and Universal Gear Company I P

4 gearsolutions.com MARCH 2020 • VOLUME 17, NUMBER 3 DEPARTMENTS 8 INDUSTRY NEWS Reports, data, and developments to keep you aware of what’s happening with your colleagues in the gear-manufacturing industry around the country and world. Exact Metrology set to open new center Buehler celebrates 100-year anniversary in Moline, Illinois. of Wilson® Hardness

In this section, the premier supporter of gear manufacturing in the United States and beyond shares news of the organization’s activities, upcoming American educational and training opportunities, technical meetings and seminars, Gear Manufacturers standards development, and the actions of AGMA councils and committees. 19 Association

24 MATERIALS 26 TOOTH 28 HOT MATTER TIPS SEAT MARK MICHAUD BRIAN DENGEL D. SCOTT MACKENZIE ROTORCRAFT GEARBOX WHAT IS A STANDARD ANYWAY? BACK TO BASICS: HARDNESS REGULATIONS: LOL Gear standards are technical documents TESTING, PART 1 The European Union’s CS-29 Amendment that are developed by governing bodies Each type of hardness test is geared toward 7 places more stringent and rigorous in order to set rules, guidelines, and a specific purpose. The Rockwell testers are testing requirements for certification of definitions for the production, assembly, suitable for general purpose testing of parts Category A type pressurized gearboxes and inspection of gears — but they can and sheet, while the Brinell tester is suitable under loss of lubrication conditions vary depending on where you are. for larger components or raw materials. compared to the previous regulation.

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

RESOURCES 54 MARKETPLACE

55 ADVERTISER INDEX JACK CONWAY President of Atlanta Gear Works COVER PHOTO: SHUTTERSTOCK (4) / ILLUSTRATION BY RICK FRENNEA

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

March 2020 5 FROM THE David C. Cooper PUBLISHER EDITOR Chad Morrison ASSOCIATE PUBLISHER The importance of lubrication EDITORIAL and broaching Kenneth Carter ithout proper lubrication, the excess friction and dry metal-to-metal contact on gears EDITOR Wwould be detrimental to their proper functioning. Jennifer Jacobson That’s why it’s vitally important to know the challenges for proper gear lubricant for- ASSOCIATE EDITOR mulation. Joe Crowe With this month’s issue, Gear Solutions is bringing you some detailed insight into this CONTRIBUTING EDITOR gear-industry necessity. A majority of industrial lubricants are still on mineral oils, but an innovative approach is gaining headway by using environmentally friendly water. SALES In our cover article, Matthias Pfadt, Elena von Hörsten, and Balasubramaniam Chad Morrison Vengudusamy share their fascinating research into the opportunities of efficiency ASSOCIATE PUBLISHER improvement using hydro lubricants. Dave Gomez Broaching is often an essential step in gear production, but with different methods of NATIONAL SALES MANAGER broaching available, it’s important to know what type of broaching is best for a specific need. Tom McNulty REGIONAL SALES MANAGER Jeff Burg with Miller Broaching takes a look at flat broach manufacturing, and how it is a tooling option that offers some advantages of circular broaching. He also looks into the importance of maintaining optimum sharpness with broaching tools. CIRCULATION And our company profile shines a spotlight on Neugart. In that article, I talk with Teresa Cooper Christian Schilling, vice president of Neugart’s U.S. location, and how the company is MANAGER working to become a world leader in the production of planetary gearboxes. And don’t forget to dive into Gear Solutions’ regularly featured columns. You’re sure to Jamie Willett ASSISTANT find something that you didn’t know before, and one of our columnists might even elicit a smile or two as well. 2020 may be a quarter of the way into the history books already, but Gear Solutions has DESIGN a whole lot more in store for you, so “stay tuned” and keep me posted on anything you’d Rick Frennea like to see or contribute in the coming months. CREATIVE DIRECTOR Have an amazing spring, and, as always, thanks for reading! Michele Hall GRAPHIC DESIGNER

CONTRIBUTING WRITERS JEFF BURG BRIAN DENGEL KENNETH CARTER, editor ELENA VON HÖRSTEN D. SCOTT MACKENZIE [email protected] MARK MICHAUD (800) 366-2185 x204 PHILLIP OLSON MATTHIAS PFADT BALASUBRAMANIAM VENGUDUSAMY

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PUBLISHED BY MEDIA SOLUTIONS, INC. Coop wants to use this one for the website CALL FOR ARTICLES Have a technical paper or other work with an educational angle? Let Gear Solutions publish it. Contact the editor, P. O. Box 1987 • Pelham, AL 35124 Kenneth Carter, at [email protected] for how you can share (800) 366-2185 • (205) 380-1580 fax your expertise with our readers. David C. Cooper Chad Morrison PRESIDENT VICE PRESIDENT Teresa Cooper 6 gearsolutions.com OPERATIONS FELLOWS 10-4 GEAR SHAPERS REMANUFACTURED IN 2017 Yeah, we’ve got that!

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March 2020 7 343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776 • [email protected] INDUSTRY NEWS NEW TRENDS, SERVICES & DEVELOPMENTS

a complete range of portable coordinate measuring machines (CMM) and custom classes for any measurement needed. Day classes and half day classes will be available. Contract services that will be offered include CMM measurement, custom programming, inspection, and reverse engineering. Inspection is important because when a part is defined by millions of points, users can see subtle deviations, slight varia- tions, and fine details, thus ensuring that a part or mold meets certain specifications. 3D inspection is recommended for first article inspections, first-off inspections (sampling), in-process inspections, die tryouts, tool and die duplication, and statistical sampling. Reverse engineering is not only used for product design but also for legacy part repair and re-manufacturing, product benchmark- ing, documentation and archival, site plan- ning, defect/deterioration documentation, medical devices, and custom-fit products. Exact Metrology’s Moline location will serve as a training, support, contract measurement, and sales center. Training will be provided on software packages including PolyWorks®. (Courtesy: Exact Metrology) Exact Metrology is ISO AS9100 certified along with being FFL and ITAR registered.

Exact Metrology set models of physical objects for industries MORE INFO www.exactmetrology.com such as aerospace, archeology, medical, den- to open new center tal, tooling, and foundry. Provided by Exact in Moline, Illinois Metrology through Hexagon Metrology, GF Machining Solutions PC-DMIS offers the most popular dimen- Exact Metrology, a comprehensive metrol- sional metrology software package. has new director ogy services provider, is adding a new facil - Hardware classes will be offered for ity. With existing facilities in Brookfield, Romer, Leica Tracker, Surphaser®, Leica of expanded sales Wisconsin; Cincinnati, Ohio; and one RTC 360, and a CMM. The Romer portable GF Machining Solutions recently promoted upcoming in Texas, the company will have measuring arms, manufactured by Hexagon Peter Eigenmann to director of expanded a center in Moline, Illinois. The new location Metrology, offer reliable 3D measurements. sales. As part of the company’s recent was scheduled to open March 1, 2020. The Leica laser trackers are ideal for measur- sales and marketing realignment efforts, need for a new space arose from the increasing medium to large parts and providing a Eigenmann’s promotion and the organiza- ing number of clients in the area. portable solution for large-scale inspection tional changes he has instituted to further The Moline location will serve as a train- and assembly applications. The Surphaser improve the company’s customer service ing, support, contract measurement, and line provides short-, medium-, and long- and communication supports GF Machining sales center. Training will be provided on range models for use in reverse engineer- Solutions’ ongoing commitment to quality, software packages such as PolyWorks®, ing, dimensional control, historical preser- innovation and long-term growth in market Geomagic, and PC-DMIS. The PolyWorks soft- vation, architecture, and forensics. Leica RTC region North and Central America. ware suite maximizes productivity, quality, empowers users to document and capture “As the marketplace becomes increas- and profit, while integrating 3D measure- environments in 3D, improving efficiency ingly more competitive, manufacturers ment technologies into an industrial manu- and productivity through fast, simple-to-use, need more than a supplier — they require facturing process. Geomagic is a leading accurate, and portable hardware and soft- a partner,” said Phil Hauser, president of GF provider of 3D software that creates digital ware. Lastly, Exact Metrology will also offer Machining Solutions in North and Central

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

8 gearsolutions.com America. “We’re committed to serving as manufactured by Buehler, an ITW Company. that partner by providing customers with The acclaimed Wilson hardness brand a fully optimized experience throughout was originally known as the Wilson the purchasing life cycle, and under Peter’s Mechanical Instrument Company. Here, leadership, that will Stanley Rockwell and founder Charles H. begin with the sales Wilson introduced the Rockwell hardness process.” tester, an industry standard. Later, Wilson Bringing with became the home of the legendary Tukon him extensive expe- line of micro-indentation testers — renowned rience in machine for Knoop and Vickers testing. These early tools, the mold and inventions revolutionized industry and die industry and paved the way for Wilson today, with inno- industrial manu- vations that improve usability and allow for Peter Eigenmann facturing opera- full connectivity and automation, like the tions, Eigenmann DiaMet software and the powerful and ver- joined GF Machining Solutions in 2013 satile Universal hardness tester. as the head of project management in Buehler’s affiliation with Wilson began Schorndorf, Germany, before serving as in 2012 when the Wilson brand of hardness the head of sales for the Southeast region. testers encompassing Reicherter, Wilson, Eigenmann received his undergraduate and Wolpert products became part of education in mechanical engineering at Buehler’s offering. the Swiss Institute of Technology in Uzwil, According to Buehler general manager Switzerland, and his master’s certificate Julien Noel, “We are proud to continue the in project management from Duquesne 100-year legacy of innovation and excellence University in Pittsburgh. in Wilson Hardness. By having our engineering, manufacturing, and service in-house, MORE INFO www.gfms.com Buehler’s Wilson products have become the preferred choice for demanding labs that need to consistently meet quality standards. Buehler celebrates In the coming year, Buehler will continue to focus on exceeding customer expectations 100-year anniversary with a new and improved Rockwell tester, ® and an extended range of hardness refer- of Wilson Hardness ence blocks according to ISO, ASTM, and JIS Buehler, a leading manufacturer of metal- standards.” lographic and hardness testing equipment, Wilson is engineered and manufactured is commemorating and celebrating the cen- by Buehler since 2012. Today, Buehler’s tennial legacy of its Wilson® hardness testers. Wilson hardness line includes a compre- The Wilson® brand encompasses Reicherter, hensive range of hardness testers includ- Wilson, and Wolpert products. Today, they ing Rockwell®, Knoop/Vickers, Universal, are all known as Wilson and engineered and and Brinell as well as the comprehensive

Buehler, a leading manufacturer of metallographic and hardness testing equipment, is commemorating and celebrating the centennial legacy of its Wilson® hardness testers. (Courtesy: Buehler)

March 2020 9 INDUSTRY NEWS

DiaMet™ software that provides control, and a barcode scanner interface. Data and Cooperation (ILAC) Mutual Recognition data management, and reporting options indent images can be exported to all com- Agreement (MRA). Buehler is accredited by up to and including fully automatic produc- mon file types in user-adaptable templates. A2LA Certificate Number 2237.01 for direct tion systems. Buehler’s hardness testers are Furthermore, DiaMet is available in differ- and indirect calibration of hardness testers complemented by a range of ISO, ASTM, and ent configurations based on the capabilities in conformance with the current ASTM and JIS-certified hardness reference test blocks, of the hardness tester. It can be applied for ISO standards. accessories, and fixtures. a basic machine, without full-automation Buehler hardness equipment is available Buehler works closely with customers hardware (motorized XY-stage and Z-axis), for demonstration at the company’s solu- in manufacturing, research, and educa- as well as a high-end automated tester that tions centers in Buehler’s global locations tion to create leading-edge hardness solu- can perform multisample testing in a full or at partner centers maintained by Buehler tions. During the last eight years, Buehler automated sequence. distributors or universities. improved upon the original Wilson designs The DiaMet software platform works and also revolutionized hardness testing seamlessly with the Wilson hardness equip- MORE INFO www.buehler.com with the fully configurable DiaMet soft- ment line. ware, the Wilson VH3100 Vickers All-in-One Buehler’s priority is to deliver world-class hardness tester, and the heavy-duty Wilson products and services, conforming to ISO Big Kaiser donates to UH4000, an eight-turret, large stage univer- 9001, ISO14001, ASTM, DIN, ISO, MIL, and JIS sal hardness tester. All hardness equipment, standards and accredited to ISO/IEC 17025 for National Robotics League test blocks, and software are manufactured ASTM and ISO calibration. Buehler’s Wilson® at Buehler facilities. Reference Block Laboratory in Binghamton, to grow next-gen workers Buehler launched the DiaMet software New York, has achieved accreditation to ISO/ Customers and partners of Big Kaiser to provide an easy operation for automat- IEC 17025 by A2LA (American Association Precision Tooling teamed up to generate ed hardness testing. The proven DiaMet for Laboratory Accreditation) for Rockwell, a $7,283 donation to benefit the National software offers specimen mapping, edge Knoop, Vickers, and Brinell hardness test Robotics League (NRL). The amount is near- detection, scanning, stitching of overview blocks and indenters. A2LA is recognized for ly 10 percent more than last year, and the images, case depth calculations, and statis- the accreditation of testing and calibration fourth year-over-year increase in NRL fund- tical analysis tools as well as weld testing laboratories and inspection bodies under ing from Big Kaiser. and geometric measurement functions the International Laboratory Accreditation The donation is a 2 percent match of all

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10 gearsolutions.com Klingelnberg to take part in Bearing World conference Bearing World, the international rolling and plain bearing conference for “Industrial Research and Science in Dialogue with Practical Application,” is taking place for the third time, dedicated to all bearing types and all involved components. The Klingelnberg follows the approach of executing two-day symposium is organized by the FVA various measuring processes as a complete — Forschungsvereinigung Antriebstechnik measurement in a single stage. (Courtesy: e.V. The mechanical engineering company Klingelnberg) Klingelnberg is taking part in the sympo- “NRL is just one more way for us to engage kids sium for the first time and will be present- invites all participants to an exclusive and promote careers in manufacturing,” said Chris ing its expertise in this field as a sponsoring exchange of expertise. The company will Kaiser, CEO of Big Kaiser. (Courtesy: Big Kaiser) partner. present its service portfolio in this seg- The experts will meet March 31-April ment, which includes the G variants of the qualified orders from NTMA and AMT mem- 1 in Hanover, Germany. The aim of the Klingelnberg Precision Measuring Centers. ber companies during the final two months conference is to promote the exchange of Klingelnberg G variant Precision of each calendar year. Manufacturers placed knowledge and experience between univer- Measuring Centers are specifically designed orders for cutting tools, tool holders, work- sities and engineers from industry who are for use in the production process of axially holding, and tool measurement systems, involved in or responsible for the develop- symmetrical components. Klingelnberg fol- earning funds for the NRL at the same time. ment, production, assembly, quality assur- lows the approach of executing various mea- “We need to get involved at every level to ance, practical operation, or maintenance of suring processes as a complete measurement grow the next-generation workforce. Our bearings. Klingelnberg is also represented in a single stage (Done in One). Klingelnberg company does that by partnering with local at the symposium with a small booth and thus makes a significant contribution to the schools, our community colleges, and the trade associations,” said Chris Kaiser, CEO Precision Mechanical Components & Assemblies of Big Kaiser. “NRL is just one more way for Standard Industrial Components | Made To Print Parts us to engage kids and promote careers in manufacturing.” “We’re not just fighting a skills gap in our workforce, we have an ‘interest gap’ too. The NRL helps create excitement about manufacturing technology and STEM careers,” said Roger Atkins, president at NTMA. “We appreciate Big Kaiser’s continued support year over year, and of course all of the NTMA and AMT members who participate in the program to support the NRL.” The National Robotics League is a manufacturing workforce development program of the National Tooling & Machining Association (NTMA) where students design and build remote-controlled robots (Bots) to face off in a gladiator-style competition. Gears, Pulleys, Shafts, Bearings, Couplings, Fasteners, Custom Gear Boxes Through the manufacturing process of Bot Value Added Features and Services building, students’ imaginations are cap- Engineering, Refurbishing & Design  Press bearings into pulleys ADD tured as they design, build, and compete Custom Made To Print Parts  Assemble bearings to shafts • Grooves • Flats • Keyways • Pins with their own robotic creations. Through Modified Standard Parts  Set backlash on gears • Threads • Staking • Pressing  Assemble drive boxes • Testing this hands-on effort along with industry Assemblies & Sub-Assemblies  Straightening partnerships, students gain practical knowl- Custom Mounts For Shafts edge of science, technology, engineering,  Welding Build Sub-Assemblies And  Kitting and math (STEM) — all essential skills for Complete Assemblies  Plating / Custom Coating manufacturing. Prototype Work  Heat treat Nordex.com [email protected] [email protected] www.GoNRL.org MORE INFO Phone: (800) 243-0986 or Call: (203) 775-4877 www.us.bigkaiser.com

March 2020 11 INDUSTRY NEWS reduction of quality costs with the G variant plastics and rubber the flexibility to develop of the precision measuring center. In partic- safe, high-performance drive units for vari- ular, the integration of measuring technol- ous applications. ogy into the production environment helps All Maxxdrive industrial gear units are to increase the productivity and output of characterized by high power density, quiet the production plants. operation, and superior reliability. Large rolling bearings ensure high axial and radi- MORE INFO www.bearingworld.org al load capacities and long service life. The rugged Maxxdrive is available in parallel shaft and right angle and offers a modular, Extruder flanges extend flexible design as well as varied mounting ® orientations and designs. versatility of Maxxdrive Nord manufactures a wide selection of gearboxes, electric motors, and drive elec- gear units tronics in various sizes and configurations Extrusion has established itself as one of the for companies in intralogistics, food and bev- most important manufacturing techniques in erage, airport baggage handling, grain and the production and processing of rubber and Nord extruder-type drives are optimized for heavy- bulk materials, and other demanding mar- thermoplastics. To provide these industries duty operations. (Courtesy: Nord) kets. The modular design offers unlimited with the high output torque their heavy-duty versatility with more than 20 million com- applications demand, Nord Gear Corporation types and sizes, while appropriately selected binations of totally unique gear motors and manufactures several extruder flanges for its thrust bearings ensure safe absorption of speed reducers available — in-line or right- Maxxdrive® industrial gear units. process forces and a long operating life. In angle, mounted by foot or flange, featuring The extruder flange option is available addition, Nord will customize an extruder solid or hollow shafts — to give customers with Maxxdrive sizes five to 11, which deliv- shaft to precisely fit a customer’s shaft and complete freedom to specify a drive solution er torque from 132,000 to 684,000 lb-in. (15 use a range of bearing variants to match that’s perfect for the job. to 75 kNm). This broad availability enables the specified requirements. This gives plant adaptation to nearly all common connection builders, manufacturers, and processors of MORE INFO www.nord.com

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12 gearsolutions.com 10 innovative product divisions across the ogies and equipment, and having a major MC Machinery hires U.S. in addition to its commitment to the presence with customers during industry regional sales success of customers, business partners, and trade shows. employees. The anniversary campaign will engage representative “The ‘United by Success’ campaign shows with customers on the web, social media, Mark Kauffman has joined the MC that our customers and our company are one and industry events, including a dedicated Machinery team as a regional sales represen- through each other’s successes and are stron- U.S. anniversary landing page and video. tative for Southern California, Nevada, and ger together,” said Torben Reher, managing Liebherr will also unveil special exhibits and New Mexico. Kauffman’s industry expertise director of Liebherr USA, Co. host VIP events to thank customers for their will help him work Plans for 2020 include Liebherr com- loyalty throughout five decades. to increase product pleting the expansion of its Newport News, The exhibits and VIP events will be held sales and customer Virginia, campus, introducing new technol- at CONEXPO-CON/AGG (Las Vegas, March satisfaction. With more than 30 years of experience in the metal fabrication industry, Kauffman is an Mark Kauffman accomplished member of the industry. His experience includes engineering, quality control, production and facility management, manufacturing, and sales. “I am excited to work alongside the MC FORGING Machinery team,” Kaufmann said. “I look forward to developing and providing customer-based solutions.” MORE INFO www.mcmachinery.com AHEAD Liebherr celebrates 50 years of business in the United States OF THE PACK Liebherr in the United States is celebrating 50 years of success as a leading manufacturer in North America. With its anniversary theme, “United by Success,” the manufacturer remains focused on its commitment to U.S. customers. Liebherr has been producing in the United States since 1970. The company is one of the leading North American suppliers of construction machinery and other technically advanced, user-oriented prod- Fast. ucts and services. The manufacturer sells and distributes products throughout its No Fine Print. own locations and through an independent No Premium. distribution network. Liebherr has built its U.S. business on a At McInnes Rolled Rings, we provide quality foundation of trust, innovation, and engage- products, shipped fast. And we partner that with ment with customers. Five decades later, exceptional customer service to forge the perfect Liebherr’s growth, diversity, and stability partnership with our customers. are evidence of how the company is united by success with customers as they work on the challenges of tomorrow and focus on the future together. 1.877.695.0301  www.McInnesRolledRings.com Throughout 2020, Liebherr will focus on

March 2020 13 INDUSTRY NEWS

10-14) and MINExpo (Las Vegas, September 28-October 1). To keep pace with its growth, a new $60 million state-of-the-art expansion will be completed in spring 2020 in Newport News, which will be home to Liebherr USA, Co. The new site is adjacent to the company’s current facilities, where Liebherr has operated for its first 50 years. The new buildings will add more than 251,000 square feet to the existing 560,000-square-foot campus. Additionally, Liebherr has 13 other locations across the country.

MORE INFO www.liebherr.com MC Machinery adds sales representative for portions of Texas From left, Dr. Joseph Foldyna, director of the Institute of Geonics of the Czech Academy of Sciences in Ostrava, MC Machinery has hired Shannon Morris Czech Republic, presented the Best Paper certificate to Michael Lo and Dr. Axel Henning of OMAX Corporation. (Courtesy: OMAX) as a regional sales representative for north/ central Texas and a portion of east Texas. Republic. The paper, titled “Particle Velocity Morris has extensive industry knowledge to in Abrasive Waterjets,” examines abrasive Retech Systems LLC help support local customers and increase speed data to help improve understanding relocates headquarters MC Machinery prod- of particle acceleration behavior in abrasive uct sales. waterjet (AWJ) nozzles. to Buffalo, N.Y. With 28 years of This year was the sixth occurrence of outside sales expe- the biannual Czech Water Jet conference. Retech Systems LLC (Seco/Warwick Group) rience, Morris has The conference is geared toward producers, has finalized plans to relocate its headquar- acquired a compre- users, designers, and other publics interest- ters from Ukiah, California, to Buffalo, New hensive background ed in the technology of high-speed water jet. York. The world’s leading supplier of plasma in sales and account It is a forum for the exchange of knowledge, cold hearth and electron beam furnaces management. Her information, and experiences in areas of will set up its manufacturing and research Shannon Morris most recent posi- research, development, and application of and development in the new facility to pro- tion was with an the water jets. duce innovative melting furnaces for global industrial gas and welding supplies distribu- “It was an honor to represent the OMAX distribution. tor as an outside sales representative in the Corporation at Water Jet 2019 and a lot of Retech, a Seco/Warwick Group company, Dallas-Fort Worth Metroplex/Oklahoma ter- fun to meet experts in the field that come will lease about 49,000 square feet of space ritory. from universities and companies in differ- at 683 Northland Avenue. Mayor Byron W. “I’m thrilled about the opportunity to ent countries,” said Michael Lo. The paper Brown said in the official statement that increase MC Machinery’s visibility in the was selected from 37 submitted articles by Retech’s facility will bring state-of-the-art, manufacturing industry,” Morris said. “I the international technical committee. high-tech products to the Buffalo and west- look forward to expanding our loyal cus- OMAX has a long history of supporting ern New York area, and into the Northland tomer base.” research and development. From motion Corridor Redevelopment Project. control systems to precision cutting, the Earl Good, Retech Systems president and MORE INFO www.mcmachinery.com OMAX researchers have discovered much managing director, said, “Retech Systems is of what has made OMAX the technological pleased to be moving to Buffalo. This decision leader throughout the waterjet industry. Just was made not only to provide flawless region- Omax team earns as when OMAX introduced its revolutionary al and global support to our customers; we cutting model, which provided improve- also thought about the future. The engineer- Best Paper at Water Jet ments on cutting speed and precision to ing and technology schools in western New all users of their machines, OMAX strives York are important incubators to support the 2019 conference to improve on components and procedures technologies that we are creating. While we Three members of the OMAX® research and to make help customers excel in an increas- are changing our location, the quality of our development team, Michael Lo, Kevin Hay, ingly competitive market. products will not be changing.” Good predicts and Dr. Axel Henning, won Best Paper at that Retech’s relocation will potentially cre- the Water Jet 2019 conference in the Czech MORE INFO www.omax.com ate about 80 new jobs over the next few years. 14 gearsolutions.com Sl⁄awomir Woz´niak, Seco/Warwick’s CEO, said, “Among other reasons, we decided to relocate Retech headquarters to Buffalo due to the close proximity of other Seco/Warwick Group subsidiaries in nearby Meadville, Pennsylvania. This decision will allow closer cooperation and improved operation management. The new location will also be a nice place to host customers and suppliers.”

MORE INFO www.retechsystemsllc.com Solar Manufacturing ships two all-metal hot zone furnaces Solar Manufacturing recently built and shipped two furnaces to Tennessee for ser- Solar Manufacturing recently built and shipped two furnaces to Tennessee for service to the medical and vice to the medical and additive manufactur- additive manufacturing industries. (Courtesy: Solar Manufacturing) ing industries. The models HFL-3848-EQ and HFL-3836-EQ both feature metallic-insulated with the SolarVac Polaris® Control System. of the additive manufacturing market set hot zones, a load weight capacity up to 2,000 “Solar Manufacturing was awarded the us apart from the competition. Additionally, pounds, and a maximum operating temper- order because we offered the best solution the customer found the premium features ature of 2,400°F. Measuring 24” wide x 24” for their vacuum furnace needs,” said Dan and benefits offered with our vacuum fur- high x 48” deep, and 24” wide x 24” high x 36” Insogna, Solar’s Southeast regional sales nace equipment impressive. We’re pleased to deep respectively, each furnace was designed manager. “Our knowledge and experience have helped them select furnaces that best

GEARING AHEAD TO MEET INDUSTRY’S DEMAND FOR PRECISION – SERVING – NEW Aircraft • Aerospace • Actuation Release Instrumentation • Optic 2019 Robotics • Radar • Medical Marine • Defense • Experimental Prototype • Production KISSsoft Highlights Hi-Performance Automotive Precision Gear Products (up to AGMA Q14): ▪ Intuitive concept design on system level Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, Clutch Gears, with KISSdesign Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, Bevel Gears, Miter Gears, ▪ Rolling bearing calculation with connection to SKF cloud Metric Gears, Internal Gears, Idler Gears, Gear Rack & Pinion, Worms, Wormshafts, ▪ Contact pattern of asymmetrical gears Splines, Spline Shafts, Serrated Shafts. ▪ Crossed helical gear with rack KISSsoft AG/Gleason Sales ▪ Feasibility assessment for „Power Skiving“ CNC Thread Grinding Brian P. Stringer Nadcap Accredited: Heat Treatment, Induction Hardening, Passivation Phone (585) 494-2470 [email protected] Free trial version at www.KISSsoft.com STD Precision Gear & Instrument, Inc. 318 Manley St. • W. Bridgewater, MA 02379 (888) STD-GEAR or (508) 580-0035 Fax (888) FAX-4STD or (508) 580-0071 E-mail [email protected] • Web site: www.stdgear.com

March 2020 15

GearSol_KISSsoft_Release2019_92_25x123_83mm.indd 1 09.05.2019 09:06:08 INDUSTRY NEWS suit the unique requirements of the industries they serve.” Solar Manufacturing designs and manufactures a wide variety of vacuum furnaces, with process capabilities including heat treating, sintering, stress relieving, vacuum temper, annealing, solution annealing, and ageing. It also offers replacement hot zones, spare parts, and professional service.

MORE INFO www.solarmfg.com Direct access to SKF bearing data now available in KISSsoft

Recently, the Swedish rolling bearing manu- SKF and KISSsoft worked together to produce software to calculate bearing performance. (Courtesy: KISSsoft) facturer SKF and the Swiss gearbox design software developer KISSsoft joined forces. The KISSsoft Release 2019 offers the possibil- data and SKF formulas which have been a seamless experience when working on a ity to calculate bearing performance by SKF validated by extensive testing at SKF facili- new gearbox design. As a result, the predic- through a cloud calculation service (Module ties. The results are separately displayed in tion of bearing performance becomes more WPK and WB1). KISSsoft and can therefore quickly be com- realistic, especially for the SKF Explorer Bearing rating life and other perfor - pared with ISO results. range and hybrid bearings. mance parameters are calculated based The SKF bearing module in on direct access to SKF bearing geometry KISSsoft enables a machine engineer to have MORE INFO www.KISSsoft.AG

YOU’VE GOT THE PRODUCTS. YOU’VE GOT THE SERVICES. NOW, LET US SHARE YOUR STORY.

Gear Solutions wants to make sure the best possible audience knows your company. Through our print, online, and social media presence, our experienced staff can get your message to an industry that wants to know what you can do.

To learn more, contact assistant publisher Chad Morrison at [email protected] or call 800.366.2185 ext. 202

16 gearsolutions.com benefit from versatility in tight spaces and FOBA upgrades portfolio easy mounting of one of the smallest mark- with Y.0200-S fiber ing heads available.”

laser marking system MORE INFO www.fobalaser.com FOBA understands manufacturers’ varying needs for direct part marking and intends to solve many of their unique laser identi- GF Machining showcases fication requirements. The new system is ideal for demanding production schedules milling, EDM offerings — especially in the electronics and automo- The FOBA Y.0200-S marking unit can be controlled at MD&M West 2020 tive supplies or metal and plastics process- using the IP65-rated 10.1-inch color touchscreen ing industries. FOBA’s Y.0200-S marking sys- laser controller. (Courtesy: FOBA) At this year’s Medical Design & tem can keep pace with the legal ID speci- Manufacturing (MD&M) West 2020, GF fications and provide a high level of code 10 mm marking head, depending on the Machining Solutions demonstrated its contrast and durability, even on robust, application. MIKRON HSM 200U LP (linear performance) high-density materials. The new laser provides seamless integra- milling machine with pallet changer (PCH) The 20-watt fiber laser provides increased tion into various production lines and users and CUT E350 wire EDM. Both high-produc- operational freedom, flexibility, and appli- can choose to control the marking process tivity, high-precision machines represent cation confidence. Users can select either using FOBA’s Touch Control Software FOBA two key operations within GF’s complete a 6 mm marking head for high-speed pro- Go on the IP65-rated 10.1-inch color touch- line of medical component processing solu- duction or a 10 mm marking head for parts screen or on most browser-based devices. tions that provide medical manufacturers marking with fine detail. “Our customers have already received with a single source for all their part pro- Improved data processing and high mark- this lightweight, compact, and agile fiber duction needs. Also included in GF’s medi- ing speed allow for enhanced productivity: laser solution very well,” said Wen Xiao, cal solutions are laser texturing, additive Up to 1,300 characters per second can be FOBA general manager in the APAC region. manufacturing, micro laser machining, and achieved with the 6 mm marking head or “Having the choice between a zero- or modular pallet technologies. up to 1,000 characters per second with the 90-degree marking head orientation, they For medical component milling, the HSM

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THE ROOT CAUSE FOR GEAR NOISE EXCITATION NOISE GEAR FOR CAUSE ROOT THE Bevel Gears | Plastic Gears Cutting Tools | Workholding INCREASING STATIC FRICTION WITH LASER THE ROOT CAUSE FOR INCREASING GEAR NOISE STATIC FRICTION EXCITATION WITH LASER COMPANY SUBSCRIBE FOR FREE PROFILE COMPANY PROFILE PISELLI ENTERPRISES

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March 2020 17 INDUSTRY NEWS

200U LP is available in 3- and 5-axis (full axes and optimized direct-drive motors for simultaneous) versions that bring speed, the B and C axes. The machine’s powerful efficiency, and precision to the machining 50,000 rpm, 11.4 hp Step- Tec spindle further of such small, highly complex components contributes to precise part details and excel- as stainless-steel denture bars or orthopedic lent surface finishes. implants. In addition, its compact size allows Paired with optional MIKRON pallet the machine to fit into most facilities, a key magazines with System 3R and Erowa inter- factor for dental labs and other shops where faces, the HSM 200U LP delivers unattended floor space is at a premium. 24/7 machining for increasing the output The HSM 200U LP generates part surface of existing workforces. The fully integrat- finishes as fine as Ra 0.05 µm thanks to lin- ed pallet magazines can be loaded without ear motor technology in its main machine interrupting cutting operations already

GF’s CUT E Series of wire EDMs, the CUT E 350, incorporates a broad range of technologies that allow medical manufacturers to increase flexibility and accelerate their time to market. (Courtesy: GF The Machining Solutions) in progress, and the automation of tool or workpiece handling is possible from three Power sides of the machine. 2 A Heidenhain iTNC 530 control system of One and smart machining modules on the HSM 200U LP provide advanced levels of monitoring — critical for the production of high- Your Objective: value precision medical parts. The system One face in perfect alignment with another. For infinity. allows the machine to automatically check and evaluate tools and workpieces, inspect tools for breakage, and perform measurements of the workpiece. The smart machine modules automatically monitor spindle vibration, calibrate machine geometry, and even transmit process status messages to an operator’s cell phone. As part of GF’s CUT E Series of wire EDMs, No problems. No distress. No delays. the CUT E 350, like the HSM 200U LP, also incorporates a broad range of technolo - That’s the same objective you have for choosing your gear producer. gies that allow medical manufacturers to Circle Gear’s objective is to engage with every customer’s objectives. increase flexibility and accelerate their One to 1000 gears time to market. These technologies include a large touchscreen HMI (human-machine Customer designed or reverse engineered interface) that is intuitive in operation Gearbox repair, rebuild or redesign and includes onboard Intelligent Collision OEM or end-users Protection, built-in machining strategies and flexible job management. ISO 9001:2015 Certified Information about geometries, machining processes, and command programs is processed in a single file. This allows jobs 1501 S. 55th Court, Cicero, IL 60804 (800) 637-9335 to be transferred among different machines (708) 652-1000 / Fax: (708) 652-1100 in the CUT E Series, with the machines auto- [email protected] matically managing all needed modifica- www.circlegear.com tions. Additionally, more than 10 automated measurement cycles are available to assist Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears • with workpiece preparation. The onboard Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears • AC CAM Easy allows an operator to prepare Worm and Worm Gears • Racks • Sprockets • ISO Certified an ISO file and post-process it into a job dur- Partnering with QualityReducer to provide ing machining. Gearbox repair, rebuilding and reverse-engineering. MORE INFO www.gfms.com 18 gearsolutions.com JennyPhillip BlackfordOlson ViceAGMA President Staff Engineer of American Communications Gear Manufacturers AGMA Association

2019 AGMA Technical Committee revising several industry standards

hanks to our many hardworking volunteer committee mem- ANSI/AGMA 1103-H07, Tooth Proportions for Fine-Pitch Spur and bers, AGMA Technical Committees have had another suc - Helical Gearing (Metric Edition). cessful year in 2019. After many years in the draft stage, two Like a well-designed machine that doesn’t break down, the expert completely new documents were published in 2019, AGMA knowledge, meticulous attention to detail and consensus-building T944-A19, Mechanisms of Powder Metal PM Gear Failures, and ANSI/ skills of our volunteer members who work hard to develop the stan- AGMA 1107-A19, Tolerance Specification for Form Milling Cutters. dards often go unnoticed in the background. The benefits of their One adoption of an ISO Technical Report, AGMA ISO 18792-A19, work, however, are front and center to the gear industry and gear Lubrication of industrial gear drives, was completed in 2019. Seven users every day. In 2020, a sampling of the work AGMA technical standards were revised to new editions in 2019: committees will be continuing is: ANSI/AGMA 1102-C19, Tolerance Specification for Gear Hobs. A new revision of ANSI/AGMA 2101, Fundamental Rating Factors ANSI/AGMA 2002-D19, Tooth Thickness and Backlash and Calculation Methods for Involute Spur and Helical Gear Teeth. Measurement of Cylindrical Involute Gearing. The revision is a complete rewrite of the 2004 edition to bring the ANSI/AGMA 2003-D19, Rating the Pitting Resistance and standard up-to-date with the latest technology. Bending Strength of Generated Straight Bevel Zerol Bevel and Spiral A new revision of AGMA 925, Effect of Lubrication on Gear Bevel Gear Teeth. Surface Distress. This will be the second revision of this informa- ANSI/AGMA 6001-F19, Design and Selection of Components for tion sheet that was first published in 2003. Enclosed Gear Drives. A new revision of AGMA 911, Guidelines for Aerospace Gearing. ANSI/AGMA 6101-F19, Design and Selection of Components for The revision is a complete rewrite and reorganization of the 1994 Enclosed Gear Drives (Metric Edition). edition to get the information sheet up-to-date with the latest tech- ANSI/AGMA 6022-D19, Design Manual for Cylindrical nology. Wormgearing. A new revision of AGMA 923, Metallurgical Specifications for ANSI/AGMA 6025-E19, Sound for Enclosed Helical Herringbone Steel Gearing, which will add a third grade to through-hardened and Spiral Bevel Gear Drives. gears and update the rest of the document to the latest industry And additionally, 11 documents were reaffirmed in 2019, which practices. Information sheets such as this will help improve quality is the process of our committees reviewing the documents for con- of raw materials by providing detailed guidelines on required speci- tinued relevance to the industry and technical accuracy: fications set by gear designers. AGMA 919-1-A14, Condition Monitoring and Diagnostics of Gear A completely new information sheet titled AGMA 943, Tolerances Units and Open Gears: Part 1 – Basics. for Spur and Helical Racks, which should standardize the different ANSI/AGMA 1003-H07, Tooth Proportions for Fine-Pitch Spur and practices used in the industry. Helical Gearing. A new revision of ANSI/AGMA 1012, Gear Nomenclature, ANSI/AGMA 1010-F14, Appearance of Gear Teeth — Terminology Definitions of Terms with Symbols, which will add more definitions of Wear and Failure. and align better with international standards. Standards such as this ANSI/AGMA 2004-C08, Gear Materials Heat Treatment and help the industry by giving everyone the common language to define Processing Manual. various gear elements and related attributes. ANSI/AGMA 2011-B14, Cylindrical Wormgearing Tolerance and A new revision of ANSI/AGMA 1103, Tooth Proportions for Fine- Inspection Methods. Pitch Spur and Helical Gearing, to update formatting, clarify the ANSI/AGMA 6011-J14, Specification for High Speed Helical Gear language, and include the latest practices. Units. A full listing of AGMA technical committees, including a scope ANSI/AGMA 6022-C93, Design Manual for Cylindrical of their activities, can be found in the Technical Committees sec- Wormgearing. tion of the AGMA website, www.agma.org. For additional informa- ANSI/AGMA 6033-C08, Materials for Marine Propulsion Gearing. tion about AGMA technical committees, standards, and informa- ANSI/AGMA 6133-C08, Materials for Propulsion Gearing (Metric tion sheets, please contact the AGMA Technical Division at tech@ Edition). agma.org. ANSI/AGMA 9004-B08, Flexible Couplings - Mass Elastic For all the valuable contributions of our committee members to Properties and Other Characteristics. help the gear industry and gear users everywhere, we thank you!

March 2020 19 Upcoming Education

Basic Training for Gear Manufacturing April 13-17 | Chicago, Illinois Learn the fundamentals of gear manufacturing in this hands-on course. Gain an understanding of gearing and nomenclature, principles of inspection, gear manufacturing methods, hobbing, and shaping. Using manual machines, develop a deeper breadth of per- spective and understanding of the process and physics of making a gear as well as the ability to apply this knowledge in working with quantify quality of a gear tooth form will be thoroughly investigated CNC equipment commonly in use. and explained. It is often stated that quality cannot be inspected into the part; however, inspection can tell us what to do to correct Basic Gear Inspection for Operators many issues. April 21-22 | Chicago, Illinois This class has been made possible with the generous donations Learn the common, current, and basics of the tools and techniques of the AGMA Foundation. used to measure and inspect gears. There are four main categories by which a gear is evaluated and classified. Gear design, manufacture, Operator Hobbing & Shaper Cutting and inspection are based on numerical scale that defines gear qual- May 12-13 | Chicago, Illinois ity. The methodology to measure and the techniques required to Learn and understand fundamentals of gear manufacturing. Acquire

American Gear Manufacturers 20 gearsolutions.comAssociation course on contract negotiating. Join us in the unique environment of Charleston, South Carolina, network with your peers at a traditional low country boil, and tour the world-class Clemson University offshore wind turbine test facility. Become an FTM Peer Reviewer 2020 Fall Technical Meeting October 19-21, 2020 | Rosemont, Illinois The abstracts are in for the 2020 Fall Technical Meeting and now it is time to review them for the meeting. Visit: www.agma.org/2020- fall-technical-meeting/ The unique qualifier for the FTM is the fact that all technical papers go through a double-blind review. Sign up to be a part of this knowledge and understanding of gear nomenclature, hobbing and unparalleled event and share your expertise to help the researchers shaping of spur and helical gears, and splines. Learn and understand showcase their greatest work. hobber and shaper machine set-up, as well as gear tooth element inspection. Understand the manufacturing process before gear tooth cutting, as well as post cutting processes. Apply concepts to further Help Get the AGMA finishing processes, i.e. heat treat, gear tooth shaving and grinding and/or skiving. Gain knowledge to establish a solid foundation for National Training Center all basic gear manufacturing. This class has been made possible with the generous donations Up and Running of the AGMA Foundation. MACHINE/MATERIAL DONATIONS NEEDED The AGMA National Training Center at Richard C. Daley College in Chicago will host multiple industry training courses, including four new operator level classes in 2020. Donations are eligible for a charitable tax deduction. For details on what is needed and how to donate, visit the “Spin It Forward” website at: agmafoundation.org/ spinitforward/, or email us at: [email protected]. For AGMA Members SEND AGMA YOUR NEWS! AGMA is proud of the work our members do, and we want to share Registration is Open! your accomplishments. Make sure to send [email protected] your press releases, so we can post them on our website. Take a look today Strategic Resources Network Meeting and see where people can find out more about what your business May 27-29 | Charleston, South Carolina is doing. The 2020 AGMA Strategic Resources Network (SRN) event has been designed for the next-generation manufacturing leaders. We are pro- DO YOU HAVE OPEN JOBS TO FILL? viding presentations that address the agile skills our current manu- Let AGMA help market your open jobs with their online job board. facturing environments require. Learn how to protect your company We know that finding the right people to work at your company can from cybersecurity threats, discuss what is keeping your peers up be time consuming and AGMA is here to help. All AGMA members at night, and learn the latest discoveries from the AGMA Emerging can post unlimited jobs to the AGMA website to help you in your Technology committees. reach efforts. To post a job, contact Rebecca Brinkley at brinkley@ This year, attendees will also receive a four-hour special training agma.org for full details.

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

1001 N. Fairfax Street | Suite 500 | Alexandria, VA 22314 | (703) 684-0211 | www.agma.org March 2020 21 CALENDAR OF EVENTS Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard in the standards process, AGMA has something to offer you. If you would like more information on any of the following events, visit www.agma.org or send an email to [email protected].

March 17 — Helical Gear Rating Committee Meeting — WebEx March 24 — Metallurgy and Materials Committee Meeting — WebEx March 25 — Aerospace Gearing Committee Meeting — WebEx MARCH March 26 — Gear Accuracy Committee Meeting — WebEx

April 1 — Bevel Gearing Committee Meeting — WebEx April 2 — Lubrication Committee Meeting — WebEx April 9 — Powder Metallurgy Committee Meeting — WebEx April 15 — Plastics Committee Meeting — WebEx April 15–17 — Working Group 2 and Working Group 7 — China

APRIL April 21 — Vehicle Gearing Committee Meeting — WebExEx April 23 — Helical Gear Rating Committee Meeting — WebEx April 24 — Metallurgy and Materials Committee Meeting — WebEx April 28 — Nomenclature Committee Meeting — WebEx

May 5–6 — Flexible Coupling Committee Meeting — Alexandria, Virginia May 12 — Nomenclature Committee Meeting — WebEx MAY May 19 — Gear Accuracy Committee Meeting — WebEx

AGMA LEADERSHIP

John Cross: Chairman Zen Cichon: Innovative Rack & Gear Company ASI Drives Michael Engesser: Reishauer Corporation Greg Schulte: Treasurer Bonfiglioli USA Bent Hervard: CFT Michael McKernin: Chairman, BMEC Ruth Johnston: Croix Gear & Machining Gear Group at United Stars, Inc. Chalmers & Kubeck Inc. Todd Praneis: Chairman, TDEC David R. Long: Cotta Transmission Company, LLC Jack Masseth: Meritor, Inc. Jim Bregi: Chairman Emeritus Scott Miller: Caterpillar, Inc. EXECUTIVE COMMITTEE Doppler Gear Company Gary Neidig: ITAMCO Shawn O’Brien: McInnes Rolled Rings

Matt Croson: President BOARD OF DIRECTORS Cory Ooyen: Global Gear & Machining, LLC Amir Aboutaleb: VP, Technical Division STAFF Jenny Blackford: VP, Marketing Carl D. Rapp: The Timken Company Sara Zimmerman: Sumitomo Drive Technologies

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

22 gearsolutions.com YOUR SOURCE FOR GEAR INDUSTRY NEWS March 17 — Helical Gear Rating Committee Meeting — WebEx March 24 — Metallurgy and Materials Committee Meeting — WebEx March 25 — Aerospace Gearing Committee Meeting — WebEx Gear Solutions magazine has been the March 26 — Gear Accuracy Committee Meeting — WebEx JOIN THE GEAR SOLUTIONS most trusted source for information COMMUNITY and technical knowledge in the gear FOR ONLY April 1 — Bevel Gearing Committee Meeting — WebEx $ manufacturing industry for more than 350 April 2 — Lubrication Committee Meeting — WebEx PER YEAR April 9 — Powder Metallurgy Committee Meeting — WebEx 15 years. April 15 — Plastics Committee Meeting — WebEx Each issue, Gear Solutions offers its readers April 15–17 — Working Group 2 and Working Group 7 — China the latest, most valuable content available from April 21 — Vehicle Gearing Committee Meeting — WebExEx companies, large and small, as well as critical April 23 — Helical Gear Rating Committee Meeting — WebEx thoughts on what this information means for the April 24 — Metallurgy and Materials Committee Meeting — WebEx future of the gear manufacturing industry. April 28 — Nomenclature Committee Meeting — WebEx Best of all, it’s free to you. All you need to do is subscribe. On GearSolutions.com, we have paired our vast May 5–6 — Flexible Coupling Committee Meeting — Alexandria, Virginia technical archives with the latest web technologies May 12 — Nomenclature Committee Meeting — WebEx GEAR SOLUTIONS MAGAZINE MAGAZINE SOLUTIONS GEAR to develop the most efficient, streamlined, user-

May 19 — Gear Accuracy Committee Meeting — WebEx friendly web experience in the gear industry.

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JUNE 2018 MARK MICHAUD REM TECHNICAL FELLOW  MATERIALS  MATTER REM SURFACE ENGINEERING

Rotorcraft gearbox regulations: LOL (not what you think) The European Union’s CS-29 Amendment 7 places more stringent and rigorous testing requirements for certification of Category A type pressurized gearboxes under loss of lubrication conditions compared to the previous regulation.

or more than a decade, one of the most intensively researched Fsubjects in aerospace engineering has been LOL. No, we are not talking about “laughing out loud.” We are talking about a rotorcraft gearbox loss of lubrication event. An LOL event occurs when a pressurized lubrication system for a gearbox fails and endangers continued flight capability. All Category A type rotorcraft use pressurized lubrication systems. Under loss of lubrication, a gearbox is no longer capable of adequately lubricat- Figure 1: Left, an as-manufactured gear; right, the failed gear due to LOL gear ing rotating parts or dissipating heat. This combination leads to (Aviation Investigation Report A09A0016). increased friction in the gears and bearings, and increased component surface temperatures. With increased surface temperatures, During the period from 2013 to 2018, newer test methodologies surface hardness can be lost resulting in the inability of the compo- trended toward more stringent, longer endurance limits for a rotor- nent to carry its designed loads. Thermal expansion in the compo- craft gearbox under loss of lubrication. For example, in the 2018 nents can also lead to the seizing of mated rotating parts. Continued Apache Technical Report cited above, an isotropic superfinished operation of the gearbox causes the temperature to reach a critical input gearbox achieved more than 60 minutes of successful inflight level, resulting in its failure. operation under LOL conditions without any indication of gear flank Many articles have been published on the subject. Some examples damage. Numerous other examples of recent loss of lubrication publi- are: cations can be found in the journals. So, what prompted these inten- “Gearbox Loss of Lubrication: Myth, Art or Science?” [1] sive LOL investigations by the rotorcraft industry? “Leonardo Strives for Greater Gearbox Loss of Lube Capability.”[2] “Evaluation for Loss of Lubrication Performance of Black BACKGROUND Oxide, Superfinished, and As-Ground Surfaces for use in Rotorcraft Unfortunately, in 2009, a helicopter crashed at sea in Newfoundland Transmissions.” [3] resulting in fatalities due to an LOL event. This caused the initiation “Oil-Out Endurance Under the Lens.” [4] of these investigations. The Canadian Government’s Investigation “Surface finishing rotorcraft gearing.” [5] Report [7] of this incident was released in December 2010. Figure 1 “AH-64 loss of lubrication study: Test of isotropic superfinished pictures, on the right, the tail rotor take-off gear which failed due AH-64 (Apache) engine nose gearbox without black oxide coating.” [6] to this loss of lubricant incident. These articles discuss historical certification testing for a gearbox Two subsequent incidents over the North Sea in 2012 involv- under LOL conditions and its shortcomings. In the past, a gearbox ing LOL events resulted in the ditching of helicopters. Fortunately, met requirement if it could survive 30 minutes under inflight test these incidents did not result in fatalities. However, the ultimate conditions. However, the requirement was ambiguous and resulted outcome of these incidents was the convening of a group of govern- in industry confusion. Longer flight missions employed in combat ment aerospace agencies and helicopter manufacturers to update theaters or offshore services suggested the 30-minute duration rule loss of lubrication certification requirements. Previously, the loss of was insufficient. lubrication certification requirements had not been updated since The articles listed above proposed several technologies to increase 1988. Managed by EASA (European Union Aviation Safety Agency), the LOL endurance limit such as: this effort began in 2012. A: Redundant (emergency) lubrication systems. B: Superfinished gear flank finishes. INITIAL RECOMMENDATION C: Adequate mated gear tolerance (backlash) to allow for thermal In November 2013, EASA released an initial Certification expansion. Memorandum, “Large Helicopter Main Gearbox Certification D: High heat tolerant gear alloys. Requirements.” [8] A Certification Memorandum (CM) is non-binding E: Reservoirs within the gearbox that drip or mist lubricate gears guidance, in this case, related to loss of lubrication testing require- and bearings after lubricant pump failure. ments. However, a CM is taken very seriously and normally is a pre-

24 gearsolutions.com that the minimum acceptable performance shall “show a capability To establish the required confidence, through testing of at least 36 minutes duration.” the gearbox must demonstrate Finally, the ambiguous phrase from the earlier specification edition “unless such failures are extremely remote” has been removed operational endurance of greater from the updated CS. This eliminates any certification without complete LOL testing. than 30 minutes. To date, it appears that new pressurized Category A type gearboxes that achieve satisfactory operational inflight testing capability of cursor to an updating of a Certification Specification. A Certification 50 to 60 minutes represent achieving the required level of confi- Specification (CS) is law within the European Union. dence. This might be why in 2018 the U.S. Army used the 60-minute The intent of the CM was to assure a rotorcraft had continued test protocol cited in reference 6 for the Apache nose gearbox for its inflight capability sufficient to safely land after the start of an LOL updated LOL test. event. The CM recommended extending bench testing beyond 30 minutes to demonstrate such a capability. After its issuance, the CONCLUSION updating to the CS for large rotorcraft continued in earnest. The European Union placed CS-29 Amendment 7 into law in July 2019. This specification places much more stringent and rigorous FINAL RULE CHANGE testing requirements for certification of Category A type pressurized EASA managed the updating of the certification requirements for gearboxes under LOL conditions compared to the previous regula- LOL from 2013 until 2019 under EASA RMT.0608 (RMT = a rulemak- tion. The U.S. Army is updating ADS-50 Drives to match these testing ing task group). Following the guidance from the CM and over several requirements. Furthermore, the FAA is expected to update 14 CFR years, this RMT took input from multiple government and industry 29.927(c) to similarly match the requirements in CS-29 Amendment 7. sources. An approximate yearlong comment-resolution period to Due to the updating of CS-29, future pressurized rotorcraft gearboxes the proposed changes represented the final phase of the updating will achieve a much safer LOL inflight capability. process. In July 2019, EASA released “Certification Specifications and Acceptable Means of Compliance for Large Rotorcraft, CS-29 REFERENCES Amendment 7.” [9] [ 1 ] [1] G. Gasparini, N. Motta, A. Gabrielli, D. Colombo. “Gearbox Loss of Lubrication Performance: Myth, Art or Science?” September 2014, RESULT European Rotorcraft Forum 2014, Southampton, UK, 2014. At first glance, this CS appears little changed from the previous regula- [ 2 ] [2] M. Tamborini. “Leonardo Strives for Greater Gearbox Loss of Lube tion in regard to loss of lubrication. Amendment 7 reads at CS29.927(c) Capability.” February 2016, Aerossurance, Design & Certification, (1): “Confidence shall be established that the rotor drive system has an Helicopters, Offshore, Oil & Gas/IOGP/Energy, Safety Management. inflight operational endurance capability of at least 30 minutes follow- [ 3 ] [3] M. Riggs et Al. “Evaluation for Loss of Lubrication Performance of ing a failure of any one pressurized normal-use lubrication system.” Black Oxide, Superfinished, and As-Ground surfaces for Use in rotorcraft However, reading the document carefully reveals it contains much Transmissions.” U.S. Army Research Laboratory (ARL), September 2016, more stringent and rigorous testing requirements related to LOL. The Technical Report ARL-TR-7815. key wording above is “confidence shall be established.” [ 4 ] [4] A. Cannella. “Oil-Out endurance Under the Lens.” January – February Today, the updated testing protocol in the CS clearly defines the 2017, Gear Technology. minimum periods and load conditions that are to be used to simulate the most severe loss of lubrication failure mode of the normal-use [ 5 ] [5] L. Winkelmann. “Surface finishing rotorcraft gearing.” September 2018, Gear Solutions Magazine. pressurized lubrication system. Once the LOL test is initiated, the cycle begins with one minute at maximum continuous power fol- [ 6 ] [6] T. Kane et al. “AH-64 loss of lubrication study: Test of isotropic superfin- lowed by the minimum power needed for continued flight at maxi- ished AH-64 (Apache) engine nose gearbox without black oxide.” September mum gross weight. The test ends with a 45-second out of ground 2018, European Rotorcraft Forum 2018, Delft, the Netherlands. effect (OGE) hover to simulate a landing. The CS further states “the [ 7 ] [7] “Main Gearbox Malfunction/Collision with Water.” Aviation Investigation test results must substantiate the maximum period of operation fol- Report A09A0016, Transportation Safety Board of Canada. Issued lowing loss of lubrication by means of an extended test duration, December 2010. multiple test specimens, or another approach prescribed by the [ 8 ] [8] “Large Helicopter Main Gearbox Certification Requirements, EASA application and accepted by EASA, and must support the procedures CM-RTS-001: 01.” European Union Aviation Safety Agency, November published in the rotorcraft flight manual (RFM).” In other words, to 2013. establish the required confidence, the gearbox must demonstrate [ 9 ] [9] “Certification Specification and Acceptable Means of Compliance for operational endurance of greater than 30 minutes. In addition, the Large Rotorcraft. CS-29 Amendment 7.” European Union Aviation Safety expected endurance limit shall be documented in the RFM. In the Agency, July 15, 2019.Refurbishment of Wind Turbine Gears via Surface explanations section of the CS (AMC 29.927(a), it is clearly defined Finishing

ABOUT THE AUTHOR

Mark Michaud, REM Technical Fellow of REM Surface Engineering, is the inventor and pioneer of REM Surface Engineerings’s chemically accelerated finishing technology. He has authored numerous patents and technical papers and served a term on the AGMA Board of Directors. He continues to serve as vice chair of the AGMA Aerospace Committee, as a member of the AGMA Wind Turbine Committee and as a shadow delegate on the ISO 61400-4 Wind Turbine Committee. He can be reached at [email protected].

March 2020 25 BRIAN DENGEL TOOTH  TIPS GENERAL MANAGER KHK-USA

What is a standard anyway? Gear standards are technical documents products in 2020 has risen to 25 percent. In the United States, the governing body for gear standards is the that are developed by governing bodies in American Gear Manufacturers Association (AGMA). They have set order to set rules, guidelines, and definitions standards for both inch and metric gears. When specifying a gear standard, the current AGMA standard for inch pitch spur gearing is for the production, assembly, and inspection AISI/AGMA 2015-1-A01. This standard is similar to the metric pitch of gears — but they can vary depending on standard ISO 1328-1:2013. One of the more complicated issues regarding gearing standards where you are. internationally are the numerous local governing body standards. In the European Union, the two main standards for spur gearing here is an old adage that goes: “Everything old is new again.” are ISO 53 and ISO 1328-1:2013. However, in Germany, spur gearing TThis is commonly used when a fad — like bell-bottom blue jeans is standardized by DIN 780, DIN 867, DIN 3961, DIN 3962, DIN 3962, — comes back into favor after a period of time. Conversely, there DIN 3963, DIN 3964, DIN 3966, and DIN 3967. In the United Kingdom, are constants, like Friday night football, that become more of a standard BS 436 is specific to inch pitch spur gearing, and the stan- tradition and never go out of style. These traditions lend themselves dard BS 4582 is specific to metric pitch spur gearing. In Japan, the to a certain standard. These standards lead to an expectation of spur gearing standard is JIS B 1702-1:2016. Japan also has a standard the experience. In the United States, the standard measurement set by JGMA (Japanese Gear Manufacturers Association). Detailed in for liquids like cow’s milk and gasoline is the gallon. However, the standard for soda Standard Accuracy Class Approximate Equivalency is the liter. The United States standard for driving distances is miles, but the standard AGMA 2000-A88 Q15 Q14 Q12 Q10 Q9 Q8 for running distances is the kilometer. The AGMA 2015-1-A01 A3 A5 A7 A8 A9 standard for children’s medication 30 years ago was the teaspoon, but today it is the mil- BS (UK) A1 A2 B C D liliter. DIN 1 2 3 4 5 6 7 8 9 10 11 12 Gear standards are technical documents that are developed by governing bodies in ISO (International) 0 1 2 3 4 5 6 7 8 9 10 11 12 order to set rules, guidelines, and definitions JGMA 1 2 3 4 5 6 7 8 for the production, assembly, and inspection of gears. They are typically developed over a JIS B 1702:1998 0 1 2 3 4 5 6 7 8 period of years by bringing together many of JIS B 1702:2016 N0 N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12 the interested parties including gear manufacturers, end-users, and academia. As the Figure 1 standards are put into use, the governing bodies reconvene their standards committees periodically in order Figure 1 is a table showing a relative comparison of various interna- to review community feedback for each standard so that the com- tional gear quality standards. mittee can evaluate any deficiencies in the standard. Over the past 25 years, the major governing standards bodies for In regard to the question of whether diametral pitch gearing gearing have been revisiting their standards and modifying them or metric gearing are the default or standard system of gearing in toward the goal of a single unified international standard. The cre- industry, the answer depends on who you ask. Although known ation of a series of universal standards for gearing will help gear as the British Imperial Units, inch dimensions were replaced by designers, gear manufacturers, and gear production equipment metric units in 1965. All other countries in the world have adopted builders by creating a singular cost-effective standard for all. metric units for all of industry, except the United States. Estimates When designing gearing, the end-user has an expectation that of gearing consumption in North America have concluded that in the gear manufacturer will supply gears that are produced to a cer- 2000, the percentage of gears was 95 percent inch and 5 percent tain standard. The use of designing to a standard allows for gears metric. By 2010, the ratio had changed to 82 percent inch and 18 produced by different companies, at different times, on different percent metric. It is estimated that the use of metric dimensioned equipment, to all meet the same performance specifications.

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

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JUNE 2018 D. SCOTT MACKENZIE, PH.D., FASM HOT SENIOR RESEARCH SCIENTIST–METALLURGY  SEAT QUAKER HOUGHTON INC.

Back to basics: Hardness testing, Part 1 Each type of hardness test is geared toward the basis for all indention hardness tests used for metallic materials. a specific purpose. The Rockwell testers are BRINNELL TEST suitable for general purpose testing of parts The Brinnell test [4] was first proposed in 1900 by Johan August Brinell, and has since become widely accepted throughout the world. and sheet, while the Brinell tester is suitable for It is primarily used on unmachined surfaces of casting and forging, larger components or raw materials. as well as other types of materials. It is accomplished by indenting the surface with a 10-mm steel ball with a 3,000-kg load. For soft metals, n a series of Hot Seat articles, we are going to discuss the various a 500-kg load is usually used because otherwise the impression is Imethods of mechanical property testing. We will be covering hard- too deep. For hard metals, a tungsten-carbide ball is used to prevent ness testing, tensile testing, and fracture toughness testing. In this distortion of the indenter. The diameter of the round indentation is article and next month’s article, we will discuss hardness testing. measured with a low-power microscope after loading. At least two Hardness testing is probably the most common type of mechani- measurements of the diameter are made, and the results are averaged. cal test performed in the United States — perhaps the most common To ensure that accurate measurements are made, the surface must be worldwide. The term hardness is poorly defined and is relative to the free of dirt and scale. The hardness expressed as a Brinnell hardness measuring device. number (BHN) is determined from the equation: There are three basic types of hardness tests: the scratch test, the indenter, and the dynamic rebound test. The scratch test is familiar to mineralogists, who use the Mohs scale. The Mohs scale is the relative hardness of 10 minerals arranged in order. Talc is the softest (Mohs 1), and diamond is the hardest (Mohs 10). Most hard metals fall in the where F is the applied load (kg), D is the diameter of the indenter range of Mohs 4-8. There is inadequate differentiation along the scale (10mm), and d is the measured diameter of the impression (Figure 1). to be of much use to a metallurgist. In dynamic tests, an indenter is The Brinnell hardness could also be calculated by measuring the dropped on the material, and hardness is defined as the energy of depth of the impression, t: impact. The Mohs scale is commonly used for rubbers and polymers. One exception is the Shore sceleroscope, which is used for metals. The indenter type of hardness test is the most widely accepted for metals. In the indenter type of hardness test, an indenter is pressed into Because of the large size of the impression made in the Brinnell the material and released, and either the diameter or the depth of test, it averages out any local inhomogeneities. It also precludes the the impression is measured. The load and the impression measure- testing of small objects or objects in which the Brinnell impression ment determine the hardness. As a hardness impression is made, can be a site of crack initiation. Therefore, it is commonly used for there is a plastic zone around the hardness castings, forgings, or raw stock. The size of indentation that is surrounded by undis- the piece tested for Brinnell hardness should turbed elastic material. This elastic zone be at least 10 times the depth of the impres- hinders plastic flow. As the plastic region is sion. Because of the plastic zone surround- constrained by the elastic region, the coming the impression and the elastic constraint, pressive strength of the material in the area additional Brinnell hardness should not be of the hardness impression is higher than measured any closer to the impression than the value of simple compression. This is a four times the impression diameter. The dis- classic problem in plasticity and should be tance from an edge when taking a hardness able to be explained by slip line theory [1]. reading should also be at least four times the However, in some types of hardness test- impression diameter. ing, the impression is asymmetric, so that The biggest source of error in Brinnell slip line theory is not applicable [2]. This is testing, is determining the diameter of the really an elastic–plastic boundary problem, impression. Light sanding of the surface to best explained from the Hertz theory of con- remove scale or other debris is often done to tact stresses [3]. This model accounts for the improve repeatability. material displaced by the indenter by the decrease (by compression) in volume of the ROCKWELL HARDNESS TEST elastic underlying material. No upward flow The Rockwell hardness test [5] is very widely around the indenter is predicted, which Figure 1. Schematic showing the basic measurements used in the United States because of its speed agrees with observation. This explanation is on a Brinnell hardness test. and its freedom from errors by operating

28 gearsolutions.com Scale Indenter Preload Major Minimum If the impression of the hardness indenter shows on the other side (kgf) Load (kgf) Thickness of the tested piece, the test is obviously invalid. Because the scale on inches mm a Rockwell hardness machine is arbitrary, it is necessary to ensure that one machine records the same hardness as another machine. A Diamond Brale 10 60 0.030 0.76 This is accomplished using standardized test blocks calibrated by the B 1/16" Ball 10 100 0.038 0.96 manufacturer. Generally, three test blocks of values throughout the C Diamond Brale 10 150 0.040 1.02 range are adequate to maintain the hardness machine in calibration. The superficial tester operates in an identical fashion to the 15N N Diamond 3 15 0.016 0.41 Rockwell hardness tester. In fact, they look very similar. Two types 30N N Diamond 3 30 0.022 0.56 of indenters are used: a 1/16” diameter steel ball (used for surface hard- nesses of brasses, aluminum sheet, etc.) and the N-Brale penetrator. 45N N Diamond 3 45 0.028 0.71 This Brale penetrator is like the one used in the standard Rockwell 15T 1/16" Ball 3 15 0.018 0.46 hardness tests except the spherical end is shaped to higher tolerances. 30T 1/16" Ball 3 30 0.024 0.61 The minor load used to seat the indenter and specimen is 3 kg. The major loads used are 15, 30, and 45 kg. The major load is applied for 45T 1/16" Ball 3 45 0.028 0.71 30 seconds, and the depth of the penetration is measured. The scale of the superficial Rockwell test is arbitrary like that Table 1: Indenters, preload and major loads of major Rockwell Hardness scales. of the Rockwell test, except that each division represents 0.001 in. The minimum thickness is based on the lowest hardness reading. in depth. The scale is reversed, so deeper impressions mean lower hardness numbers. As the loads used on the superficial Rockwell Hardness testing is probably the tester are different from those used for the Rockwell tests, different scales were established defined by the load and indenter as most common type of mechanical shown in Table 1. test performed in the United States, CONCLUSIONS In this article, we have discussed some of the various hardness testing perhaps the most common worldwide. methods. Each type of hardness test is really geared toward a specific The term hardness is poorly defined purpose. The Rockwell testers are suitable for general purpose testing of parts and sheet, while the Brinell tester is suitable for larger and is relative to the measuring components, or raw materials, where the large indentation will not affect function. device. Next month’s installment will discuss the two remaining common hardness tests. Vickers hardness, widely used throughout the world, is technicians. The impression is small, making it possible to test a wide used for both large-component testing as well as finer measurements variety of parts. of microstructure at very small loads. Finally, the Knoop hardness In this test, a minor load of 10kg is applied to the part to seat the test is used for very fine hardness measurements of case depth or indenter and part; then the major load is applied. After 30 seconds, microstructural phase fields. the depth of the impression is measured and exhibited on a rotary Should you have any questions or comments regarding this dial or, in newer machines, on a digital readout. Some machines are or have suggestions for further articles, please contact the editor equipped with printer ports or USB interfaces for communicating or myself. with a computer. The scale used in Rockwell testers is based on 100 divisions, with each division equal to a depth of 0.00008 in. The scale REFERENCES is reversed, so that a small impression results in a high hardness num- [ 1 ] R. Hill, The Mathematical Theory of Plasticity, Oxford, UK: Clarendon Press, ber. The number from the Rockwell test is an arbitrary number that 1950. is only consistent within the same scale. This is unlike the Brinnell [ 2 ] M. C. Shaw and G. J. DeSalvo, “A new approach to plasticity and its applica- and Vickers hardness tests, which provide numbers that are based on tion to blunt two dimensional indenters,” J. Eng. Ind., vol. 92, p. 469, 1970. mass per unit area (kg/mm2). [ 3 ] S. Timoshenko and J. N. Goodier, Theory of Elasticity, New York: McGraw- More than one indenter can be used with the Rockwell test. The Hill, 1972. most common is the Brale indenter, which is a 120° diamond cone and is used for the Rockwell C test. Other indenters used are 1/16” and 1/8” [ 4 ] ASTM International, “ASTM E10-18 Standard Test Method for Brinell Hardness of Metallic Materials,” ASTM International, West Conshohocken, diameter steel balls. Major loads can be varied from 60 to 150kg. If a PA, 2018. carburized surface is measured, the hardness reading may be lower than expected because of a greater depth of impression. [ 5 ] ASTM International, “E18-19 Standard Test Methods for Rockwell Hardness The material supporting the test piece may also influence the hard- of Metallic Materials,” ASTM International, West Conshohocken, PA, 2019. ness reading. As a rule of thumb, it is wise to test only test pieces [ 6 ] G. L. Kehl, The Principles of Metallographic Laboratory Practice, New York: that are at least 10 times as thick as the depth of the impression [6]. McGraw-Hill, 1949.

ABOUT THE AUTHOR D. Scott MacKenzie, Ph.D., FASM, is senior research scientist-metallurgy at Quaker Houghton Inc. For more information, go to https://home.quakerhoughton.com/

March 2020 29 ISSUE LUBRICATION / BROACHING FOCUS

OPPORTUNITIES OF EFFICIENCY IMPROVEMENT BY THE USE OF HYDRO LUBRICANTS

Printed with permission of the copyright holder, the American Gear Manufacturers Association, 1001 N. Fairfax Street, Suite 500, Alexandria, Virginia 22314. Statements presented in this paper are those of the authors and may not represent the position or opinion of the American Gear Manufacturers Association. (AGMA) This paper was presented October 2019 at the AGMA Fall Technical Meeting in Detroit, Michigan. 19FTM11

30 gearsolutions.com While searching for a material that meets all of the general and branch-specific lubrication requirements, water is a visionary, yet obvious, raw material available worldwide that’s non-toxic and non-combustible.

By MATTHIAS PFADT, ELENA VON HÖRSTEN, and BALASUBRAMANIAM VENGUDUSAMY

1 INTRODUCTION that can offer friction benefits much better than PGs, Although different base oil types exist in the market water-based concepts have been an obvious choice. and are widely in use, the majority of industrial lubri- The Hydro Lubricant presented in this study is of ISO cants are still based on mineral oils due primarily to VG 460 according to [1] with a kinematic viscosity of low cost and easy miscibility with other oils. However, approx. 460 mm2s-1 at 40°C suitable for gear applica - despite their widespread use, conventional lubricants tions. Water as base fluid is mixed with a synthetic reach functional limits in various scenarios. In addi- fluid in order to obtain the viscosity grade. Table 1 lists tion to the limitations of natural resources, their safe some basic properties of the test Hydro Lubricant in and environmentally sound handling, use, and dis- comparison to a PG of similar ISO VG and a commonly posal often require considerable efforts. used reference mineral oil in FZG testing protocol. At the same time, industrial operators’ expectations All lubricants contain typical gear oil additives such toward innovative specialty lubricants are increasing. They range from opera- Hydro Polyglycol Mineral tional and food safety to biodegradabil- Lubricant gear oil oil ity, longer life cycles, and reduced emis- ISO viscosity grade, sions and energy consumption. DIN ISO 3448 460 460 100 While searching for a material that meets all of these general and branch- Base fluid 1 Water Polyglycol Mineral oil specific requirements, water is a vision- Base fluid 2 Synthetic fluid — — ary, yet obvious, raw material available worldwide that’s non-toxic and non- Additives CI / EP / AW 1 CI / EP / AW 2 CI / EP / AW 3 combustible. The benefits are clear, but Viscosity Index (VI), some challenges include its low viscos- in acc. DIN ISO 2909 >200 >200 Approx. 100 ity, evaporation, freezing point, corro- siveness, and sensitivity against micro- Pour Point, DIN biological growth. Overcoming these ISO 3016 <-20°C <-20°C <-5 challenges would bring a greener solu- Table 1: Test Lubricant description; AW: Antiwear, EP: Extreme pressure, CI: tion to the gear industry with higher Corrosion Inhibitor. machine efficiency and energy savings than existing solutions. This paper presents one such as extreme pressure (EP), anti-wear (AW), and corro- lubricant concept based on water and highlights its sion inhibitors (CI). The viscosity indices (VI) of Hydro benefits in comparison to a conventional mineral and Lubricant measured according to DIN ISO 2909 [2] are polyglycol (PG)-based synthetic gear lubricant. more than double compared to the reference mineral oil that causes a rather constant viscosity change with 2 DEFINITION AND PROPERTIES temperature as shown in Figure 1. The pour point mea- OF HYDRO LUBRICANTS surements made according to DIN ISO 3016 [3] demon- Hydro Lubricants unfold their innovative traits by strate for the Hydro Lube that the freezing point of using water either as a base oil or as an additive, hence water can be overcome through proper additivation the name “Hydro Lubes.” Initial results indicate it is a and a low temperature behavior comparable to a syn- promising technology with a great potential to deliver thetic PG-based gear oil and better than the mineral high performance; some include high thermal and oil. Furthermore, in Figure 1 the possible operating electric conductivity, super-low friction and good temperatures are shown where the low temperature load-carrying capacity on the FZG four-square test operation is limited near the pour point of the fluids. machine. It is widely known that elastohydrodynamic The short-term maximum operating temperature for (EHD) friction of mineral oil is higher than synthetic Hydro Lubes is about 90°C at ambient pressure, which hydrocarbons (SHCs), followed by PG. This means PGs is basically limited by the boiling point of water. Typical can offer better energy efficiency benefits compared operating temperatures should be on a level about 60°C. to mineral oils. When looking for lubricant solutions From the large study conducted, some example

March 2020 31 results related to corrosion protection, load-carrying capacity, and electrical properties are shown in the following sections.

2.1 CORROSION PROTECTION The ability of lubricants to prevent corrosion was evaluated by a copper corrosion test conducted according to DIN EN ISO 2160 [3] but at a relatively low temperature of 80°C and a steel corrosion test according to DIN ISO 7120 [4] method A. The results of the ISO VG 460 Hydro Lubricant are shown in Figure 2 where it can be seen that the Hydro Lubricant exhibits good anticorrosion properties. The Hydro Lubricant showed a copper corrosion value that equals the protection level commonly offered by conventional gear oils (see Figure 2a and 2b). The steel corrosion test also showed an excellent result with the Hydro Lubricant (see Figure 2c). In addition to the static immersion tests, a dynamic test method Figure 1: Viscosity-temperature behavior of test lubricants. to evaluate the corrosion-protection properties of the Hydro Lube was chosen. The test rig shown in Figure 3 is commonly used for testing the anticorrosive properties of roller bearing greases in a wet envi - ronment (EMCOR test). The Hydro Lubricant ISO VG 460 was filled instead of a grease, and the bearing was operated for 164 hours at 80 rpm intermittent operation in accordance to ASTM D6138-16 [5]. After two test runs, no corrosion was observed on the outer bearing raceways, which equals a zero as a best possible test result. Further tests have shown gearbox surfaces that are exposed to condensed water and not wetted by the Hydro Lubricant need to be Figure 2: Anti-corrosion properties Hydro Lubricant ISO VG 460. Copper strip from protected by the application of a corrosion protection spray that is com- the copper corrosion test (a) before test, (b) after 24 hours at 80°C and (c) steel patible with the gear fluid. finger after corrosion test.

2.2 LOAD-CARRYING CAPACITY The load-carrying capacity was evaluated by a modified scuffing test using an FZG four-square test machine according to ISO 14635-1 [6]. The Hydro Lubricant was tested at a reduced starting temperature of 60°C (FZG A/8.3/60) instead of 90°C, which was kept constant by cooling. For a constant lubricant composition, the breather plug was closed. In this test, elevated surface temperatures due to high surface pressures and sliding velocities cause a local welding of the tooth flanks of pinion and wheel. A higher failure load stage from this test is an indicative measure of high relative scuffing load-carrying capacity of gear lubricants. The tested Hydro Lubricant reached a failure load stage greater than 12. In comparison, some industrial Figure 3: Dynamic Anti-corrosion properties of Hydro Lubricant ISO VG 460. PG-based gear oils achieve an API GL-5 [7] classification as a measure EMCOR test rig according to ASTM D6138-16 [5]. of highest scuffing protection. The result clearly indicates the water-containing Hydro Lubricant provides a good tooth flank surface protection even at high temperatures in the gear mesh.

2.3 ELECTRICAL RESISTIVITY Another important property of lubricants that contain a significant amount of water is the low resistivity. As shown in Figure 4, the specific electrical resistance of the ISO VG 460 Hydro Lubricant is comparable to tap water and therefore significantly lower than conventional PG gear oil. As the resistivity is depending on the polarity of the base oil, these values are higher for mineral or SHC oils [4]. This behavior is particularly beneficial in systems where electric discharge (ED) is a problem, such as those found in electric motors. It is well known that bearings used in variable-speed electric motors Figure 4: Specific electrical resistivity of different fluids. experience fluting — a damage commonly found on the surface of bearing raceways caused by electric arcs that surpass the lubricant. trical conductivity [8]. The Hydro Lubricant presented in this study The resulting electric discharge could potentially degrade the lubri- possesses an excellent electrical conductivity property compared cants by high local temperature rise. One way to reduce the risk and to conventional oils, indicating that it could potentially reduce the severity of damages caused by ED is to use lubricants with high elec- damage caused by ED.

32 gearsolutions.com Figure 5: Dynamic elastomer compatibility test rig [12].

perature of 80°C instead of 130°C frequently used for FKM rubbers, and the lubricant composition was kept constant with a reflow device. The test results show a good static compatibility between the lubricant and elastomer. According to the limits of Freudenberg Sealing Technologies FB 7311008-eng [10], two points of a possible three were achieved.

3.2 TEST RIG AND METHOD DESCRIPTION The dynamic elastomer lubricant compatibility that correlates more with practice [11] than static testing was tested on a test rig shown in Figure 5 according to [12]. The engine drives a shaft, and the RSS is mounted in a cover. The lubricant is filled to the middle of the shaft, and the test rig housing can be pressurized to increase the stress for the RSS. The test rig was operated for 42 cycles of 20 hours of running time at 3,000 rpm and 4 hours of stand still. A lubricant sump temperature of 45°C was chosen, and furthermore, an overpressure of 0.25 bar was applied to simulate a gearbox with a closed breather plug that causes a higher radial force on the seal edge. During the test period, the tightness of the seal was controlled visually once a day.

3.3 SEAL DESCRIPTION A special seal with two seal lips shown in Figure 6 was used. The rub- Figure 6: Modular Sealing solution [13]. ber parts highlighted in blue were made of the elastomer 75 FKM 585 that was used for the static compatibility testing under 3.1. The left 3 EVALUATION OF GEARBOX TIGHTNESS seal lip a) was in direct contact with the Hydro Lubricant whereas the If a gearbox is lubricated by a Hydro Lube, the compatibility of lubri- seal lip b) was a second seal lip in contact with the ambient air. The cant and seal is of utmost importance. A gearbox must be tight over space between the two seal lips was lubricated with a grease based a long seal lifetime to achieve long service intervals and avoid break- on lithium soap, synthetic oil of the viscosity 110 mm2s-1 at 40°C, downs. The compatibility of sealing material and Hydro Lubricant and consistency of NLGI grade 1. ISO VG 460 was tested first with static immersion tests and after- The seal edge a) uses the geometry of a sinus curve instead of the wards in dynamic radial shaft seal (RSS) tests in order to provide a conventional seal edge b). The sinus provides a wider contact area and long-lasting solution. less friction and heat generation. The additional conventional seal edge b) with a reduced spring strength is used for higher operational safety. 3.1 STATIC COMPATIBILITY The static elastomer compatibility was evaluated according to DIN 3.4 DYNAMIC COMPATIBILITY TEST RESULT 1817 [9] with the seal elastomer 75 FKM 585 from Freudenberg Test results have shown an operation with a single radial shaft seal Sealing Technologies. The test was performed at a reduced tem- like seal lip b) causes high wear of shaft and seal, avoiding long seal

March 2020 33 With the wide range of demonstrated benefits, Hydro Lubricants offer a more sustainable solution for gearboxes with high demands in low friction and temperature reduction.

lifetimes. However, a radial shaft seal with a single seal lip of type a) operated tight for 1,008 hours at low wear rates of 0.15 to 0.19 mm of the seal edge. The deviation of two tested radial shaft seals of type a) was high, which is why the seal concept in Figure 6 was evaluated. The tested modular sealing solution with two seal lips shown in Figure 6. was tight over 1,008 hours of operation and is a good candidate for long time tests or serial applications. 4 FRICTION MEASUREMENTS Efficiency testing has been performed on a ball-on-disc tribometer as well as on an FZG four-square test machine. Exemplary test results are shown in this chapter.

4.1 TRIBOMETER TESTS Friction measurements were made on steel/steel contact using a ball- on-disc tribometer (EHD2, PCS Instruments) at a realistic test temperature of 60°C and a mean speed ensuring EHD full film condition (2.5 m/s). It is evident from Figure 7 that the Hydro Lubricant exhibits Figure 7: Traction curves showing EHD friction coefficient measured at 2.5 m/s a super-low friction compared to the conventional PG gear oil. mean speed and 60°C. It should be noted that among the different base oil types available, PGs are known for their low friction properties due to their is equipped with a torque measuring clutch and a loss torque meter molecular structure. The Hydro Lubricant presented in this study in order to evaluate the efficiency with the smallest possible error. shows a much lower friction than the current low friction PG, indi- The test method according to FVA 345 [13] is shown in Figure cating that the Hydro Lubricant can potentially offer a significant 9 where a mapping of the gearbox efficiency at different speed energy saving benefit. and load conditions is performed. A temperature variation causes different lubrication regimes at the mentioned operating condi- 4.2 GEAR EFFICIENCY TESTING tions. The gear efficiency testing was performed on an FZG four-square test In the test procedure, a candidate oil compared with a reference machine modified to evaluate the efficiency performance of Hydro oil as an absolute evaluation of one lubricant is not possible. In addi- Lubricants with a higher correlation to practice than the ball-on-disc tion to the efficiency mapping, the steady state temperature is mea- tribometer tests. sured after five hours of constant operation at load stage KS7 and 8.3 m s-1 peripheral speed. For the tests with the Hydro Lubricant, the 4.2.1 TEST RIG AND METHOD DESCRIPTION test stage with sump temperature of 120°C was removed, and the The FZG four-square test machine shown in Figure 8 used for this test breather plug was closed [14].

34 gearsolutions.com to 20 m s-1. The lubricant sump temperature was kept at 60°C by cooling both test and slave gearboxes. Both lubricants show an increase of losses with higher peripheral speeds, which is representative for a Stribeck curve in the regime of fluid friction. Furthermore, the Hydro Lubricant exhibits lower friction properties over the whole speed range. Depending on the operating point, this causes energy savings in the order of 10 to 48 percent. In the next step, the load stages were varied to lower (KS5) and higher (KS9) flank pressures while the speed and temperature were kept constant. It can be seen from Figure 11 that the level of losses increases with the load, and the energy saving benefits are highest at load stage KS7 (1343 N mm-2) at 8.3 m s-1. Nevertheless, the Hydro Lubricant shows lower losses than the PG gear oil over all loads. Figure 8: FZG back to back test rig for efficiency evaluation [13]. In addition, different fluid sump temperatures were investigated at a moderate speed and load shown in Figure 12. The loss torques of both lubricants decrease with increasing sump temperatures and what correlates with the viscosity-temperature behavior shown in Figure 1. The energy savings of the Hydro Lube versus the PG gear oil are 32 percent at 40 and 60°C. A higher viscosity compared to the PG gear oil due to evaporated water might explain the lower savings of 27 percent at 90°C. The test rig was operated safely at a sump temperature of 90°C as mass temperatures of the gears were even higher. Hence, a short- term operation with sump temperatures of 90°C is possible with a Hydro Lube whereas a constant operation at sump temperatures Figure 9: Operating points and test sequences FZG efficiency test [13] Hertzian pressure at pitch point [N of about 60°C is recommended. mm-2]: KS0: no load; KS5: 962; KS7: 1343; KS9: 1723. The steady state temperatures of both test lubricants and the mineral oil reference were evaluated at load stage KS7 at peripheral speed 8.3 m s-1 over a duration of five hours. The results are shown in Figure 13, combined with the loss torque representing the efficiency of a gearbox. This test simulates the operation of most gearboxes in practice as heat- ing or cooling devices are seldom due to cost reasons. The loss torque of the Hydro Lubricant is 17 percent lower compared to the PG gear oil and on the same level as a mineral oil of ISO VG 100. In combination with the better thermal properties, this causes a temperature reduction of 13°C compared to the PG and 9°C to the mineral oil of lower viscosity. One potential reason for the lower level of loss torque reduction against the PG in the steady state temperature test compared to the 32 percent at the same speed in the previous measurements (see Figure 10) is the temperature dif- Figure 10: Efficiency comparison of Hydro Lube vs. PG gear oil ISO VG 460 at ference of 13°C, which in turn causes the Hydro Lubricant to have different speeds and load stage KS7: 1343 N mm-² [14]. a higher viscosity.

4.2.2 GEAR EFFICIENCY TEST RESULTS 5 CONCLUSION The test of the Hydro Lubricant and the PG gear oil on the FZG test Some key challenges of Hydro Lubricants like pour point and corro- rig showed excellent repeatability [14]. Loss torque measurements at sion protection have been solved by proper and advanced formula- load stage KS7 are shown in Figure 10 over a speed variation from 0.5 tion. Various radial shaft seals for industrial gearboxes have been

March 2020 35 evaluated and suitable solutions of Hydro Lubricants and radial shaft seals are available. The low electrical resistivity offers benefits in systems with high risk of damages caused by electrical discharge. The demonstrated lower friction, higher efficiency and lower operating temperatures of the Hydro Lubricants in comparison to a PG-gear oil of similar ISO VG 460 unfold new possibilities in the design of gearboxes. With the wide range of demonstrated benefits, Hydro Lubricants offer a more sustainable solution for gearboxes with high demands in low friction and temperature reduction. BIBLIOGRAPHY [ 1 ] DIN ISO 3448, 2010, Flüssige Industrie-Schmierstoffe – ISO- Viskositätsklassifikation (ISO 3448:1992). [ 2 ] DIN ISO 2909, 2004, Mineralölerzeugnisse – Berechnung des Viskositätsindexes aus der kinematischen Viskosität (ISO 2909:2002). Figure 11: Efficiency comparison of Hydro Lube vs. PG gear oil ISO VG 460 at -1 [ 3 ] DIN EN ISO 2160, 1999, Mineralölerzeugnisse – Korrosionswirkung auf different loads and peripheral speed: 8.3 m s [14]. Kupfer – Kupferstreifentest (ISO 2160:1998). [ 4 ] DIN ISO 7120, 2000, Mineralölerzeugnisse und andere Flüssigkeiten – Bestimmung der Korrosionsschutzeigenschaften in Gegenwart von Wasser (ISO 7120:1987). [ 5 ] ASTM D6138-16, Standard Test Method for Determination of Corrosion- Prevention Properties of Lubricating Greases Under Dynamic Wet Conditions (Emcor Test). [ 6 ] DIN ISO 14635-1, Gears – FZG test procedures – Part 1: FZG test method A/8,3/90 for relative scuffing load-carrying capacity of oils (ISO 14635- 1:2000). [ 7 ] API Publication 1560, Seventh Edition, 1995, “Lubricant Service Designations for Automotive Manual Transmissions, Manual Transaxles, and Axles” F15607, American Petroleum Institute, Washington, D.C. [ 8 ] Gemeinder, Y., 2016, “Lagerimpedanz und Lagerschädigung bei Stromdurchgang in umrichtergespeisten elektrischen Maschinen” Ph.D., Figure 12: Efficiency comparison of Hydro Lube vs. PG gear oil ISO VG 460 at IWV, Bonn. different temperatures and peripheral speed: 8.3 m s-1 load stage KS7: 1343 N -2 [ 9 ] DIN ISO 1817, Elastomere – Bestimmung des Verhaltens gegenüber mm [14]. Flüssigkeiten (ISO 1817:1999). [ 10 ] Freudenberg Sealing Technologies, FS PLM 111 0119, 2018,“Statische Ölverträglichkeitstests mit Freudenberg Simmering – Werkstoffen zur Freigabe für den Einsatz in Flender Getrieben (Tabellen T 7300),” Flender GmbH, Freudenberg Sealing Technologies. [ 11 ] Dr. Adler, M., 2017, “Understanding the Dynamic Influences of Gear Oils and Radial Shaft Seals” American Gear Manufacturer Association Fall Technical Meeting, AGMA. [ 12 ] Freudenberg Sealing Technologies, FB 7311008-eng, 2018, “Dynamic oil compatibility tests for Freudenberg radial shaft seals to release the usage in FLENDER-gear units applications (Table T 7300),” Flender GmbH, Freudenberg Sealing Technologies. [ 13 ] Forschungsvereinigung für Antriebstechnik E.V., FVA 345, 2003, “Method to Determine the Frictional Behaviour of Lubricants Using a FZG Gear Test Rig,” FZG Gear Research Centre, Technische Universität München. [ 14 ] FZG, 2018, “Expertise Investigations of the Efficiency of four Lubricants,” Figure 13: Efficiency and steady state temperature comparison of Hydro Lube FZG Gear Research Centre, Technische Universität München. versus PG gear oil ISO VG 460 at 8.3 m s-1 load stage KS7: 1343 N mm-2 [14].

ABOUT THE AUTHORS

Matthias Pfadt obtained his master’s degree in mechanical engineering from Technical University of Munich in 2015. He has been a manager for gear lubrication at Kluber Lubrication, Munich for four years. He is currently a power transmission specialist at Kluber Lubrication North America, Londonderry New Hampshire. Elena von Hörsten graduated in micro- and nanotechnology (M.Sc.) and chemical engineering (B. Eng.) from the University of Applied Sciences Munich before joining Kluber Lubrication, Munich in 2016. She has been working in the research and development of Hydro Lubricants since then. Balasubramaniam Vengudusamy graduated in mechanical engineering and obtained his Ph.D in tribology from Imperial College London, U.K.. He has been working in the field of tribology for about 15 years. He is currently a senior research tribologist at Kluber Lubrication, Munich.

36 gearsolutions.com YOU’VE GOT THE PRODUCTS. YOU’VE GOT THE SERVICES. NOW, LET US SHARE YOUR STORY.

To learn more, contact assistant publisher Chad Morrison at [email protected] or call 800.366.2185 ext. 202

March 2020 37 ADVANTAGES OF FLAT BROACHING MACHINES

Even if you don’t see signs on the broach tool or your products, carefully watch the process. (Courtesy: Miller Broach)

38 gearsolutions.com Flat broach manufacturing is a tooling option that offers some advantages to circular broaching, but the tools need to maintain optimum sharpness in order to be effective.

By JEFF BURG

broaching machine requires precision broaching tools to increase productivity and efficiency. New broaching tools can be expensive and A difficult to customize. Continuous use quickly dulls broach tools, and sharpening services can be time-consuming. If a broaching tool is cracked, bent, or otherwise seriously damaged, sharpening services are no longer capable of restoring the tooling. In order to find an affordable alternative, it may be necessary to work with a premier broach manufacturer. A newly designed broach tool is easy to swap out in your equipment. This allows you to keep moving forward with minimal downtime. Affordable broaching tools allow you to postpone sharpening services and quickly swap out your cutting tool to keep your production facility moving forward all day long. When A dull broach can stall your entire process and reduce the you’re working with high-volume components, a single quality of your broached components and, in turn, your final product. (Courtesy: Miller Broach) broaching tool issue can create significant issues until repaired or replaced. A flat broach is a straightforward tooling option machine. Miller works with any industry that requires that offers some unique advantages to circular broach- consistent, custom, and creative components for their ing and other alternative options. Depending on your manufacturing process. Your workpieces are only as workpiece and cut requirements, you may need a good as your tools, so choose a leading company that rectangular, octagonal, round, or square broach. offers the best in precision broaching tools. Miller has Sophisticated software, like the type used at Miller experience with many industries, including: Broach, can be used to review your current broaching Aerospace. methods and create an exact match or an improved Automotive. design for the same process. Industrial manufacturing. Agriculture. CUSTOM BROACH DESIGNS Oil and gas. A new flat broach tool is completely customizable for Firearms. your equipment and manufacturing needs. Factors in Fasteners, gears, and more. which you will need to control while you design a new broach tool include: SHARPEN FLAT BROACH Length. Your broaching machine needs to outpace other Thickness. broach manufacturers and offer precise components Material. at high volumes. A dull broach can quickly halt this Tooth pattern. process and cost your company significant amounts Amount. of time and money. Whether you’re creating one-of-a-kind patented products to fit an industrial niche or turning out high- DANGERS OF A DULL BROACHING TOOL volume basic workpieces, flat broaching tools must be Your broach tool uses a series of small, sharp teeth maintained in order to keep your equipment running to pull or push through your workpiece. Depending at peak efficiency. on the material and broach machine, this typically happens at high speeds throughout your production VERSATILE PERFORMANCE FOR process. A new broaching tool effortlessly cuts through YOUR INDUSTRY a workpiece to provide consistent, accurate parts. Flat broaching tools, such as ones offered by Miller Over time, a broaching tool can become dull. Broach, need to be as versatile as your broaching Broaching tools wear out more quickly if you’re work-

March 2020 39 A sharpened broaching tool offers like-new performance without the cost of replacing your broaching tool. (Courtesy: Miller Broach) ing with hard metals, but even soft plastic and wood workpieces can BENEFITS OF PRECISION SHARPENING SERVICES dull a broaching tool. Continued use of a dull broaching tool can Maintain your flat broach tool to improve your productivity and decrease the accuracy of each cut, slow your work process, and even decrease your costs. Here are just a few benefits of quality sharpening damage your broaching machine. and reconditioning services: As a leading broach company, you need to efficiently produce Improved cutting precision. precision components. An inefficiency in the process could cost a sig- Increased tool life. nificant amount of productivity. A dull broach can stall your entire Decreased cost of repair. process and reduce the quality of your broached components and, Reduced downtime. in turn, your final product. Here are some signs of a dull broach tool A sharpened broaching tool offers like-new performance without that needs broach sharpening: the cost of replacing your broaching tool. If your factory is consis- Tears. tently replacing broaching tools that are dull, bent, or otherwise Galling. compromised, you could be spending far more in parts and down- Poor finish. time than necessary. Dull broach cutting edge teeth. Signs of rollover. RESTORING BROACHING TOOLS Damaged or missing cutting edge teeth. At Miller Broach, the latest software and tooling techniques can be Holes below size. used to restore your flat broaching tools quickly and affordably. Even if you don’t see signs on the broach tool or your products, Reconditioning and sharpening involves a careful inspection of carefully watch the process. Sometimes, a dull broach can cause the your broach tools to help you determine the remaining tool life. material to stick to the tool and temporarily pick it up. You may also A sharpening schedule is recommended to maintain your tooling. notice more effort or pressure being used to create holes. Once you have a maintenance schedule in place, you can plan ahead A major sign that you need to start a maintenance program is if for flat broach sharpening services and avoid unexpected broken you consistently break broach tools. If your blades routinely snap, broaching tools. you may be using a dull broach. This is particularly common when Full-service support is often needed in order to ensure the best attempting to produce high-speed cuts in hard materials, where a quality custom flat broaches and related services. sharp blade is essential. Learn how you can accelerate your production and enjoy afford- A dull broach quickly becomes a bent or broken one. Comprehensive able, custom flat broaches for all your equipment. Don’t let a dam- sharpening and reconditioning services, such as the ones offered by aged or inaccurate broaching tool hold you back, but discover ulti- Miller Broach, aren’t possible once your broaching tool is broken. mate precision and cost-effective performance today.

ABOUT THE AUTHOR

Jeff Burg is technical sales manager with Miller Broach Inc. Miller Broach is a leader in broaching tool manufacturers. From bulk broaching tools to a few custom flat broach tools, Miller Broach specializes in affordable and cutting-edge solutions. For more information, go to millerbroach.com.

40 gearsolutions.com ARE YOU MAXIMIZING YOUR EXPOSURE? Connect your company to the gear industry with a storefront in the Gear Solutions Community. Storefronts paint a portrait of your company with a 500-word description and include your logo, website link, phone number, email addresses, and videos. Your social media pages such as Twitter and Facebook are integrated with live updates, which may also be re-posted through our social media feeds. With a community storefront, your company also receives a premium listing in the annual Buyer’s Guide published each November. Premium listings feature graphic treatments to draw more attention to your company.

March 2020 41 COMPANY NEUGART PROFILE

OFFERING MODULAR PLANETARY GEARBOX DESIGN

With its product features, the NGV planetary gearbox is specifically designed for use in driverless transport vehicles — AGVs for short. The bearings are designed and positioned to allow high radial loads at the output. (Courtesy: Neugart)

42 gearsolutions.com Starting out almost a century ago by making clock parts, Neugart now develops, produces, and sells planetary gearboxes and custom gearboxes all around the world to a variety of industries.

By KENNETH CARTER, Gear Solutions editor

earboxes are, quite literally, the driving force to solve the puzzle for the customer,” he said. for dozens of industries, and Neugart makes Once Neugart receives and reviews a customer’s reliable, quality gearboxes that have helped RFQ, they make sure they have all the information G push the family-owned company into the glob- needed to offer the optimal solution, according to al arena. Christian. Once those steps are completed, Neugart A large part of that success is due to Neugart’s abil- will move on to gearbox sizing and analysis. ity to create gearboxes using a modular design. “We want to give a prompt response to the customer “It’s that modular design that allows us to pretty as soon as possible, get in touch with them, under- much provide a solution for every challenge we get stand their application, and their needs to find the from the customer,” said Christian Schilling, vice perfect solution for them,” he said.” And from the RFQ president of Neugart’s U.S. location. “With our modular gearbox system, we’re using fewer parts to offer a wide range of gearboxes. It’s kind of fascinating that we can actually build a seemingly infinite number of gearbox variants with a modest number of parts.” VARIETY OF PLANETARY GEARBOXES To that end, Neugart offers a wide variety of planetary gearboxes, as well as customized gearboxes that can be very specialized, including bevel gearboxes, spur gearboxes, and more, according to Christian. But more often than not, Christian said Neugart can find a gearbox that fits specific needs. And those gearboxes are designed to last — usually clocking in at about 30,000 hours of use. “In my experience, planetary gearboxes are like those kinds of gearboxes that fit most applications,” he said. “However, we also offer high point gearboxes or bevel gearboxes or combinations of them with the With the HLAE planetary gearbox, Neugart has developed a planetary gearboxes.” hygienic solution especially for use in the process industry. However, customized solutions also fall squarely in The now renewed certification of the HLAE by 3-A SSI is Neugart’s wheelhouse as well, according to Christian. considered the highest standard on the market. This means that “We can build whatever the application requires, the gearboxes in Hygienic Design version offer even greater but sometimes the customer wants to have a specific advantages in many plants in the food, pharmaceutical, and kind of gearbox when other gearboxes might fit the cosmetics industries. (Courtesy: Neugart) application better,” he said. “We consult with the customers, advise them, and let them know, ‘Hey, this we would find a solution, prepare a quote, and try to is pretty much a perfect solution for your challenge.’ give the best solution not only in quality but also in We try to stick to the standards, but every once in a price. I would say we have fair market prices.” while, you need to have a customized solution for the customer in order to make it work.” BUILDING A GLOBAL PRESENCE Neugart’s roots are of a local company that began in WORKING WITH THE CUSTOMER the Black Forest region of Germany in 1928, but the Whatever the customer may need, it boils down to company has aspired to become a gearbox supplier working closely with them in order to ascertain what around the globe, according to Christian. will work best for them, according to Christian. “In the beginning, of course, we were very local “Every challenge is different, and that’s the most in the Black Forest mainly, and nowadays we have interesting part about it I think, but also the variety of locations all over the world,” he said. “But also the the challenge gives us a variety of solutions and ways expectations from the customers changed a lot. Now,

March 2020 43 Neugart’s offered product range includes numerous innovative, technologically mature, and highly reliable gearbox solutions. The 19 standard planetary gearbox series cover a wide range of applications — from the highest precision to the highest performance. (Courtesy: Neugart)

a prompt response time is very important, as are high expectations facturer to introduce a 3A-Replacement Part and System Component for customization and modification, not only on the product side certified hygienic design gearbox.” but also around service for the product.” The HLAE achieved the 3-A Replacement Part and System Neugart takes those services to the next level by giving a lot of Component Qualification Certificate (3A-RPSCQC) in 2014, and this the deciding power back to its customers, according to Christian. was recently renewed in a Third Party Verification, according to “We are offering tools and services that help the customer to size Christian. their gearboxes by themselves and get the response they need in time but also order processing via an EDI interface, or customized MAKING CLOCK PARTS packaging, customized labels, and more,” he said. “We are striving Not a bad track record for a company that began by making gear to be the Amazon of gearbox manufacturing.” parts for watches and clocks. “The clock industry in the Black Forest was very big a hundred A MARKET LEADER years ago,” Christian said. “Later on, they started manufacturing or To that end, Christian said Neugart is quite proud to be a market developing mantel clocks, mechanical razors, and mechanical oil leader when it comes to economy planetary gearboxes. level indicators.” “Our PLE series is one of the very first series that we provided on In 1975, Neugart developed its first planetary gearbox for a step- the market in 1993, and we still offer that product,” he said. “The per motor manufacturer, according to Christian. name, PLE, has its origins in the 1990s, but the technology inside “That’s the point when it all began with the complete gearboxes,” has been continuously improved and updated for the new decades.” he said. “In the late 1980s and early 1990s, Neugart started with their And Neugart continues to increase its gearbox-manufacturing first catalog-based product, the PL and PLE series. Those were the first presence around the world, according to Christian. Between 2014 standard gearboxes we developed.” and 2018, Neugart increased its sales by 65 percent. In 1997, Neugart opened its first U.S. location in Pittsburgh, “That’s a lot,” he said. “And we are actually the first gearbox manu- Pennsylvania, and in 2003, the company opened its first sales loca-

44 gearsolutions.com “Gearbox technology itself will still play a big part in our society and in our culture – especially since electronic mobility is getting bigger and bigger for cars, and that will need gearboxes as well.”

DEMO

G&E Model 120GH CNC Gear Gasher • 150” Diameter – can extend to 8M Diameter • NEW CONDITION

Neugart’s U.S. location. (Courtesy: Neugart)

tions in Italy and France. A year later, Neugart had a location in China to serve the Asian market. That expansion continued into 2011, when Neugart opened sales offices in Turkey and Brazil. The company employs more than 700 people worldwide, including more than 600 at its headquarters in Kippenheim in southwest Germany. Moreover, since Neugart is an owner-managed family business, ‘13 Gleason 210H 6-Axis CNC Vertical Gear it is important to the company that it operate in a way that not only ’07 Samputensili S-750 Gear Hobber Hobber-Siemens 840D Controller makes sound business sense, but also makes sure it is diligent in its sustainability efforts. This includes, among other things, a commitment to low-impact use of nonrenewable resources, optimum environmental protection, and fair dealings with its employees and its local community. FUTURE GOALS But Christian said Neugart is not resting on its laurels and intends to continue its growth aspirations into the future. “I know we would like to be among the top three gearbox manufacturers; that’s our target,” he said. Christian expects gearbox technology to continue to grow in the next 10 to 20 years. ‘06 Liebherr LFS-800 CNC Gear Shaper ‘05 Gleason Pfauter GP-150S Gear Shaper “Gearbox technology itself will still play a big part in our society and in our culture — especially since electronic mobility is getting bigger and bigger for cars, and that will need gearboxes as well,” he 820 Cochran Street Statesville, NC 28677 704.609.0766 • [email protected] said. “I am a curious person. I’m always thinking: What gearbox can I invent that no one has invented before?” www.pisellient.com

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March 2020 45 PRODUCT SHOWCASE NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS

deep or shallow bends. The unique ‘sketch’ function allows users to create a first tube from just a few digitized hard points, while automatic report creation ensures that results can be shared instantaneously to any location. TubeShaper v2 is available for purchase immediately.

MORE INFO www.hexgon.com Big Kaiser adds new carbide inserts to its tool offering Hexagon’s well-established tube inspection software platform gets a fresh new look and greater flexibility. Big Kaiser Precision Tooling is adding more (Courtesy: Hexagon) than 30 pressed-geometry carbide inserts for its tools. The new insert design is the result design teams to create and plan measure- of extensive research and testing. Hexagon offers ments without creating bottlenecks that The new grades and geometries offer: TubeShaper update for disturb the operators on the shop floor.” Improved chip control due to optimized With this update, the wide range of bend- chip breakers, even when boring gummy tube design, production ers with which TubeShaper is compatible has materials such as low-carbon or stainless been expanded and covers machines from steel. Leading metrology software and hardware market leaders including Eaton Leonard, Improved coatings for increased speed developer Hexagon released a much-antici- BLM, Addition MT, Numalliance, and more. and better wear resistance. pated update to tube design, analysis, and This new version of TubeShaper still fea- More positive cutting geometries to production platform TubeShaper. This new tures the wide range of popular features that reduce cutting forces, chatter, and vibration version delivers important new functional- have made it an industry leader since the when used in deep-hole boring operations. ities to customers in tube and pipe manu- platform was first launched in 2015, includ- Longer tool life. facturing, including inspection of rectangle- ing spring-back management and in-bend Up to 20 percent savings when com- section tubes and new reporting functional- measurements for more accurate results in pared to current grades. ity. TubeShaper v2 also offers an innovative new licensing concept that makes it more economical for multiple users to share measurement results and bending plans across different locations. Under this new licensing concept, a new, low-price ‘offline’ license allows production supervisors, engineers and designers to work on TubeShaper projects separately from operators measuring tubes on the shop floor so that more tasks can run concurrently, saving time as well as minimizing software investment. “Efficiency is key in tube production because the volumes are so high, so with this new version of TubeShaper we have focused on how we can help our customers save time,” said Anthony Vianna, product manager for portable measuring arms at Hexagon. The new Big Kaiser pressed-geometry carbide insert design is the result of extensive research and testing. “The new offline license is designed to allow (Courtesy: Big Kaiser)

46 gearsolutions.com Big Kaiser offers a range of insert grades and geometries for rough and finish boring, grooving, and precision cutting, including indexable inserts.

MORE INFO www.bigkaiser.com United Grinding rebuilds new productivity into machines After 14 years in service, a Studer S40 grinding machine that had more than 45,000 hours of run time now produces precision components to tolerances it achieved when brand new. The Studer factory in Switzerland performed the rebuild that involved completely overhauling the machine, and while doing so also provided the machine’s owner, LMT Kieninger, with a loaner to ensure the customer’s production would continue uninterrupted. Studer grinding headstock before, left, and after overhaul. (Courtesy: United Grinding) A rebuild, or machine overhaul, makes sense not only economically, but also in compressor, hydraulic, and general machine adjustment of the turret wheelhead (B-axis the fact that operators continue to run a manufacturing with 25 employees since fine). machine that is familiar to them for a seam- 1946. Among its cylindrical grinders, the Studer not only updated the S21 with less transition after the machine has been shop had an 18-year-old Studer S21 with the latest developments, but also retrofit- rebuilt. two external spindles and continuous fine ted it to suit the needs of Ingold Tools AG. In the Studer factory, the rebuild specialists disassemble machines down to all their individual parts. The specialists completely refurbish guideways, overhaul the assemblies, and replace all worn electrical cabinet components as well as all worn hydraulic and lubricating systems and valves. If spare parts are no longer available, Studer provides alternative solutions. For the final stages of the rebuild, the casting and components are sand-blasted and receive a fresh coat of paint. Grinding fl uids Once reassembled, the machine’s geometry synthetic intelligence in perfection is like that of a new machine. “After our rebuild, we really noticed the difference,” said Heiko Braun, group manager of cylindrical/surface grinding and assembly at LMT Kieninger. “Since the overhaul, we have been grinding with the precision of a new machine. The rebuild process went without a hitch, and the investment has paid off because a 1,600-mm grinder is worth its weight in gold for us.” If a customer wishes to expand a and machine’s component range, the Studer overhaul process can also include a retrofit smart micro fi ltration systems during which a machine is modified to a customer’s particular requirements. This opens up new production possibilities on the same machine, which was the case with oelheld U.S., Inc. – innovative fl uid technology 1100 Wesemann Drive • West Dundee, IL 60118 Ingold Tools AG. Phone: +1-847-531-8501 • Fax: +1-847-531-8511 Ingold Tools had been producing high- [email protected] • www.oelheld.com precision and complex parts for spindle,

March 2020 47 PRODUCT SHOWCASE

The cylindrical grinding machine now has allowing customers to increase production an additional internal grinding spindle rates and maximize uptime while delivering for internal cylindrical grinding and the micro geometries and superb surface finish. relevant fixture for swiveling the tailstock The CAM.3 represents a new era of micro into the park position. The machine also has grinders and medical component grinding. a new spindle cooling system with its own Completely designed from the ground up, circuit, as well as a hydraulically swiveling the CAM.3 micro grinder is built for high dressing unit. So that all grinding machines performance and efficiency. Parts are fed have the same mounting, the universal tool through the machine and spun at a higher headstock was upgraded from MK4 to MK5. velocity, resulting in a quick grind maxi- According to Ingold Tools AG’s two man- mizing uptime and throughput. The CAM.3 aging directors, Christoph Jenzer and Edgar grinding wheel runs with a 16-inch diameter Stich, the Studer retrofit resulted in them and up to 3 inches wide. The work wheel is getting a second-hand machine with 50 per- powered by a direct drive servo motor and The automated CNC wheel dresser’s rigid large cent new hardware. ABEC 7 spindle bearings. It can also be out- casting slides improve wheel dressing quality, using a fitted with an internal balancing system large diameter 15,000 RPM twin grip dressing roll and MORE INFO www.grinding.com minimizing vibration while running at high absolute encoders on both axes. (Courtesy: Glebar) speeds. The CAM.3 is built for speed, allowing into a wire. Glebar announces new customers to increase production rates and CAM.3 Highlights: maximize uptime. Mineral Cast Machine Base: Built on a microgrinder for medical The machine is built to feed, spin, and mineral cast base, weighing approximately produce at a much faster rate. The collet feed- 4,500 pounds for superior vibration dampen- device industry ing system is placed closer to the work wheel, ing. Integrated air and oil lines reduce clut- The CAM.3 builds upon Glebar’s 68-year his- enabling the CAM.3 to handle longer and ter and allow pressure to be set by the HMI. tory of providing grinding solutions to the shorter components. In addition, the Y-axis The enclosure is streamlined with safety medical device industry. A revolution in can be tilted, enabling the operator to grind interlocks and the platform accepts 6-axis micro grinding, the CAM.3 is built for speed, sharp corners and put complex geometries robots, pallets, gaging, and other processes within the work envelope to facilitate automation. Grinding Wheel Spindle: The CAM.3’s grinding wheel is 16 inches in diameter, up MAXIMIZE YOUR EXPOSURE to 3 inches wide, and is capable of achieving up to 20,944 surface feet per minute. The Connect your company to the gear industry with a storefront spindle is also offered with a built-in wheel in the Gear Solutions Community. auto-balancing system. CAM.3 is designed to be able to grind stock material from 0.005”- Storefronts paint a portrait of 0.375” in diameter. JOIN THE GEAR SOLUTIONS your company with a 500-word HMI Controls and Custom Software: COMMUNITY The 16:9 touchscreen HMI uses intuitive, FOR ONLY description and include your logo, $ website link, phone number, email simple to operate, functionality enabling 350 simple multi-axis motion control. PER YEAR addresses, and videos. Your social media pages such as Twitter and Automated CNC Wheel Dresser: Rigid Facebook are integrated with large casting slides improve wheel dressing live updates, which may also quality, using a large diameter 15,000-rpm be re-posted through our social twin-grip dressing roll and absolute encod - media feeds. With a community ers on both axes. storefront, your company also Versatile and connected with industry 4.0: The IIoT connections monitor tempera- receives a premium listing in the ture, pressure, and vibration, alerting the annual Buyer’s Guide published operator of errors before they happen. The each November. CAM.3 can easily be automated with the integration of a 6-axis robot for any pick and place application. Gaging and alternate For information on how you can participate in the GearSolutions.com feeding systems can be implemented simply community storefront, contact [email protected]. under the new control structure. Chad Morrison – national sales manager To improve production monitoring, 800.366.2185 x 202 operators can use the integrated MT Connect or OPC-UA interface with Glebar Advanced Analytics. This program interprets and syn-

48 gearsolutions.com thesizes the data, delivering actionable real- allow for faster cutting with better surface the same tool life as new reamers, making time analytics on easy-to-read dashboards, finishes and roundness. Solid, straight, or them efficient and cost effective. They are allowing operators and managers to reduce left-hand fluted designs ensure stoutness ideal for high speed reaming applications, scrap and increase machine capacity, uptime throughout its long service life. Different long production runs, large hole reaming, and output. cutting materials and coatings are avail- and whenever precise, repeatable reaming able to ream a wide variety of part materi- is required. MORE INFO www.glebar.com als, special geometries upon request. Holders Monaghan Tooling Group provides the come with internal coolant as standard. The world-class engineered tooling and services, top speed ring holders are made with either including application-related consulting, Request quotes for tools cylindrical shanks or module connections to solve machining challenges. They have for run-out compensation. The top speed partnered with industry-leading standard a new feature in latest ring can be repaired/re-tipped, and achieve and custom tooling manufacturers includ- KISSsoft update A new feature allows the user to directly request quotes for tools in KISSsoft. A report is generated containing all data of the gear to be produced as well as the tool itself, which is available in KISSsoft. Currently, the following tool types are supported: hobbing cutters, shaper cutters, and power skiving tools — others will follow. This new feature is available in Version 2019, Patch C. PERFECTION New buttons have been added to the man- CREATED ufacturing tab with an “@” icon, while the text on hovering over button reads, “Request BY PRECISION. offer for a tool.” Please see our short instruc- tions for a better understanding of how this new feature works. www.heat-treatment-services.com In many companies, design and manufacturing departments are separated. When a gearbox design is completed, and the designs of the components are transferred to manu- ALD is a leader in vacuum facturing, it is usually too late for the modi- Global service centers process technology and fications necessary for an optimal manu- heat treatment services. facturing process. The consequences are ▪ LIMBACH OBERFROHNA increased manufacturing costs. If you would Pr ecision and perfection in the pieces that GERMANY we treat under our patented thermal like to learn more on this topic, you can find ▪ process. the article “Combining Gear Design with PORT HURON, MICHIGAN ▪ Leaders in the control of distortion Manufacturing Process Decisions” from Dr. Ing. U. Kissling, KISSsoft AG; Ing. U. at https:// ▪ USA ▪ Low Pressure Carburizing ▪ High pressure gas quenching tinyurl.com/u67lmbd. RAMOS ARIZPE, COAHUILA ▪ ▪ Gas Nitriding ▪ Ferritic Nitro Carburizing ▪ MEXICO MORE INFO www.kisssoft.ag ▪ Normalizing ▪ Hardening ▪ Annealing ▪ Brazing Monaghan’s top ▪ Cryogenic Treatments Thomas Lord, Sales Director ▪ Engineering services and process development United States ALD Port Huron speed ring allows ▪ Prototype and trials ALD Thermal Treatment Inc. 70% higher feed rates 2656 24th Street Port Huron, MI, USA 48040 Monaghan Tooling Group introduces its Cell Number +1 (810) 300-1437 Edwin Orozco, Sales Director – Mexico Email: [email protected] Office Phone +52 844 866 9791 easily assembled top speed ring, a reamer Cell Phone +52 1 844 277 2257 that allows up to 70 percent higher feed Christopher Totten, Sales – Canada / USA, [email protected] rates than traditional cutting rings. These Office Phone +1 810 357 0634 [email protected] Cell Phone +1 810 300 3601 modular top speed rings require no setting, e-mail: [email protected] Moises Garcia – Sales Director - Bajio so they are ready to use right out of the box. Cell Phone +521 (844) 277 2254 They have a diameter range from 50,600 Mexico ALD Tratamientos Térmicos S.A. de C.V. [email protected] mm – 225,000 mm (1.9921”-8.8583”). Four extra teeth compared to expandable rings

March 2020 49 PRODUCT SHOWCASE

higher feed rates are possible, while avoiding center-cutting. Large stepovers provide an excellent surface finish. Programming is simplified within the Mill-Turn module by a new automatic contour feature splitting capability, enabling hyperMILL to automatically determine the area to be machined based on the turning contour. The grooving job will automatically recognize if a contour is a groove, making it faster and easier to program certain areas. A new hyperMILL automation center allows users to automate the job list creation processes in hyperCAD® -S, serving as both a development and runtime environment. New features also include the ability to select and position the clamping device, as well as define a uniform process for all Monaghan Tooling Group provides top-engineered tooling and services, including application-related programmers. consulting, to solve machining challenges. (Courtesy: Monaghan Tooling Group) The powerful additive manufacturing process in hyperMILL CAM software supports ing Elliott Tool Technologies, Diatool, UC benefits in complex machining applica- 3D printing/ additive processes and provides Tools, RE-AL, MK-Tools, Reamtec, and Axis tions including mold and die. Enabled by a efficient hybrid processing with simultane- to address the challenges of precision metal simple instruction, corners can be machined ous additive manufacturing and subtractive finishing and high performance cutting. largely by vertical stroking motions. Then machining on one machine tool. hyperMILL traditional z-level steps can be used to blend additive manufacturing technology offers MORE INFO www.monaghantooling.com with the vertical section and the lower f loor flexible strategies for additive material appli- youtu.be/HvEDnWtO7x0 area. The top section has an automatic sur- cations, including filling strategies for both face extension to enable the production of planes and free-form shapes, and in 2D and sharp edges. 3D sections. Applications also include hybrid ® New hyperMILL Suite hyperMILL 2020.1 features a new 5-axis machining to fix damaged parts and additive blade tangent milling strategy that increas- machining of an existing component. offers 3D, 5-axis es efficiency and improves surface quality Improving probing, new hyperMILL when milling with conical barrel cutters CAM software includes slot-rib probing to enhancements that have a large primary angle. As a result, measure slots and ribs using familiar tech- Open Mind Technologies AG, a leading developer of CAD/CAM software solutions worldwide, has introduced hyperMILL® 2020.1, a new version of its advanced, comprehensive CAD/CAM software suite. In addition to powerful 3D and 5-axis machining enhancements for complex part manufacture, the new version increases ease-of-use and over- all programming performance, and includes key new automation and additive manufacturing strategies. “The new version of hyperMILL encompasses a wide range of user-friendly enhancements and important new machining strategies, further advancing the capabilities for accurate, efficient 3D and 5-axis machining,” said Alan Levine, managing director of Open Mind Technologies USA, Inc. “We are also very pleased to reinforce our commitment to additive manufacturing and automation in hyperMILL 2020.1.” For highly productive rest material machining, hyperMILL 2020.1 offers new corner rest machining strategies for 3D and hyperMILL® 2020.1 offers new corner rest machining strategies for 3D and 5-axis techniques. (Courtesy: Open 5-axis techniques that provide significant Mind)

50 gearsolutions.com nology parameters. For high stock removal rates, 3D machining strategies in hyperMILL 2020.1 now include 3D Optimized Roughing in high-performance hyperMILL MAXX machining mode. The roughing process also offers improved area sorting, resulting in fewer retractions and improved collision checking. In addition, two new user-friendly functions are now available in 3D profile finishing including automatic face extension and free tool geometry. Automatic face extension can be used during programming to extend the circumference of selected milling surfaces, eliminating the need to modify the milling faces in the CAD system before- hand. Free tool geometry enables the use of The Schunk VERO-S NSE mikro 49-13 is suitable for metal cutting applications, and for test applications and in any tool type for highly detailed program- the field of automation. (Courtesy: Schunk) ming and collision control. Headquartered in Germany, Open Mind (6,000 N). Depending on the thread size of tion. The module opens pneumatically and is one of the world’s leading developers of the clamping pin (ø 10 mm), the holding a system pressure of 6 bar is sufficient. The powerful CAD/CAM solutions for machine forces amount to 3,000 N (M3) or 5,000 N module is actuated via lateral or bottom air and controller-independent programming. (M4). Locking is done mechanically via a connections. For ensuring a long service The company develops optimized CAD/CAM spring assembly; it is self-retaining and locks life time and the greatest possible process solutions that include many innovative fea- form-fit. The position of the clamping slide safety, all functional parts such as base body, tures unavailable elsewhere, to deliver sig- is detected via dynamic pressure monitoring. clamping pins, and clamping slide are made nificantly higher performance in both pro- Therefore, the miniature module (ø 49 mm, of stainless steel. gramming and machining. Strategies such height above the table 13 mm) is suitable for as 2.5D, 3D, as well as 5-axis milling, mill/ metal cutting applications and for automa- MORE INFO www.schunk.com turning, and machining operations such as HSC and HPC, are efficiently designed into the hyperMILL CAM system, providing maximum user benefit and compatibility YOUR INDUSTRY NEWS SOURCE with all current CAD solutions and extensive programming automation. Gear Solutions magazine has been the most trusted source for information and technical knowledge in the gear manufacturing industry for more than MORE INFO www.openmind-tech.com 15 years. Each issue, Gear Solutions offers its readers the latest, most valuable content available from companies, large and small, as well as critical thoughts on what this Schunk offers information means for the future of the gear manufacturing industry. sealed miniature Best of all, it’s free to you. All you need to do is subscribe.

clamping module

MAGAZINE SOLUTIONS GEAR

Schunk has developed a completely sealed GEAR SOLUTIONS MAGAZINE miniature clamping module specifically for Your Resource for Machines, Services, and Tooling for the Gear Industry compact applications in the metal cutting Your Resource for Machines, Services, and Tooling for the Gear Industry industry, assembly, and handling, as well as

ISSUE FOCUS

for measurement technology. It combines ISSUE FOCUS

THE ROOT CAUSE FOR GEAR NOISE EXCITATION NOISE GEAR FOR CAUSE ROOT THE Bevel Gears | Plastic Gears Cutting Tools | Workholding compact dimensions, high pull-down and INCREASING STATIC FRICTION WITH LASER THE ROOT CAUSE FOR holding forces, a high dimensional stability, INCREASING GEAR NOISE and a high repeat accuracy of < 0.005 mm. STATIC FRICTION EXCITATION WITH LASER The VERO-S NSE mikro 49-13 is actuated via COMPANY PROFILE SUBSCRIBE COMPANYFOR FREE PISELLI ENTERPRISES an axial piston, and therefore achieves high PROFILE pull-down forces despite the compact dimen- www.gearsolutions.comWEILER ABRASIVES sions. The patented drive concept consists of 2018 DECEMBER APRIL 2019 a dual-stroke system, and by using the inte- APRIL 2019 gearsolutions.com

DECEMBER 2018 grated standard turbo function, pull-down gearsolutions.com forces of 1,500 N are achieved, meaning that the module is ranging between the NSE mikro 49 (400 N) and the NSE mini 90-25

March 2020 51 PRODUCT SHOWCASE

Starrett upgrades on its workstage. Available with optical edge detection, the popular benchtop HB400 Benchtop model is a workhorse of the broad line of Starrett comparators, providing optical comparator performance levels previously only available The L.S. Starrett Company, a global manu- with floor standing machines. “Customers facturer of precision hand tools and gages, will surely welcome this enhancement, as metrology systems, and more, has expanded the HB400 now has the longest standard the Horizontal X-Axis Travel on its HB400 X-Axis travel of its comparator class in the benchtop optical comparator from 12 inches industry,” said Mark Arenal, general man- to 16 inches (300mm to 400mm), providing ager, Starrett Kinemetric Engineering, Inc. users the versatility to measure larger parts The Starrett HB400 optical comparator YOUR SOURCE FOR GEAR INDUSTRY NEWS Starrett Company has recently expanded the Horizontal X-Axis Travel on its HB400 benchtop optical comparator, providing users the versatility to measure larger parts on its workstage. (Courtesy: Starrett) Gear Solutions magazine has been the most trusted source features a large 16-inch (400mm) diameter for information and technical knowledge in the gear viewing screen, the new 16-inch (400mm) manufacturing industry for more than 15 years. horizontal travel, a 6-inch (150mm) Y vertical travel, a 2-inch (50mm) focus travel and Each issue, Gear Solutions offers its readers the latest, most valuable content a 110-pound. (49.9 kg) workstage load capac- available from companies, large and small, as well as critical thoughts on what ity. The HB400 also has rugged all-metal con- this information means for the future of the gear manufacturing industry. Best struction with a hard-anodized stage tooling of all, it’s free to you. All you need to do is subscribe. plate, LED profile and surface lighting rated to 50,000 hours, and touch-screen opera-

tion. Featuring a linear encoder glass scale

on both X and Y-axes and digital protractor GEAR SOLUTIONS MAGAZINE MAGAZINE SOLUTIONS GEAR

GEAR SOLUTIONS MAGAZINE for angle measurement of 1’ resolution via

Q-axis readout, the HB400 is exceptionally

Your Resource for Machines, Services, and Tooling for the Gear Industry accurate and reliable. Your Resource for Machines, Services, and Tooling for the Gear Industry The Starrett HB400 has a single bayonet style lens mounting system that accepts a choice of six fixed interchangeable lenses, as ISSUE FOCUS

ISSUE FOCUS well as OV2 Zoom or TOV2 fixed telecentric

THE ROOT CAUSE FOR GEAR NOISE EXCITATION NOISE GEAR FOR CAUSE ROOT THE Bevel Gears | Plastic Gears Cutting Tools | Workholding INCREASING STATIC FRICTION WITH LASER THE ROOT CAUSE FOR magnification video camera systems. The INCREASING HB400 is available with MetLogix M1 tab- GEAR NOISE let, M2, or M3 measuring software (when

STATIC FRICTION EXCITATION using OV2 and TOV2) PC, or digital readout WITH LASER systems. COMPANY COMPANY PROFILE PROFILE The L.S. Starrett Company, founded PISELLI ENTERPRISES WEILER ABRASIVES in 1880 and headquartered in Athol, Massachusetts, is a global manufacturer of

DECEMBER 2018 DECEMBER precision measuring tools and gages, optical APRIL 2019 SUBSCRIBE FOR FREE gearsolutions.com APRIL 2019 comparators and vision systems, and force www.gearsolutions.com and hardness testing solutions. Starrett also

DECEMBER 2018 gearsolutions.com manufactures laser measurement systems, custom engineered granite solutions, custom gaging, band saw blades, power tool accessory saw blades, workshop tools, and jobsite tools.

MORE INFO www.starrett.com 52 gearsolutions.com Ewag Laser Line Ultra percent better than the equivalent ground The Ewag drill and mill module are soft- drill bit. ware options which enable users of the Laser simplifies micro In general, lasered spiral tool surfaces, Line Ultra to fabricate spiral tools made of regardless of material, exhibit surface WC or PCD between 0.4 mm to 3 mm in cutting production roughness values for Ra and Rz of <0.25 µm diameter. Like the Helitronic tool studio As products grow thinner and lighter to and <1.5 µm respectively. Additionally, cut- from Walter, parametric programming and meet the needs of the electronics, medical, ting edge radii are typically ≤5 µm and are automatic recommendations for laser pro- and micromechanics industries, United symmetric with a K-factor typically equal to cessing parameters contribute to the mod- Grinding and Ewag have developed the 1±0.2. In terms of diameter stability, a toler- ule’s ease of use. Laser Line Ultra for machining the incred- ance of ±0.005 mm can be achieved given ibly precise microtools required for these a production run of 12 hours in a climate- MORE INFO www.grinding.com applications. Specializing in the laser fab- controlled facility. www.ewag.com rication of cutting tools made of hard and ultrahard materials such as tungsten carbide (WC), polycrystalline diamond (PCD), chemical vapor deposition diamond (CVD- D) and cubic boron nitride (CBN), the Laser Line Ultra uses an 8-axis configuration and picosecond lasers to machine complex micro geometries in cutting tools regardless of the material’s hardness and with negligible heat- affected zones. To ensure homogenous hole quality with micro-sized drill bits, wear-resistance of the tools is of utmost importance and can only be achieved by micro-cutting tools made out of ultrahard materials. By using ultrashort laser pulses and the Ewag drill module, the Laser Line Ultra enables diameter-to-length ratios up to 1:20. This technology allows manufacturers to produce tip thinning or chamfers, and unlike conventional techniques, the force-free process eliminates waste from tool breakage. Laser processing ordinarily removes material according to thermal-based mechanisms. However, by using ultrashort laser pulses and correct laser parameters, the pulse is so short that significant heat has no time to be conducted into the cutting tool, creating little, if any, heat-affected Elevate. zones. For example, carbide drill bits fabricated with the Laser Line Ultra can accept the same processing chain and recipe for physical vapor deposition (PVD) coatings as ground cutting tools. Applications of micro end mills include profiling printed circuit boards (PCBs), milling of enclosures such as mobile phone cases and for the fabrication of molds and We’ve welcomed pan-renewable and multi-technology businesses at WINDPOWER dies. By using the Ewag mill module, the for years. In 2020, we’re throwing the doors open, creating an even bigger Laser Line Ultra is able to fabricate 4-flute opportunity for companies in wind, solar, storage and other clean energy PCD end mills from cylindrical blanks with technologies to learn and do business across the utility- scale power sector. primary and secondary clearance faces These industries will converge at CLEANPOWER 2020, bringing together all the major developers, utilities, OEMs, suppliers and buyers under one roof. fabricated both at the tip and circumference as well as a smooth, uninterrupted interface between PCD and WC — a crucial LEARN MORE AT CLEANPOWEREXPO.ORG factor in the quality and chip evacuation performance of spiral tools. As a result, the surface quality of lasered WC surfaces is 20

March 2020 53 MARKET WE’RE CERTIFIABLE PRECISION GROUND PLACE Our ISO 17025 A2LA Laboratory is available RACKS AND PINIONS to certify or recertify your Master Gears and Spline Gauges or Contract Contact Gear Solutions Inspection of your gears. at 800-366-2185 to Our rapid turnaround service minimizes the feature your business “out of service” time. in the Marketplace! A.G.M.A. Class 12 or Better CAPABILITIES  Rack Cutting/Grinding up to 192”  64 Pitch down to .625 Pitch  Surface Grinding up to 144”  CNC Milling up to 120” 6161 Webster Street, Dayton, Ohio 45414 18235 Weaver St., Detroit, MI 48228 937-660-8182 [email protected] Ph 313-836-4131  Fax 313-836-1023 www.gearinspection.com Email [email protected]

KORO for Quality Hob Sharpening Service  Quick Turnaround 2 Day Service  · Custom gear racks in AMERICAN and Spur Shaper Cutter Sharpening METRIC standards, STRAIGHT and  HELICAL, VARIOUS materials, FINE and HSS & Carbide Hob with center hole COARSE pitch (254 D.P. – 0.5 D.P.; 0.10 and straight flutes Module – 50 Module); hard-cut (up to  Thin Film Coatings 60 Rc) and soft-cut (up to 40 Rc); 32” face width; Up to 82” lengths – longer  Length up to 7 inches lengths through resetting · Custom gears in AMERICAN and METRIC standards (3 D.P. – 72 D.P., 10” Diameter)  Diameter up · Precision Quality up to AGMA 12 to 5 Inches · Prototype & Production quantities · Breakdown Service Available  Precise rake · Reverse Engineering and spacing guaranteed · Unique Tooth Configurations to AGMA standards · Heat Treating · Complete CNC Machining  RUSH SERVICE AVAILABLE Koro Sharpening Service 9530 85th Ave North

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REACH MORE CUSTOMERS

Advertise with us in print and online, and you can reach over 45,000 potential readers – many who are key decision makers at their companies.

To learn more, contact assistant publisher Chad Morrison at [email protected] or call 800.366.2185 ext. 202

54 gearsolutions.com ADVERTISER INDEX CONTENTS PAGE NO.

ALD Thermal Treatment Inc...... 49 SHOP HARDENED SOLUTIONS

UNITE-A-MATIC™ SURF-A-MATIC™ ROLL-A-MATIC™ All Metals & Forge Group...... 9

American Precision Gear Co...... 10

AWEA (American Wind Energy Association)...... 53

Circle Gear & Machine Co Inc...... 18

PD INSPECTION SURFACE FINISH INSPECTION RUNOUT INSPECTION Forest City Gear...... IFC

Innovative Rack & Gear...... 54 SIMPLE ACCURATE REPEATABLE

KAPP Technologies...... 17

KISSsoft USA LLC...... 15 www.united-tool.com Koro Sharpening Service...... 54 est. 1973

Lawler Gear Corporation...... 54

McInnes Rolled Rings...... 13

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

New England Gear...... 7

Nordex Inc...... 11

Oelheld...... 47

Penta Gear...... 54

Penta Gear Metrology LLC...... 12

Piselli Enterprises Inc...... 45

Russell Holbrook & Henderson Inc...... 10

STD Precision Gear & Instruments Inc...... 15

Stor-Loc...... 55,IBC

Tech Tool Company...... 54

The Broach Masters Inc...... 4

Toolink Engineering Inc...... 1

United Tool Supply...... 55

March 2020 55 Q&A JACK CONWAY INTERVIEW WITH AN PRESIDENT  ATLANTA GEAR WORKS INDUSTRY INSIDER

“We have a very talented staff of engineers and assembly technicians who are capable of doing anything gear related.”

What’s a typical day like for you at Atlanta Gear Works? There really is not a typical day. We are an extension of the maintenance department for large manufacturing facilities with process- critical gearboxes. So, though we always hope a day will go as planned, any day can change with a phone call from a customer telling us something at their facility has broken, and they are down, need us to fix it and get them back up and running. At that point, our goal here is to reduce our customer’s downtime. We’ll direct any resources we need to correct the problem as soon as possible.

What brands do you work on? We have a very talented, dedicated staff of engineers and assembly technicians who are capable of doing anything gear related. So, we work on all brands - any make, any model. We started out with Beloit gearboxes, but now we do Falk, Hanson, Flender, Sumitomo, to name just a few, as well as custom gearboxes. We can work on any piece of Atlanta Gear Works began custom-manufacturing gears early on because suppliers couldn’t meet the standards essential to ensuring long-term reliability. gear-related rotating equipment. (Courtesy: Atlanta Gear Works)

What makes Atlanta Gear Works unique to the gear industry? ate 24 hours a day when a customer has a crisis. Often, there’ll be an Basically, it’s our willingness to do whatever it takes to get a customer emergency somewhere out of state, and our guys will just call home back up and running fast. We’ve continued to add services and new and say, “I won’t be home tonight. I’m off.” I haven’t seen any extent machining capabilities to support that mission. For instance, we’re they won’t go to in order to solve a problem for a customer. expanding our plant this year. We’re adding another 10,000 square feet, which we hope to be in by July. All of our efforts are dedicated to How has the Atlanta Gear Works coped with an ever-changing keeping our customers running and reducing their downtime. gear market? Are you dealing with any of the Industrial Internet of Things, or is that something that’s still on the horizon for you? How do you approach a customer when they come to you with a It’s still on the horizon for us. What we have seen is better predic- challenge? tive maintenance from our customers. They’re using more advanced The first thing we do is find out what’s wrong and what happened. vibration analysis. They’ve got load systems on their motors and their Typically, a customer just knows the gearbox stopped running. They gearboxes, and they’re getting better at predicting failures because, don’t know why. We’ll try to figure it out — as best we can — and give obviously, what everybody would like to have is a planned outage them a root cause analysis of what the problem really is. instead of an unplanned one. From there, we’re going to design parts to either go back in to repair The advances in machinery just keep taking big leaps, and that’s the unit or upgrade it to make it more reliable for them moving for- where we continually invest in our shop so we can produce the best ward. We guarantee our repairs and rebuilds to be equal to original available, most reliable product for our customer. quality or better. Customers also call us, especially for field service, to look at a gear- Where do you see the gear industry in the next decade and box as a preventive measure. They may not actually even know there’s Atlanta Gear Works’ place in that future? a problem with it until we get there. Part of the reason they deal with I see the gear industry continuing to expand. Gears are still an efficient us is no matter what problem we uncover, even on a routine inspec- way to control torque and speed. We will continue to add services. For tion, we have a solution for them. We don’t just identify the problem. instance, field service is a growing area for us. Since our customers We give them a solution and a way to get back up and running, and have a retiring base of knowledge in their companies, they are relying that’s one of our biggest advantages. In the shop, we continue to add more and more on outside vendors to come in to help them with their capacity because the more we manufacture in house, the more control process-critical gearboxes. They’re really looking for a reliable resource of quality and timing we have on any of the products that we service. that can come in, diagnose the problem and fix it in a timely manner. And that’s what we continue to do every year. We make large invest- We do everything we can to be sure that we are that resource. ments in our facility to continue to expand our capacity and serve our customers. And then there’s the people element. Our field-service guys keep atlantagear.com their backpacks packed at all times, and it’s not unusual for us to oper- MORE INFO

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