Non-Ferrous Alloys for Worm Gear Application and Advantages of Centrifugally Gears Cast

GE AR SOLUTIONS MAGAZINE NON-FERROUS ALLOYS FOR WORM GEAR APPLICATION AND ADVANTAGES OF CENTRIFUGALLY GEARS CAST

Non-Ferrous Alloys for Worm Gear Application and Advantages of Centrifugally Cast Gears ISSUE FOCUS Forging/Casting Gear Grinding COMPANY PROFILE: Advanced Jiffy Machine Products Inc. MAY 2017

MAY 2017 Your Resource for Machines, Services, and Tooling for the Gear Industry gearsolutions.com

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GS-Book.indb 2 4/25/17 3:58 PM GMTA_AD5030_Gear Solutions_January 2015 IS YOUR GEAR DEBURRING STILL IN THE STONE AGE

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Reduce your manual labor and increase productivity with one of our Cutting-Edge 2017 James Engineering gear deburr machines. Please contact Toolink Engineering directly for additional information and to schedule machine demonstrations.

GS-Book.indb 1 4/25/17 3:58 PM Achieving Increased Profits and Response Times with Modular Vacuum, Atmosphere Furnaces

“Initially, what appealed to us about this Ipsen equipment was its general purposefulness ... We wanted a low-cost, off-the-shelf-type solution that would allow us the flexibility we required – which is what the ATLAS and TITAN® delivered. Now after having performed some pre-training, I would say what stands out the most for both are the ease of use and control of the equipment.” – Continuous Improvement Manager

Customer Story

As a leading global technology provider, this From supervising the installation to providing customer decided to move their existing facility to operator training, the Ipsen Field Service a new location so they could continue to grow and Engineers took the pressure off the customer and advance. As such, any new equipment they chose had the equipment up and running in no time. The needed to be able to handle the everyday range of customer also took advantage of Ipsen U, a requests, from different processes and part three-day training that gave them a deeper geometries to different load sizes. understanding of how to effectively operate and maintain their new investments. They have also After much consideration, it was Ipsen’s ability to started to notice some of the advantages the provide modular platforms for both vacuum and atmosphere furnaces provide, including … atmosphere furnaces in the form of the TITAN® and ATLAS, as well as the necessary training and support, that interested them.

Discover this customer’s winning outcome: www.IpsenUSA.com www.IpsenUSA.com www.IpsenUSA.com/Customer-Stories

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GS-Book.indb 2 4/25/17 3:58 PM FEATURES

Achieving Increased Profits and Response Times with Modular Vacuum, Atmosphere Furnaces

“Initially, what appealed to us about this Ipsen equipment was its general purposefulness ... We wanted a low-cost, off-the-shelf-type solution that would allow us the flexibility we required – which Advanced Jiffy Machine Products Inc. is what the ATLAS and TITAN® delivered. Now By Molly J. Rogers after having performed some pre-training, I would With a motto of “If you’re not looking ahead, you’re already behind” and a focus on customer satisfaction, quality, and innovation, Advanced Jiffy Machine Products is a custom gear manufacturer say what stands out the most for both are the that’s continuously increasing its capacity and efﬁ ciency. ease of use and control of the equipment.” 28 – Continuous Improvement Manager Review of Microstructure and Properties of Non-Ferrous Alloys for Worm Gear Application and Advantages of Customer Story 32 Centrifugally Cast Gears By Giri Rajendran and Jason Hassen A review of the microstructure and properties of tin bronze, manganese bronze, and aluminum As a leading global technology provider, this From supervising the installation to providing bronze material that make them suitable for specific worm gear applications is presented, customer decided to move their existing facility to operator training, the Ipsen Field Service as well as results from mechanical tests and microstructural studies comparing the centrifugally a new location so they could continue to grow and Engineers took the pressure off the customer and cast and static-cast gear bronze (tin bronze) alloy. advance. As such, any new equipment they chose had the equipment up and running in no time. The Introducing a New Machine Concept for High-Productive needed to be able to handle the everyday range of customer also took advantage of Ipsen U, a Gear Grinding requests, from different processes and part three-day training that gave them a deeper 42 geometries to different load sizes. understanding of how to effectively operate and By Deniz Sari, Klaus Peiffer, and Enrico Landi maintain their new investments. They have also A breakthrough design has been developed to optimize stiffness, stability, and speed of the After much consideration, it was Ipsen’s ability to started to notice some of the advantages the gear generating grinding machine, reducing non-productive time in the process. provide modular platforms for both vacuum and atmosphere furnaces provide, including … atmosphere furnaces in the form of the TITAN® and ATLAS, as well as the necessary training and support, that interested them. Case Study: How Advanced Gearbox Testing Drove the Need 46 for the Lost Foam Casting Process Discover this customer’s By Chris Lake winning outcome: Demands for higher loads, complex geometries, flexibility for change, and predictable materials are www.IpsenUSA.com moving the transmission test stand industry away from fabrications to lost foam casting. www.IpsenUSA.com www.IpsenUSA.com/Customer-Stories

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GS-Book.indb 3 4/25/17 3:59 PM and Universal Gear Company

1605 Industrial Drive Auburn, CA 95603 Phone: (530) 885-1939 Fax: (530) 885-8157

Call 530-885-1939 or visit www.broachmasters.com

GS-Book.indb 4 4/25/17 3:59 PM DEPARTMENTS

INDUSTRY 08 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. Ipsen USA Provides Comprehensive Toyoda Wins 2017 Automotive News Support for Heat-Treating Systems PACE Award Shipped Around the World

In this section, the premier supporter of gear manufacturing in the United States American and beyond shares news of the organization’s activities, upcoming educational and training opportunities, technical meetings and seminars, standards development, Gear Manufacturers and the actions of AGMA councils and committees. 17 Association

MATERIALS 52 PRODUCT 60 Q&A 22 MATTER SHOWCASE Bill Miller James Carosiello VICE PRESIDENT OF SALES AND SERVICE INDUSTRY STANDARDS FOR STEEL CLEANNESS Kapp Technologies L.P. With limitations on today’s industry standards for measuring steel cleanness, using the right mix of methods should be carefully considered.

TOOTH 24 TIPS Rick Miller DESIGNING QUIET GEARS The gear design phase is the easiest, least costly, and most effective way to influence gear noise.

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. HOT Periodicals Postage Paid at Pelham AL and at additional mailing offices. Printed in the USA. POSTMASTER: 25 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, SEAT Richmond Hill, ON L4B4R6. Copyright®© 2006 by Media Solutions, Inc. All rights reserved. D. Scott MacKenzie METALLURGICAL REASONS FOR GRINDING CRACKS AND No part of this publication may be reproduced or transmitted in any form or by any means, electronic THEIR DETECTION 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 Aggressive grinding can result in thermal damage and magazine, or who are not specifically employed by Media Solutions, Inc., are purely their own. All “Industry potential cracking of a ground part, but methods exist News” material has either been submitted by the subject company or pulled directly from their corporate web and Universal Gear Company site, which is assumed to be cleared for release. Comments and submissions are welcome, and can be submitted to detect grinding burns and cracks. to [email protected]. 1605 Industrial Drive Auburn, CA 95603 Phone: (530) 885-1939 Fax: (530) 885-8157 MAY 2017 Call 530-885-1939 or visit VOLUME 15 / NO. 5 www.broachmasters.com Cover: MCC International MAY 2017 5

3.TOC-2017-05.indd 5 4/25/17 4:16 PM EDITOR'S David C. Cooper LETTER PUBLISHER FELLOWS 20-4 GEAR SHAPERS REMANUFACTURED IN 2016 Chad Morrison ASSOCIATE PUBLISHER Welcome to the May issue of Gear Solutions magazine! EDITORIAL Molly J. Rogers If you are just returning from the AGMA Annual Meeting last month, I hope you had EDITOR an enjoyable time and were able to glean some ideas and bring them back with you. With Kenneth Carter interesting presentations and networking events, AGMA has reason to celebrate another ASSOCIATE EDITOR successful event behind them. And for some of you, now the work is just ahead, whether it’s keeping up with the latest technology, trying new techniques for managing millennials, SALES ’ve or making smart business decisions in today’s economy. h, we got t Chad Morrison a h However you are feeling about the future, be sure to read the letter in this issue’s AGMA e at ASSOCIATE PUBLISHER Y ! Update from Jim Bregi. It’s a wonderful story about 1943 found memorabilia, his grandfather’s life in the gear industry, and some thoughts on looking ahead. Dave Gomez For this issue’s company profile, I had a chance to speak with Mark Jackson of Advanced REGIONAL SALES MANAGER Jiffy Machine Products about his takeaways from attending the Annual Meeting. This small family-operated gear-manufacturing shop is focused on innovation and automation CIRCULATION technologies, and Mark talks about ways they will continue to advance, right along with Teresa Cooper industry. Check out his tips in the profile for minor things anyone can do to implement MANAGER Internet of Things (IoT). And with advancements in technology come advancements in gear machine design. This Jamie Willett ASSISTANT issue, we feature an article from Samputensili’s new gear technology manager, Deniz Sari, along with authors Klaus Peiffer and Enrico Landi, who discuss a new concept that optimizes Cole Morrison stiffness, stability, and speed of its gear generating machine. This concept is also available ASSISTANT on its dry-grinding machine introduced last year and the first of its kind. In this issue’s Q&A, Bill Miller of Kapp Technologies also shares some advancements that ART Kapp has made in the grinding world as well as in metrology. Bill was recently promoted Shane Bell to vice president of sales and service following the retirement of Jim Buschy after his 26 CREATIVE DIRECTOR years with Kapp. Michele Hall This issue of Gear Solutions also takes a closer look at gear and gearbox casting. First, GRAPHIC DESIGNER MCC International authors Giri Rajendran and Jason Hassen, who presented their paper at last year’s AGMA Fall Technical Meeting, discuss non-ferrous materials for worm gears and show results from a comparison of centrifugally cast and static-cast tin bronze test CONTRIBUTING pieces. You’ll also find a case study from Chris Lake of RedViking who details the steps in WRITERS the process of lost foam casting for a helicopter test stand gearbox. JIM BREGI JAMES CAROSIELLO Gear Solutions columnists Rick Miller talks about gear noise reduction in Tooth Tips, JASON HASSEN Scott MacKenzie covers methods to detect grinding cracks and burns in Hot Seat, and new CHRIS LAKE ENRICO LANDI contributor James Carosiello with TimkenSteel continues the Materials Matter column on D. SCOTT MACKENZIE measuring steel cleanness. RICK MILLER I want to thank all of the contributing writers and our talented columnists who took the KLAUS PEIFFER GIRI RAJENDRAN time to share their insights and expertise with you. DENIZ SARI We have the world’s largest stock Vertical Logo Horizontal Logo I hope you enjoy this issue of Gear Solutions, and as always, thanks for reading! of used late-model Fellows Gear Shapers.

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

Coop wants to use this one for the website PUBLISHED BY MEDIA SOLUTIONS, INC. REMANUFACTURED P. O. BOX 1987 • PELHAM, AL 35124 RETROFITTING Molly J. Rogers (800) 366-2185 • (205) 380-1580 FAX 860-223-7778 Editor David C. Cooper Chad Morrison CUSTOM MACHINES www.NewEnglandGear.com Gear Solutions magazine PRESIDENT VICE PRESIDENT [email protected] Teresa Cooper (800) 366-2185 x205 OPERATIONS 343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776 6 gearsolutions.com

GS-Book.indb 6 4/25/17 3:59 PM FELLOWS 20-4 GEAR SHAPERS REMANUFACTURED IN 2016 Yeah, we’ve got that!

We have the world’s largest stock of used late-model Fellows Gear Shapers.

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

REMANUFACTURED RETROFITTING 860-223-7778 CUSTOM MACHINES www.NewEnglandGear.com

343 JOHN DOWNEY DRIVE • NEW BRITAIN, CT 06051-2907 • PHONE 860-223-7778 • FAX 860-223-7776

GS-Book.indb 7 4/25/17 3:59 PM INDUSTRY NEW PRODUCTS, TRENDS, SERVICES, NEWS AND DEVELOPMENTS John Burch Appointed Chief Executive Officer of Bison Gear & Engineering

The board of directors of Bison Gear & Engineering recently announced the appointment of John Burch as chief executive officer effective May 1, 2017. Burch succeeds Marcus J.S. Bours, who served as interim CEO since June 2016. The board expressed its appreciation for Bours’ service during the transition period. Burch has more than 25 years of general management, marketing, sales, business development, and operations experience across a variety of industrial business-to-business markets. He joined Bison in 2008 as regional sales manager progressing to his current role in November 2015 as the executive vice president of Go To Market. Burch has an MBA from Kent State University and a BS in general engineering from the University of Illinois.

FOR MORE INFORMATION: www.bisongear.com

International VDI Congress “Drivetrain for Vehicles” Is July 5-6 in Bonn

At the international VDI Congress “Drivetrain for Vehicles” on • Prof. Dr.-Ing. Karsten Stahl, full professor, Institute of Machine July 5-6, 2017, the Congress will place its focus on innovations and Elements, director of Gear Research Centre (FZG), Technical novelties in the field of transmission development as well as the University of Munich, Garching electrification of the powertrain and the challenges that are inher- ent with the design of conventional transmissions. This year, the Facts and Figures: international get-together of experts in the transmission field is at • More than 80 international expert lectures the World Conference Center in Bonn for the first time. • More than 1,500 participants The electrification of the powertrain implies one of the mega • More than 100 international exhibitors at the trade show trends in transmission development. This technical advancement • Two context-specific conferences held in parallel: “Control Solutions has affected the entire automotive industry and affects everyone for Transmissions” and “Transmissions in Commercial Vehicles” from the manufacturers, the suppliers, and subcontractors, up to the drivers themselves. Making the switch to electrical operation entails a One of the highlights is the accompanying trade show, which has number of challenges in the adaptation of transmission concepts and grown over the years to become a major marketplace. More than 100 elements and likewise compromises the layout of IT security in the organizations from around the world present their solutions covering vehicle drive system. In addition, the modification of the powertrain all aspects of the automotive transmission and its components. through various electrified components offers different ways of how The conference “Control Solutions for Transmissions” will be held to shape the entire vehicle. simultaneously where improvement potentials in the transmission The predicted impact and influence of the new electric and hybrid control will be addressed that originate from new actuator and sen- vehicles on the market in terms of suitability for mass production sor systems as well as software developments. The VDI conference will provide enough food for discussion. The focus is placed on the “Transmissions in Commercial Vehicles” will be run at the same time. requirements that electrified drive systems have to fulfill and how they The focus will be on innovations and trends in the logistics sector inspire manufacturers and suppliers in engineering and mechatronics and developments in conventional and electrified drive systems, as to propel innovative developments to new heights. well as considering the challenges in the manufacturing process that Top speakers include: go along with that. • Dipl.-Ing. Arnold Paluch, general director, Global Manual VDI Wissensforum GmbH, headquartered in Düsseldorf, has Transmission & Electrification, Adam Opel AG, Rüsselsheim been one of the leading educational institutions that promotes • Alexander Mankowsky, social scientist, Daimler AG, Stuttgart knowledge transfer among engineers as well as key technical and • Dr.-Ing. Stefan Sommer, CEO ZF Friedrichshafen AG, managerial staff in the technology field. More than 1,300 annual Friedrichshafen events cover the whole range of relevant sectors. They offer seminars • Prof. Christoph Ebert, managing director, Vector Consulting and technology forums, modular training courses with subsequent Services GmbH, Stuttgart certification, as well as expert meetings and congresses. In light of

Companies wishing to submit materials for inclusion in Industry News should contact the editor, Molly J. Rogers, at [email protected]. Releases accompanied by color images will be given first consideration. 8 gearsolutions.com

GS-Book.indb 8 4/25/17 3:59 PM this, ongoing market research combined with an extensive network of experts and the strong expertise of the VDI (Verein Deutscher Full Service Standard & Custom Ingenieure) (Association of German Engineers) ensures the events’ Gear Production superior quality. FOR MORE INFORMATION: ™ www.transmission-congress.com • www.vdi-wissensforum.de P ET OL Gear i n g

Gear Dynamics and Gear Noise Short Course Gear Milling of external involute gear forms at Ohio State September 18-21 including, but not limited to: • Helical – Double Helical – Spur – Herringbone The upcoming four-day Gear Dynamics and Gear Noise Short Metric Course on the Ohio State campus (at the Fawcett Center) is tooth forms September 18-21, 2017. Over the years, these courses have been ••ReverseUp to AGMA Engineering 12 Quality of StandardLevel (Standard & 2000-A88) extremely successful since they provide the attendees with a solid background in the fundamentals, while yielding insights into the Tooth Profile Modification for prototypes or practical side such as how to reduce noise and dynamic loads of production gears, how to interpret data, and more. • The course content is based on the results of 30-plus years of gearing research, problem solving, and consulting work at the •Custom Metrology ZEISS GearLab that is recognized as the most comprehensive gear PRISMO® Navigator with rotary axisq research center in the U.S. Likewise, the research and educational efforts of the Acoustics and Dynamics Laboratory are widely known around the world. Colleagues who are new to the gearing world or about to undertake real-life gear dynamics or noise projects, could benefit from the course. It will allow engineers involved with design, computational, or experimental work to quickly get up-to-speed on extremely pertinent gearing pDMG and dynamics topics. DMC 160 FD duoBlock® Note: This course usually fills up about two months in advance, 5 axis vertical mill-turn so plan to register early. The early-bird registration rate is valid if the fees are paid by August 1, 2017.

FOR MORE INFORMATION: www.nvhgear.org

ALD Receives Contract for Third SyncroTherm System Slated for the North American Aerospace Industry

ALD Vacuum Systems Inc. in Wixom, Michigan, has received a purchase order from a North American-based aerospace manufacturer for a SyncroTherm® brand, fully integrated vacuum heat-treating system. This system will primarily perform low-pressure carburizing (LPC) and is the direct replacement for two vintage batch IQ atmosphere carburizing furnaces. In addition to LPC, the unit Capacity also will perform austenitizing, vacuum brazing, gas quenching, cryogenic treating, and tempering. This fully integrated, compact heat-treating cell will be among the first known captive LPC opera- •2" to 16" OD pinions up to 64" in length tions west of the Mississippi. •Up to 56" OD gears and 20" face width ALD continues to expand the SyncroTherm presence in the heat- •Metrology:~ ISO 9001 (X)62" Quality (Y)118" System (Z)55" Certified ~ treating world with applications for the automotive drivetrain, con- Manufacturing quality products since 1927 sumer tool, textile, bearing, commercial heat-treating, hydraulics, aerospace, and fuel systems markets. This will be the third SyncroTherm to support the needs of NADCAP (National Aerospace and Defense Clifton, Texas • www.gearench.com Contractors Accreditation Program), and it will be comprised of [email protected] • (254)675-8651 • fax (254)675-6100 five independently controlled hot zones, each rated for load sizes of MAY 2017 9

GS-Book.indb 9 4/25/17 3:59 PM 24-inch by 20-inch by 9-inch high and up quench and incorporate support processes such tracking and complete process history reten- to 110 pounds. SyncroTherm systems oper- as cryogenic and temper sequences in a fully tion are key functions within the system along ate using recipe-selectable high-pressure gas automated, lights-out fashion. Individual part with a consistent process cadence.

FOR MORE INFORMATION: www.aldvac.com

Kapp Niles Announces New Metrology Division

Kapp Niles recently announced the expansion in Aschaffenburg, Germany, leverages the Kapp Niles Metrology designs and builds of its product portfolio by adding high-end wealth of experience and technology of R&P customized large 4- and 5-axis analyzers built metrology solutions. The newly found divi- Metrology GmbH whose employees and to VDI/VDE class I. A derivative of the sion, Kapp Niles Metrology GmbH, based management join the new company. technology is a transportable 3-axis device for analyzing gears in the shop on cutting machines or even in a gearbox. An expansion into the metrology sector complements the Kapp Niles product portfolio for gear and profile grinding up to 8 meters. The new company also will provide sales The and support in Europe and Asia for the smaller gear analyzers and products of Penta Gear Power Metrology of Dayton, Ohio, which joined Kapp Technologies in 2015. Both Kapp Niles 2 Metrology GmbH and Penta Gear Metrology of One are innovators in their respective sectors and join forces for further advancements. Industry Your Objective: 4.0 is just one of the areas customers will ben- One face in perfect alignment with another. For infinity. efit from these extensive integrated solutions to the gear industry.

FOR MORE INFORMATION: www.kapp-niles.com

Solar Atmospheres of Western PA Awarded Rolls Royce No problems. No distress. No delays. Approval That’s the same objective you have for choosing your gear producer. Circle Gear’s objective is to engage with every customer’s objectives. One to 1000 gears Customer designed or reverse engineered Gearbox repair, rebuild or redesign OEM or end-users ISO 9001:2015 Certified

1501 S. 55th Court, Cicero, IL 60804 (800) 637-9335 Solar Atmospheres of Western PA (SAWPA) (708) 652-1000 / Fax: (708) 652-1100 recently announced it was awarded Rolls [email protected] Royce Approval. The adherence to strict spec- www.circlegear.com ification requirements, process execution, and a daily commitment to quality processing are Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears • Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears • evident among all employees at Solar. Worm and Worm Gears • Racks • Sprockets • ISO Certified “The successful certification of our SAWPA facility is a testament to our commitment to Partnering with QualityReducer to provide Gearbox repair, rebuilding and reverse-engineering. continual improvement and to growing our business within the aerospace industry,” said 10 gearsolutions.com

GS-Book.indb 10 4/25/17 3:59 PM Quality Manager Susan Generalovich. “We fication will allow and the added confidence are excited about the opportunities this certi- it provides to our customers.”

FOR MORE INFORMATION: www.solaratm.com

Advanced Heat Treat Corp. Announces New President

Advanced Heat Treat Corp. (AHT) recently “Advanced Heat Treat Corp. is at the announced the appointment of Mikel Woods forefront of heat treating services,” Woods as president. Woods previously served as said. “Successful companies turn to AHT on senior vice president and has been with AHT a daily basis to find answers to their tough- since 2005. Gary Sharp will be stepping est surface treatment issues. I am excited TECHNOLOGY down as president but will remain active in to be part of the AHT family, building on the company and will continue to serve as AHT’s well-known processes and continued CEO and owner. partnership. Working with our customers “Mikel has been leading AHT since I semi- from the conceptual stage to production, Advanced retired and has taken the responsibility of all we strive to maximize product value and of the day-to-day issues,” Sharp said. “In his performance. With the need for materials to role as president, he will continue to coor- hold up under tough conditions, more and Technology. dinate the major functions of the business. more enterprises require the capability and His results-oriented approach, problem solv- service that AHT delivers, and I’m proud to The Focus of ing, sound business judgment, and ability to be part of that. I look forward to leading the think strategically will play a pivotal role in AHT family with the core values that Gary Our Innovations extending our track record of servicing our has instilled in every one of us and hope to • Shortest cycle times customers with UltraGlowing results, while make him proud.” • Longest MTBF helping us continue to grow.” Prior to AHT, Woods held several leader- • Lowest cost/piece Under Woods’ leadership, AHT has main- ship positions at Husco International, the • Fine & polish grinding tained its position as a worldwide leader in leader in developing hydraulic and electro- nitriding, with locations in Iowa, Alabama, hydraulic control systems for mobile equip- • Twist control and Michigan. Service offerings have been ment applications. He served as program expanded to include UltraOx® for corrosion manager, accounting and financial reporting resistance, which has benefited numerous manager and senior financial analyst for the industries from firearms to oil and gas. He Industrial Products Division. Woods has a has also been instrumental in refocusing the bachelor’s degree in accounting from The leadership team to follow Traction key prin- University of Iowa and executive MBA from ciples, to name a few of his accomplishments. the University of Wisconsin.

FOR MORE INFORMATION: www.ahtweb.com

The Hardinge Machine Technology Show Is June 6-8 In Elmira, New York TECHNOLOGY AUTOMATION

The Hardinge Group is hosting its Hardinge The show opens at noon June 6 and runs SCAN THE CODE TO LEARN MORE Machine Technology Show (HMTS), June through June 8. 6-8, 2017, at its Elmira, New York, headquar- June 6 will be dedicated as a “Local Youth ters. This show will feature products from Education Day” as the company has invited the full Hardinge Group portfolio including students from local schools and technical BOOTH #1135 turning, milling, grinding, and workholding. training centers. The main show dates will See live cutting demos, new technology from be June 7-8. Hardinge and its sponsors, its U.S. manufac- HMTS is a great place to network with turing facility, seminars, and prize giveaways. a variety of companies in the industry. Go The show also will have several vendors online to register for free and find a full list on-hand from the machine tool and technol- of participating companies, details on the ogy industry. show, and accommodations. Reishauer Corporation • (847) 888-3828 • www.reishauer.com FOR MORE INFORMATION: www.hardinge.com MAY 2017 11

GS-Book.indb 11 4/25/17 3:59 PM Ipsen USA Provides Comprehensive Support for Heat-Treating Systems Shipped Around the World

Focused on providing advanced equipment and comprehensive support to industries around the world, Ipsen USA recently shipped eight vacuum heat-treating systems to customers in Costa Rica, India, Germany, and the United States. This equipment will be used to support the additive manufacturing, aerospace, medical, MIM, and tooling industries. Several customers also took advantage of Ipsen’s full-scale support offerings, including Ipsen U training, spare parts kits, and installation. The vacuum furnaces shipped included a We’ll Keep You vertical MetalMaster® furnace with a 5,000- pound (2,268 kg) capacity, a custom-built furnace for debinding and sintering, horizontal MetalMaster and TurboTreater® furnaces, a Titan® DS (debinding and sintering) furnace, and several H2- and H6-sized Titan vacuum furnaces equipped with the SAFE PdMetrics® software platform for predic- Forest City Gear’s exceptional reliability means tive maintenance. This software platform you’ll sleep better at night. Safeguard your next gear securely connects to a network of integrated sensors on the furnace to gather and analyze production project. data, run algorithms, and provide real-time 815.623.2168 diagnostics that improve the health and www.forestcitygear.com integrity of the equipment. To best support these industries, Ipsen’s global ICS (Ipsen Customer Service) team BOOTH #606 Excellence Without Exception facilitates system installations, as well as provides expert training, startup assistance, and 360-degree support throughout the entire life span of the equipment for any brand.

FOR MORE INFORMATION: www.IpsenUSA.com

Toyoda Wins 2017 Automotive News PACE Award

JTEKT Toyoda Americas Corporation was named a 2017 Automotive News PACE Award winner at an awards ceremony April 3 in Detroit, Michigan. The prestigious award recognizes automotive suppliers for superior innovation, technological advancement, and business performance. Toyoda was recognized for its high-speed synchronization technology on the GS300 and GS700 multitasking horizontal machining centers. This innovative process has reshaped the standard gear manufacturing 12 gearsolutions.com

GS-Book.indb 12 4/25/17 3:59 PM TOOLING

process that requires a single part to travel from machine to machine — thereby sig- Superior nificantly increasing concentricity error. Comparatively, Toyoda’s innovation takes five processes traditionally spread across five Tooling. separate machines and integrates them into one machine while using high-speed syn- • Diamond Rolls chronization to produce parts with more • Wheels made to order accuracy, less time, less cost, and less risk to in days rather than the manufacturer. weeks or months “In this ever-challenging industry, Toyoda is committed to proactively tran- • Custom workholding scending industry standards — striving fixtures, mechanical or to develop new products and processes hydraulic that will better the manufacturing com- munity,” said Howard Michael, president and COO of JTEKT Toyoda Americas Corporation. “Toyoda’s Gear Skiving machines serve as an exemplary represen- tation of this philosophy. We are honored to be recognized by PACE as an organization that brings innovative technologies to the automotive industry.” The 23rd annual PACE (Premier Automotive Suppliers’ Contribution to Excellence) awards were presented by Automotive News, EY, and the Original Equipment Suppliers Association (OESA). TECHNOLOGY AUTOMATION The competition was open to suppliers that contribute products, processes, materials, or services directly to the manufacture of cars or SCAN THE CODE TO LEARN MORE trucks. The Automotive News PACE Award is accepted around the world as the industry benchmark for innovation. J. Ferron, PACE director of judging, said BOOTH #1135 this year’s awards recognize the technology vincing OEMs that those barriers will fall in pressures the industry is facing as automakers time to launch vehicles,” Ferron said. push for fuel economy gains and autono- JTEKT Toyoda Americas Corporation mous-drive capabilities. earned an Automotive News PACE Award “Innovating products and processes for following an extensive review by an indepen- these future needs means surmounting today’s dent panel of judges including a comprehen- technical barriers while simultaneously con- sive written application and a site visit. Reishauer Corporation • (847) 888-3828 • www.reishauer.com FOR MORE INFORMATION: www.toyoda.com MAY 2017 13

GS-Book.indb 13 4/25/17 3:59 PM Seco/Warwick Wins “Production Company of the Year” in the “Leaders of the Manufacturing World” Competition

The title given to Seco/Warwick is recognition of a company’s expertise, innovative technologies, and solutions in the manufacturing sector while achieving significant growth dynamics. “Seco/Warwick is not afraid to reach for IT solutions from the world’s top shelf, which captured the attention of the competition jury,” said Paweł Wyrzykowski, CEO of the Seco/Warwick Group. “With our knowledge and experience, we contribute to the development of the manufacturing market and the most interesting solutions for Industry 4.0. We know what breakthrough technologies are and have a vision for their creation and application in industrial production.” Innovative metal heat-treatment solutions by Seco/Warwick have revolutionized the world’s metallurgical industry. Seco/ Warwick is among the top five giants of this field due to the use of disruptive technology and constant cooperation with universities in Europe and abroad. Today, Seco/Warwick has about 30 trademarks and 50 patents, dozens of awards and technical certifica- tions, and nearly 4,000 solutions in operation with customer in 70 countries. At the III Innovative Manufacturing Forum during the presentation of “Mixed Reality in Industry 4.0 — Redefining Reality in Industrial Production,” Seco/Warwick presented its latest innovation — Seco/Lens, an MANDO G211 application using augmented reality technology, based on the latest HoloLens holographic Segmented mandrel for gear cutting computer. It is the first such application in Poland and one of the first in the world used in heavy industry. Segmented mandrel with slim interference contour “Digital technology is the basis for the development of the fourth industrial revolu- Rigid radial clamping with pull-back effect tion we are currently witnessing,” said Dariusz We have all Largeheard theclamping phrase WORKrange andSMARTER, vibration NOT dampening HARDER. Makes Piotrowski, board member at Microsoft in sense, right? In times of economic uncertainty, it’s SMART to maximize the due to vulcanized clamping bushings Poland. “The driving force behind these con- efficiency of every one of your resources. Workholding technology- thatal cepts are concrete solutions that utilize the lows you to go from in a matter of seconds In-stockO.D. standard to I.D. tosegmented 3-jaw clamping clamping bushings Internet of Things (IoT), cloud computing, without readjustment can maximize the production – and the profits – of your augmented reality, and advanced analytics. existing machines. Three Nowend-stop that is WORKINGlevels SMARTER. Seco/Warwick is at the forefront of the digital Integrated flushing channels revolution in the manufacturing industry, demonstrating how to effectively leverage digital tools to create innovative solutions and models. Based on Microsoft technol- 1.800.281.5734 ogy, the company has created an integrated Germantown, WI USA ecosystem of data, applications, and systems www.hainbuchamerica.com that support its growth and improve the efficiency of processes, especially those of an innovative nature.” 14 gearsolutions.com

GS-Book.indb 14 4/25/17 3:59 PM “This is a new era of Seco/Warwick equip- technology to our production, maintenance ment application — the interaction era,” and service of Seco/Warwick systems, has said Katarzyna Sawka, Seco/Warwick global become reality and is going to result in marketing director. “Cyber-goggles, so far substantial benefits for us and our clients, associated more with the gaming world than for example, by increasing the mobility, the industry, have been embedded in the effectiveness, and shortening our technicians real world. The implementation of virtual reaction times.”

FOR MORE INFORMATION: www.secowarwick.com

Big Kaiser Launches World’s Smallest Hydraulic Chuck for HSK-E25 Machine Spindles SERVICE

Big Kaiser announced the introduction of the world’s smallest hydraulic chuck for HSK- Customer E25 machine spindles, thus completing its extensive range of Big Kaiser Super Slim hydraulic chucks. Service. The Super Slim type of hydraulic chucks a gauge length of 1.575 inch (40 mm) makes (HDC) are the ideal toolholders for precision it compact and precise. Each tool is preci- The Focus of finishing processes in confined areas with sion balanced for speeds up to 60,000 rpm drills, reamers, ball mills, end mills, diamond and runout accuracy of less than 3 microns Our Innovations reamers, and grinding tools. Cutting tools (.00012 inch) at 5xd. • Wide range of spare parts with shank diameters of 3 or 4 mm can be “Our HSK-E25 toolholder lineup now stocked in Elgin, IL clamped directly and are ideally suited for includes Big Kaiser’s high precision, low • 17 technicians in the US high-speed micro-machining applications in runout, hydraulic chucks,” said Jack Burley, the automotive, aerospace, medical, die, and vice president of sales and engineering at Big • Technical help over electronics industries. Kaiser. “These ultra-precise hydraulic chucks, the phone Big Kaiser designed the Super Slim HDC with their extremely slim design, are perfectly to require only a single wrench for clamping suited for high-precision finish milling work and unclamping, a much easier and safer on ultra-high speed spindles on machines solution compared to heat-shrink toolholders. with small work envelopes.” These chucks can clamp ultra-small end mills The Super Slim HDCs for HSK-E25 and drills directly, without needing a reduc- machine spindles are available from stock; tion sleeve. The external body diameter of the they are also available for the HSK-E 32 and chuck nose is a mere 0.551 inch (14 mm), and HSK-E 40 spindle types.

FOR MORE INFORMATION: www.us.bigkaiser.com

New Version of KISSsoft 03/2017 Is Available TECHNOLOGY AUTOMATION

On April 24, 2017, the new version of KISSsoft SCAN THE CODE TO LEARN MORE 03/2017 was released with a number of innovations. The following highlights are available: • Reliability evaluation of gear units on system level. • Simplified modeling using predefined gear stages BOOTH #1135 in KISSsys. • Calculation of root stresses with FE for cylindrical gears. • Variation calculation for the inner geometry of bearings. • Determination of the unbalance response during the vibration calculation of shafts. Reishauer Corporation • (847) 888-3828 • www.reishauer.com FOR MORE INFORMATION: www.kisssoft.com MAY 2017 15

GS-Book.indb 15 4/25/17 3:59 PM Finish First

New Genesis® GX Series takes gear grinding quality and productivity to an entirely new level, with single-tool setup, integrated automation, twist- controlled and polish grinding – and Closed Loop networking with GMS® inspection.

www.gleason.com/GX

Booth 1411

GS-Book.indb 16 4/25/17 3:59 PM Jim Bregi American Chairman, AGMA Board of Directors, Gear Manufacturers President, Association Doppler Gear Company

A Historical Perspective on Change

The 2017 AGMA Annual Meeting focused of gear shaving machines in Europe and ther and his company felt the same way, and on the future of our businesses, industry, the rest of the world as well. Back at home, it justified their membership just as it does and the world we live in. It was filled with he was accumulating dozens of patents in mine today. Those of us in the gear industry fantastic speakers on topics of generational gear generation and finishing. Ben was active need a deep understanding of the horizontal demographics, disruptive trends, and a con- in AGMA standards development. He gave integration (due to mergers and increased nected, rapidly changing world. One of the technical lectures in South America, and he capabilities within existing gear companies) biggest benefits of attending the Annual even traveled to Russia during a brief thaw and the vertical integration (power transmis- Meeting is discussing the real-world chal- in the Cold War. In 1966, he was promoted sion systems from beginning to end) as well as lenges and applications of these presentations to president of National Broach. He stayed disruptive and emerging technologies. Those with industry peers. It is fascinating to hear active in the gear industry after retirement, who stand still have shrinking opportuni- how leaders, managers, and technical experts most notably, with my father’s purchase of ties, and those who are willing to invest and are dealing with change in their own orga- Doppler Gear Company in 1986. innovate have growth potential. AGMA is the nizations and how they view the future. My So, what does this have to do with the 2017 primary source for information on the gear own analysis was strongly influenced not by AGMA Annual Meeting this past March? industry and is working to assist companies the present, but by the past. Primarily, the topic of change. I heard a lot and people that innovate. Recently, my 100-year-old grandmother of feedback on the “looking ahead” and “the So, what insights can be drawn from our passed away, and I was given a box full of my coming age” presentations. A few people I grandparents’ meeting in 1943 and our meet- grandfather’s documents from a lifetime in talked to shared a sense of dread about the ing this year? Innovate, educate, and embrace. gear manufacturing. In that box was a 1943 future. Understandably so, considering pre- We are making the future, and our grandchil- AGMA Annual Meeting program. My grand- senters were stating: “If you haven’t started dren will be watching. father, Ben Bregi, was an engineer at National now, you are already behind and always will Broach and Machine Tool, and his notes are be” and “you won’t be able to drive your own penciled in the margins. All events are listed car (it will drive itself)” and “there will be no in “Eastern War Time,” considering we were such thing as privacy as we know it.” one-third of the way into World War II. Perhaps it is human nature to see one’s The first address of the afternoon was titled current epoch and assume that it is the most “Gears and the National War Effort” and was volatile, most disruptive, and most fraught given by a group from the War Production with peril. That’s not to say we don’t live Board. Can you imagine the state of manu- in disruptive times, but to overestimate the facturing at the height of World War II? downside and underestimate opportunity is The innovation and emerging technologies a mistake. If you want to know about fun- being discussed at these meetings? The scale damental life-altering change, asking your of gear production for airplanes, ships, sub- 100-year-old grandparent would be a good marines, trucks, tanks, instrument gears for place to start. In their lifetime, technology Norden bombsights, and everything else? progressed from Ford Model T’s to regular Judging from the presentation topics of 1943, flights of the space shuttle. the gear industry played an immense role in The value in looking back through my the war effort. grandfather’s life is that I find my own uncer- As I dug through that cardboard box, I tain future less worrisome. Those who have could retrace the steps of my grandfather’s creativity and natural curiosity will not only career and, in a way, the gear industry as find a way to live in the world of tomorrow, but a whole. After the war, he traveled exten- they also will innovate and create it. AGMA sively. Europe was rebuilding industry and is full of those people and participating with Ben Bregi’s 1943 Annual Meeting program can be viewed infrastructure with the help of the Marshall them is an excellent way to advance yourself in its entirety at www.dopplergear.com/agma-annual- Plan, and National Broach was selling a lot and your organization. I’m sure my grandfa- meeting-1943/ MAY 2017 17

GS-Book.indb 17 4/25/17 3:59 PM Upcoming AGMA Advanced Course Gear Manufacturing & Inspection: Methods, Practices, Application, and Interpretation for the Design Engineer June 20-22, 2017 | St. Augustine, Florida Instructor: Raymond J. Drago Learn key factors in the inspection process that lead to better design of gears. Develop a broad understanding of the methods used to manufacture and inspect gears. Discover how the resultant information can be applied and interpreted in the design process. This course includes a tour of Riley Gear in St. Augustine, Florida.

LEARNING OBJECTIVES: • Identify methods of manufacturing external and internal spur, ing the inspection data for purposes other than simply determining single and double helical, and bevel and worm gears. accept/reject status. • Describe the methodology and underlying theory for basic manu- • Specify the data required to control both the manufacturing and facture and inspection of each. inspection processes on an engineering drawing. This includes • Discuss the “features” associated with each manufacturing method both the data to be defined and the presentation of the data on with regard to their impact upon and their ability to refine, guide, the engineering drawing. and optimize the design process. • Discuss the basics of a variety of destructive and nondestructive • Take two views of the same results: meeting a “specification” and inspection tests, including their underlying theory, application tech- determining acceptability for a specific application, and interpret- niques and, most importantly, interpretation of the resultant data.

$1,495 First registrant per member company | $1,295 additional registrant FEE: $1,995 First registrant per non-member company | $1,795 additional registrant

AGMA Presented Awards at the 2017 Annual Meeting Distinguished Service Award

Michael Goldstein of Goldstein Gear Machinery and publisher and editor-in-chief of both Gear Technology magazine and Power Transmission Engineering magazine received the Distinguished Service Award from AGMA board president, Dean Burrows. Goldstein received this for his career contributions to the gear industry. Chairman’s Awards

Joe Arvin, president of Arvin Global Solutions, received a Chairman’s award from AGMA board president, Dean Burrows. Arvin received the award for his contributions to the gear industry through his long career. “Joe could be considered the father of the AGMA Gear Expo,” Burrows said as he presented the award. “Gear Expo held it first event in Chicago in 1987 with the help of Joe, and we all know what Expo has become since then.” Thomas “Buzz” Maiuri, senior product manager at The Gleason Works, received a Chairman’s award for his years of contributions to the AGMA Technical Committees and his four years as chairman of the AGMA Technical Division Executive Committee. “Through the years, Buzz has contributed his own work and research to the gear manufacturing industry,” Burrows said. “He has authored technical papers, including a 2008 FTM paper on hob tool life technology, articles, and webinars on various gear-related subjects. He has also participated in many gear seminars for AGMA and SME, speaking on various gear-related topics.”

American Gear Manufacturers 18 gearsolutions.comAssociation

GS-Book.indb 18 4/25/17 3:59 PM AGMA Welcomes Incoming Board Members Michael Engesser, President, Reishauer USA Michael Engesser began his professional career with Reishauer AG, Switzerland, in 1989 as an application engineer in thread grinding. He received his bachelor’s degree in mechanical engineering from ZHAW School of Engineering, Switzerland. In 1991, Engesser moved to Reishauer USA as product manager for thread grinding machines. He established Reishauer’s hob profile grinding machines at Pfauter-Maag Cutting Tools. In 2001, with the launch of Reishauer’s next generation of gear grinding machines, he emerged leading key accounts within North American automotive. He expanded his expertise in 2006 moving back to Reishauer AG as CMO to run global sales. In 2011, he returned to Reishauer USA in his current role of president. Mike McKernin, President, Circle Gear and Machine Company Mike McKernin has been involved in the gear industry for 32 years and has spent the last 28 at Circle Gear and Machine Company in Cicero, Illinois, where he serves as president. When McKernin started at Circle Gear, the company consisted of seven skilled machinists manufacturing custom gears from a tiny, overcrowded shop in Chicago. The company has since grown to more than 60 employees, producing high-quality gears of all configurations, in a 125,000-square-foot production facility. Being directly involved in the accelerated growth of a small company, McKernin has had the opportunity to experience every aspect of the organization from executive strategic planning to machine tool operator and every position along the way. His greatest professional satisfaction comes from creating solutions to mechanical problems and developing relationships during the process. McKernin holds a bachelor’s degree from Bradley University in manufacturing engineering technology. Born and raised in Chicago, he appreciates all of the available potential living and working in a great city. Cory Ooyen, President, Global Gear and Machining LLC Cory Ooyen joined Global Gear in November 2006 and was hired to assume full P&L responsibility of the company and lead the company’s sales growth and diversification efforts. Prior to joining Global Gear, Ooyen served as the manufacturing operations manager for a high-volume auto- related precision machining company that expanded from $20 million to $85 million in sales during his 18 years with the company. Ooyen’s industry background includes management of specialized machining operations, sales and engineering, and new process development activities. He has 35 years’ industry experience and has been trained in operational finance and management, specialized tooling applications, lean operations, the Toyota Production System, and operational metric design. Greg Schulte, President, Bonﬁ glioli USA Greg Schulte is president of Bonfiglioli USA, a leading manufacturer and distributor of gearmotors, drive systems, and planetary gearboxes for industrial processes, automation, mobile machinery, and renewable energy applications. He joined Bonfiglioli in 2002 as sales manager of the Mobile Solutions division, North America, prior to becoming the vice president of sales. He surpassed the company’s aggressive growth strategy and sales grew by over 1,000 percent, giving the company a dominating presence in the U.S. and leading the way to further development and expansion. In 2008, Schulte became president of Bonfiglioli USA. Under his leadership, the company has seen consistent year-over-year growth and has become the best-performing branch within Bonfiglioli Group worldwide. Both he and the company have been recognized for leadership and growth during his tenure, including Schulte’s nomina- tion as Ernst & Young’s Entrepreneur of the Year (2009) and the company’s numerous awards and nominations for growth including Inc. 5000 (2014 nominee), Fast 55, Emerging 30, Tri-state Success Award, Thoroughbred Award, Manny Award, and Green Energy Award. Schulte has been an active member of AGMA and has served on the AGMA Foundation Board of Trustees. He is an active volunteer with local nonprofit organizations as well.

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 MAY 2017 19

GS-Book.indb 19 4/25/17 3:59 PM 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]. Events are open to AGMA members only. Not a member? Send an email to [email protected].

Wind Turbine Gear Committee Meeting — May 15 WebEx Metallurgy and Materials Committee Meeting — May 16 WebEx Strategic Resources Network (SRN) Event — May 16-18 Tulsa, Oklahoma Computer Programming Committee Meeting — May 18 WebEx Sound & Vibration Committee Meeting — May 22 WebEx MAY Helical Gear Rating Committee – Subcommittee 925 — May 23 WebEx Technical Division Executive Committee — May 24-25 Alexandria, Virginia Nomenclature Committee Meeting — May 26 WebEx Metallurgy and Materials Committee Meeting — May 30 WebEx

JUNE Wormgearing Committee Meeting — June 15 WebEx Plastics Gearing Committee Meeting — June 15-16 Detroit, Michigan Gear Manufacturing and Inspection Education Course — June 20-22 St. Augustine, Florida Helical Gear Rating Committee – Subcommittee 925 — June 20 WebEx Materials & Metallurgy Committee Meeting — June 22 WebEx Your requirements are Kapp solutions. Computer Programming Committee Meeting — June 22-23 Alexandria, Virginia Helical Gear Rating Committee — June 27 WebEx With the KX260 TWIN you can focus on what is important. AGMA LEADERSHIP Kapp continous generating grinding with Kapp single or multi-rib dressers. Jim Bregi: Chairman Nitin Chaphalkar: DMG Mori USA Doppler Gear Company Michael Engesser: Reishauer Corporation John Cross: Treasurer ASI Technologies Inc. David Long: Chalmers & Kubeck Inc. 2 work spindles for idle time as little as 3 sec. John E. Grazia: Chairman, BMEC Michael McKernin: Circle Gear and Machine Company GearTec Inc. Integrate any automation type from any supplier Global Gear & Machining, LLC Todd Praneis: Chairman, TDEC Cory Ooyen: Cotta Transmission Company, LLC Carl D. Rapp: The Timken Company Automatic exchange and checking of clamping arbor Dean Burrows: Chairman Emeritus Power for heavy duty truck gears, speed for mass production EXECUTIVE COMMITTEE Gear Motions Inc. Tania Sabados: Rapid Gear Andrea Scanavini: Somaschini North America Closed-loop process control via on-board or remote inspection Matt Croson: President Greg Schulte: Bonﬁ glioli USA

Amir Aboutaleb: Vice President, Technical Division BOARD OF DIRECTORS Brian Schultz: Great Lakes Industry, Inc. Jenny Blackford: Vice President, Marketing Jill Johnson: Director, Member Services George Thomas: Bison Gear & Engineering Corp. What color do you want? Call for a quote. Casandra D. Blassingame: Director, Education Hastings Wyman: Klingelnberg America, Inc. SENIOR STAFF KAPP Technologies General requests: [email protected] | Membership questions: [email protected] | Gear Expo information: [email protected] 2870 Wilderness Place Boulder, CO 80301 Technical/Standards information: [email protected] | AGMA Foundation: [email protected] kapp-niles.com [email protected] (303) 447-1130 precision for motion. 20 gearsolutions.com

052017_KappAdd_TBC.indd 1 4/12/2017 2:10:33 PM GS-Book.indb 20 4/25/17 4:00 PM Wind Turbine Gear Committee Meeting — May 15 WebEx Metallurgy and Materials Committee Meeting — May 16 WebEx Strategic Resources Network (SRN) Event — May 16-18 Tulsa, Oklahoma Computer Programming Committee Meeting — May 18 WebEx Sound & Vibration Committee Meeting — May 22 WebEx Helical Gear Rating Committee – Subcommittee 925 — May 23 WebEx Technical Division Executive Committee — May 24-25 Alexandria, Virginia Nomenclature Committee Meeting — May 26 WebEx Metallurgy and Materials Committee Meeting — May 30 WebEx

Cutting Tools Committee Meeting — June 5 WebEx Aerospace Gearing Committee Meeting — June 5-6 Salt Lake City, Utah Helical Gear Rating Committee Meeting — June 6 WebEx Lubrication Committee Meeting — June 8 WebEx Flexible Coupling Committee Meeting — June 12-13 Alexandria, Virginia Gear Failure Analysis Education Seminar — June 12-14 Big Sky, Montana Bevel Gear Committee Meeting — June 14 WebEx Wormgearing Committee Meeting — June 15 WebEx Plastics Gearing Committee Meeting — June 15-16 Detroit, Michigan Gear Manufacturing and Inspection Education Course — June 20-22 St. Augustine, Florida Helical Gear Rating Committee – Subcommittee 925 — June 20 WebEx Materials & Metallurgy Committee Meeting — June 22 WebEx Your requirements are Kapp solutions. Computer Programming Committee Meeting — June 22-23 Alexandria, Virginia Helical Gear Rating Committee — June 27 WebEx With the KX260 TWIN you can focus on what is important. Kapp continous generating grinding with Kapp single or multi-rib dressers.

2 work spindles for idle time as little as 3 sec. Integrate any automation type from any supplier Automatic exchange and checking of clamping arbor Power for heavy duty truck gears, speed for mass production Closed-loop process control via on-board or remote inspection

What color do you want? Call for a quote.

KAPP Technologies 2870 Wilderness Place Boulder, CO 80301 kapp-niles.com [email protected] (303) 447-1130 precision for motion.

052017_KappAdd_TBC.indd 1 4/12/2017 2:10:33 PM GS-Book.indb 21 4/25/17 4:00 PM JAMES CAROSIELLO MATERIALS SENIOR MATERIALS SPECIALIST MATTER TIMKENSTEEL CORPORATION INDUSTRY STANDARDS FOR STEEL CLEANNESS With limitations on today’s industry standards for measuring steel cleanness, using the right mix of methods should be carefully considered.

THE CORRELATION OF STEEL CLEANNESS TO THE PERFOR- ers. These methods also have limitations in that higher ultrasonic mance of parts made from steel has been recognized by engineers for frequencies are needed to detect the smaller inclusions of very clean many years. This has been especially true in the design and manufac- steel. (While use of a 10 MHz testing frequency was common in the ture of anti-friction bearings and the establishment of the cleanness early development of ultrasonic cleanness testing, 50 MHz is now in level for needed fatigue life as “bearing quality” steel. But cleanness is regular use.) This diminishes the advantage of these methods in that important for gears as well, with many gear manufacturers adopting higher frequencies have lower penetration resulting in smaller volumes bearing-quality cleanness requirements. From the design perspective inspected. As ultrasonic methods continue to evolve, however, more of the bearing and gear engineer, the challenge is deciding how much use of them can be expected in new and revised industry standards. cleanness the application requires and how to specify that cleanness The most powerful and relatively new way of supplementing E45 in the most meaningful way. is scanning electron microscopy combined with simultaneous energy- There are a number of industry standards that deal with the measure- dispersive X-ray spectroscopy. This method combines optical imaging ment of steel cleanness, and almost all are based on macroetch testing, of relatively large areas (compared to E45) and the chemical analysis of fracture testing, magnetic particle testing, or light optical microscopy. each inclusion detected. The latter method involves the evaluation of relatively small areas of material at 100x magnification to usually measure just the largest nonmetallic inclusions in a prescribed number of fields (worst-field method) or for higher cleanness materials with both the size and number of inclusions in a prescribed number of fields (field-counting method). However, a standard that covers all of these tests is ASTM E45 — Standard Test Methods for Determining the Inclusion Content of Steel. This standard was first issued in 1942 and has been continually updated since. It is an important tool for cleanness assessments for bearings, gears, and many other applications where stress and fatigue are key design parameters. One limitation with E45 (and other similar optical methods) is that, as steel cleanness has improved over the years, the methods described in E45 have become less discriminat- ing of cleanness. This became apparent with the advances in clean- steelmaking technology years ago and has been demonstrated by bearing and gear manufacturers by life testing of steels with similar E45 values yet produced different fatigue results. Figure 1: Pseudo-ternary phase diagram of a “clean heat” Today, there is also a growing awareness among gear manufacturers with SEV = 42.6278 max (micrometers) that gear failures due to a lack of cleanness are becoming more preva- lent as gear-manufacturing technology advances. This is primarily due to improved surface finishes reducing surface-initiated fatigue failures that then allow subsurface nonmetallic inclusions to become the mode of failure. So, while E45 is an important tool for broadly classifying steel cleanness, it does not go far enough in differentiating the cleanness of today’s very clean steels. It is, though, a good starting point to establish a minimum level for cleanness of the steel used in bearings and gears; it just needs to be augmented by other methods to create a comprehensive assessment of cleanness and its relationship to part performance. The first method to establish its usefulness in this regard was ultrasonic testing. The primary advantage of ultrasonic testing for cleanness is that volume — not just area — is being evaluated, allow- ing much more material to be inspected than the area-based methods of E45. There are several industry standards that define ultrasonic cleanness methods, but due to their complexity, they have typically Figure 2: Pseudo-ternary phase diagram of a “very clean heat” been used only by bearing steel producers and bearing manufactur- with SEV = 14.4651 max (micrometers) 22 gearsolutions.com

GS-Book.indb 22 4/25/17 4:00 PM With the traditional light optical microscopy method of E45, nonmetallic inclusions are classified into one of four categories based primarily on morphology, even though these inclusion types are widely recognized by their nominal chemical composition: manganese tomorrow’s sulfide, alumina, silicate, and globular oxide (and globular calcium sulfide in calcium-treated steels). A rating is manually determined machines by a metallographer comparing the inclusions in a steel specimen to size and frequency diagrams associated with E45. In cleaner steels, the ratings become lower but also less descriptive in terms of the total inclusion population due to the small area inspected. today In comparison, with scanning electron microscopy, a total area much greater than that of E45 can be automatically scanned. All nonmetallic inclusions are detected with their length, width, area, aspect ratio, and chemical composition captured. With the right software, the results can be expressed in terms of the traditional E45 ratings, but this categorization is unnecessary since a comprehensive nonmetallic inclusion characterization is generated. The resulting data is most useful (for application design) when expressed as the number of oxide inclusions greater than some critical size (defined by the stresses applied and the fatigue life expected of the application). The data can also be expressed in terms of extreme value statistics (SEV), which is the prediction of the most probable largest inclusion based on the frequency of the largest inclusions actually detected. The USACH 100-T4 CNC ID/OD This machine offers a variety of features These values are expressed as square-root area maximums — the precision grinding machine is ideally and options like: parameter most relevant to fatigue life. Extreme value statistics is suited for a variety of different • four motorized grinding spindles covered by ASTM E2283 and scanning electron microscopy by industries. Combining ID, OD, face, • high precision measuring probe ASTM E1245, but there is not yet an industry standard that combines taper, radii and contour grinding in • latest torque motor based B-Axis design these along with the use of energy-dispersive X-ray spectroscopy for one chucking. Thanks to the generous • automation inclusion characterization. cross axis travel of 500 mm/19.68” • high precision hydrostatic work Additional information that only scanning electron microscopy with (X-Axis), the machine processes parts head swivel B1-Axis spectroscopy provides is the pseudo-ternary phase diagram of inclusions up to 450 mm/17.7” in diameter at • Siemens or Fanuc control based on their relative chemical compositions. For example, the chemical a weight capacity up to 272 kg/500 lbs. composition of oxide inclusions is often expressed as a phase diagram with aluminum, magnesium, and calcium. Knowing the relative propor- tions of inclusion compositions and the number of these inclusions can let us help you findthe right grinding solution guide the steelmaker, as well as the bearing and gear manufacturer, in optimizing the inclusion types for specific applications. 800-843-8801 Note: To demonstrate the value of scanning electron microscopy with spectroscopy, two “bearing quality” heats with similar chemical www.HardingeGrindingGroup.com compositions and almost identical E45 ratings were analyzed. The pseudo-ternary phase diagram for oxide inclusions of the two heats, along with the most probable largest oxide inclusion, are shown in plan to attend • june 6-8 Figures 1 and 2. visit www.hardinge.com/hmts2017 In summary, answering the question of how much steel cleanness an application requires begins with deciding how cleanness is to be measured. While all of the aforementioned measurement methods have their place, the more that cleanness determines the performance of a part, the more sensitive the method needs to be in order to more fully characterize the nonmetallic inclusion population. The conun- drum is that industry standards provide for timely and cost-effective order fulfillment but lack sensitivity; more sensitive methods are relatively expensive and time-consuming. The compromise for the bearing and gear engineer is to use an appropriate mix of both.

ABOUT THE AUTHOR: James Carosiello is a senior materials specialist in the technology center at TimkenSteel Corporation. He is a graduate of The Ohio State University and is active in standards-writing organizations including ASTM International. Carosiello can be reached at jim.carosiello@ timkensteel.com. MAY 2017 23

GS-Book.indb 23 4/25/17 4:00 PM RICK MILLER TOOTH PRESIDENT TIPS INNOVATIVE DRIVE SOLUTIONS DESIGNING QUIET GEARS The gear design phase is the easiest, least costly, and most effective way to influence gear noise.

IN TODAY’S INDUSTRIAL AND COMMERCIAL ENVIRONMENT, Contact ratio also plays an important role in this process. Higher gear noise is increasingly undesirable. Conversely, quiet gears are contact-ratio gears, whether spur or helical, have more on average necessary and important in nearly every industry and for every gear teeth in contact at any one time and less deflection. application. Helical gears have contact in both the transverse and the axial For example, in the electric-car industry, quietness in all aspects planes. This lessens the gear tooth impact and provides smoother of the vehicle is critical. Quiet gears and gearboxes are particularly engagement because of the higher total contact ratio. important in electric cars because these vehicles have no internal High contact-ratio spur gears, which I discussed in the April 2017 combustion engine to generate additional noise to cover up the gear Tooth Tips column in Gear Solutions, have some of the same advan- and gearbox noise. There is only an electric motor, which is scary tages as helical gears. Helical gears also can be designed with a high quiet, that by design does not cover up or compete with the noise contact ratio in the transverse plane. produced by the gears or gearbox. In this market, noisy gears would In either spur or helical gears, high contact ratio (HCR) is defined not be accepted or tolerated. as greater than 2.0 in the transverse plane. Achieving a high-quality Much research, thought, and development have gone into the effort level and greater accuracy is important in HCR gears because of the to reduce gear noise. This effort is best and most effectively addressed multiple teeth in contact. in the design phase; however, other phases that also affect gear noise Isotropic superfinishing also reduces noise due to reduced friction positively or negatively are the manufacturing and assembly phases. and a smoother gear tooth surface. Regarding the assembly phase, it is well-known that simply assem- Designing gears for high strength versus low noise sometimes bling and then disassembling and reassembling the same gearbox has requires opposite design characteristics due mainly to the reduced an effect on gear noise, sometimes in the same order of magnitude as contact ratio, coarser diametral pitch, and fewer gear teeth typical of the differences between two dif- most high-strength gears. ferent gear pairs. While all these In general, the goal is to achieve stages do, in fact, influence gear “In general, the goal is to achieve low low tooth-to-tooth transmission noise, the gear design phase is error, which relates to gear teeth the easiest, least costly, and most tooth-to-tooth transmission error, which relates to entering the mesh to each other effective way to address this. in the exact position and location Gear noise involves multiple gear teeth entering the mesh to each other in the that they should, as well as con- factors. It originates from the trolling gear tooth deflections. impacts of gear teeth coming exact position and location that they should, as The Ohio State University Gear into contact in the mesh cycle. Lab has developed a program that Sometimes a gear contacts its well as controlling gear tooth deflections.” defines and measures tooth-to- mating gear tooth and enters the tooth transmission error called mesh cycle before or after it is the Load Distribution Program expected to, and this causes the gear tooth to either instantaneously (LDP). This program takes into account macro and microgeometry speed up or slow down the mating gear tooth because of this out- effects as well as speed, torque, and other related factors. of-position and location situation. The gear excitation and resulting Microgeometry is typically defined as tip and root relief on the noise can then be transmitted to the other adjacent components such flanks of the gear teeth. Optimizing this microgeometry is beneficial as shafts, bearings, housings, etc. And then it can be radiated away and important in reducing gear noise because it eases the entry and from the gearbox and to the listeners’ ears. exit of the gear teeth in the gear mesh. Here, I will concentrate on the impacts of the gear teeth entering In summary, contact ratio is important and, to some degree, the and leaving the mesh cycle, because it has the highest rate of return higher the better. Although a high contact-ratio spur gear set benefits in gear noise reduction among all the elements of design. from a contact ratio of greater than 2.0, it is also thought that a gear set In general, the maximum gear tooth contact and minimum deflec- with any contact ratio above 1.8 is beneficial in reducing gear noise. A tion is best. Gear teeth with no errors and with little to no deflection quiet gear set is the result of a high contact-ratio spur or helical design, would be extremely quiet. is isotropic superfinished, and has a high quality level.

ABOUT THE AUTHOR: Rick Miller is president/sole member of Innovative Drive Solutions LLC, which provides gear design engineering services for optimizing gears, gearboxes, and other geared devices. Miller has created over 300 original gearbox system designs. He is a member of AGMA, SAE, and ASME, and he holds three patents. He is vice chairman of the AGMA Vehicle Gearing Committee. For more information, visit www. innovativedrivesolutions.com. 24 gearsolutions.com

GS-Book.indb 24 4/25/17 4:00 PM D. SCOTT MACKENZIE HOT SENIOR RESEARCH SCIENTIST - METALLURGY SEAT HOUGHTON INTERNATIONAL INC. METALLURGICAL REASONS FOR GRINDING CRACKS AND THEIR DETECTION Aggressive grinding can result in thermal damage and potential cracking of a ground part, but methods exist to detect grinding burns and cracks.

GRINDING IS OFTEN A FINAL MACHINING STEP TO ACHIEVE Oxidation burn is primarily a discoloration of the workpiece. It desired surface finish or final dimensions. Grinding is a high-energy is characterized by a typically blue temper scale on the part’s sur- process where a lot of frictional energy is concentrated over a small face. The freshly ground surface of a part will form an oxide that region [1]. This localized energy is confined to the surface layers of changes colors due to thin-film interference as the part is heated. the part being ground, resulting in a local rise in the surface tem- The part’s color or oxide film indicates the part’s temperature. perature. Depending on the increase in temperature, changes in the Typical colors and respective temperatures are shown in Figure 2. residual stress state and microstructure can result. Cracking is the Oxidation burn is observed on the ground surface and in adjacent limiting case of residual stress. areas. The surface temperature, as evidenced by the temper colors, Grinding defects can be classified into four categories [2]: indicates aggressive grinding. 1. Oxidation burn Thermal softening, which is a reduction of the hardness of the 2. Thermal softening heat-treated part, occurs when the grinding temperatures exceed 3. Residual tensile stress the tempering temperature. The temper colors can give an accurate 4. Re-hardening burn indication if thermal softening has occurred. Residual tensile stress, with cracking as the limiting case, is due The relative temperatures at which the various types of burning occur to thermal stresses exceeding the yield stress. This residual tensile are shown in Figure 1. stress can reduce the fatigue life of an in-service part. If the residual thermal stress exceeds the ultimate tensile stress, then cracking can result. This is illustrated in Figure 3. The residual stress can be from either mechanical or thermal effects [5]. Mechanical effects and proper grinding result in a compressive residual stress at the surface. This is beneficial for fatigue. Thermal effect produces the opposite effect, with a residual tensile field at the surface. As the part is locally heated, the surface layer expands, but it is constrained by the lower undisturbed material. Compressive residual stress occurs at the surface. As the part cools, the surface layer contracts due to thermal contraction, resulting in a stress reversal — similar to that occurring during quenching. If the thermal stress is greater than the ultimate tensile strength, then cracking can occur. If the temperatures developed during grinding exceed the austenitizing temperature of the steel, transformation to martensite also can occur. This austenite, Figure 1: Different types of thermal damage occurring during grinding and the when cooled, transforms to martensite. Martensite, upon transforma- relative temperatures at which they occur [3] tion, has a volume expansion associated with transformation. This

Figure 2: Tempering colors of steel indicative of exposure temperatures [4]: (A) normalized; (B) as-quenched; (C) 350°F (176°C); (D) 400°F (204°C); (E) 440°F (227°C); (F) 500°F (260°C); (G) 540°F (282°C); (H) 590°F (310°C); (I) 650°F (343°C); and (J) 730°F (388°C) MAY 2017 25

GS-Book.indb 25 4/25/17 4:00 PM 1200 expansion is on the order of 3 percent and is dependent on the percent of carbon present. This expansion, combined with the thermal stresses, 1000 can result in locally high residual stresses that can exceed the ultimate 800

tensile strength and crack the part. This is known as re-hardening burn 600 or cracking. This is illustrated in Figure 4 [5]. Burning also can occur without cracking. A martensitic transforma- 400

tion can occur, but no cracking occurs. A cross-section through the 200

material would show a high surface hardness with a soft heat-affected Residual Stress, Mpa zone (see Figure 5). 0 The carbon equivalent (CE) is a good measure of determining -200

if the steel is prone to grinding cracks. It is identical to the carbon -400 equivalent used to determine sensitivity to quench cracking. A com- -600 Removal Depth, µm mon formula used to determine sensitivity to quench cracking and 0 50 100 150 200 250 300 350 400 450 500

grinding cracks is the Dearden & O’Neill formula [6]. Normal Abusive

Figure 3: Illustration of the residual stress field resulting from normal and abusive grinding results, its use in a production facility is limited due to severe fire The mechanism of quench cracking and grinding cracks is identical. risk. Environmental and fire regulations often preclude the use of The cracks are typically intergranular and follow prior austenite grain nital etching as an inspection method. boundaries. The cracks, when opened, may have a light oxide film on Nital etching is time-consuming and not typically suitable for high the crack faces [7]. production. It is still used for 100-percent inspection of low-volume aerospace applications, such as the grinding of landing gears. This EVALUATION OF SURFACE INTEGRITY method cannot be automated and requires an operator to make There are four primary methods for the detection of grinding burns: a judgment on the severity of the burn. In some applications, the nital etch, eddy current, X-ray diffraction, and Barkhausen noise. presence of any evidence of burn is cause for rejection (see Figure 6). Nital etching involves immersing the part in a solution of nitric One problem with nital etching is the potential to cause hydrogen acid and either water or alcohol. This method is a large-scale method embrittlement. This is particularly true if the heat-treated hardness is similar to that used for metallographic examination. The typical above 36 HRC. To avoid hydrogen embrittlement, it is necessary to concentration of nitric acid is 5 to 10 percent depending on the perform a hydrogen embrittlement stress relief. This is performed at process specification. While alcohol (methanol) provides the best 275-350°F (135-176°C) for up to 24 hours.

Figure 4: Mechanical and thermal effects from grinding [5] 26 gearsolutions.com

GS-Book.indb 26 4/25/17 4:00 PM Eddy current is an effective method to detect grinding burns and 65 does not suffer the environmental or fire hazards of nital etching. Like nital etching, eddy current testing will only detect a grinding 60 burn if a metallurgical transformation has occurred. It can detect surface softening but is not able to detect residual stresses. It is an effective method for determining if a part has cracks. 55 Eddy current testing can be automated but requires the method to have appropriate standards developed for the application. Hardness, HRC X-ray diffraction is the most sensitive method to residual stress. It is 50 quantitative, but slow. It is performed in a laboratory setting and yields quantitative results. Examination of residual stress as a function of depth is possible but requires laborious surface removal. This can often obscure 45 results if proper care is not taken to remove the progressive surface layers. 0.00 0.10 0.20 0.30 0.40 0.50 Barkhausen noise is named after German scientist Heinrich Depth below ground surface, mm Barkhausen at the Technische Hochscule Dresden, who discovered Figure 5: Hardness distribution near the surface due to abusive grinding the Barkhausen effect in 1919. He discovered that when a changing magnetic field is observed in a ferrous material, the magnetism of the material changes in a series of small jumps. These discrete jumps in the magnetic field are the result of magnetic domains suddenly moving past lattice defects. This method is sensitive to residual stress and hardness, and it has a significant penetration depth [8]. It is readily automated. It also is recognized by specification for aerospace and automotive applications [9]. A comparison of the methods for detection of grinding burns is provided in Table 1. Figure 6: Illustration of abusive grinding detected by localized nital etching CONCLUSIONS Eddy X-ray Barkhausen Grinding is used in many applications during final finishing of heat- Feature Nital Etch Current Diffraction Noise treated parts. It is a high-energy process with much of the energy Non-destructive No Yes Yes Yes converted to heat. This heat can cause detrimental residual stress and Standardized Yes Yes Yes Yes microstructural changes that can reduce product life. Proper control of the grinding operation is critical to reduce grinding burn. Use of Chemicals Yes No No No Automated No Yes Yes Yes

REFERENCES Objective No Yes Yes Yes

1. 1. Malkin, S. (1984). Grinding Metals - Theory and Applications. Quantitative No Yes Yes Yes Journal of Applied Metal Working, 3 (2), 95-109. Reliable No Yes Yes Yes 2. 2. Sundarrajan, K. D. (2012). Study of Grinding Burn Using Design of Experiments Approach and Advanced Kaizen Methodology. Evaluation Through Coatings No Yes No Yes Dissertations and Student Research, Paper 26, University of Nebraska, Danger of Hydrogen Yes No No No Embrittlement Industrial and Management Systems Engineering, Lincoln, NE. Influenced by Both Stress No No Yes Yes 3. 3. Badger, J., & Torrance, A. (2000). Burn Awareness. Cutting Tool and Microstructure Engineering, 52 (12). Fast No Yes No Yes 4. 4. Retrieved from https://commons.wikimedia.org/wiki/ Can Easily Examine Yes Yes No Yes File%3ATempering_standards_used_in_blacksmithing.JPG Large Areas 5. 5. He, L., Li, X., Wang, G., & Rong, Y. (2010). A preliminary study on an improved grinding process integrated with induction heating Table 1: Comparison of different methods to evaluate grinding burns [10] technology. Trans. NAMRI/SME, 38, 121-126. Journal of Materials Processing Technology, 240, 104-117. 6. 6. Lancaster, J. F. (1999). Metallurgy of Welding. Abington 9. 9. SAE. (n.d.). Barkhausen Noise Inspection for Detecting Grinding Publishing. Burns in High Strength Steel Parts. Warren, PA: SAE International. 7. 7. Kunitake, T., & Susigawa, S. (1971, May). Quench Cracking 10. 10. Wojtas, A. S., Suominen, L., Shaw, B. A., & Evans, J. T. Susceptibility of Steel. Sumitomo Search, 16-25. (1998). Detection of Thermal Damage in Steel Components After 8. 8. Neslusan, M., Cizek, J., Kolarik, K., Minarik, P., Cillikova, M., & Grinding Using the Magnetic Barkhausen Noise Method. 7th Melikhova, O. (2017). Monitoring of grinding burn via Barkhausen European Conference on Non-destructive Testing, May 26-29, noise emission in case-hardened steel in large-bearing production. (p. 41). Copenhagen, Denmark.

ABOUT THE AUTHOR: D. Scott MacKenzie, Ph.D., FASM, is a senior research scientist of metallurgy at Houghton International, a global metalworking fluids supplier. He obtained his B.S. from The Ohio State University in 1981 and his Ph.D. from the University of Missouri-Rolla in 2000. He is the author of several books and over 100 papers, articles, and chapters, and he is a member of ASM International. He is vice president of the International Federation of Heat Treatment and Surface Engineering. MacKenzie can be reached at [email protected]. MAY 2017 27

9.HotSeat-2017-05.indd 27 4/25/17 4:19 PM COMPANY PROFILE

Pictured from left to right: Kevin, Mark, and Bryan Jackson Advanced Jiffy Machine Products Inc.

GS-Book.indb 28 4/25/17 4:00 PM With a motto of “If you’re not looking ahead, you’re already behind” and a focus on customer satisfaction, quality, and innovation, Advanced Jiffy Machine Products is a custom gear manufacturer that’s continuously increasing its capacity and efficiency.

By Molly J. Rogers

AT THE RECENT AGMA ANNUAL MEETING, MARK “It’s robot-loaded and can run lights-out, too,” Mark Jackson, process engineer at Advanced Jiffy Machine said. “We can more than double our output efficiency Products, heard much discussion about the Internet of with the automation. And, we do live monitoring on the Things (IoT). And while it may seem overwhelming for cells, so we can monitor processes on our phones to see any business to keep up, he feels confident that, for a small if anything alarms out or when more parts need to be gear manufacturing company in Monett, Missouri, they are loaded on the conveyors. I don’t know of many shops steadily staying on the cutting edge by implementing the our size that have implemented the level of automation latest technology with automation and machine monitoring. that we have. And we will continue to add more to “As a small company, it’s sometimes hard to implement our equipment.” everything that you want, and everything takes more time Its strategic focus on technology seems to be working than you wanted it to, but with that said, the IoT talk at for Advanced Jiffy Machine Products, which began in the Annual Meeting was very relevant, and it doesn’t have 1979 by Mark’s father, Kevin Jackson. to be major things,” Mark said. “An example for simple “My dad started the company doing small tool sharpen- machine monitoring: You can set up a Nest camera to ing as a general machine shop,” Mark said. “And in 1983, monitor your machines — that could be a small step to they started making gears. That was a niche they found. implementing IoT. You are communicating, live stream- We’ve been making gears ever since.” ing, and watching your processes. Or, putting a voltage Today, the company specializes in cutting helical and reader on your machine. Connect that in, and then you spur gears from 1 inch to 12 inches and some gear shaping get the reports straight to your smartphone or computer. in a similar size range. It serves the industrial market with You just implement some little things like that, and you many different helical gear sets; the oil and gas industry can instantly see efficiency increase without being over- with components that go into pump jacks; winch gears whelmed. And we will continue to add more and more for military-grade winches; and farm implements. The IoT as time goes on.” majority of its customers are within about a 250-mile Advanced Jiffy Machine Products has also focused radius, but Mark says they are working to expand their on increasing efficiency and lean production, beginning reach into Ohio, Indiana, and Illinois, where there are with its first piece of automation — a custom, automated more needs for gear manufacturing. RoboDrill cell — about three years ago. Its facility has nine gear-cutting machines and several “We were over capacity in our turning area, so instead turning and milling centers to support gear production. of taking extra time to do live milling on our lathes, Kevin says some important milestones for the com- we added the automated RoboDrill cell. That cut our pany have been adding the new machinery and com- lathe cycle times in half and increased our throughput,” pleting building additions in 1991, 1994, and 2014, as Mark said. “It worked so well that we ended up adding well as having his two sons come on-board full-time, a Nakamura AS200 to that same cell during our next becoming a truly family-operated business with about phase of automation.” 15 employees. With the increased capabilities, Mark says they can do “Mark started in 2008,” Kevin said. “He had been out lights-out automation overnight and weekends, setting of college awhile, and he wanted more out of what his up roughing operations to run through, without anyone current job could offer him. He wanted more of a chal- having to be there. lenge. So he came into the gear manufacturing business “In that cell, we can do roughing and finishing, milling with us. Mark’s younger brother, Bryan, also started here only, or both turning and milling in the same operation,” about the same time, and he continues to expand his role Mark said. “And there are a lot of different applications as production manager as time goes on.” that we can run through it. We can do the turning on With a degree in biology and chemistry minor, Mark the Nakamura, and then the robot will take it from the was working as a microbiologist before joining his dad Nakamura and load it into the RoboDrill. We can sepa- at Advanced Jiffy Machine Products. rate the processes and have better throughput.” “It’s not that much of a jump, from biology to gear In the third phase of implementing automation, manufacturing,” Mark said. “There are some parallels, they also added another cell with a robot, a Mitsubishi more than people think. There’s the strong attention GE15 gear hobber, and a Mitsubishi FE30 gear-shaving to details, using a scientific process and approach, and machine, where all of its helical gear sets run through. looking at things on a very small scale.” MAY 2017 29

GS-Book.indb 29 4/25/17 4:00 PM Advanced Jiffy Machine Products works with a variety of materials for the gears it man- Liebherr Performance. ufactures, mainly carbon alloy steels 8620s, 4140s, 1018s, but also aluminum bronze for worm gears, as well as nylon, phenolic, and stainless steels for other applications. “We do exotic materials, too, such as Inconel, Monel, and Nitronic 50, mostly for oil-and-gas applications due to the anti- corrosion benefits, as the parts go deep into the ground or submersed in the ocean,” Mark said. “There are not a lot of materials that we haven’t worked with.” Having this experience with a variety of materials helps the company solve problems that its customers may be facing and offer recommendations for different materials to When the coolant becomesWhen a Liquid the coolant Tool. becomes a liquid tool. achieve better performance. “We have a customer in the racing industry that came to us when their gears were not holding up very well,” Mark said. “So we rec- ommended that we change the materials, use an 8620, and carburize it. They were using a soft material without heat-treating it, and the gears were tearing up and not lasting long. So we modified the profile by shaving it, and we hardened and carburized it. We made them stronger and last longer.” For the future, Advanced Jiffy Machine Products expects to add more services such as consulting, as well as inspection services with a new machine recently ordered, the Wenzel WGT 280. It is also adding outside inspection services to complement its capabilities and to support its current products as well as contract and support for all products. With its continued focus on new technologies, Advanced Jiffy Machine Products plans to increase automation as well as more implementation of IoT into its processes. “We are looking at adding an automated deburr cell later this year,” Mark said. Gear hobbing machine LC 180 DC Gear hobbing machine LC 300 DC Chamfering machines LD 180 C and LD 300 C Chamfering in the work area “After that, we are hoping to add another automated roughing and finishing cell similar to the one we have but with improve- nd Simultaneous chamfering with ChamferCut – e a see ments. We will also update software and Cutting fluids to m u o s optimize productivty, C ! automate some more processes. Once we The best and most economical solution economic efficiency get the inspection machine, we would like Established process in gear production and machining quality. to try to get more into higher-production Very precise chamfer geometry Booth #300 automotive, and aerospace is a target area as well. Premium chamfer quality and reproducibility “Technology moves so fast, but as long No bulging or material deformation as we keep looking forward and aim to be Standard tooth-root chamfering Our specialists support you to get the best out of your machines and tools with the progressive and innovative, I think we are Very long tool life Liquid Tool. Please contact us for your local distributor. heading in the right direction,” Mark said. Lower tool costs compared to alternative processes

Blaser Swisslube Inc. Goshen, New York Phone 845-294-3200 [email protected] www.blaser.com Liebherr Gear Technology, Inc. FOR MORE INFORMATION: 1465 Woodland Drive www.advancedjiffymachineproducts.com. Saline, Michigan 48176-1259 Phone.: +1 734 429 72 25 E-mail: [email protected] 30 gearsolutions.com www.liebherr.com

GS-Book.indb 30 4/25/17 4:00 PM 2014-001_17 AZ Aufbau ChamferCut_216x279_GB_02.indd 1 28.03.17 13:02 Liebherr Performance.

Gear hobbing machine LC 180 DC Gear hobbing machine LC 300 DC Chamfering machines LD 180 C and LD 300 C Chamfering in the work area

Simultaneous chamfering with ChamferCut – The best and most economical solution Established process in gear production Very precise chamfer geometry Premium chamfer quality and reproducibility No bulging or material deformation Standard tooth-root chamfering Very long tool life Lower tool costs compared to alternative processes

Liebherr Gear Technology, Inc. 1465 Woodland Drive Saline, Michigan 48176-1259 Phone.: +1 734 429 72 25 E-mail: [email protected] www.liebherr.com

GS-Book.indb2014-001_17 AZ 31 Aufbau ChamferCut_216x279_GB_02.indd 1 4/25/1728.03.17 4:00 13:02PM 32 gearsolutions.com

GS-Book.indb 32 4/25/17 4:00 PM Review of Microstructure and Properties of Non-Ferrous Alloys for Worm Gear Application and Advantages of Centrifugally Cast Gears A review of the microstructure and properties of tin bronze, manganese bronze, and aluminum bronze material that make them suitable for specific worm gear applications is presented, as well as results from mechanical tests and microstructural studies comparing the centrifugally cast and static-cast gear bronze (tin bronze) alloy.

By Giri Rajendran and Jason Hassen

WORM GEARS ARE USED FOR LARGE GEAR REDUCTIONS. Gear ratio ranges of 5:1 to 300:1 are typical. Generally, worm gear setup is designed so that the worm can turn the gear, but the gear cannot turn the worm. The angle of the worm is shallow, and as a result, the gear is held in place due to the friction between the two. (Note: Worm gear sets should not be considered self-locking. Under certain load conditions, worm wheel movement in reverse is possible.) An electric motor or engine applies rotational power to the worm, and the worm rotates against the worm gear. As the worm slides across the teeth, the power is transferred to the worm gear wheel. Figure 1 shows the cross-sectional view of the worm gear setup. ADVANTAGES OF WORM GEARS The main reason one would choose a worm gear over a standard gear is the high reduction ratio. A worm gear can have a massive reduction ratio with little effort — Figure 1: Worm gear and worm inside the housing [1] all one must do is add circumference to the gear wheel. Thus, you can use it to either greatly increase torque or greatly reduce speed. NON-FERROUS MATERIALS FOR It will typically take multiple reductions of a conven- WORM GEARS AND MICROSTRUCTURES tional (gear set) to achieve the same reduction level of a Tin Bronze single worm gear, meaning users of worm gears have fewer Tin bronze is essentially copper-tin alloy with 8 to 12 moving parts and fewer places for failure. percent tin. A second reason to use a worm gear is the inability to Adding tin to copper makes the alloy hard by replac- reverse the direction of power. Because of the friction ing some copper atoms with tin atoms. During the between the worm and the wheel, it is virtually impos- casting process, the first dendrites to form are rich sible for a wheel with force applied to it to start the worm in copper, and the interdendritic spaces are enriched movement. On a standard gear set, the input and output in tin, forming a CuSn compound called the “delta can be turned independently once enough force is applied. phase.” This delta phase is very hard, and the pres- This necessitates adding a backstop to a standard gearbox, ence of this phase provides the good wear properties further increasing the complication of the gear set. necessary for the worm gear wheel. Figure 2 shows the

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 2016 at the AGMA Fall Technical Meeting in Pittsburgh, Pennsylvania. 16FTM05 MAY 2017 33

GS-Book.indb 33 4/25/17 4:00 PM 50mm 500mm

Figure 2: Typical microstructure of C90700 tin bronze [2] Figure 3: C95400 cast annealed and heat-treated [2]

typical dendritic microstructure of a C90700 tin bronze with the delta phase shown in light blue color.

Nickel Tin Bronze Nickel has more affinity for copper than tin, and as a result, less tin is held in the first phase to solidify, and more goes into the formation of the interdendritic harder delta phase. As a result, nickel tin bronze has higher tensile strength than regular tin bronze. Nickel tin bronze has higher load-bearing capacity.

Leaded Bronze The main function of the leaded bronze group of alloys is to improve the machinability. With advances in the machine tool capabilities, the machinability of unleaded bronzes is not an issue anymore. Lead 250mm is a heavy metal and does not dissolve well in copper, which generally poses casting issues such as fine porosities. The manufacture Figure 4: C95500 cast and heat-treated [2] of leaded alloys can lead to workplace safety and environmental concerns. Also, the customer has to deal with the issue of properly Aluminum bronzes are designated as UNS C95200 to UNS disposing the lead-contaminated lubricants when the gearbox oils C95900. The two well-known aluminum bronzes used in worm are changed. gear applications are grades C95400 and C95500. They contain Generally, the mechanical strength of leaded bronzes is lower other alloying elements, such as iron and nickel, in addition than regular tin bronze and nickel tin bronze. The only other to aluminum. advantage of leaded bronze is that the spheroids of the lead in the The microstructure of aluminum bronze alloys with aluminum microstructure smear over the bearing surface under conditions of content below 8.8 wt% is the single phase (referred to as the inadequate lubrication. alpha phase). Between 8.8 wt% and 11.8 wt% aluminum, the alloy contains Aluminum Bronze multi-phases (alpha plus beta or gamma phase). The beta phase Aluminum alloys rich in copper are known as aluminum bronzes. increases with aluminum content.

AS CAST AS CAST & HEAT TREATED* Min/typical Min/typical Brinell Minimum Minimum Minimum Minimum % GRADE % elongaon Brinell Hardness Hardness (@3000 Tensile Yield strength Tensile Yield strength elongaon min Range (@3000 kg kg load) (Ksi) (Ksi) (Ksi) (Ksi) min load)

150 C95400 75 30 12 190 90 45 6 (170 typ)

C95500195 typ90406230 typ110 60 5

* temper code TQ50 Table 1: CDA specification for C95400 and C95500 [1] 34 gearsolutions.com

GS-Book.indb 34 4/25/17 4:00 PM Aluminum bronzes such as C95400 and strength at elevated temperatures. But they C95500, which contain iron and nickel in generally have poor conformability (unlike addition to aluminum, will have an addi- tin bronze) and are therefore best suited tional phase rich in iron and nickel (known for heavy-duty, low-speed application with as the kappa phase). good lubrication. Figures 3 and 4 show the microstructures The Copper Development Association of heat-treated (water-quenched) C95400 (CDA) specification for hardness and and C95500 aluminum bronze alloys, mechanical properties of as-cast and heat- respectively. treated C95400 and C95500 aluminum Aluminum bronze worm gears are used bronzes are provided in Table 1. for their combination of high strength and excellent corrosion resistance and Manganese Bronze Figure 5: Static casting wear properties. They are heat-treatable Manganese bronzes contain zinc and small for higher strength, and they retain their additions of manganese, aluminum, and

Bimetallic Line Axis of Rotation Mold Impurities gather in Pouring Cup bore, then machined out.

Casting/Shell Metal Rotational Direction

Figure 6: Vertical centrifugal casting

Don Abbott Schafer A-Team member

Figure 7: Mold set for centrifugal casting Production Supervisor and world-class gearhead

Experience. According to Don, you’d be hard pressed to find guys who are better at turning, hobbing, grinding and shaping gears than the ones he works with at Schafer Industries. Like Don, most have 25 to 30+ years of expertise. From 1” to 32” diameters, our machinists manufacture gears right. Deliver them on time. It makes sense to put our experience to work on your gears. Let’s talk.

INDUSTRIES schafergearheads.com

Figure 8: Casting being poured MAY 2017 35

GS-Book.indb 35 4/25/17 4:00 PM Figure 10: (a) Centrifugally cast bimetal gear bronze; (b) closeup view of C90700 tin bronze and C86400 manganese bronze showing the wall thickness

iron. The right combination of these alloying elements increases Manganese bronzes have the same conformity issue as aluminum the strength of the material. The most common manganese bronze bronzes; they generate frictional heat under continuous operating con- used in worm gear application is UNS C863000, which has over ditions if not adequately lubricated. Therefore, some of the high-strength 110 ksi tensile strength. The manganese bronze worm gear pro- manganese bronze alloys have high lead content to provide lubricity. vides anti-seizing properties and some corrosion resistance. They can be used for high speeds and heavy loads. They are harder than the tin bronze but more brittle.

Figure 9: Solidification pattern of (a) centrifugal casting versus (b) static casting

Figure 11: Schematic showing the tensile test bar locations 36 gearsolutions.com

GS-Book.indb 36 4/25/17 4:00 PM CENTRIFUGAL CASTING PROCESS VERSUS STATIC CASTING Figures 5 and 6 show the differences between static casting and vertical centrifugal casting process methodologies. As shown in Figure 5, a pattern — metal delivery system (gates and risers) — is constructed out of hard wood. Sand containing bonding material is packed around the pattern. The pattern is removed, and core and chill are placed in the mold cavity. Molten metal is poured into the cavity, and the metal solidifies. Sample size approximately 25 mm (1 inch) wide x 38 mm (1.5 inch) height x 76 mm (3 inch) long As shown in Figure 6, a permanent mold Casting size: 292 mm (11.5 inch) diameter x 152 mm (6 inch) long is rotated about its vertical axis. The mold is Figure 12: Orientation of samples sectioned from (a) static casting and (b) centrifugal casting spun at 50-100 times the gravity force. The molten metal is poured through the pouring cup. Molten metal is centrifugally thrown toward the inside wall. The outside of the mold is water-cooled to enhance the directional solidification. Figure 7 shows the centrifugal casting mold Spiral Bevel Gear Cutting, setup, and Figure 8 shows the operator pouring the metal into the pouring cup of the caster. The Best Performance Over Price

Solidification Characteristics In the vertical centrifugal casting process, solidification starts as a thin layer at the outside diameter and moves toward the bore. Due to this directional solidification, shrinkage voids move toward the bore and are completely removed later by machining operation. In the static casting, solidification occurs from the top and bottom of the mold, leading to centerline shrinkage, which is fed by the riser. The elimination of the shrinkage is highly dependent on how well the riser head is designed. The solidification pattern during centrifugal casting and static casting is depicted in Figure 9. CNC Spiral Bevel Gear Cu�ng Machine Also, in the centrifugal casting, the metal solidifies at high g-forces (50-100 times the Maximum work OD 100 mm, maximum module M3 gravity). The less-dense materials such as Five (5) synchronized axes driven by Siemens 840D sl controller slag, impurities, entrapped gas, etc., float to Cup type milling cutter with HSK tool holder, spindle speed at 4000 rpm the inside diameter (ID) of the casting and Microsoft Windows© based intelligent spiral bevel gear cutting software developed by Luren are subsequently removed by machining. Easy adjustment on contact pattern by dragging Therefore, we end up with cleaner and dens- Spiral bevel gear grinding LVG-100 also available er metal in the gear rim, which improves the ultimate tensile and fatigue properties of the Our Gear Cutting Tools Hobs Shaper Cutters Master Gears worm gear. The cleaner, denser metal yields a more efficient gear-cutting operation. For over 20 years of manufacturing, Luren has been offering a wide variety of custom and standard gear cutting tools using the BIMETAL GEAR BLANK highest quality materials and accuracy to Bimetal gear blank is the process whereby two ensure your longest possible tool life. different alloys are poured and centrifugally cast to become a metallurgically bonded gear Corporate Headquarters North American Headquarters Luren Precision Co., Ltd. Luren Precision Chicago Co., Ltd. blank. The outer rim of the gear blank (where No.1-1, Li-Hsin 1st Road, 707 Remington Road, Suite 1, the teeth are cut) is cast with tin bronze, Hsinchu City, Taiwan, 30078 Schaumburg, IL 60173, U.S.A. while the inner portion (where the shaft to Phone : +886-3-578-6767 Phone : 1-847-882-1388 Email : [email protected] Email : [email protected] be keyed, splined, or iron spider bolted) is Website : www.luren.com.tw Website : lurenusa.com cast with manganese bronze or other alloys. MAY 2017 37

GS-Book.indb 37 4/25/17 4:00 PM

Centrifugally cast Stac cast Centrifugally cast Stac cast Centrifugally Stac cast close OD - close OD - Locaon of close OD - transverse close OD - transverse Longitudinal Longitudinal from OD to ID - Radial from OD to ID - Radial sample direcon direcon

test 1test 2 avg test 1test 2avg test 1test 2 avg test 1test 2avg test 1test 2 avg test 1test 2 avg

Sample ID A656 A657 A662 A663 A658 A659 A664 A665 A654 A655 A660 A661

sample locaon T1 T2 T1 T2 L1 l2 L1 L2 R1 R2 R1 R2 Ulmate tensile 42.2 48 45.1 37.6 31.7 34.7 47.842.4 45.1 32.1 34.1 33.1 45.540.9 43.2 28.9 24.8 26.85 (Ksi) Yield Strength 20.1 20.9 20.5 20.6 19.7 20.2 21.220.8 21.0 20.4 20.4 20.4 21.820.6 21.2 20.6 20.2 20.4 (ksi)

elongaon (%) 22.3 31.1 26.7 15.6 9.5 12.6 30.221.3 25.8 8.910.3 9.6 22.814.3 18.55 n/a* n/a* n/a * 0.375" diameter bar is used instead of 0.500" bar Table 2: Mechanical test results

Bimetallic Gear Methodology C90700 tin bronze in the rim portion and C86400 manganese The casting process of a bimetallic gear blank involves introduc- bronze in the web portion. ing a predetermined amount of shell metal such as tin bronze (which forms the rim of the gear) into the mold, followed by Advantages of Bimetal Gears core metal (such as manganese bronze). The time delay between The inner portion of the gear can be cast with higher-strength pouring the shell metal and core metal is precisely established manganese bronze and therefore higher load-bearing capacity. The before pouring to achieve a good metallurgical bond between the bimetal gear is also better for handling shock-loading situations. two alloys. The thickness of the shell and core is determined by the Bimetal gears provide a combination of strength and wear proper- gear teeth geometry and customer requirements. Figure 10 shows ties required for the worm gear. Also, manganese bronze costs less the 12.25 inch (311 mm) diameter bimetallic gear blank with than tin bronze.

NEW Release 03/2017

KISSsoft Highlights ● Reliability evaluation on system level ● Simplified modeling using predefined gear stages ● Calculation of root stresses with FE ● Variation calculation for bearings ● Determination of the unbalance Precision Gear Products response for shafts RUSSELL, STOCK : HOBS : HSS & CARBIDE KISSsoft USA, LLC ● And many more ... & STOCK : SHAPERS : Disc & Shank 3719 N. Spring Grove Road HOLBROOK Johnsburg, Illinois 60051 STOCK : MASTER GEARS Phone (815) 363 8823 Get your free trial version at HENDERSON, INC. RFQ on specials gear tools welcome 25 E Spring Valley Ave., Maywood, New Jersey 07607 [email protected] www.KISSsoft.com P: 201-226-9000 F: 201-226-9004 E: [email protected] Diametral Pitch 12 and finer CELEBRATING 100 YEARS IN BUSINESS STOCK AVAILABLE www.tru-volute.com

38 gearsolutions.com

GearSol_KISSsoft_Rel_03_2017_Highlights_92_25x123_83mm.indd 1 30.03.2017 13:35:56

GS-Book.indb 38 4/25/17 4:00 PM Sourcing Made Simple

Sourcing Made Simple

TEST RESULTS: COMPARISON OF CENTRIFUGAL CASTING AND STATIC CASTING 0 1/2” 1” Mechanical Test Results In order to compare the mechanical properties of centrifugal casting and static casting, test castings were cast using an 89% Cu - 10.8% tin - 0.13% P bronze alloy. The centrifugal casting was cast in a 292 mm (11.50 inch) diameter graphite mold, spinning at 600 rpm. The as-cast size was approximately 289 mm (11.5 inch) OD x 76 mm (3.0 inch) ID x 152 mm (6 inch) long. The static casting was cast in the same mold by continuously Figure 13: Grain structure of centrifugally cast test piece feeding the hot metal through the bore until completely solid. The as-cast size of the static casting was 292 mm (11.5 inch) OD x 152 mm (6 inch) long. In order to compare the mechanical proper- Sourcing Made Simple ties in the transverse, longitudinal, and radial directions, two test bars were cut in each direction, as shown in Figure 11. The test results are provided in Table 2. The results show that the ultimate tensile strength (UTS) of test bars cut from centrifugal casting is higher than theTrusted static Gear Blank casting in all directions, while the yield strength remained the same. In the trans- Trusted Gear Blank verse direction, the UTS is 30 percent Supplier Since 1950 higher, and in the longitudinal direction, Supplier Since 1950 the UTS is 36 percent higher. The elongation of test bars from centrifugal casting Consistent Quality shows approximately 50-percent higher Consistent Quality than the static casting. Since a mini test bar was used in the radial direction, the Broad Capability & Capacity Broad Capability & Capacity elongation was negligible on the static cast- Exceptional People ing and therefore not used for comparison. Exceptional People The variation between UTS and percent Trusted Gear Blank On-time Delivery elongation between test 1 and 2 can be On-time Delivery Supplier Since 1950 attributed to the inhomogeneous nature of alloy microstructure. Consistent Quality ISO 9001 and TS 16949 registered. Presses up to Broad Capability & Capacity 8800T and volumes up to 750K/year. Supported by Microstructure Results ISO 9001 and TS 16949 registered. Presses Exceptional upPeople to In order to compare the grain structure of On-time Delivery in-house heat treat and an ISO 17025 metallurgical lab. centrifugal and static castings, test 8800T pieces and volumes up to 750K/year. Supported by were sectioned from OD to ID and polished,in-house heat treat and an ISO 17025ISO 9001 metallurgical andand TS 1694916949 registered. Presseslab.Presses up up to to and the grain structure was revealed by macro 8800T4000T and volumes up up to to 750K/year. 750K/year. Supported Supported by by in-house heat treat and an ISO 17025 metallurgical lab. etching. Figure 12 shows the orientation and in-house heat treat and an ISO 17025 metallurgical lab. size of the samples sectioned from the casting. Figures 13 and 14 show the grain structure of centrifugally cast and static-cast test pieces, respectively. The grain structure of the centrifugally cast walkerforge.com | 414.223.2000walkerforge.com | 414.223.2000 test piece showed fine equiaxed grain close to the OD, followed by columnar grain, due to the directional solidification. The static-cast test piece showed equiaxed grain throughout walkerforge.com | 414.223.2000the section, but the grain size is much larger compared to the centrifugally cast test piece. It is postulated that the higher UTS of the cen- MAY 2017 39

GS-Book.indb 39 4/25/17 4:00 PM trifugally cast test pieces was partially attributed to the differences in the grain structure. In order to compare the microstructure of the centrifugally cast and static-cast pieces, samples cut from both the casting and metallographic samples were prepared. Figures 15 and 16 show the microstructure of static-cast and centrifugally cast test pieces. In comparing the microstructures of static- cast and centrifugally cast test pieces, it was clear that the delta phase is much coarser in the static-cast piece compared to the centrifugally cast piece. It is postulated that in the centrifugal casting process, due to Figure 14: Grain structure of static-cast test piece greater chill and centrifugal force, more nuclei were available for alpha dendrites to form and grow. This leads to smaller interdendritic spaces for the delta phase to form. The coarse (hard) delta phase makes High Tech is our Business the material brittle, and it is possible that the lower elongation of static casting reported in the mechanical test may be attributed to ALD is a leader in vacuum this microstructure. process technology and Heat It is the authors’ opinion that a fine grain treatment services. structure with a finely dispersed delta phase (as opposed to coarse columnar grains and LEADERS IN THE coarse delta phase) in the rim portion of the CONTROL OF DISTORTION gear should minimize pitting and friction, ALD Thermal Treatment, Inc. which is important for worm gear application. + Low Pressure Carburizing + High pressure gas quenching CONCLUSIONS + Gas Nitriding The common non-ferrous materials available

+ Ferritic Nitro-Carburizing for worm gear application and their micro- + Plasma Carburizing structures have been reviewed. The differ- + Normalizing ences between the centrifugal casting method + Hardening of manufacture and static casting method + Annealing of manufacture have been presented. The + Brazing mechanical property and microstructural dif- + Cryogenic Treatments ferences between centrifugally cast and static- + Engineering services and cast tin bronze test pieces have been evalu- process development ated. The centrifugally cast tin bronze test + Prototype and trials piece showed about 30 to 36 percent higher

ultimate tensile strength compared to static casting, in all three directions (transverse, Global Service Centers longitudinal, and radial). Also, the percent elongation of centrifugally cast test piece Enrique Lopez – Sales and Marketing is approximately two times higher than the  Limbach-Oberfrohna Email: [email protected] Germany Phone +1 (810) 357-0685 static-cast test piece, in all three directions. It is postulated that the microstructural differ-  Port Huron, Michigan ALD Thermal Treatment, Inc. ences, such as fine grain size and finer delta USA 2656 24th Street phases between the two castings, may explain  Ramos Arizpe, Coahuila Port Huron, MI 48060, USA the differences in the mechanical properties. Mexico Also, the cleaner, denser metal and the fine grains in the rim portion of the gear should www.aldtt.net improve the operating efficiency of the worm gear set. These conclusions are made based on the limited number of tests carried out on the tin bronze material. Future testing will be

ALD is a subsidiary of AMG Advanced Metallurgical Group N.V. required to confirm if such differences exist in other materials. 40 gearsolutions.com

11.Feat1-WormGears-2017-05.indd 40 4/25/17 4:20 PM Figure 15: Microstructure of static casting, 100x Figure 16: Microstructure of centrifugal casting, 100x REFERENCES 1. Gonzalez, C., 2015, “What is the differences between spur, helical, bevel and worm gears,” Machine Design, July 30, 2015 issue. 2.

ABOUT THE AUTHORS: Giri Rajendran graduated from Drexel University with a master’s degree in materials engineering and received an MBA from Waynesburg University. He joined Miller Centrifugal Casting Company (now known as MCC International) in 1991 as a quality control manager and was later promoted to vice president of technology. He was involved in the development of several new alloys for rolling mill rolls, bimetal casting technology for gear blanks, and steel mill rolls. He is the co-author of two patents on multi-carbide composite alloys. He is currently semi-retired and works as a part-time consulting engineer at MCC International. Jason Hassen graduated from Youngstown State University with a bachelor’s degree in industrial engineering in 2005. Eleven years of his work experience has mostly been in the field of quality control and process improvement. He has worked for MCC International as a process/quality improvement manager and safety coordinator for eight years. He also manages the ISO 9001 quality management program and spends time performing microscopy analyses.

MAY 2017 41

GS-Book.indb 41 4/25/17 4:01 PM 42 gearsolutions.com

GS-Book.indb 42 4/25/17 4:01 PM Introducing a New Machine Concept for High-Productive Gear Grinding A breakthrough design has been developed to optimize stiffness, stability, and speed of the gear generating grinding machine, reducing non-productive time in the process.

By Deniz Sari, Klaus Peiffer, and Enrico Landi

THE INCREASING DEMAND FOR EFFICIENCY AND seconds because the spindles are located on a rotary table noise emission of gears pushes the grinding process to that is hydraulically locked in position but is inaccurately its limits. With the widening range of applications for floating while moving. Unlocking, settling after moving, automatic planetary transmissions and increased number and locking it into the new position take more time than of speeds (currently up to 10), gears on average are smaller the motion itself and cannot be any faster by design. and smaller, while production volumes are increasing. The Samputensili G 160 presents a new design to solve The same applies to industrial applications, for example, this. Furthermore, it optimizes static and dynamic stiff- geared motors, which are currently introduced in many ness compared to current standard machine architectures. actuation systems, even in homes. The vast majority of Instead of using a rotary table to carry the workpiece this kind of gear fits into a range of 160 mm in diameter spindles, the G 160 splits the X-axis of current machines and below a module of 3 mm. into two linear slides (X1 and X2) — each of them carry- Smaller gears result in shorter grinding times and, if ing one workpiece spindle (see Figure 1), thereby eliminat- the machine is not capable of significantly shortening ing the rotary table and all the constraints connected to the non-productive time, the ratio of productive versus it. Both work spindles and the associated radial X-axis non-productive time can become even worse. Especially slides are continuously under full position control, and for planetary pinions, grinding times are currently down both can be moved in and out of the workspace simulta- to six to seven seconds, so a non-productive part change neously without interfering with each other. This is the of five seconds can easily result in a machine utilization first time that “on-the-fly” synchronization between the of less than 50 percent. workpieces and the grinding wheel can be fully utilized. Over the past decade, productivity in hard-gear finish- In addition, repositioning the grinding wheel for the ing, especially in threaded wheel grinding, has not evolved next part can also be done at the same time. No axis is much. Grinding technology, tools, and application data waiting for another — everything moves simultaneously. have reached a state of the art that cannot be significantly further improved — at least for the time being. Therefore, stiffness, stability, and speed of the gear generating grinding machine have become the main design targets for this high-dynamic process. New machines have been introduced by a variety of suppliers; however, they follow similar concepts, which, for technical reasons, do not allow a production improvement because of constraints of the concept itself. Most current gear grinding machines have two workpiece spindles to reduce non-productive times when changing parts. While a gear is ground on one spindle, parts are changed on the other. Despite this, the non-productive time has never been under five Figure 1: Each linear slide carries a workpiece spindle MAY 2017 43

GS-Book.indb 43 4/25/17 4:01 PM Being driven by high-dynamic linear motors, G 160 the change of workpieces comes down to Automo+ve Planetary Pinion record-breaking 1.6 seconds including meshing, synchronization, and simultaneous repo- Automatic Transmission Planetary Pinion sitioning of the tool. And this is achieved not Number of teeth z 23 by overloading machine components, but Normal module m 1.356 mm by the concept of the G 160 (see the sample application in Figure 2). Normal pressure angle α 17°30’00” Another significant part of the new con- Helix angle ß 18°51’43” cept is the elimination of the physical shifting Face width b 20.6 mm axis. Threaded grinding wheels fully utilized Nominal stock per flank q 0.08 mm need to be shifted (displaced) along their axis between workpieces to bring in “fresh” grids. They also need to be shifted during grinding Roughing Pass Finishing Pass to create a diagonal instead of a pure axial No. of Starts 5 motion. To accomplish this, all current grind- Grinding Speed 80 m/s ing machines use a physical Y-axis underneath Axial Feed Rate 0.67 mm 0.25 mm the grinding spindle. Unfortunately, there are Grinding Time 1.9 sec 5.1 sec serious space constraints in this area, so this Idle Time 1.0 sec Y-axis typically is designed small with low stiff- Part Change 2.0 sec ness. On the other hand, only this axis along its Floor-to-Floor Time 10.0 sec direction is carrying the highest dynamic load, which is created by the generating process. 1 Figure 2: Sample application for an automotive planetary pinion The new Samputensili concept of the G 160 addresses this constraint. Rather than stiffen- ing the Y-axis, the G 160 completely eliminates it. By doing so, not only is this “weak spot” removed, but also, instead of stacking four axes — radial (X), axial (Z), swivel (A), and shifting (Y) — only three axes are stacked onto each other (Y, Z, and A) before arriving at the grinding spindle. This architecture with three stacked axes instead of four is a breakthrough. When compared to existing machines, this architecture significantly increases the overall system rigidity, thus enhancing productivity and grinding quality. With the shifting axis not physically present, its motion is simulated by an interpolation of the Z and the Y axes, referred to as the virtual shifting axis (see Figure 3). Both of these axes are not restricted by space constraints and are therefore massive, strong, and rigid. There is also no additional axis needed to perform the dressing cycle. The dresser is mounted on the X1 axis slide next to the workpiece spindle. So, the precise and highly Figure 3: Virtual shifting axis dynamic motion of the linear motor can also the user needs for operating, setting, and loading position. This is where clamping fix- be used to fine-tune the geometry of the servicing the machine. tures, including tailstock centers, are changed, grinding wheel and the corresponding gear. It Changing tools is simplified by moving the and meshing sensors are adjusted. The load- enables topological modifications of the gear main column’s Y-axis and the tool spindle ing and unloading interface is designed to flank at an unprecedented quality. Having close to the operator’s door. In this way, attach a variety of external loading systems, the dresser located on the same slide as the the wheel flange comes directly in front of ranging from simple pick-and-place to flex- workpiece spindle makes it now totally insen- the operator, and it’s a short reach into the ible robot systems. To avoid sacrificing cycle sitive to thermal or other types of deviations. machine to access the grinding wheel. The time by the loading system, double grippers same applies to the dresser, which is located are used for cycles faster than 20 seconds. ACCESS TO THE MACHINE next to the operator’s door. Cycle times down to eight seconds can still When developing the G 160, particular atten- A secondary loading door provides access to be reached at full productivity by using an tion has been paid to ergonomics, addressing the two work spindles when retracted into a internal SCARA loader. 44 gearsolutions.com

GS-Book.indb 44 4/25/17 4:01 PM All mechanical, fluid, and electrical components are easily accessible for service or maintenance either from outside the machine or by opening a door to the service aisle between the machine and electrical box. All built-in motors and encoders have separate covers to provide access if needed. All these features fit into an incredibly small total floor space. Finally, this same concept is also available on the SG 160 Sky Grind machine, enabling the newly developed, patented dry grinding READY technology. On this machine, the process is split in two main passes: roughing and finishing. For the roughing process, skive hobbing is implied, whereas worm grinding is used for the finishing process. The SG 160 Sky Grind removes the majority of the stock allowance with the first pass using a hobbing TO tool, which has the advantage of not heating the workpiece excessively. Subsequently, with the second finishing pass, a grinding wheel removes the remaining stock without causing problems of overheating the workpiece, therefore resulting in a completely dry process. The additional advantages include: ROLL • The overall cost of consumables and the total investment are significantly reduced because of the lack of oil and all installation connected to it (such as pumps, tanks, filtration, chiller, and oil mist extraction). EXPANDING YOUR EXPECTATIONS • The footprint is much smaller because many external units are no longer necessary. McInnes Rolled Rings continues to expand not only our facility, • The health of workers and the environ- but also your expectations of what responsive service should be. mental impact of the production are sig- We’re committed to the delivery of quality products with the nificantly improved. fastest shipping times in the industry. CONCLUSION Samputensili is making a major step forward Speed. Quality. in gear grinding with the development of the G 160 and its “green” sister, the SG 160 McInnes Rolled Rings. Sky Grind. Building partnerships with major automotive and industrial companies and the continuous positive feedback demonstrate the acceptance of these new concepts.

ABOUT THE AUTHOR: Dr.-Ing. Deniz Sari is gear technology manager at Samputensili. 1.800.569.1420 • 1533 E 12TH STREET • ERIE, PA 16511 Dr.-Ing. Klaus Peiffer and Ing. Enrico Landi contributed to this article. For more information, www.McInnesRolledRings.com visit www.star-su.com or call 847-649-1450. MAY 2017 45

GS-Book.indb 45 4/25/17 4:01 PM CASE STUDY How Advanced Gearbox Testing Drove the Need for the Lost Foam Casting Process

Helicopter test stand gearboxes can weigh up to 10,000 pounds 46 gearsolutions.com

GS-Book.indb 46 4/25/17 4:01 PM Demands for higher loads, complex geometries, flexibility for change, and predictable materials are moving the transmission test stand industry away from fabrications to lost foam casting.

By Chris Lake

Figure 1: RedViking helicopter main gearbox transmission test stand

FOR DECADES, POWERTRAIN TEST systems incorporated custom test stand gearboxes constructed with fabricated gearbox housings. In some cases, fabricated housings are still a viable option. But for more complex, dynamic component testing — especially with critical performance requirements, heavy loads, complex geometries, and machine integration constraints — cast gearbox housings are chosen. RedViking has built powertrain test systems since the early 1990s. Early on, these were used for the automotive industry, and the integrated test stand gearboxes were relatively straightforward with parallel shafts and simple box shapes. Fabricated housings were efficient and cost effective for gearboxes with Figure 2: CNC machines create foam patterns simple geometries. That all changed as RedViking began helicopter trans- degree of vibration isolation for test article verification mission testing. A helicopter transmission test stand must and analysis. duplicate the real-world speeds and loads seen during With helicopter test stand gearboxes, there are a lot flight and connect to the complex interfaces of the test of forces and dynamic properties in play. These are piece. When compared to automotive testing, helicopter high-powered gearboxes, so getting castings with good test stand gearboxes are much larger, have higher power, consistent material and known properties is critical so and must handle much higher loads. They also involve that the design can be validated. RedViking analyzes complex geometric orientations and require a higher the test stand gearbox and the loading that it’s going MAY 2017 47

GS-Book.indb 47 4/25/17 4:01 PM Figure 3: Foam sections are aligned to create large patterns

GEARING AHEAD TO MEET INDUSTRY'S DEMAND FOR PRECISION – SERVING – Aircraft • Aerospace • Actuation Instrumentation • Optic Robotics • Radar • Medical Marine • Defense • Experimental Prototype • Production Hi-Performance Automotive Precision Gear Products (up to AGMA Q14): Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, Clutch Gears, Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, Bevel Gears, Miter Gears, Metric Gears, Internal Gears, Idler Gears, Gear Rack & Pinion, Worms, Wormshafts, Splines, Spline Shafts, Serrated Shafts. CNC Thread Grinding 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

48 gearsolutions.com

GS-Book.indb 48 4/25/17 4:01 PM to see to ensure it will be appropriate for helicopter testing. Fabricated gearbox housings weren’t up to the task due to the following: • Mechanical design and fabrication print generation is costly and complex. • Fabricating complex housings with non- parallel sides is difficult and expensive. • Welded housings can be more challenging to accurately analyze due to inconsistencies in material and the fabrication process. • Fabricated boxes with complex geometries and acute angles can be difficult to completely weld and seal due to limited access. Figure 4: Sand mixture is hand-tucked to ensure proper compaction • Corners of fabricated housings have stress concentrations and weak points, requiring design accommodations and gussets. • Even a slight variation in welding could INNOVATIVE affect loading and vibration analysis. • Insufficient or inconsistent welding could PRODUCTION compromise structural integrity. • The design and build process, already GRINDING lengthy, was further prolonged by extensive fabrication and annealing. SOLUTIONS RedViking turned to Betz Industries, which uses the lost foam casting process. Betz has been in the casting business since 1933 and has been using the lost foam casting process since the early 1960s. Prior to that, it used wood patterns, but as model changes became more frequent, its customers required greater flexibility. “A new wood pattern was required for every new design, and wood patterns are very expensive and take a lot of time to build,” said David Moorhead, vice president at Betz Industries. “In the foundry, the pattern would need to be pulled out of PARTNER FOR the sand mold once the sand cured, then a highly skilled person would have to set all PRECISION the internal cores. Once the mold was put The JUNKER Group is the ultimate partner worldwide for all needs related back together, you hoped that cores didn’t to grinding and air filtration technology. shift and things weren’t misaligned. In Maximum precision and absolute passion comparison, the foam pattern looks exactly for what we do makes us a pioneering technology leader. It is our mission to like the part, but no cores need to be set, set new standards and justify the trust so core shifting isn’t an issue.” placed in us by discerning customers from a vast array of industrial sectors. THE LOST FOAM CASTING PROCESS Moorhead describes the process of lost foam casting: “We receive the part data from our customer. Our CAD programmer takes that model, and slices it into multiple layers ERWIN JUNKER because our CNC machines cut in three axes MACHINERY, INC. only (X, Y, and Z). The foam block, which 2541 Technology Drive, #410 www.junker-usa.com represents the thickness of any given layer, Elgin, IL 60124 USA is placed on the CNC machine table, and +1 847 488 0406 the machine mills out all of the unwanted [email protected] foam.” (See Figure 2.) MAY 2017 49

GS-Book.indb 49 4/25/17 4:01 PM Follow the Part Print it goes into the coating process. The pattern is Molding and Curing “Once those layers are all machined, they are coated with our refractory wash, and the wash “Then the coated pattern is moved into the taken to assembly, and they put that part back has two main purposes: It is the barrier between sand molding department. It’s placed on a together. They follow an instruction booklet the iron and the molding sand during the pour- steel bottom board with a steel flask around created by the CAD operator, and they rebuild ing process, and it gives the foam pattern a it. The sand is disbursed out of a mixer that part by gluing the layers together, sanding more solid structure. Once the wash hardens, it all around the pattern and hand-tucked to the seams and any surface imperfections. The becomes a very hard, ceramic-like material that ensure proper compaction. A binder and cata- pattern is checked to the print or to the solid keeps the pattern in its original shape.” lyst are added to the sand to set a specific model to make sure that everything is right. tensile strength before it’s disbursed from the Then, we ship the foam pattern to the foundry.” Blocking Provides Support mixer.” (See Figure 4.) (See Figure 3.) “From there, we go into blocking where we pre- “Once the sand cures and the mold is pare the coated pattern for molding. The block- ready, it’s rolled over, and the bottom plate is Two Purposes to the Coating Process ing provides additional structure to prevent any removed. Then, a gating system is attached, “Once the pattern is received in the foundry, twisting or bending during the molding process.” which is basically the plumbing to guide the iron’s flow into the mold. “We then put another flask on top, and Quality solutions since 1960 we mold more sand on that half. We run the gating system up into a pouring basin, and once that is all cured and set, we stage a group Shop Nordex.com of molds for pouring.”

[email protected] [email protected] Ductile Iron (800) 243-0986 (203) 775-4877 “We have three 20-metric-ton electric furnaces, each with 8 megawatts of power. We take steel, put it in the furnace, turn the EnginEEring & DEsign power on, and start melting. We add carbon, Quality Above and silicon, and manganese, depending on what Beyond Our Customer’s Expectations type of iron we’re pouring. Our experienced engineering staff coupled with “A sample of the furnace bath is taken our skilled manufacturing technicians will partner and tested on the spectrometer, making with you to produce your product. View our Online sure our base metal is within specification. catalog of standard components www.nordex.com. RedViking requires a ductile iron for its helicopter test stand gearbox housings, so additional alloys such as nickel, copper, and MEDical magnesium are added as iron is tapped out Certified and Registered of the furnace.” (See Figure 5.) ISO 9001:2008 RvA/ANAB “Once the liquid metal enters the mold, Certified Class 100 Clean Room the foam is vaporized, and the iron takes the shape of the foam pattern. Castings then have For your medical laboratory, instrument, robotics, semi- to cool for a certain amount of time, because conductor, automation or other precision application. if you pull them too fast, you could create stresses, cracking, twisting, and warping in the parts. Hold time is critical and standard- prosthEsis ized by part size.” Over 32,400 Standard Components From prototype to production. Manufacturing, BETTER STRESS RELIEF engineering, assembly, testing, custom machining, THAN ANNEALING and gears for every application. Offering a full line of In-mold cooling lowers the temperature of mechanical components: gears, pulleys, racks, shafts, the casting slower than a typical annealing and related products. oven, eliminating the need for a secondary stress relief process and provides uniform material properties. robotics Once the part is cool enough, it is pulled Utilizing the Latest Technologies from the sand mold and moved to the cleaning room. A shot blast machine removes any Find what you are looking for. remaining sand or coating, and a cleaning Custom/configurable parts. room team member removes any gates, burn- Complete quality testing. in, or burrs from the casting. The empty mold is shaken out; the sand is reclaimed, and the flask is reused for another pattern. 50 gearsolutions.com

GS-Book.indb 50 4/25/17 4:01 PM Figure 5: Liquid metal is tapped out of the furnace DESIGN AND INTEGRATION ADVANTAGES For RedViking, moving to lost foam cast gearbox housings provided additional design and integration benefits. The casting process used by Betz allows the RedViking team to cast in enclosures within the gearboxes so that they can house electronics and lubrication systems. They are able to accommodate a lot of the different input and output angles, and it ends up being a custom solution for a complex design requirement. Helicopter transmissions are large and heavy. Cast housings facilitate precise designs, such as thickening or thinning walls, depending on what they’re supporting, the location of the bearings, and the direction of forces. Corners in castings can be designed to avoid stress concentrations. Material properties are consistent and predictable, providing a stronger and safer test stand. ADVANCED VIBRATION ANALYSIS When testing helicopter transmissions, RedViking identifies and analyzes vibration on the test articles so the test stand gearbox can not vibrate or contribute any noise. With one uniform material, the analysis of the gearbox becomes simpler and more predictable. When dealing with a fabricated housing and trying to do model analysis of the structure in 3D-modeling software, all of the welded joints have to be simulated. The welding consistency has to match up with the simulation; otherwise, there will be varying results. With a solid casting, RedViking can work with the structure and the shape of the corners to affect the analysis and dial in the performance of the gearbox without worrying about all the joints. ADDITIVE MANUFACTURING? In looking toward the future of casting, Moorhead sees a place for additive manufacturing for smaller parts but expects that casting will continue to be the best option for large parts such as those for aerospace, since helicopter test stand gearbox housings can weigh between 5,000 and 10,000 pounds. FINAL PRODUCT The final finished products are the Corvettes of gearbox housings. Lost foam casting offers a way to create a highly complex, dynamic test stand gearbox with excellent vibration isolation, durability, and safety.

ABOUT THE AUTHOR: Chris Lake is the vice president of Dynamic Test Systems for RedViking, headquartered in Plymouth, Michigan. RedViking designs and builds manufacturing and test solutions for some of the world’s largest manufacturers in aerospace, automotive, defense, commercial vehicles, heavy equipment, and construction equipment. RedViking is a member of the Control System Integrators Association (CSIA). For more information, go to https://www. csiaexchange.com.

MAY 2017 51

GS-Book.indb 51 4/25/17 4:01 PM PRODUCT NEW PRODUCTS, TRENDS, SHOWCASE SERVICES, AND DEVELOPMENTS GLEASON’S 300GMSL INSPECTION SYSTEM NOW INCLUDES LASER SCANNING INTEGRATION

The versatile platform of Gleason’s 300GMSL inspection system provides the classic tactile probing methods for inspect- ing conventional gear data on spur and helical cylindrical gears as well as straight, spiral, and hypoid bevel gears with a diameter and space requirements by offering multiple aerospace and automotive industries and well- of up to 300 millimeters. In addition, the technologies on a single machine platform. suited for the inspection of high-quality gears new inspection system allows non-contact Gleason also offers its 300GMSP analyti- in other sectors of industry. laser sensor scanning of tooth flanks to sup- cal gear inspection system that was designed The closed-loop function, available for port gear development. for use directly in the production environ- many years in bevel gear production and Complete topography data can be recorded ment and yields reliable measured results in developed by Gleason for cylindrical gears more rapidly than with conventional tactile demanding environmental surroundings. To in 2015 for direct transmission of measured probing, with comparable results. achieve this, the 300GMSP has integrated data to the production machine, is part of Further options such as surface finish systems to compensate for temperature fluc- the standard repertoire of the GMS series of measurement or Barkhausen noise analysis tuations and to dampen vibration in the machines from Gleason Metrology Systems. to inspect grind burn reduce operating costs, production environment. The 300GMSP annual maintenance and certification costs, is especially suitable for applications in the www.gleason.com JUNKER OFFERS SIMULTANEOUS GRINDING WITH THREE GRINDING WHEELS

With its various sizes and numerous grinding care of the shoulder (Z/X2), while the last spindle versions, the Jumat series offers versa- spindle grinds the internal diameter and tility, and the engineers at Junker have once shoulder (Z/X3). again expanded their portfolio with the new Further advantages include the redevelop- Jumat 6S 18-20-18. The simultaneous use of ment of the gear wheel grinding, which is three grinding wheels guarantees maximum based on the use of a perfect workpiece sup- quality by utilizing a single clamping setup port. This ideal support is achieved through with an extremely short grinding time. the center clamp, consisting of hydrostatic precision manufacturing technology — from All wheel heads feature a separate X and Z bearing and precision power chuck. The low grinding tool costs as a result of extended axis, which enables simultaneous workpiece center clamp enables the workpiece to be grinding tool life to tailor-made solutions to grinding with all three grinding wheels. ground simultaneously on both sides. meet customer requirements. One grinding spindle ensures precise taper The Jumat 6S 18-20-18 shows the potential and plane surfaces (Z/X1), another takes that lies behind optimizing every detail for www.junker-group.com LIEBHERR OFFERS TECHNOLOGY FOR INTERNAL GEAR TOOTH PROFILE GRINDING

Based on its OPAL (observation, parametriza- profile grinding technology involving a belt new GH 5.0 and GH 6.0 grinding heads. The tion, analysis by Liebherr) grinding technol- drive spindle, which can be fitted to the stan- internal gear grinding arm is initially available ogy, Liebherr offers a new internal gear tooth dard GH 4.0 grinding head as well as to the in two different sizes, with other sizes to follow. 52 gearsolutions.com

GS-Book.indb 52 4/25/17 4:01 PM Custom internal gear grinding arms can successfully tested using CBN and corundum be developed to match customer workpieces. disks. Where dressable grinding disks are Gear grinding to Liebherr quality stan- used, the internal gear grinding arm travels dards is feasible for internal gears, using a up to the grinding dresser that is also used range of different grinding arms that fits the for external gear grinding. GH 4.0, GH 5.0, and GH 6.0 grinding heads. All internal gear grinding arms are modeled “Simple changeover between external and in 3D and can be used in confined spaces. internal gears takes a maximum of half an “Collision inspections are simple and hour,” said Hansjörg Geiser, head of the gear extremely reliable,” said Andreas Mehr, cutting machinery development and design who is responsible for grinding and shaping engineering team. “You detach the external technology development and consultancy at gear grinding disk or worm, hang the inter- Liebherr-Verzahntechnik GmbH. “Small- nal gear grinding arm on the hardened stop diameter internal gear teeth can therefore bars to ensure repeat accuracy, and fix it in also be machined quickly and easily.” place with a handful of screws, then tension Liebherr-Aerospace, which uses Liebherr the belt-drive disk and the belt and attach gear-cutting machinery to manufacture its the cover.” own components, is one of three first buy- Internal gears can be ground using a grinding ers of this new technology. As in the case of disk of 100 or 125 millimeters in diameter — external gears, this new internal gear teeth a Liebherr innovation. The external gear technology works with a multi-rib grinding grinding head does not have to be touched, disk system that can do rough and finish and external gear grinding quality is again the grinding. That is particularly important to same as before once the internal gear grinding users who regard speed and costs as impor- arm has been detached. tant customers from the aerospace industry, The innovative IG Opal 4.0 functions at for instance. Grinding disks made of dress- a maximum spindle speed of 12,000 rpm. able corundum or electroplated CBN can be A larger version, the IG Opal 4.1 featuring used in conjunction with the spindle. These a maximum grinding disk diameter of 125 are also manufactured at Liebherr’s plant in millimeters, is also available. Both arms were Ettlingen, Germany. www.liebherr.com KLINGELNBERG AS9100 Rev C / ISO 9001:2008 Certified ITAR Compliant UNVEILS ITS P 16 G NEW AT CONTROL 2017 Viper 500 K Internal & External Form Grinder Workpiece Diameter 500mm (19.7 inch) Workpiece Stroke 500mm (19.7 inch) Klingelnberg celebrated its premiere of the Module/DP .5-22 Mod (50-1.15 DP) Wheel Width 60mm (2.36 inch) new P 16 G: a measuring center for round Wheel Diameter 300-25mm (11.81-.98 inch) components developed specifically for use Swivel Angle -45 / +180 degrees on the production floor. The P 16 G is designed around measurement tasks outside IN HOUSE of gears. CNC Gear Grinding, CNC Gear Shaping, CNC Gear Hobbing, CNC Form Grinding, Whether turning blanks, ground work- CNC Turning & Milling (up to 5 Axis), CNC OD & ID Grinding, CNC EDM, CNC Gear pieces, circular blades, spacers for circular Inspection, CNC CMM Inspection, CAD/CAM, Jig Boring and Engineering Services. blades, or ball bearings, the latest addition to the P series eliminates the use of gages during production and quality assurance of axially symmetrical parts. In fact, the “G” in P 16 G stands for “gage.” With this latest innovation, Klingelnberg combines its experience in developing machine tools with its expertise in precision measuring 800-773-GEAR technology. www.gearmfg.com “The P series has long been a fixture in the gear manufacturing industry,” said Manufacturer of precision gears and machined parts, gearboxes, mechanical Christof Gorgels, head of the Precision assemblies and electro-mechanical assemblies for Aerospace, Department of Measuring Center business unit at Defense, Aviation, Medical, Power Generation, Oil and Gas, Optical, Automotive, Klingelnberg. “Close cooperation with our Marine and Commercial/Industrial industries. customers demonstrated the potential of MAY 2017 53

GS-Book.indb 53 4/25/17 4:01 PM Hoff Machinery 162299 ad.qxp_1/3 page vertical 1/16/1

applying the high mechanical accuracy of the Klingelnberg machine design and our powerful software in other industries and sectors as well.” The goal is to replace component- specific gages and multiple-position measuring devices, which are capital-intensive and inflexible. Therefore, Klingelnberg’s approach REBUILT is to combine all typical measurement tasks for a broad range of round components on Bryant and a single measuring machine — one designed for use directly in the production environ- Technica ment. This makes the P 16 G an economi- cally appealing strategy for direct produc- Center Hole tion monitoring. The P 16 G is a precision measuring center that is fine-tuned specifically for the produc- Grinders tion of round components in the small diameter range and optimized for use on the shop • Standard & floor. Experience gleaned from the compact Extended P 16 machine design, which Klingelnberg Length also presented at Control two years ago, was incorporated into the P 16 G. Instead of gear Models software, the P 16 G comes equipped with P 26 and P 40 Solutions for software for dimension, form, and position Gear Measurement • Work measurement. The software records diameter Klingelnberg’s P 26 and P 40 precision mea- Rotation & and cylindrical form/conicity; measures axial suring centers for small diameter ranges are Steady Rest runout, evenness, and angularity; and delivers optimal solutions for gear quality management a wealth of information for quality manage- processes. The machine and software concept Attachments ment as required. of the P series is optimized for measurement of Available. complex drive components using a technology Roughness Measurement Now Also that replaces up to four conventional measur- • All Machines Rebuilt on Internal Gearings ing machines: gear measurement, general coor- and Guaranteed to The Klingelnberg roughness measurement dinate measurement, form and position mea- New Tolerances. system, which has already been successfully surement, and roughness measurement. These used in several hundred P machines, has measurement tasks can be fully automated in now been expanded to include internal gear a single clamping. All machine models can be measurements. The possibility of carrying enhanced with individual options. This solu- out systematic measurement using a fully tion is particularly interesting for the vehicle automatic, CNC-controlled measuring run and aerospace industries with their large num- is what differentiates the Klingelnberg sys- bers of drive components; however, other sec- tem from many other roughness measuring tors benefit as well. The P series represents a devices and is why the system is valued by widely used standard in the industry and serves users. With the same benefits, the surface as a reference for metrology institutes. roughness of internal gears can now also be measured on the machines of the P series. www.klingelnberg.com Scan for Spec Sheet SANDVIK COROMANT UNVEILS ALL-DIRECTIONAL INCORPORATED TURNING CONCEPT 1325 Quincy St. NE Minneapolis, MN 55413 Cutting tool and tooling system specialist the industry’s first true “all-directional turn- Tel: 612.521.5700 Sandvik Coromant has unveiled a revolution- ing” solution. Fax: 612.521.9358 ary new turning concept that offers improved Unlike conventional turning operations, www.hoffmachinery.com machining flexibility and the potential for which have remained largely unchanged for significant productivity gains. The company’s decades, PrimeTurning allows machine shops [email protected] PrimeTurning™ methodology and supporting to complete longitudinal (forward and back), tools provide manufacturers, particularly in facing, and profiling operations with a single the aerospace and automotive sectors, with tool. The methodology is based on the tool 54 gearsolutions.com

GS-Book.indb 54 4/25/17 4:01 PM 60 YEARS ON THE CUTTING EDGE

Then and… NOW

The new PrimeTurning methodology and CoroTurn Prime A-type (left) and B-type (right) tools from Sandvik Coromant enable turning in all directions for the first time

entering the component at the chuck and delivers. PrimeTurning™ solves these problems removing material as it travels toward the end by combining a perfect reach at the shoulder of the component. This allows for the appli- and the application of 25-30° entering angles cation of a small entering angle, higher lead with excellent chip control and maintained 60 Years on the angle, and the possibility of machining with tolerances. This innovation presents countless higher cutting parameters. Furthermore, con- possibilities to perform turning operations SouthernCutting Gear & Machine Edge is celebrating ventional turning (from part-end to chuck) in much more efficient and productive ways. 60 years of leading the way in custom can be performed using the same tools. It’s not just a new tool; it’s a totally new way precision gear manufacturing. Our Sandvik Coromant believes applications of turning.” Southernongoing investment in technology Gear and could see productivity increases in excess PrimeTurning is initially supported by the Thenpersonnel and keeps... usNOW on the cutting edge of 50 percent through the deployment of introduction of two dedicated CoroTurn® of gear manufacturing, providing the PrimeTurning rather than conventional tech- Prime turning tools and the PrimeTurning highest quality gears to the world’s most niques. Some of these improvements are a code generator, which supplies optimized pro- demanding industries. result of the small entering angle and higher gramming codes and techniques. CoroTurn lead angle, which creates thinner, wider chips Prime inserts have three edges/corners — one that spread the load and heat away from the for longitudinal turning, one for facing, and nose radius. The result is both increased cut- one for profiling — thus, delivering efficient Southern Gear & Machine is celebrating ting data and extended tool life. In addition, edge utilization and longer tool life. 60 years of leading the way in custom as cutting is performed in the direction mov- Two unique and dedicated inserts are ing away from the shoulder, there is no danger offered: CoroTurn Prime A-type features precision gear manufacturing. Our of chip jamming (a common and unwanted three 35° corners and is designed for light ongoing investment in technology and effect of conventional longitudinal turning). roughing, finishing, and profiling, while personnel keeps us on the cutting edge Higher machine utilization as a result of CoroTurn Prime B-type, with its ultra- of gear manufacturing, providing the reduced setup time and fewer production strong corners, is designed specifically for highest quality gears to the world’s most stops for tool changes also enhance overall rough machining. Suitable for ISO P (steel), demanding industries. productivity. S (heat-resistant super alloys and titanium), CALL US TODAY TO FIND PrimeTurning will be particularly ben- and M (stainless steel) category materi- OUT HOW WE CAN HELP eficial to manufacturing industries such as als, nine CoroTurn Prime A-type and six CALL US TODAY TO FIND aerospace and automotive, where there is a CoroTurn Prime B-type inserts are available, WITH YOUROUT PRECISION HOW WE CAN HELP need to perform external turning operations with expansion to other materials planned. WITH YOUR PRECISION in large batch productions or where multiple The inserts are supported by 52 variants GEARGEAR NEEDS! NEEDS! setups and tool changes are often required. of toolholders, including Coromant Capto®, “Experienced operators know that a small CoroTurn® QS, and shanks. SOUTHERN GEAR & MACHINE, INC. entering angle allows for increased feed rates,” The PrimeTurning code generator not only 3685 NW 106 Street Miami, Florida 33147 said Håkan Ericksson, global product spe- ensures maximum output but also process secu- (305) 691-6300 cialist at Sandvik Coromant. “However, in rity with suitably adjusted feed rate and entry (800) 248-5152 conventional turning, they are restricted to radius parameters. It creates ISO codes that are www.southerngear.net [email protected] using entering angles of around 90° to reach compatible with various CNC systems. the shoulder and avoid the long, curved chips Cutting Edge Technology in Experienced Hands that a small entering angle characteristically www.sandvik.coromant.com

SoGearMarch2017GearSolutions.indd 1 MAY 2017 2/20/17 558:52:41 AM

GS-Book.indb 55 4/25/17 4:01 PM

CONTACT GEAR SOLUTIONS AT MACHINERY 800-366-2185 TO LIST YOUR MACHINERY.

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In addition, our Website: www.mwgear.com FELLOWS (1) 50-8 Hydrostroke Shaper s/n 36607 w/ 6 axis 16iMB Fanuc (2009) REF#105 Michigan 870, Crowning, Power Stocks, Very Light Use, Excellent REF#102 FELLOWS (1) 20-8 Hydrostroke Shaper s/n 35932 w/ 6 axis 16iMB Fanuc (2009 REF#105 National Broach GCY 18”, Crowning, Max. 19=1/2”, Rebuilt or Under Power REF#102 education courses will keep you New England Gear – REF #105 FELLOWS (1) #7 125A Face Gear Machine REF#105 National Broach GFF, Crowning, Heidenhein Scales, Servo Drives, 1993 REF#102 YOU Phone: 860-223-7778 • Fax: 860-223-7776 FELLOWS (2) #3 Face Gear Machine REF#105 Raso Sicmat 400 CNC, Fanuc 16iM, Chip Separator, 2001 REF#102 up to date on how to avoid Email: [email protected] (1) 4ags with adjustable Helical Guide s/n 30634 REF#105 gear and bearing failures, Website: www.newenglandgear.com (1) #7 125A adjustable Helical Guide REF#105 GEAR TESTERS/CHECKERS (INCL CNC) FELLOWS (3) Tilt Table 10-4 / 10-2 w/ 4 axis 21i Fanuc Controller (2009) REF#105 gearbox maintenance and Drive home Phoenix Tool & Thread Grinding – REF #106 FELLOWS (2) Swing-away center support for 10-2 / 10-4 REF#105 FELLOWS (1) RL-600 Roll Tester s/n 35814 REF#105 Phone: 216-433-7008 • Fax: 216-433-7067 FELLOWS (1) FS630-170 Hydrostroke Shaper s/n 36732 w/ 6 axis 16iMB Fanuc FELLOWS (1) 24H Lead Checker s/n 32289 REF#105 lubrication. with new Email: [email protected] (2009) REF#105 GLEASON (1) #14 Tester s/n 31907 REF#105 Website: www.phoenixthreadgrinding.com FELLOWS (2) FS400-170 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#105 GLEASON (1) #6 Tester s/n 19316 REF#105 insights and FELLOWS (4) FS400-125 Hydrostroke Shaper w/ 6 axis 16iMB Fanuc (2009) REF#105 FELLOWS (1) 20 M Roller Checker REF#105 FELLOWS (1) 20-4 Shaper s/n 35687 w/ 4 axis 21i Fanuc Controller (2009) REF#105 FELLOWS (1) 20 M w/ 30” Swing Roller Checker REF#105 technology for GEAR ACCESSORIES, PARTS & TOOLING FELLOWS (1) 48-8Z Shaper w/ 14” throated riser (53” of swing) REF#105 FELLOWS (1) #8 Micaodex s/n 36279 REF#105 FELLOWS (1) Horizontal Z Shaper s/n 21261 REF#105 Fellows 24M Involute, Response Electronic Recorder, Hot Pen REF#102 FELLOWS Model #10-4/10-2, All Parts Available REF#105 FELLOWS (1) 4-B Steering Sector Gear Shaper w/ 18iMB 4 axis Fanuc controller Fellows 36” Space Tester, Hot Pen Guaranteed REF#102 your business. Tilt Tables for 10-2/10-4, Qty 2 REF#105 s/n 34326 REF#105 Fellows 8M Redliner, 13 5/8”, Recorder (2) REF#102 FELLOWS (1) 36-10 Gear Shaper REF#105 Gleason 6, 7-1/2” Indicator Check, Pinion .00015, Gear .00001 REF#102 GEAR HOBBERS/CUTTERS CNC FELLOWS (1) 10x6 Horizontal Z Shaper REF#105 Gleason 17A Running or Rebuilt Guaranteed REF#102 FELLOWS (1) 36-6 Gear Shaper w/ 13” riser s/n 27364 REF#105 Gleason 511, 20” Reconditioned in 2010 Guaranteed REF#102 for more information, visit Pfauter PE150, 15MB Fanuc, Chip Conveyor, Auto Load REF#102 FELLOWS (1) 10-4 Shaper w/ 3” riser w/ 4 axis 21i Fanuc Controller (2009) REF#105 Gleason 502, 10”, Hydraulic Chucking, Automatic Backlash, Eliminator REF#102 Pfauter PE150, Siemens 3M, Magnetic Chip Conveyor, Oil Chiller REF#102 All Parts for 10-4/10-2 Fellows Gear Shapers REF#105 Gleason 513 20” Gear, 10’ Pinion Electronic Meter Reading of Sound (3) REF#102 Pfauter PE150, Fanuc 15, with light hob slide 8” REF#102 Gleason 515, 24” REF#102 www.gearexpo.com/gearsolutions Pfauter PE80, 15MB Control, Auto Load, Light Curtain REF#102 GEAR DEBURRING/CHAMFERING/POINTING Gleason 520, 30”, Hyd. Chucking, Auto Splash Doors/Backlash, Eliminator REF#102 Liebherr LC82 15M Fanuc Control, Auto Load REF#102 Gleason 523, 20” Reconditioned, 2010 REF#102 Liebherr LC502, 20”, Fanuc 16im, 2007 REF#102 Cross 55 Gear Rounder, 18” Chuck, Hydraulic Unit REF#102 Gleason 528 Cutter Inspection, Proximity Type Gage, 3.5”-25”, Conventional REF#102 Liebherr LC380, 440mm W/100mm Hob, 2008 REF#102 Cross 65, 10” Gear Pointer, Power Cylinder, Cutter, Change Gears REF#102 Illinois 1731-3C, Hob & Worm Lead Tester, Electronic Recorder, Master Hob REF#102 Cross 85 10” Chamfer, (2) Cutter Heads, Bevel, Spur, Helical REF#102 Illinois 3412B-3C, 12” Involute with 1606 Electronic Recorder, Master Gauge REF#102 GEAR HOBBERS/CUTTERS Samputensili SCT3 13.7”, SM2TA 10”, (5), 2003 REF#102 Illinois 3824-1-3B Spline & Spur Lead Tester, Max. Centers 52”, Networking, On-site Demonstrations, Samputensili SM2TA, 10”, Max. Face Width 4”, Hyd. Work Clamping, 1983-2003 REF#102 1606 Recorder REF#102 TOS OFA Series Conventional Gear Hobbers, 12” & 40” Dia REF#103 Mitsubishi MA30 CNC, 11”PD, Fanuc Control, Powermate, 1999 (2) REF#102 Illinois 3912-3C Lead Tester, 12”, 1607 Electronic Recorder, 1980 REF#102 TOS OHA Series Conventional Gear Shapers, 12” & 40” Dia REF#103 Klingelnberg PFS600 W/Masters, Recorder, Extras, 23.6”, 0.59-23.6” REF#102 PFAUTER P1251 Hobbers s/n 25-276 and 25-277 REF#105 GEAR HONERS M&M 3015, 15” Gear Analyzer, P2 Computer Software, 12”Mag. Chuck REF#102 AND TOP-NOTCH EDUCATION PFAUTER (1) RS-00 s/n 17593 REF#105 BARBER COLEMAN (1) 16-36 multi cycle s/n 4404 REF#105 National Broach GHG 18”, Power Stock, Crowning, Variable Speed REF#102 GEAR THREAD & WORM, MILLERS/GRINDERS JOIN THOUSANDS of design, EXPLORE A SOLD-OUT EXHIBIT GET NEW IDEAS during Lees Bradner 7VH, 8”PD, 10” Face, , Magnetic Chip Conveyor , Hob Shift REF#102 Toyo T465 CNC, 160M Fanuc 5-Axis, Power Stock, Uses Fassler Tooling, REF#102 Lees Bradner 7VH, 8”PD, 4PD, Magnetic Chip Conveyor, Hob Shift REF#102 Ex-Cell-O 36 External Thread Grinder REF#106 manufacturing and application HALL filled with the latest education sessions led by Barber C. 16-15, 4” Hob, Crowning, Differential, Double Cut, 3 DP, 1977 REF#102 GEAR GENERATORS Jones & Lamson 12 x 45 Automatic Thread Grinder REF#106 engineering professionals equipment and machines to industry experts who provide G & E 36H, 36”, Hi-Column, Differential, From AEM Toolroom, Excellent REF#102 Lees Bradner HT 12 x 54 Thread Miller REF#106 as well as gear buyers and G & E Model 48HS, 48”PD, 18” Face, 2.5 DP, Hi-Column, Heavy Duty, 8” Hob REF#102 Gleason 11 Spiral Bevel, 13”, Stock Divider, Hyd. Chucking, Roughers & Finishers REF#102 make your operations more relevant and timely solutions Liebherr L301, 12” Crowning, Double Cut, Differential, Hob Shift REF#102 Gleason 12”, Gears, Gauges Tool Blocks REF#102 MISCELLANEOUS manufacturers to network and efficient and your systems made to the challenges you and Liebherr L401, 16”, Differential, 2-Cut Cycle, Chip Conveyor, 7.566” Hob Dia. REF#102 Gleason 16 Spiral Bevel, 18”, 2-1/2 DP, Modified Roll, Chip Conveyor REF#102 build relationships that drive to the highest quality. See them your team face every day. Liebherr L402, 2-Cut, Infeed, Differential, Tangential Feed, 19.3 OD W/4” Hob REF#102 Gleason 24 Rougher, Gears, Finishing Tool Holder REF#102 WARNER & SWAYSEY #4A M-3580 Turret Lathe, 28 1/4 Swing, 80” Centers, Cleveland 1886, Hi-Helix, Hob Head, Auto Hob Shift, 4-Pitch, 1975 REF#102 Gleason 116 Rougher & Finisher (6) REF#102 12” Spindle Hole 50/25 Motors, 480/3 Phase, Year 1965 REF#104 profits for your company. in action firsthand. Gleason Phoenix 175HC CNC – 1994 REF#102 Springfield Vertical Grinder, 62" Table, #62AR/2CS, 3.5A Rail Type, 70" Swing REF#105 GEAR HOB & CUTTER SHARPENERS (INCL CNC) Gleason 22 Rougher & Finisher (8) REF#102 TOS SU & SUS Series Conv Lathes REF#103 Gleason 26 Spiral Bevel, 33-36”, Mod. Roll, Stock Divider, Coolant, Change Gears REF#102 TOS SUA Series CNC Flat-Bed Lathes REF#103 TOS OHA Series CNC Gear Shapers, 12” & 40” Diameter REF#103 Gleason Phoenix 450HC, Spiral Bevel, 150MB Fanuc REF#102 Gleason: Change Gears, Cutter Heads, Cams, Index Plates, Workholding REF#102 TOS OFA Series CNC Gear Hobbers, 12” & 40” Diameter REF#103 Gleason 610 Combination Rougher & Finisher, 1988 REF#102 G & E: Change Gears, Arbors REF#102 Columbus, OH Barber Colman 10-12, Water Guards, Dresser, Index Plates REF#102 Gleason 608 & 609 Rougher & Finisher REF#102 Barber Colman: Change Gears, Arbors, Parts for All Models REF#102 Star 2VHS, 6”x6”, Coolant, Change Gears, REF#102 Gleason 645 Spiral Bevel, Helical Motion, Chip Conveyor, Variable Rate of Roll REF#102 Liebherr: Change Gears, Parts REF#102 October 24–26, 2017 Greater Columbus Convention Center Star 4 x 4 (G691), 0-7000 Spindle Speeds, Auto Cycle, Coolant REF#102 Gleason Cutters, 3” to 25” in stock, 1000 REF#102 Reishauer: Wheel Mounts REF#102

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WHAT DRIVES Gear Expo drives innovation. It’s where power transmission and drive technology experts come to discover advancements in the gear industry. In addition, our YOU education courses will keep you up to date on how to avoid gear and bearing failures, gearbox maintenance and Drive home lubrication. with new insights and technology for your business. for more information, visit www.gearexpo.com/gearsolutions

Networking, On-site Demonstrations, AND TOP-NOTCH EDUCATION JOIN THOUSANDS of design, EXPLORE A SOLD-OUT EXHIBIT GET NEW IDEAS during manufacturing and application HALL filled with the latest education sessions led by engineering professionals equipment and machines to industry experts who provide as well as gear buyers and make your operations more relevant and timely solutions manufacturers to network and efficient and your systems made to the challenges you and build relationships that drive to the highest quality. See them your team face every day. profits for your company. in action firsthand.

Columbus, OH October 24–26, 2017 Greater Columbus Convention Center

GS-Book.indb 57 4/25/17 4:01 PM

Achieving Increased Profits KORO for Quality and Response Times Hob Sharpening Service As a leading global technology  Quick Turnaround 2 Day Service provider, this customer decided to  Spur Shaper Cutter Sharpening move their existing facility to a  HSS & Carbide Hob with center hole MARKET new location so they could and straight flutes continue to grow and advance.  Thin Film Coatings PLACE As such, any new equipment they  Length up to 7 inches

chose needed to ...  Diameter up Manufacturing excellence through Read the article: to 5 Inches Download Quick Scan or quality, integration, materials, QR Droid app to scan code  Precise rake and spacing guaranteed maintenance, education, and speed. to AGMA standards

 RUSH SERVICE AVAILABLE Koro Sharpening Service 9530 85th Ave North Maple Grove, MN 55369 763-425-5247 IpsenUSA.com/Customer-Stories [email protected]

Complete Gear Manufacturing

· Custom gear racks in AMERICAN and METRIC standards, STRAIGHT and HELICAL, VARIOUS materials, FINE and COARSE pitch (254 D.P. – 0.5 D.P.; 0.10 Module – 50 Module); hard-cut (up to 60 Rc) and soft-cut (up to 40 Rc); 32” face width; Up to 82” lengths – longer lengths through resetting · Custom gears in AMERICAN and METRIC standards (3 D.P. – 72 D.P., 10” Diameter) · Precision Quality up to AGMA 12 · Prototype & Production quantities · Breakdown Service Available PHONE: 815-874-3948 · Reverse Engineering · Unique Tooth Configurations · Heat Treating www.raycargear.com · Complete CNC Machining

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TECHNOLOGY think FIRST CLASS outside the box

MANDO G211 Segmented mandrel for gear cutting

303-447-1130 www.kapp-niles.com Made by aMerican 1.800.281.5734 • Germantown, WI USA 1-800-786-7562 craftsMen in the Usa [email protected] www.hainbuchamerica.com 1-800-storloc www.storloc.com

58 gearsolutions.com

GS-Book.indb 58 4/25/17 4:01 PM ADVERTISER NEW! INDEX Two More Services from the Experts at Federal Broach CONTENTS PAGE NO.

ALD Thermal Treatment Inc...... 40 All Metals & Forge Group...... 51 Blaser Swisslube Inc...... 30 Circle Gear & Machine Co Inc...... 10 Engineered Tools Corporation...... IBC Erwin Junker Machinery Inc...... 49 FULL SERVICE PRODUCTION Federal Broach & Machine Company...... 59 GEAR TOOL BROACHING MAINTENANCE SERVICE Flaire Communications (Hoff Machinery)...... 54 Forest City Gear...... 12 Hob, Shaper, Shave Tool, Prototype, Short Run Broach Sharpening or Full Production Gearench...... 9 & Recoating Gear Expo ‘17...... 57 NEW! TiN Coating TiCN Coating Gear Manufacturing Inc...... 53 COATINGS UP TO 107" GL Coating Super Dry 3 Gleason...... 16 Broaching Machines & Gear Cutting Tool Experts GMTA (German Machine Tools of America)...... IFC 1961 Sullivan Drive Hainbuch America...... 14, 58 Harrison, MI 48625 989-539-7420 Hardinge Inc...... 23 www.federalbroach.com Innovative Rack & Gear...... 58 Inquiry to [email protected] Ipsen USA...... 2, 58

KAPP Technologies...... 21, 58 TM KISSsoft USA LLC...... 38 UNITE-A-MATIC Koro Sharpening Service...... 58 Lawler Gear Corporation...... 58 MODEL 2020 · ID SPLINE GAUGE Liebherr...... 31 Luren Precision Chicago Co Ltd...... 37 FLEXIBLE ID GAUGE McInnes Rolled Rings...... 45 OPTIONAL: SPC CAPABLE WITH MITUTOYO MEASURLINK DIMENSIONS: Mitsubishi Heavy Industries America Inc...... BC L-16” D-16” H-10” New England Gear...... 7 WT-95# Nordex Inc...... 50 ID RANGE: Penta Gear Metrology LLC...... 41 20-75MM P & G Machine & Supply Co Inc...... 48 Raycar Gear & Machine Co...... 58 Reishauer...... 11, 13, 15 Russell Holbrook & Henderson Inc...... 38 Schafer Industries...... 35 SMT...... 36 Southern Gear & Machine...... 55 STD Precision Gear & Instrument Inc...... 48 Stor-Loc...... 58 The Broach Masters Inc...... 4 Toolink Engineering Inc...... 1 United Tool Supply...... 59 UNITE-A-MATIC.COM Walker Forge...... 39 MAY 2017 59

GS-Book.indb 59 4/25/17 4:01 PM BILL MILLER VICE PRESIDENT OF SALES AND SERVICE Q&A KAPP TECHNOLOGIES L.P.

What’s your role at Kapp? dard for vane pump slot grinding. We’ve added I’ve worked in numerous roles for Kapp Niles metrology solutions to our portfolio to match beginning in 1981, including service man- the same range of production machines. We’ve ager, application engineer, product manager, announced Kapp Niles Metrology GmbH to regional sales manager, and since 2007, vice complement our Penta Gear Metrology divi- ning in several plants. Production of conical president of sales at Kapp Technologies. I’m sion for a full range of solutions. gears for V-drives, targeting of specific tooth a graduate from the University of Cincinnati bias, as well as using generating grinding for with a BSME and owe my career path to Ford Give an example of how Kapp has prototypes are common today. Our plated tool Motor Company, where I started in 1978 as a met the needs of its customers. business remains strong, as new jet aircrafts gear lab engineer during a new transmission Kapp has been known for developing solu- have specialized gears and splines. Utilization launch. Since Jim Buschy has now retired tions to “grind the ungrindables.” Our pio- of larger CBN grains such as B852 is produc- after his 26 years with Kapp, I’ve added neering work and introduction of the precise ing metering screws from solid more eco- “Service” to my title. Service and support are CBN-plated form grinding wheel in the late nomically than whirling or milling. strengths for us, and by teaming with Michael 1970s led to essentially a stampede for Kapp Ruppert and Michael Kapp, our focus is on machines to utilize the technology. The tech- What’s in the future for Kapp? continued excellence. nology enabled the adoption and growth of One frontier is advancing process control tooth grinding from small internal splines, for long-term process capability. Digitized Tell us a little more about Kapp. using 15-mm-diameter wheels, to large process data is streamed during the grind- Kapp Technologies in Boulder, Colorado, screw compressor rotors, using wheels up to ing process to customer databases real-time serves 130 customer sites in North America 300 mm in diameter. Economical grind- as part of embracing Industry 4.0. Rapid with 500 machines in operation — the oldest ing from solid became a reality for vane measurement before and after grinding with one delivered in 1983. Our headquarters is in pumps with 1-mm-wide slots. We chose to closed-loop feedback from on-board and inte- Coburg, Germany, where two manufacturing prove every new application of the technology grated gages is another example. Kapp Niles sites are located plus a third site in Berlin, before agreeing to a machine sale. Metrology GmbH offers a portable analyzer Germany. There are over 700 employees glob- for involute and helix certification directly on ally. Kapp Niles is a family-owned business. How has Kapp met industry demands? large machines. Penta Gear Metrology offers Michael Kapp is the grandson of the founder Tooth modifications to target specific geometry pre-grind and post-grind integrated gages for and manages Parts and Service in Boulder. are now unlimited, which frees designers to real process control. We employ 35 in Boulder for service, parts, specify exact tooth forms. All software is writ- and plated CBN as well as DIA tool design ten and tested in-house. We designed and built What will Kapp showcase at and manufacture. Regional service, parts, our own CNC in 2001, which was necessary Gear Expo 2017? and sales employees are located in Mexico, to meet the precision. We were the first to offer We’ll showcase our latest generating grinding Illinois, Indiana, and Ohio, where I reside. a standard Siemens CNC for gear grinding machine series, technology, and new features Our products serve OEMs in the aerospace, without a “black box” in 1997. Remaining at the that reduce time to “first part off.” Besides automotive, energy, and construction seg- forefront of control development for advances revealing a new machine, we’ll also put an ments. We also enjoy success with small and required from CNC suppliers is essential for us. emphasis on metrology developments. Our family-owned companies that serve as tier 1 Solution Center presentation will highlight and 2 suppliers to these industries. Does Kapp offer training? the benefits of specific developments consis- Kapp Niles machines are always available in tent with the Industry 4.0 standard. Describe the machines and solutions our Boulder facility for tests and learning by that Kapp offers. our engineers as well as simulation of customer Do you envision retirement since your We build grinding machines to produce gears applications. We offer our Rocky Mountain colleague, Jim, just retired? as large as 8,000 mm in diameter to as small Profile Grinding School (RMPGS) — a fall I’m excited about new technology developments as 0.3 module. We offer specialized machine school focused on profile grinding — and a and by a recognition that America needs to series for each gear application as well as spring school for advanced training on gear emphasize manufacturing. I’m fortunate to have non-gear precision profiles. The KX series finishing methods (RMGFS). Both schools a great group of young engineers and managers delivers optimum mass production that uses devote more than 50 percent of time to grind- to coach. Dean Smith retired at 65 and advised generating grinding. Our VX series is the ing machine setup and technology. current North Carolina basketball coach Roy premium solution for aerospace external and Williams not to make the same mistake. internal gearing. The ZE and ZP series profile What are some of Kapp’s latest grinding machines serve large gear and shaft technologies? requirements, including military standards Tooth polishing added as a post process to FOR MORE INFORMATION: and demands. The HGS series sets the stan- generating and profile grinding is now run- www.kapp-niles.com 60 gearsolutions.com

GS-Book.indb 60 4/25/17 4:01 PM Choose the stick that works, cause work doesn’t stop

Cutter body HSS Blade Sets & solid body HSS straight bevel Spring loaded Cutter hardware cutters for Spiral Bevel Gears gear cutting tools body screws

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WE PURCHASE USED CUTTER BODIES IN ANY CONDITION engineeredtools.com

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Input Gear Data from process sheet or part print. Input distance from work table to bottom of gear. Our Technologies, Your Tommorow

CNC Gear Machine 2

Programming: Input Cutter Data from cutter drawing Easy as or box.

1-2-3 3

Cutting speeds and feeds automatically calculated as well as cutter paths.

Advanced Gear Cutting Capabilities at Your Finger Tips The many-generations-improved Mitsubishi CNC gear cutting machine simpliﬁ es programming like never before. It features Conversational Programming with built in macros for calculating cutting speeds and feeds based upon material hardness and gear class with no need to know complicated G-code programming like traditional CNC machine tools. For more information visit Easy to understand graphics and help screens allow new operators mitsubishigearcenter.com to master programming within a day after installation—and shops that have or contact Sales at 248-669-6136. never cut a gear before can quickly cut their teeth and expand production.

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