July/August 2005 Gear Technology

GEJULY/AUGUST 2005AR TECHNOLOGYThe Journal of Gear Manufacturing www.geartechnology.com

GRINDING & FINISHING • Opportunities for Gear Grinders • Gear Superfinishing, The State of the Art, Part II • Reducing Tooth Profile Error by Finish Roll Forming FEATURES • Gear Expo Pre-Show Coverage • The Outlook for Gear Manufacturing • Influence of Case Depth in Carburized Gears • Gear Research at Aachen • Plus: Our regular in-depth product information, events coverage and industry news

THE GEAR INDUSTRY’S INFORMATION SOURCE GEAR EXPO '05 BOOTH #422 KEEPING THE WORLD IN MOTION ™ GEAR EXPO '05 BOOTH #422

Also on display at Gear Expo: the full line of Gleason cutting tools and workholding. HIGHER QUALITY, FASTER THROUGHPUT Introducing Gleason-M&M Precision Systems, latest addition to Gleason Corporation. See the latest Gleason technology at Gleason Booth #422, Gear Expo '05:

The 245TWG Threaded Wheel Grinder The P 90 Hobbing Machine � Cuts floor-to-floor times for grinding � NEW! SIGMA 5 Gear Inspection System. � Twice the cutter drive output and 20% spur and helical gears to half that of � Quick change 3-D probe for superior more capacity than the popular P 60. conventional grinders. measurement flexibility. � Combines high cutting speeds with an � Uses Gleason multi-threaded grinding � Direct-drive linear motors for optimum extremely fast, fully integrated gantry wheels for production rates 5-10 times speed, precision and flexibility. loader system, for significant improve- faster than single-start wheels. � Windows® based interface for in-plant ments in overall cycle times. � Dresses multi-start wheels in less than connectivity; fully compatible with Gleason � Designed for dry hobbing, but can the time it takes to grind a gear. GEMS™ Expert Management System. accommodate a full range of wet or dry cutting conditions.

1000 University Ave., P.O. Box 22970 • Rochester, NY 14692-2970 U.S.A. Phone: 585/473-1000 • Fax: 585/461-4348 • [email protected] www.gleason.com

Bevel Gear Production Cylindrical Gear Production Full Line of Cutting Tools Software Application Support ��

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�� JULY/AUGUSTGE 2005AR TECHNOLOGY The Journal of Gear Manufacturing GRINDING & FINISHING Opportunities for Gear Grinders A look at some emerging trends in gear grinding...... 28 Superfinishing Gears: The State of the Art, Part II Exploring some misconceptions about chemically accelerated vibratory finishing...... 30 Reducing Gear Tooth Profile Error by Finish Roll Forming 30 A study detailing the development of a new rack-type rolling process...... 34 FEATURES

Gear Expo 2005 All the details about the gear industry’s upcoming main event...... 18

Detroit's Makeover The home of this year’s Gear Expo has undergone dramatic change in recent years...... 20 18 Outlook for the Gear Industry A European Perspective...... 22

Systematic Investigations on the Influence of Case Depth on the Pitting and Bending Strength of Case Carburized Gears 20 How too much or too little case depth can affect the life of carburized gears...... 40 Gear Research at Aachen One of the world’s top gear research centers is advancing the science of gears...... 49 DEPARTMENTS

Publisher’s Page Face to Face in the Gear Industry...... 7 Product News Reishauer’s latest gear grinder, Balzers coatings developments and more...... 8 Events 8 EMO, Gleason bevel training, a broaching seminar and other events ...... 52 Industry News

GEJULY/AUGUST 2005AR TECHNOLOGYThe Journal of Gear Manufacturing www.geartechnology.com The latest developments from the gear industry...... 58

GRINDING & FINISHING Advertiser Index • Opportunities for Gear Grinders • Gear Superfinishing, the State of the Art, Part II • Reducing Tooth Profile Error by Finish Roll Forming Use this directory to get information fast...... 61 FEATURES • Gear Expo Pre-Show Coverage • The Outlook for Gear Manufacturing • Influence of Case Depth in Carburized Gears • Gear Research at Aachen • Plus: Our regular in-depth product information, events coverage and industry news Classifieds Services, Heat Treating, Websites and Gear Manufacturing...... 62 THE GEAR INDUSTRY’S INFORMATION SOURCE Addendum Cover photo courtesy of REM Research Group. The Gear Mix...... 64

2 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com GT Jul-Oct.qxp 6/16/2005 1:10 PM Page 1

TheThe best best is will automatic be there

Visit the KAPP KX300 P at the KAPP-NILES booth #244

AND LEARN HOW TO Raise Your Bottom Line.

KAPP Technologiesechnologies 2870 Wilderness Place Boulder, CO 80301 Ph: 303-447-1130 Fx: 303-447-1131 www.kapp-usa.com [email protected]  Tarney 2 8/6/04 12:42 PM Page 57 Tarney 2 8/6/04 12:42 PM Page 57

...but can they slice a tomato? GEAR TECHNOLOGY The Journal of Gear Manufacturing

EDITORIAL • Economical • PrecisionPrecision sstocktock sspiralpiral alternative to Publisher & Editor-in-Chief Savvy gear manufacturers bevelbevel ggearsears QQ-9-9 ttoo QQ-13-13 Michael Goldstein Savvy gear manufacturers custom gears willwill discussdiscuss operatingoperating con-con- Managing Editor William R. Stott ditions,ditions, commoncommon modesmodes ofof Associate Editor Joseph L. Hazelton • Sizes up to • Easily • • tooltool failure,failure, andand desireddesired per-per- 16 inches modified Assistant Editor Robin Wright Editorial Consultant Paul R. Goldstein formanceformance resultsresults withwith theirtheir tool manufacturers to find • Engineering Technical Editors tool manufacturers to find • Robert Errichello, Don McVittie assistance • Ground tooth the best material for a given • Robert E. Smith, Dan Thurman the best material for a given available sets available operation. operation. • Carburized, hardened • ART andand matchedmatched inin setssets Graphic Designer Kathleen O'Hara

Arrow Gear engineers don’t suggest using our stock gears for cutting ADVERTISING tomatoes, but, if you need an economical gear solution, we’re ready to Advertising Sales Manager Ryan King assist you. For more information visit www.arrowgear.com. Business Development Manager Daniel Pels 2301 Curtiss Street Downers Grove, IL 60515 CIRCULATION 630-969-7640 Circulation Coordinator Carol Tratar www.arrowgear.com

Visit us at Gear Expo 2005, Booth #572 INTERNET Web Developer Dan MacKenzie

Gear Industry Home Page™ Sales Daniel Pels

powertransmission.com™ Sales Clark Hopkins

RANDALL PUBLISHING STAFF President Michael Goldstein Vice President Richard Goldstein Accounting Luann Harrold

Phone: 847-437-6604

D E A I N E-mail: [email protected] M D E A I N M � Web: www.geartechnology.com U �. S . A U www.powertransmission.com . S . A with precision Quality Gear & Machine Inc., a name synonymous with expertise in the manufacturing of precision gears. We create new or replacements for your particular needs and can help you develop specialty gears from your design. Ring Gears Spiral Bevels Worm Gears Compound Gears Splines Spur Gears VOL. 22, NO. 4 Straight Bevel Helical Gears GEAR TECHNOLOGY, The Journal of Gear Manufacturing Rack (ISSN 0743-6858) is published bimonthly by Randall Publishing, Inc., 1425 Lunt Avenue, P.O. Box 1426, Elk Grove Village, IL - From your Sample or Drawing - 60007, (847) 437-6604. Cover price $5.00 U.S. Periodical post- age paid at Arlington Heights, IL, and at additional mailing office (USPS No. 749-290). Randall Publishing makes every effort to Tell Us What You Think . . . ensure that the processes described in GEAR TECHNOLOGY Tell Us What You Think . . . conform to sound engineering practice. Neither the authors nor the E-mail [email protected] to The source you have been looking for. publisher can be held responsible for injuries sustained while fol- E-mail [email protected] to lowing the procedures described. Postmaster: Send address changes • Rate this article to GEAR TECHNOLOGY, The Journal of Gear Manufacturing, • Rate this article Quality Gear & Machine, Inc. 1425 Lunt Avenue, P.O. Box 1426, Elk Grove Village, IL, 60007. • Make a suggestion ©Contents copyrighted by RANDALL PUBLISHING, INC., 2005. • Make a suggestion AN AFFILIATE OF HY-TECH MACHINE, INC. No part of this publication may be reproduced or transmitted in any Or call (847) 437-6604 to talk to one of 531 Mulberry Avenue Punxsutawney, PA 15767 form or by any means, electronic or mechanical, including pho- Or call (847) 437-6604 to talk to one of tocopying, recording, or by any information storage and retrieval our editors! Telephone (814) 938-5552 FAX (814) 938-5592 system, without permission in writing from the publisher. Contents our editors! of ads are subject to Publisher’s approval.

4 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com 0408_Sigma_Anzeige 11.04.2005 14:22 Uhr Seite 1

One partner for all gear tasks.

Klingelnberg, Liebherr and Oerlikon. Three strong brands, which fulfill the promise of the Sigma Pool’s common logo. Unlimited system com- petence in all fields of gear technology-machines, tooling and application. At all times, in all places. More information at: www.sigma-pool.com

Visit us at Gear Expo 2005 Booth #452

For the US-market pls contact: Liebherr Gear Technology Inc. 1 4 6 5 W o o d l a n d D r i v e Saline, Michigan 48176-1259 Fo n : 0 01 - 7 3 4 - 4 2 9 - 7 2 2 5 Fa x : 0 01 - 7 3 4 - 4 2 9 - 2 2 9 4 i n f o @ l g t . l i e b h e r r. c o m SIGMA POOL · c/o Peterstr. 45 · D-42499 Hueckeswagen Visit us at Gear Expo 2005 Booth #543 PUBLISHER’S PAGE

Face to Face in the Gear Industry

Nothing beats the power of a face-to-face meeting. example, the AGMA Fall Technical Meeting is running concur- Recently the city of London was elected to host the 2012 sum- rently with the show, with more gear-related technical presen- mer Olympics, after a competition that came down to two fierce tations than ever before. Also, three separate sessions of the competitors, London and Paris. For many weeks, it seemed, Paris classroom portion of AGMA’s gear school will be held during had the upper hand, but in the end, London won out, largely due show hours. Rounding things out will be seminars hosted by to the efforts of Britain’s prime minister, Tony Blair. the American Bearing Manufacturers Association, the Forging In the closing days before the decision by the International Industry Association and SME, as well as a Solutions Center, Olympic Committe, Blair jumped on a plane and headed to where many exhibitors will give presentations on topics related Singapore—despite the fact that he was hosting the important G8 to their expertise. summit the following week in Gleneagles, Scotland. According In addition, Gear Expo will have a wide variety of exhibits, to reports, Blair met with 25 members of the IOC in those waning including suppliers of machine tools, cutting tools, materi- days, one right after the other, charming them, schmoozing them, als, inspection equipment, software and much more, as well lobbying his case. as providers of services like machine tool rebuilding, coatings Many observers, as well as members of the IOC quoted in and heat treating. Those of you who outsource gears will find a the press, attributed London’s success in large part to Blair’s last- good selection of exhibits featuring leading gear manufacturers minute campaign. The personal face time paid off. as well. In today’s impersonal age of e-mail and text messaging, it’s Many of the most important faces of the gear industry will be easy to forget how important face-to-face meetings can be, even in Detroit this October. Will one of them be yours? Gear Expo on a much smaller scale—say, the everyday goings-on of the provides many opportunities, but you can’t take advantage of gear industry. them unless you go. We all interact with others in the industry. Often, the things A lot can be accomplished in just a couple of days—just ask you learn in a face-to-face conversation would never come out Tony Blair. I’m not suggesting that every trip to Gear Expo will over the phone or by e-mail. In addition, such a meeting often result in benefits to your organization of Olympic proportions, pays dividends well into the future, as you become a face and but I’m confident there are many victories to be won for those an individual—rather than just a name and a title—to the person who come to the show. you’re doing business with. With Gear Expo coming October 16–19, we all have a tre- See you in Detroit. mendous opportunity to meet face-to-face with suppliers, customers and colleagues. P.S. For more information about Gear Expo, turn to page 18 or Many of you who make gears for a living are now extremely visit www.gearexpo.com. busy. Some of you are even scrambling for capacity. Maybe a little face-to-face time with the sales and technical experts might get your machine tool delivery bumped up the schedule, or maybe you’ll at least gain insight about when you can really expect delivery and be able to plan accordingly. The people with the answers will be at Gear Expo. Maybe you’ve been making gears the same way for a long time and you need a better understanding of competitive processes. The people with the answers will be at Gear Expo. Maybe talking over your problems and opportunities with suppliers will provide you with solutions you hadn’t thought of. Different tools, different processes, even other potential suppliers. The people with the answers will be at Gear Expo. If it’s answers you’re looking for, Gear Expo is the place— even if you don’t yet know all the questions you should be asking. I’ve always described this show as the greatest collection of gear knowledge available all at one time, in one place. This year, the show’s organizers have made some changes Michael Goldstein, Publisher & Editor-in-Chief to provide even more learning opportunities for visitors. For

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 7 PRODUCT NEWS

Reishauer’s RZ150 Speeds Up Production Bob Sakuta, president and owner of Delta Research in Livonia, MI, runs one of the world’s most highly advanced gear manufacturing cells. “We’re making these gears with total automation,” Sakuta says. “They come out of the cell without a person ever touching them.” The cell includes the complete manufacturing process: hobbing, grinding, roll testing, deburring, rustproofing, washing and turning. The cell produces left- and right-hand versions of a helical gear for automotive use—at the rate of 750,000 pieces per year. The company runs the cell for one manned shift during the day and, on average, 1.5 unmanned shifts after hours. The dual-spindle design of the Reishauer RZ150 allows one part to be loaded (C1) while another is be- Its high-tech features include the ability ing ground (C2), reducing cycle time. to contact an operator on call during the unmanned shifts. For most workpieces, the part At the heart of the cell is the RZ150, changeover time is about four seconds, the newest model gear grinding machine says Dennis Richmond, vice president from Reishauer, which was designed of Reishauer Corp. of Elgin, IL. He adds from the ground up to reduce cycle time that the machine shaves cycle time in while maintaining the highest levels of other areas as well. quality. For example, while one part is being The RZ150 comes equipped with ground, the next workpiece is pre-syn- some features that make it especially chronized to the thread in the grinding well suited for high-level production. wheel. This helps minimize idle time The most obvious of those features is the during the grinding portion of the cycle, machine’s dual-spindle design. Richmond says. And in a high-produc- “As we’re grinding one part, the tion environment, every bit of cycle time The RZ150 takes up just 54 square feet of floor second spindle is being loaded,” says is precious. space. Sakuta. “You have almost no load time. Another key advantage of the machine The RZ150 can grind parts with the That’s the biggest advantage.” is its small footprint, Richmond says. The following specifications: “The double spindle is, for us, revolu- machine itself, not including the coolant • OD of 20–150 mm tionary,” says Laslo Ferenz, senior project system, takes up just 54 square feet of • Gear face width up to 50 mm engineer at the Vehcom Manufacturing shop floor space. For companies that use • Shafts up to 350 mm (with the division of Linamar Corp. in Guelph, a central coolant system, such as Vehcom optional tailstock) Ontario. His company uses the RZ150 to Manufacturing, that means the RZ150 • Pitch rating of 1–3 module grind transfer shafts for a Big Three cus- takes up “about as much space as a small • Helix angles to +/– 40º tomer. “With other machines, you have milling machine,” Ferenz says. • Grinding wheel diameter 206–275 mm just one spindle, and you’re losing time But even when the machine is • Grinding wheel width up to 125 mm in the loading and unloading. So here, equipped with a material handling sys- Like all Reishauer machines, the there’s no additional cycle time required tem and coolant/filtration system, the RZ150 uses the continuous generation for loading and unloading.” footprint is just 15 x 20 feet. method of grinding (similar to hobbing in

8 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com PRODUCT NEWS principle) and employs a threaded wheel. machine startup, Richmond says. The Reishauer, these devices synchronize the To maximize the productivity, many encoders also tie in with the machine’s independent work spindle axes to the manufacturers use a multi-start grinding Siemens 840 D CNC control system, corresponding master axis. The EGB wheel on the machine. The machine at which continuously monitors NC axes module runs on its own computer system, Delta Research is equipped with five- to prevent potentially dangerous move- but it is embedded in the Siemens control start grinding wheels, for example. ment in the case of hardware or software system. The machine’s dressing unit is locat- failure. The RZ150’s machine interface ed on the turret assembly, rotating along Another special control feature is allows the entering of all necessary data with the two work spindles. Alignment the electronic gearboxes. Developed by from a gear blueprint. A wide range of of the dressing tools to the thread on the grinding wheel is facilitated by the Visit us at Gear Expo 2005, Booth #624 use of acoustic sensing devices and is completely automatic, Richmond says. This automatic alignment helps assure fast and accurate positioning, eliminates the possibility of damage to the tool and helps extend the life of the diamond tool, he adds. The machine’s automatic stock- dividing sensor ensures a precise mesh for the subsequent grinding operation. Located outside the working area near the second spindle’s loading position, this sensor determines the required tooth width and tooth gap for all teeth to be ground and determines the corresponding angular position for best fit of workpiece in relation to the grinding worm thread, Richmond says. Also, the system provides an added safety feature. Because it counts the teeth and determines whether the tooth widths are in the right range, the machine knows if an incorrect workpiece has been loaded and can reject that part. The RZ150 includes 12 numerically controlled axes, most of which are equipped with absolute encoders. This results in fewer reference movements at

Users can enter gear parameters via the RZ150’s interface.

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 9 PRODUCT NEWS modifications is possible via the data the operator to visually check whether employee is worth the price when con- input screen, and separate screens are the input data is correct. This allows the sidering that it takes just three operators available for tooth modifications and operator to evaluate the topology of a to run the cell and produce 750,000 parts tooth corrections. Small deviations to the gear flank, Richmond says. per year. gear flank form can be corrected via pro- With all these features, though, “It Also, Sakuta says, the maintenance gram input without changing the original takes a high-level skilled operator to staff has to pay special attention to the gear modification data. When the data make this thing sing,” Sakuta says. machine’s paper bag filtration system. has been entered, a graphic representa- But, he adds, this is not a problem Because of the high volume of gears tion appears on the screen, which allows at Delta Research. Even a highly skilled being ground, the system can fill up quickly with sludge and therefore has to be monitored. But what matters most to these manufacturers is the reduced cycle times and high throughput that this machine allows. At Vehcom Manufacturing, the grinding cycle time on the RZ150 is 25–30 seconds. “The machine is very, very fast,” says Ferenz. Sakuta’s parts are also being ground in less than 30 seconds. “There was nothing like it at the time for the throughput. If you had shown me this gear five years ago and said, can you grind the teeth in 30 seconds, I would have laughed at you. Today, this machine spits these things out, one right after the other.” The speed is essential to Delta Research. Its customer wants even more parts next year. Sakuta already has another RZ150 on order.

For more information: Reishauer Corp. 1525 Holmes Rd. Elgin, IL 60123 Phone: (847) 888-3828 Fax: (847) 888-0343 E-mail: [email protected] Internet: www.reishauer.com

10 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com PRODUCT NEWS

face hardness and support (load bear- ments,” so it calls them STAR coatings. ing capacity) for the superposed carbon The coatings, BALINIT DLC STAR and coating. The company adds that the layer C STAR are both modified diamond- also improves the fatigue and corro- like carbon coatings with enhanced load sion resistance of its parts—and provides bearing capacity. Also, a special DLC-R good wear resistance under emergency coating was designed for superior run- running conditions. ning-in performance. Balzers Introduces Self- Balzers describes the new coatings DLC-R’s extra feature comes from Supporting Diamond-Like as having “superior tribological arrange- a film of softer carbon. According to Carbon Coatings Balzers AG has created a new PVD �� coating system designed to permit greater �� load bearing capacity than its conventional diamond-like carbon coatings. �� The coatings are suitable for engine �� components, high-pressure pump parts and other highly loaded tribological applications. They can also be applied to �� components made of softer materials that �� are used in food processing machinery, �� for medical components and in the aero- �� space industry. �� Balzers developed the coatings to be �� self-supporting, so they could be used on �� materials that aren’t self-supporting and �� [email protected] that tend to have an “egg-shell” effect. These materials have low hardnesses and lack adequate support when placed under The high surface pressure. They include metal Gear Motions alloys, stainless steel, and lightweight materials. Grinding Network “We are able to coat softer substrate material,” says Raphael Mertens, Balzers’ project manager–R&D for coated components in Liechtenstein. According to Balzers, its STAR coatings include a hard, tough, metal-based �� layer of chromium nitride, providing sur- ��

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www.gearmotions.com

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 11 New Products 12/20/04 5:19 PM Page 16

PRODUCT NEWS

Balzers, the film doesn’t affect a coated and automotive companies. The cost to part’s wear resistance, but it eliminates apply a STAR coating to a gear var- wear on the mating part, especially dur- ies depending on its type and size, but ing the running-in phase. Mertens estimates the cost at $10–$50 for DLC STAR was designed for heavy- common gear geometries in low quanti- duty valve train components, piston ties. assembly parts and sliding bearings that The coatings can be applied at run against hard surfaces. five Balzers sites in Germany, Japan, The STAR coatings, each with more Liechtenstein, the United States and the than two functional layers, can be applied United Kingdom. directly onto bronze, steel, case-hard- Balzers created the STAR coatings ened steel or nitrided steel. Moreover, at the request of customers, mainly auto- Mertens says the layers can be applied in motive racing customers. Appropriately, one step in a Balzers’ The coating Innovation chamber. 200 is the company introduced the STAR coat- Gears wouldn’t have to designedbe removed to compete from ings at a motorsport show, Autosport the chamber during vacuumwith grinding processing. processes International, in January in the U.K. They wouldn’t be exposedfor the manufacture to outside of Three months later, Balzers introduced internal threads. air, where they might oxide, damaging the coatings to the U.S. market. Ground Gear the coating. Leistritz engineers say Innovation 200 “We think, especially for gears, this is For more information: Quality can cut faster than grinding but still a very important thing,” Mertens says. Balzers Inc.produces a high quality AtAt ShavedShaved Also, the C STAR coating was 2511 Technologysurface Drive., finish. Suite 114 Gear Prices tested for scuffing resistance at the Elgin, IL 60123 ® Technical University of Munich by the Phone: (800) 792-9223 New Gleason 245 TWG Gear Gear Research Centre (FZG). Mertens Grinder offers fast, accurate Fax: (847) 844-3306 and economical solutions. describes the test conditions and results. E-mail: [email protected] We recently installed a first-of-its-kind The test was conducted on an A-type Internet: www.bus.balzers.com Gleason® 245 TWG, High Speed Threaded gear using an FZG test rig and, for com- Wheel Grinder. This latest technology parison, included runs for an uncoated in high speed production grinding will meet your most demanding needs on gear and a gear with a regular carbon PRICE, on QUALITY and on TIME. coating. All the test gears were made of • Eliminate process related deviations 20MnCr5, case-hardened to 60–62 HRc, and heat treat distortion • Maintain critical size on a consistent basis and were run with RL 144, a Coordinating • Improve profiles and eliminate errors European Council reference oil, a mineral and other undesirable excitations via oil with no additives. direct drives • Affordable hard finishing using The runs were conducted with a pin- unthinkable metal removal rates ion speed of 2,250 rpm, a pitch-line • Optimize contact and load carrying velocity of 8.3 m/s, an oil temperature of characteristics via algorithmic software 90°C, and with torques ranging from 3.3 Contact Niagara Gear and put our Nm to 714.2 Nm. The test was designed world class, precision gear grinding team to work for you today. to run the gears through stage 14, with 1-800-447-2392 each stage lasting 15 minutes. Fax: 716-874-9003 The uncoated gear failed in stage 6. e-mail: [email protected] The regular carbon-coated gear lasted www.niagaragear.com 941 Military Rd, Buffalo, NY 14217 through stage 12, then started to scuff in stage 13. Mertens says the gear coated with C STAR didn’t fail, and it was run through stage 14: “This coating didn’t show any scuffing.” Balzers has applied the STAR coat- GROUND GEAR SPECIALISTS ings to the gears of gear manufacturing

12 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com The best is easy

The NILES ZE Series EASY TO INSTALL, OPERATE, OWN. Get all of the facts at KAPP-NILES booth #244

KAPP Technologiesechnologies 2870 Wilderness Place Boulder, CO 80301 Ph: 303-447-1130 Fx: 303-447-1131 www.kapp-usa.com [email protected]  PRODUCT NEWS

New The S250CD, S250CDA and S250CDX chamfer/deburring machines Chamfer/Deburring from Star SU replace the older SCT and Machines SM series in the U.S. market. A new from Star SU CDM version integrates with the S150– S300 hobbing series to offer a fully automated hobber-chamfer/deburr machine Engineered Plastic

as a standalone product for performing all Gears made of three operations with one unit. The S250CD is the basic version and operates as a standalone for flexible Calaumid small and medium lot sizes with manual loading only. The S250CDA is a standalone machine for production with automatic loading by an integrated gantry loader. The S250CDX is designed for simultaneous or consecutive chamfering/ deburring of shafts with a maximum of five different gears, or a family of different ring gears and pinions that have a common clamping system. The CDM is a chamfer/deburr unit that can be completely integrated into a hobbing machine to provide mass production solutions.

For more information: Timco’s Calaumid Gears offer the best properties of Star SU LLC both steel & plastics. The alloy core allows you to run a 5200 Prairie Stone Pkwy., Suite 100 nylon gear on the same size shaft as a steel gear, with- Hoffman Estates, IL 60192 Phone: (847) 649-1450 out the need for an enlarged keyway. Calaumid gears Fax: (847) 649-0112 are corrosion resistant, reduce noise, provide shock E-mail: [email protected] absorption and eliminate lubrication requirements. Internet: www.star-su.com

New Process Monitoring System from Marposs A new tool and process monitoring system from Marposs is designed to 1-800-792-0030 provide continuous monitoring of metal- TIMCO INC., P.O.Box 2059, Peekskill NY 10566 working processes through several differ- Tel: 914-736-0206 • Fax: 914-736-0395 ent types of sensors that enable control of Email: [email protected] • www.timco-eng.com various machine functions, thus allowing cycle optimization as well a reduction of

14 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com New Products 12/20/04 5:19 PM Page 14

PRODUCT NEWS

�� scrap and machine downtime. �� According to the company’s press �� release, five products are utilized for �� monitoring. A vibration monitor analyzes �� vibrations in rotating devices, such as �� machine tool spindles, to permit the high- �� est possible tool revolutions. �� PERRY JOHNSON �� A force monitor is included for the REGISTRARS, INC. �� direct and reliable identification and con- Visit us at Gear Expo 2005, Booth #572 trol of the strain and forces acting on the tool to optimize the cutting parameters powertransmission.com™ and production cycles. A power monitor exists for controlling the variations in the The Ultimate Shopping Mall for Power cutting process through continuous and Transmission Components absolute surveillance of power absorbed by the machine’s axis or spindles. A displacement monitor measures distances in high resolution using wear-free, non- contact sensors for applications such as automatic compensation for thermal drift. Temperature monitors sense tempera- tures in critical machine tool sub-systems such as near-moving components, like axes, gears and spindles.

For more information: Join the thousands who visit every day. Marposs Corp. Log on to www.powertransmission.com to 3300 Cross Creek Pkwy. Auburn Hills, MI 48326 find suppliers of the components you need. Phone: (248) 370-0404 Fax: (248) 370-0991 • Gears • Bearings • Motors • Speed Reducers Internet: www.marposs-us.com. • Sprockets • Actuators • Linear Motion… and more

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 15 PRODUCT NEWS

New Double Reduction Gearmotors are available with the Gearmotors from Bodine company’s 30R AC, 24A DC and 22B brushless DC motors. The double reduc- The new Type 3RD gearmotors from tion design provides gear ratios from Bodine Electric are designed for applica- 80:1 up to 3,600:1, allowing a relatively tions requiring slow rotation and high small motor to produce up to 150 lb.-in. torque, like conveyor systems, food proc- of torque, according to the company’s essing and medical equipment and press release. Gearheads are offered with factory automation. outputs ranging from 0.5–3.1 rpm. The Visit us at Gear Expo 2005, Booth #517 3RD models are unvented with bronze and hardened steel worm gears, and gearmotors carry various built-to-order shaft options including single, double or hol- Quality Spiral low-shaft configurations. In addition, the gearmotors can be face-mounted on the drive-shaft Bevel Tools side, the side opposite the driveshaft, or from the bottom of the gearhead. A/W Systems Co. is your quality alternative manufacturing source of spiral gear roughing and finishing cutters and bodies. We can also manufacture new spiral cutter bodies in diameters of 5" through 12" at present. For more information: A/W can also supply roughing and finishing cutters for most 5"–12" diameter bodies. Bodine Electric Co. Whether it’s service or manufacturing, consider us as an alternative source for cutters and bodies. 2500 W. Bradley Pl. Chicago, IL 60618 You’ll be in for a pleasant surprise. Phone: (773) 478-3515 Fax: (773) 478-3232 Internet: www.bodine-electric.com

New Power Transmission Package from Brevini The new High Power Series from Brevini combines the gear design of the S Series planetary gearboxes with modular features of the PIV POSIRED 2 family of helical and bevel-helical gearboxes. According to the company’s press release, the combination of the planetary and bevel/helical technology pro- Royal Oak, MI 48067 vides effective cooling and the ability Tel: (248) 544-3852 • Fax: (248) 544-3922 to overcome problems of increased power losses.

16 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com PRODUCT NEWS MILWAUKEE GEAR Additional features include five New Gear Lubricant COMPANY harmonically-developed sizes, nominal torque for 37,000–370,000 N-m, trans- from Klüber The Klübertop P 39-462 spray from mission ratios of 100–670, and nominal Klüber Lubrication facilitates the adjust- power from 160–950 kW. ment of load-bearing patterns in gears and is resistant to synthetic lubricants. For more information: According to the company’s press Brevini Riduttori S.p.A. Via U. Degola 14 release, the air drying inspection paint for 42100 Reggio Emilia load bearing patterns provides a contrast POWER Italy to the gear surfaces. Its good adhesion Phone: +(39) 0522-9281 enables inspection in the –40° to +200°C Fax: +(39) 0522-928200 temperature range over longer periods. E-mail: [email protected] Internet: www.brevini.com For more information: TECHNOLOGY Klüber Lubrication 32 Industrial Dr. Londonderry, NH Phone: (603) 647-4104 Fax: (603) 647-4105 Internet: www.klueber.com PRECISION

●Tight Speciﬁ cations ●In House Heat Treating New Tool Chuck ●Design Capabilities from Hydra-Lock ●Ground Tooth to Q-14 The diamond OD tool chucks from New CNC Honing System Hydra-Lock Corp. increase performance without vibration and chatter. from Micromatic Textron According to the company’s press The Microhone CNC tooling and abrasive system from Micromatic Textron release, a built-in hydraulic holder has a is designed to operate as a conventional dampening effect that allows for quick honing machine in a flexible manufactur- tool changes while eliminating vibration ing environment. and chatter. According to the company’s press The tool incorporates several diamond release, the Microhone was designed for cutters on the outside diameter while pre- use with CNC machining centers to allow cisely locating a diamond-chipped tool the manufactured part to remain in place with the hydraulic chuck. All of the tool throughout the various tool changes. holders are precision balanced. For more information: MILWAUKEE For more information: Micromatic Textron GEAR Hydra-Lock 7202 E. 87th St., Suite 114 25000 Joy Blvd. Indianapolis, IN COMPANY Mt. Clemens, MI 48043 Phone: (317) 841-8805 Phone: (810) 783-5007 Fax: (317) 841-9443 5150 N. PORT WASHINGTON RD. Fax: (586) 783-7576 Internet: www.micromatictextron.com MILWAUKEE, WI 53217-0615 E-mail: [email protected] Phone: 414-962-3532 Internet: www.hydra-lock.com www.milwaukeegear.com www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 17 JOE 8/6/04 9:19 AM Page 74

Q—What activities are going Finally, even our domestic or AGMA on within the Association to standard activities include participants incorporate some new gear from our international members. G E Amaterials R and manufacturing Several people travel several times each processes, such as plastics year to the U.S. to participate in com- 2 0 0 and powder 5 metal? mittee meetings. Other members receive It is imperative that AGMA recog- the minutes and committee documents nize the trend toward alternative mate- by e-mail and participate electronically. rials for gearing applications. EXPOSeveral years ago, we created an Q—Looking at the bigger pic- Emerging Technologies Council that ture, why should a company DETROIT, MICHIGANevolved into two distinct groups: one join AGMA? AGMA Strategic for companies that manufacture or sup- AGMA offers a large number and Objectives: ply plastic gearing and its analog for variety of programs and activities, but • Continue AGMA’sGear Expo leader- 2005—Thepowder metal gears.Worldwide These groups Gearare members Industry tell me that Event they join and con- ship role in the development developing technical standards, have tinue in the association not for dis- of domestic and international heldOctober technical workshops, 16–19, and 2005 have counts or specific programs. Rather, technical standards. participated in technical conferences they are here for three broad reasons I • Help members compete/ben-Cobo organizedConference/Exhibition by other groups. As this is a have Center categorized as access, credibility efit in global growth. newer activity, it is growing and defin- and voice. • Stimulate interest in careers1 Washingtoning itself as it grows.Blvd., We areDetroit, also look- MI 48226 in gears and gear/coupling- ing at similar groups for specific prod- Q—OK. Tell us about access. relatedAs always, products. Gear Expo will be the onlyucts, chance such in as two precision years gear heads.Other associationsYou are asked getting earlier in about the educationnetworking; game as for• much Provide of the forindustry the to long-term meet face-to-face, but this year the well, appealing towell, both that’s gear amanufacturers lot of what access and isthose about. in related Americanviability Gear of Manufacturers the AGMA mem-AssociationQ—Why is emphasizing should the aindustries. member Members have very easy access to most educationalbership component through of leadership the event. volunteer to work onThe one Forging of other Industry members Association to help solve and Forgingproblems, Defense development.New content for 2005 includes the Gearthe Expo association’s Solutions Manufacturing standards Consortiumrecognize best will practices hold a seminar and advance titled “Gear Center,• Communicate an on-floor educational important exhibit wherecommittees? companies can Forging Solutions–Simulationtheir company’s and objectives.Rapid Tooling.” When A you segment industry information in the give 20-minute presentations that are free to Members attendees. of AGMA As of canof participate the program on willlook cover closely a rapid at our tooling membership, process, more including of its most effective/efficient man- July 8, 26 companies had reserved time to anypromote of our the technical latest committeesin capabilities, for which applicationsour members and benefits. do not compete with each ner to get the desired positive equipment, processes and technology in gearthe manufacturing.primary objective is the creationAlso, and the other American than do. Bearing Manufacturers response. Members also have access to infor- AGMA is sponsoring other training maintenance opportunities of at technicalthe Association, standards. along with NSK and SKF, is sched- • Provide value to the organi- Many companies assign key employees to mation not commonly available to non- Cobo Center as well. The classroom portion of the Basic uled to hold a primer seminar titled “Why Bearings Fail.” zation and to meet and grow participate as a way for them to stay members through the several programs Gear Training Course will be led by Ron Green of The Gear End users and OEMs will provide insight on bearing design, revenue through membership aware of the latest developments in the open only to members. We find that mem- Consulting Group. Half-day courses will be offered from Oct. features and proper bearing application. growth and retention. industry and to make sure that technical bers tend to form bonds and become life- 16–18. It includes Finally, the Society of Manufacturing Engineers will provisions important to their competitive time friends with other members. standards; nomen- hold three seminars, as it has every Gear Expo for the past position are represented. It is a good way to have friends who clature; gear involute decade. The first is titled “Understanding Gear Metrology & Less formally, many of the industry’s understand what you face every day. At geometry; inspec- Inspection” and focuses on those metrology issues unique to the leading engineers tell me that—follow- one of our recent regional meetings, one tioning school—this procedures and is really gear where industry. they of the participants said that the best part interpretationlearned about gearing. of ParticipantsOn Tuesday, Oct.of AGMA 18, the meetings SME seminarwas being on in “Effective a room Heat results;have the manufactur-opportunity to sitTreating at the table and Hardeningfull of people of Gears” who understood will include what speeches he on ingwith processes, the industry’s includ- top expertsevaluating in every alternativewas sayingheat treating when he methods used industry and controlling jargon. the ingfield hobbing, of gearing. shaping process. and Itshaving; may not trouble- be obvious to Thethose following who Q—What day, SME about will introduce credibility? a discussion on shootingdo not participate, the gear but those“Advanced companies Gear ProcessingCredibility and is Manufacturing.”shorthand for the Participantsben- manufacturingand individuals who proc- developwill a discuss standard the investigationefits that come of tochronic those companiesproblems, factorsthat that ess;are the improvements ones who know itimpact best. You tool will life andopenly performance, state they asare well part as of compare this indus- the latest infind productivity; that the companies and thattechnologies. are recog- try. AGMA membership is such a state- discussionnized as the ofindustry’s com- competitiveSpecific and times,ment. locations, A few timesdates each and year,prices I getof aseminars fran- will montechnological problems. leaders alwaysbe available have at a www.gearexpo.comtic call from someone as Gear who Expo “must” nears. join staff person at these meetings. AGMA immediately because a contrac- AGMA’s Gear Expo. 62 SEPTEMBER/OCTOBER 2004 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com 18 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com For those who also want the personal interaction of a trade show, Gear Expo 2005 promises not to disappoint. According to Kurt Medert, AGMA vice president–business management division, the figures are adding up. In 2003, there were 152 companies exhibiting at the show. As of July 8, 2005, already 148 companies had made deposits guaranteeing booth space. “Our goal for 2005 is to get 175 exhibitors,” he says. “The economy is good and people are busy, so we are very optimistic.”

The registration fee for Gear Expo is $15 through September 30. After that date, registration is on-site and costs $30. For more information, visit www.gearexpo.com.

AGMA’s Fall Technical Meeting Beefs Up Programming

This year’s AGMA Fall Technical Meeting, which will be “Hypoid Gear Lapping Wear Coefficient and Simulation” by C. held Oct. 16–18 in conjunction with Gear Expo at Detroit’s Gosselin and Q. Jiang. Cobo Center, will have a record-breaking 21 presentations. Special presentation of the new AGMA bevel gear rating suite Bill Bradley, vice president of AGMA’s technical division, by the AGMA Computer Software Committee at the end of says that this year’s format has been adjusted to accommodate Session II. the increased number of presentations. In previous years, the Fall Technical Meeting has consisted of four sessions with Session III—Innovative Application Solutions four to five papers each. In 2005, each of the four sessions will “Finite Element Study of the Ikona Gear Tooth Profile” by J.R. cover five to six topics. In addition, the first session will be Colbourne and S. Liu. held Sunday, Oct. 16 to allow time on Monday for visiting the “Low Loss Gears” by B.-R. Höhn, K. Michaelis and A. Wimmer. exhibition floor. “Modal Failure Anaysis of a Gear and Drive Ring Assembly” The exact content of each technical session is yet to be by D.D. Behlke. determined, but is tentatively arranged as: “Evaluation of the Scuffing Resistance of Isotropic Superfinished Precision Gears” by P.W. Niskanen, B. Hansen and L. Session I—Manufacturing and Testing Gears Winkelmann. “Molded Plastic Face Gears: Design and Manufacture” by I. “Determining the Shaper Cut Helical Gear Fillet Profile” by G. Lian. Laskin and E. Reiter. “The Effects of Pre-Rough Machine Processing on Dimensional Session IV—Making Gears Work for Life Distortion During Carburizing” by G. Blake. “Repair of Helicopter Gears” by S. Rao, D. McPherson and G. “Modeling Gear Distortion” by P.C. Clarke. Sroka. “The Development of a Three Disc Micropitting Test Method” “H47D Engine Transmission Input Pinion Seeded Fault Testing” by M.G. Talks. by J. Petrella, J. Kachelries and S. Holder. “Tooth Meshing Stiffness Optimization Based on Gear Tooth “Influences of Bearing Life Considerations on Gear Drive Form Determination for a Production Process Using Different Design” by F.C. Uherek. Tools” by U. Kissling. “The Application of Very Large, Weld Fabricated, Carburized, Hardened and Hard Finishing Advanced Technology Gears in Session II—Hypoid and Bevel Application Design Steel Mill Gear Drives” by R. Drago. “Simulation of Face-Hobbing Process for Hypoid Gears: Surface “Planet Pac: Increasing Epicyclic Power Density and Generation, Contact Analysis and Fillet Stress Calculation” by Performance Through Integration” by D. Lucas. A. Piazza and M. Vimercati. “Analysis of a Dual Drive Conveyor Failure” by M. Konruff. “A Model to Predict Friction Losses of Face Hobbed Gears” by H. Xu, A. Kahraman and D.R. Houser. The registration fee for the Fall Technical Meeting is $525 “Spiral Bevel and Hypoid Gear Cutting Update” by T.J. Maiuri for AGMA members and $795 for non-members. For addi- “New Developments in Tooth Contact Analysis for Bevel Gear tional registration information, contact the AGMA by tele- Drives: A Universal Surface Generation Algorithm and Finite phone at (703) 684-0211 or on the Internet at www.agma.org. Element Model” by Qi Fan and Lowell Wilcox.

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 19 MichiganMichigDETROIT an “The World is Coming” is plastered on billboards throughout downtown Detroit, and that’s never been more true than in the next six months—when thousands of sports fans will descend on the town for Major League Baseball’s All Star Game and the NFL’s Super Bowl XL. Another important group to hit the new Northwest terminal at Detroit’s Metro Airport? The gear manufacturing community! A Model T accelerates through Greenfield The face of downtown Detroit has changed since Gear Village. Credit: The Henry Ford. Expo 2001. Notably, a $500 million redevelopment of the GM headquarters at the Renaissance Center (200 Renaissance Center) is now complete. The Marriott Renaissance Center, an AGMA-approved hotel for Gear Expo, is situated in Michigan’s tallest structure and opens up to an unob- structed view of the Detroit River. The lower levels of the Renaissance Center include a vehicle center housing 35 GM production or vintage vehicles. The electric-powered cars on the floor can make for great conversation tidbits on the Cobo Comerica Park welcomes the All-Star game. Credit: Vito Palmisano. Center floor or at the Renaissance Center’s Coach Insignia restaurant. It’s worth a trip to the 72nd floor just to hop on the famous Lily Tomlin (Detroit native) chairs or check out the GM logo that actually stretches more than 20 stories high. While sipping martinis or swishing wine at the Coach Insignia’s lounge, visitors are treated to an uncompromised view of Casino Windsor, located just across the river. This year, gamblers don’t need passports to play the slots. The MGM Casino, MotorCity Casino and Greektown are all Las A good investment for show-based Vegas-sized and bustling with activity at any hour. Commissions. Credit: DMCVB. Greektown Casino (555 E. Lafayette Ave.) houses Detroit’s only blackjack room—perfect for company bond- ing at the tables. When you cash in your winnings, stop for some saganaki in one of Detroit’s most vibrant neighbor- hoods. Family-friendly entertainment options are available as well. The Henry Ford Museum (20900 Oakwood Blvd., Dearborn) is home to the vehicle in which JFK took his last ride, as well as the famous Rosa Parks bus. The Ford Rouge Factory Tour is housed within The

The underwater Polar Passage. Credit: Vito Henry Ford Museum and debuted to the public in May 2004. Palmisano.

20 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com Visitors take a walkway to the Ford F-150 truck assembly plant Where the Gear Industry Sleeps for a panoramic view of the 2-million-square-foot facility. *To receive the negotiated group rate, all hotel Approximately one-third of a mile through the plant, visitors reservations must be made by September 26, 2005. can see key points in the final assembly process. The Legacy • Detroit Marriott Renaissance Center—$149/night. Lobby houses a 1929 Ford Model A Roadster, a 1932 Ford V8 Reservations: (313) 568-8000 or (800) 352-0831. Victoria, a 1949 Ford Club Coupe, a 1956 Thunderbird and a AGMA discount code: gexgexa. Three blocks from the Cobo Center with indoor access to the People 1965 Mustang. Mover. In that same vein, the Detroit Historical Society (5401 • Detroit Downtown Courtyard by Marriott— Woodward Ave.) contains a car body slowly dropping on the $139/night. Reservations: (313) 222-7700 or (800) assembly line, using the actual machinery from the Clark St. 321-2211. AGMA discount code: AGMAGMA. Cadillac plant. Accompanying exhibits break down each Detroit Located across the street from the Detroit Marriott community’s unique contribution to 100 area automobile Renaissance Center and complex. Indoor access to the People Mover. Room renovations currently companies. underway. Mexican muralist Diego Rivera expanded on life at the • Hotel Pontchartrain—$129/night. Reservations: Rouge plant in his 1932 fresco that occupies two entire walls (313) 965-0200. AGMA discount code: at the Detroit Institute of Arts (5200 Woodward Ave.). The AMGEA. Located directly across the street mural was commissioned by the Ford Motor Co. and Edsel from the Cobo Center. Guest rooms, common areas, Ford, president of the Arts Commission, to provide a glimpse lobby currently under renovation. into the daily production and manufacturing operations for the • Holiday Inn Express Hotel & Suites—$109/night. 1932 Ford V8. Reservations: (313) 877-7000 or (800) HOLIDAY. AGMA discount code: AGM. Located within No doubt, Gear Expo will be time-consuming, but dozens two blocks from the Cobo Center and a of additional entertainment options exist beyond the half block from the People Mover. Renovation com- boundaries of the exhibition hall. For more information, pleted in 2003. visit www.visitdetroit.com. Room reservations can also be made at www.gearexpo.com.

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www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 21 A EUROPEAN PERSPECTIVE

Hagen H. Hofmann

Hagen Hofmann, president of Höfler GmbH, the German manufacturer of gear grinding machines, presents his views on global trade, competition and the future of the gear industry.

In the coming years, we will be faced who in many cases seek cheaper suppliers different at our competitors. We all slept with increased competition from all over on the Internet and purchase gears in innocent, with no reason to bother about the world. Modern, fast communication online auctions. All of a sudden, many of improvements and higher performance. systems will increase the pace even more. us are in a situation we had never even We all had our customers and market Global trade invites nations with hungry thought of. shares, almost without competition. people to participate in the market, and But it’s not the fi rst time something The bitter wake up came, absolutely they are willing to work for any price. like this has happened. From my own unexpected, when the Iron Curtain got Because we are not able to compete with experience, I would like to tell you how holes in it. The Berlin Wall collapsed and these wages and other price-reducing my company reacted in a similar situation communism lost its power over Eastern factors, we must fi nd solutions to and what we did to solve the problem. Europe. Almost everything changed maintain our market share and even to Höfl er has manufactured gear grinding overnight. increase it, although it would sometimes machines since 1966. With the exception The Eastern Bloc stopped buying be better if we changed our traditional of minor improvements, the fi rst design machines. Germany lost more than 30% businesses completely and became more was sold worldwide from 1966 until of its machine tool export markets. Many specialized. 1981 almost unchanged. For 15 years, companies went broke or out of business, Global Trade the machines had the same grinding time, including famous names. Our main East Global trade does not always work the same achievable accuracy, and the German competitor was all of a sudden in our interest. We cannot depend on the same complicated setup. We weren’t the a Western company, which received loyalty of our regular customers anymore, only ones who did it like that; it was no tremendous government support to

22 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com slow machines, but their operating costs were low, with wages being a fraction of ours. The challenge for us was to survive together with our longtime customers. Many gear grinding machines were installed in companies all over the former Eastern Bloc. Those companies were restructure and to invest. customers called and asked if we could seeking work because their markets, And yet, this threat was exactly what help them, because they were not able to mostly Russian, were gone, too. They the company needed to wake up—to compete against companies from Poland, had the advantages of cheap labor, stand up and ﬁ ght for survival—for the Czechoslovakia and East Germany selling machines that were long written off, and ﬁ rst time in our history. in their traditional markets. governments helping their clientele to And it was not only us. Our longtime Those eastern companies had the same accept orders below cost.

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 23 There was only one way for us workers, with a minimum of to survive: Develop faster and less research and development, expensive machines—machines marketing and labor costs. our customers would buy in order The company pays wages to stay in business. amounting to $160–$180 per We had to redesign our month, which is roughly $1 complete manufacturing program per hour. This is about one- and to build completely new twentieth of what we have to and different machines, without pay our workers in Germany compromise, in the shortest even before all the social and possible time. Those machines had tax costs. to be less expensive to buy, yet With one-twentieth of the run faster and more economically cost per worker, guess who than all the machines we had ever will make more money, the built before. original or the Chinese copy? From the beginning, it was This is hard to beat. The evident that we had to design original has only one choice if everything differently from those it wants to stay in business in expensive machines that were already Asia: Go there and start a business, too, available on the market. We used mineral Their wages are rising faster than ours. which the company did. cast material for the heavy machine Soon, the difference will be insignifi cant. Because of their expected limited parts instead of cast iron, which made The danger is over. quality, those copied motor drives will— us independent from steel prices and But many of us now are concerned in the beginning—probably be sold in lowered machining cost, besides other with new foreign competitors, not Asia only. technical advantages. just in our own backyards, but around They surely won’t come to Europe. We replaced the expensive worm and the world. But they ruin the market in Asia for the worm gear drives in machine tables with China: Opportunity and Threat original. A well-known company, with an much better and more accurate direct I have visited China and Korea on already existing export market, may want drives. We standardized components to a regular basis since 1974—30 years— to live with this competition or go into the use them in many different machine sizes, on average three times a year. After lion’s cage as well, to beat the competition and so on. my fi rst visits to China, I was largely with their best weapon—the wages. And Believe it or not, today, a 48" grinder convinced, especially with its communist indeed, fact is, more and more companies costs about half what it cost only three to regime, that China would need a long, go to Asia to produce there, to participate four years ago. And it is a lot better and long time to become an industrialized in the incredibly fast growing market. more universal-to-use machine. nation, being too far behind to keep up And there is nothing wrong with it. Our With these new machines being more with our technology. I’ve had to change automobile companies, for instance, have than fi ve times faster, labor cost all of my mind in the last three to fi ve years. done the same for a long time already a sudden was no longer an issue. Our One can witness almost daily how fast without selling one car fewer made in customers were back in business. things happen. their homelands. The problems for our customers were Last year, I visited a brand new But who of us can go to China? solved, but only for those who invested company built and getting ready to The answer is very, very few. in new equipment. All others continue compete with the biggest German And we cannot produce gears in China to compete with their slow, outdated gearmotor manufacturer. A 140,000- and tell our German customers they are equipment, battling rising labor costs— square-foot manufacturing building under made in Germany. in my opinion, without a future. These one roof was waiting to be furnished with We cannot buy open gearing there and machines might earn the salaries of the modern machine tools. Some of them had only put them together here. What if those operators but will not contribute a single already arrived and were being installed. gears are not of the expected quality? dollar for new equipment. The offi ce building was extremely Would you want to discuss warranty In the meantime, the equipment that representative, made from granite and questions in Mandarin with your Chinese former Eastern Bloc competitors brought marble, and it was equipped with modern supplier, over thousands of miles? into the market is now more than 15 furniture and electronic communicating Would you like to go to court with a years old and ready to be replaced, if the systems. Once fully operative, the Chinese company in case they delivered funding is available. Mostly, it is not. company will employ more than 500 substandard gears? How about liability?

24 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com Would you want to check thoroughly very normal thing. I, for instance, live 10 comparable wages, taxes, etc., and pay the gears you receive and maybe have miles from France and 120 miles from the same prices for steel, bearings and to rework them? Your calculated profi t Switzerland. castings, where is the difference between would be gone. We go to other countries for shopping, one and the other company? Why do No, this is no solution for us. even for lunch and dinner. I grew up some do very well and others not? I am strongly convinced that Chinese calculating exchange rates. There must be a difference. Or do companies start looking for business in I believe Europeans have an advantage some have better sales guys? I doubt it. their own neighborhood, in Asia. This over the average American when it comes It has to have something to do with the market is much bigger than we expected, to international trade. If you are living so methods we use to make these gears and it’s developing extremely fast. They close to each other, you cannot survive and the grade of specialization some will try to enter our markets only if the not knowing your neighbor, not knowing companies have developed. quality of their products is comparable your competitor. Knowing what he does is Specialization with ours. of substantial importance. But you do not During the last 10–15 years, I have If this happens, we’ve done something want to copy; you want to differentiate, noticed in Germany a very strong trend wrong. develop your own profi le. You constantly towards specialization. If we continue to struggle month after have to be more inventive and you have to All the bigger companies reduced month to work for the paycheck only, sell it harder with very good and proven the number of their product lines and instead of planning ahead, and to line up facts. It is simply a matter of survival. their activities. As an example, there is and strengthen our corporations to meet a big gear manufacturer where you once new competitors, we will have the same could order a single gear or a tailor-made problem I had with my company 15 years gearbox. No longer. The organization has ago. I woke up surrounded by enemies, become so specialized, it cannot handle and it was almost too late. The day they small orders anymore. By the time you knock on our door and ask to come in would get a quote, a smaller company will come sooner than we expect, so get would already have shipped the product, prepared. and time is money. But couldn’t that happen at home as Instead, the company now con- well, with our next-door competitor? centrates on making large numbers of wind power gearboxes in all sizes, especially European Perspective? big ones. Because this business is highly Although I don’t believe Europeans fl uctuating, only 50% of the company’s have different strategies than Amer- gears are made in-house. The rest is icans—we all want to survive and subcontracted, but only to those who can prosper—I do believe there is a remark- In this very competitive environment, cope with the specs—and these are tight. able difference between our industry in profi t margins are thin, unless you have In doing so, the company keeps its own Europe, especially Germany, and the gear something new to offer. Inventions, equipment loaded over three shifts, and industry in the U.S. however, come seldom in the gear the risk of fl uctuation is with the small We live much closer together. If industry. We can state that gears have suppliers, who can handle fl uctuations you think you know all the German already been invented, just like the fork, much better. companies, you start learning about the knife or spoon. Everybody can make These wind power gearboxes become Italian, Spanish, British and others. Every gears—if we speak about the normal gear. bigger and bigger. Small companies year, more nations join the European But, if we all use the same equipment, pay cannot jump on this business because of Community with all the advantages the high investment cost for big production this huge market has to offer. And machines. Internal gear cutters and they all compete against each other. grinders, machining centers for planetary We communicate in so many different gear housings, test stands and so on are languages that we need to be very fl exible. just too much for a smaller company. Try to sell a Frenchman a gear using the Today, the wind power manufacturers English language. Not only does he not are highly specialized; they are a closed understand, he simply does not want to society. You will fi nd this trend all over. understand. You have to talk to him in Specialization warrants the optimum French. We export and import all the use of the equipment and perfects time and know foreign currencies as a the product.

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 25 graduated mechanical engineers in a very Wind Power profi table business. practical way. Often declared dead, wind power is This could be as a specialist in large The industry offers apprentice training as alive as ever. Being the second biggest series production or as a repair business over a period of 3.5 years, normally steel consumer after the automobile with close customer contact. It does not for approximately 5% of the total industry, wind power has created matter what we do as long as we specialize numerous new jobs in all areas. instead of trying to dance at every The German gear industry, like party. no other, invested very early in In any case, we need to the research and development be prepared for meeting new of this technology. Fortunately competitors. The good news is, the companies were able to new markets are also offering start with small units in the be- new opportunities for us. Three ginning, gradually increasing billion people who one day want the size to ever-higher kilowatt to live like we do have all kinds output. Five years ago, a 650- of needs and desires. Great things kilowatt unit was standard. can be achieved in the building Today we are building gearboxes of power plants and transport for up to 5 megawatts of power. systems, the providing of health Internal, helical planetary ring care and supplying of water. gears with 100" in diameter are However, they will be able to pay in sight. for it only if they are allowed to Often erected close to housing areas, sell their services to us. Headline: number employed. This training might wind towers, which can be more than Global trade. In the beginning they pay for be complemented by further education 300 ' high, have to run quietly and reliably. it with cheap labor, with manpower. Later up to various grades, including access Correspondingly, the requirements on they will want to supply cheap mass to university studies. University and for these gearboxes are high. Every products, including, possibly, gears. apprenticeship are cost-free to the student. manufacturer advertises his product with Therefore many of our companies The apprentice even gets a remarkable the argument of having quiet running must get prepared for this new situation, monthly payment. Unfortunately, it’s still gears. His secret is the know-how to get and, if necessary, must change their not enough. there. But one property they all have manufacturing programs. in common: The normal, unmodifi ed The Outlook for Gear Manufacturing We cannot resist this pressure. We In my opinion, there will always be gear tooth is history. Totally new tooth cannot withstand the attraction of low- gears—at least for a long, long time. geometries were developed and optimized cost products for a long time. Changes We will continue to increase their in practical tests. And good for us machine don’t come easy. They are like big ships: effi ciency and life and try to produce tool builders; they cannot be produced on You turn the steering wheel and nothing perfect gear reducers needing as little old machines. Sub-suppliers to the wind happens. The ship goes on straight. maintenance as possible. Some gear power industry are accepted only if they Only slowly will it change its direction. applications will certainly be substituted have the know-how to grind all kinds of Therefore, if we accept what’s happening, by electrical or other alternative drives. modifi cations without distortion. Also, let’s turn the wheel early enough to avoid Other applications will come into being after grinding, the gears must be nital any collision that could ruin our industry. (example: wind power). etched for tooth burning—100%. The future of our gear industry, An earlier version of this article The Need for Education whether in Europe or the United States, was presented at the 2004 AGMA For this very demanding new also depends on our ability to comply Annual Meeting in Tucson, Arizona. technology, we must realize how with the ever-growing requirements and important it is to educate people on topics to accept new technologies. This won’t be like gear noise, tooth load, surface fi nish cheap. In fact, it will be almost impossible and lubrication, just to name a few. And for the smaller companies. Education and in this point I believe there is another science are prerequisite for our success. difference between Europe—especially Furthermore, it will be necessary for Germany—and the United States. companies to position themselves to use By tradition, German technical their best know-how, to specialize and universities educate a high number of fi nd a niche where each one can run a

26 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com Page 19 8/6/04 8:23 AM Page 1 Page AM 8:23 8/6/04 19 Page CERATIZIT USA Inc. 777 Old Clemson Road Columbia South Carolina 29229 Toll 1902 736 1165 29229 803 Carolina 334 free: Fax: 800 South Columbia Road Clemson Old 777 CERATIZITInc. USA technology! cutting gear the for solutions Clever allowance. grinding minimum and tolerances tight grades, micrograin class First hobs: for blanks carbide CERATIZITsolid G e a r

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www.ceratizit.com Opportunities for Gear Grinders— Insights from the Machinery Front Tom Lang, Vice President, Kapp Technologies Tom Lang Economic times have definitely turned the corner in our large investments, they stayed out of the market. The current industry. Interest in gear-related products is soaring again. trend is allowing these companies to enter those markets previ- However, many large companies aren’t as eager to spend their ously unavailable to them. Outsourcing allows everyone to have own capital on new machines as they once were. Our largest a share in the profits with a reduced risk of investment. corporate customers are still purchasing equipment, but they are As an example, a longtime customer of ours had been not buying enough equipment to manufacture 100 percent of manufacturing low- to medium-lot quantities of high precision their requirements. Instead, they are turning to smaller compa- gearing for many years. Recently, this customer was awarded nies to do the work for them. a long-term contract to provide thousands of parts per month Outsourcing can be successful for several reasons. Many from a large manufacturer that normally produced all of its smaller companies have wanted to get into hard finishing gears in-house. gears, but with the uncertainty of sufficient business to justify In another case, we recently delivered a machine to a new customer that landed its first contract for hard finishing gears from another, larger corporation. Again, our customer was able to justify the machine purchase based on the larger company’s outsourcing program. Along with the move towards outsourcing, quite a few of the smaller companies have implemented automation technology to meet their increased production needs. American manufacturers have traditionally been very labor intensive, but in order to compete in the global market, we have had to find ways to minimize our labor content. In years past, one way to minimize labor was to build cells or groups of machines with one operator loading two to four machines. However, with many current cycle times running at 60 seconds or less, it is impossible for one man to load and unload any more than one machine at a time. One way to solve this challenge is by using efficient and affordable automation systems. Automated systems aren’t new. They were invented and first installed by the automotive industry years ago. Today, many small machine shops are adopting similar technology to improve their efficiency and consequently increase their com- petitiveness. Overall, the process is simple. A machine is set up to automatically run enough parts on a carousel or in a magazine for one or two hours, or for an entire eight-hour shift. Therefore, the operator can still run multiple machines, and labor expenses can be once again reduced dramatically. Not only does automation effectively reduce labor costs, it Figure 1—Automation is no longer just for the automakers. Even the smaller increases machine productivity. It’s not hundreds of thousands shops have significant opportunities to reduce labor costs and production times of parts that are being run on these machines, it’s the few by integrating automation. hundreds to low thousands—this is an entirely different level of automation.

28 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com Even though automation technology has been around for a decade, 10 years ago it was very expensive, and five years ago, no one was in an economic position to utilize it. All of that has now changed. Quite a number of companies are now seriously looking at automating their processes. Not surprisingly, many of these companies have relatively few employees for their output. They look first at how the process can be automated with the goal of “0” labor content. These are the companies that will prosper in tomorrow’s market. The fact is that when you have six or seven major U.S. automotive projects going on at one time, you know that the The Kapp KX 300P is offered with complete automation packages. economy is on the upswing. What is different than in previous times is that only about half of these programs are slated to be For More Information: manufactured by the automakers themselves. The others will be Kapp Technologies 2870 Wilderness Place outsourced. Boulder, Colorado 80301 At Kapp-Niles, we continue to invest in new technology, Phone: (303) 447-1130 and our engineers are challenged to produce new and innovative Fax: (303) 447-1131 products for our industry. For example, we have recently intro- E-mail: [email protected] duced a new machine series with integrated automation. It’s all Internet: www.kapp-usa.com about being competitive in the world market.

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�� Also�� visit us at the coming �� EMO show in Hannover �� 14-21,�� September 2005 for broaching talk ��

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www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 29 ��

��

�� SUPERFINISHINGTHE STATE OF THE ART, PART GEARSII Superfinishing Gears THE STATE OF THE ART, PART II Gary J. Sroka and Lane Winkelmann

Management Summary Chemically accelerated vibratory finishing of gears using high density, non-abrasive ceramic media has gener- ated much interest among gear designers and users. Increas- ingly, this gear superfinishing technology is being used to solve real-world problems. However, implementing of this technology has been hindered by several mis conceptions. In a previous Gear Technology article, the authors identified and discredited two misconceptions surrounding this gear superfinishing process. In this article, they dis cuss three more misconcep tions. Their discussion includes evi- dence supporting that the performance benefits of superfinished gears are real, that the process can reduce gear noise/ Introduction dimpled surface were required to facili- vibration/harshness, and that More than eight years ago, chemically tate oil retention. superfinishing doesn’t distort accelerated vibratory finishing using high The second misconception was gear geometry. density, non-abrasive ceramic media first that the relationship between surface appeared in the gear industry. rough ness parameters and component Gary J. Sroka is research & devel- As with any new technology, well- functionality was not well understood, opment manager for REM Research Group Inc., located in Brenham, intentioned opposition is usually present and required advanced mathematics and TX. He holds a doctorate in physi- before there is widespread acceptance. sophisticated software to master, leav- cal chemistry. His research interests Chemically accelerated vibratory finishing no simple method of determining include development of new products ing—superfinishing—has often faced which surface would exhibit the desired and processes for superfinishing gear such opposition because of several mis- performance. and bearing alloys using chemically conceptions. In our prior article, we showed that accelerated vibratory finishing. In Gear Technology’s November/ superfinishing gears using high density, Lane Winkelmann is a senior December 2003 issue, we identified non-abrasive ceramic media did in fact research associate at REM Research and discredited two misconceptions sur- produce an isotropic micro-texture on the Group. He has developed proprietary rounding this gear superfinishing proc- surface that facilitated lubrication. The products and processes for the super- ess. The first of these was the notion that superfinished surface was free of stress finishing of stainless steels, brass, gear teeth with mirrorlike surfaces would raisers, distressed metal, and peak asperi- and carbon steel alloys and has not exhibit adequate lubrication properties—all of which would reduce the life published several gear-related tech- ties because residual machine lines or a nical articles. of a gear.

30 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com Also, laboratory and field tests supported the conclusion that monitoring of only average roughness (Ra) was necessary during the process in order to attain the best surface. It was shown that an Ra of < 3.0 µin. (0.08 µm) ensured optimum per formance benefits (Ref. 1). In addition to those two misconceptions, there are three more that need to be addressed: 3.) Superfinishing has no supporting theory, so its performance benefits must be looked upon with suspicion. 4.) Superfinishing doesn’t reduce noise/vibration/harshness. 5.) Superfinishing distorts gear Figure 1—Graphic showing the interaction between surfaces with the same nominal Ra. The upper graphic illustrates random surfaces brought into contact. The bottom graph- geom etry. ic shows two planarized surfaces brought into contact. The film thickness required to sepa- Misconceptions rate the planarized surfaces is much less than that required to separate the random surfaces. Misconception No. 3. Superfinishing has no supporting theory, so its per- Spiral bevel gear sets, having high ed because the process has an inher- formance benefits must be looked upon sliding ratios, especially benefit from ent char acteristic: It will remove more with suspicion. superfinishing. The process not only stock from the tip of a gear tooth than Gears, like many inventions now reduces noise/vibration (Refs. 2–3), but from the root area. The reason is simple. taken for granted, were used for centuries also improves fuel economy in automo- Since the proccess is chemical/mechani- with great success before the advent of tive applications (Ref. 4). cal, the tip will have greater contact modern analytical tools and methods. Although new gears may be very frequency with the media and therefore Many parameters have since been cre- quiet initially, they often become noisier be subjected to more mechanical rubbing ated to fully characterize the properties with usage. Wear, scuffing and micropit- than the root fillet area. The amount of of a surface, and tribologists continue in ting usually lead to unacceptable gear bias depends on gear size and dia- their work for a theoretical correlation geometry distortions. Such changes in metral pitch, media size and shape, and between gear performance and these sur- geometry increase transmission error with processing parameters. face properties. a concomitant increase in noise/vibra- Is this inherent characteristic a major Moreover, existing theories may not tion/harshness. Superfinishing, however, obstacle? Not necessarily. A skilled tech- take full account of the unique surface reduces wear, scuffing, and micropitting, nician can develop a process whereby the proper ties imparted by chemically accel- thereby slowing noise growth (Ref. 5). amount of bias is negligible. erated vibra tory finishing. For example, Moreover, noise can also result from Aerospace gears, for example, are typically final ground to an R of 12–16 in a mated pair, superfinished surfaces, surface undulations introduced during a µin. (0.30 0.41 µm). Therefore, only a each with an R of 8.0 µin. (0.20 µm), will a gear’s machining/grinding stage. In a small amount of stock must be removed interact much differently than a mated superfinishing, the media is large enough to achieve an R of < 4.0 µin. (0.10 to bridge the crests of the undula tions, a pair in which each surface has been µm). Consequently, when superfinishing, reducing their amplitude. finely honed to an Ra of 8.0 µin. (0.20 potential geometry distortion is easier to µm) (see Figure 1). The difference is due Superfinishing has reduced noise/ control in aerospace gears—and high-end to superfinishing’s creation of planarized vibration/harshness in a number of gear auto-racing gears—than in other lower surfaces. These surfaces are essentially applica tions. For example, Sikorsky quality gears. free of peaks that can penetrate the lubri- Aircraft Corp. uses the process on its In fact, several years ago, aerospace cating film. S-76C+ helicopter gearboxes, reducing AGMA Q13 spiral bevel gears with a

Misconception No. 4. Superfinishing noise from the second-stage bevel gears starting Ra of 12 µin. (0.30 µm) were doesn’t reduce noise/vibration/harshness. by 3.7 dB and from the bull gear’s first superfinished to an Ra of < 3.0 µin. (0.08 Since gears have a sliding compo- harmonic by 7 dB (Ref. 2). µm), and still complied with the AGMA nent, superfinishing reduces noise/vibra- Misconception No. 5. Superfinishing Q13 tolerance specifications (Ref. 6). tion/harshness in the majority of cases distorts gear geometry. Since that time, the success of this project because it lowers friction and facilitates Superfinishing gears requires skill has been repeated with a large number of lubrication. to avoid unwanted results. Skill is need- aerospace gears having a wide assortment

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 31 of geometries. gears ranging in weight from just a few “Reducing Wear with Superfinish On the other hand, for automotive grams to more than 4,000 pounds (1,814 Technology,” The AMPTIAC Quarterly, applications, the start ing average rough- kg). Vol. 7, No. 1, 2003, pp. 3–9. ness (Ra) typically ranges from 60–80 Also, once optimal superfinishing 6. Arvin, J., A. Manesh, M. Michaud, µin. (1.5–2.0 µm) with a mean peak-to- conditions have been established, subse- G. Sroka, L. Winkelmann, “The Effect valley height (R ) of approximately 300 z quent processing is virtually guaranteed of Chemically Accelerated Vibratory µin. (7.6 µm). The R indicates that about z to be successful because the process Finishing on Gear Metrology,” AGMA 300–400 µin. (7.6–10.2 µm) of stock must Paper 02FTM1, AGMA Fall Technical be removed to achieve a surface that is itself is extremely robust and requires free of asperities. For ring-and-pinion little skill. Meeting, St. Louis, MO, October 2002, gear sets, which are usually lapped after Summary pp. 1–18. carburization and kept as pairs, a much In the past several years, superfinish- 7. Winkelmann, L., J. Holland and R. more uni form stock removal process is ing of gears—that is, chemically acceler- Nanning. “Superfinishing Motor Vehicle required to avoid altering the contact pat- ated vibratory finishing using high den- Ring and Pinion Gears,” AGMA Paper tern and/or increasing the transmission sity, non-abrasive ceramic media—has 04FTM13, AGMA Fall Technical error. been increasingly accepted by the gear Meeting, Milwaukee, WI, October 2004, In one case, a DANA 44 lapped ring- indus try. To date, there is no tribological pp. 1–16. and-pinion gear set was superfin ished theory to explain the gear performance 8. Vinayak, Harsh, et al. “Gear tooth to a 3.0 µin. (0.08 µm) R after optimiz- a imparted by this basis-metal surface topological modification for reducing ing the media and process. The amount engineering. Nonetheless, this process noise and vibration in transmission sys- of stock removed from tip to root and removes peak asperities, stress raisers tems.” U.S. Patent Application Number across the spiral was extremely uniform. and the layer of distressed surface metal 20040088861, Filed April 22, 2003. The contact pattern was maintained and from gears and gives them an isotropic transmission error did not increase over micro-texture that facilitates lubrication. baseline. A paper presented at the 2004 AGMA Fall Technical Meeting reported References the results of this study (Ref. 7). 1. Sroka, G. and L. Winkelmann. On rare occasions, however, one “Superfinishing Gears—The State of the comes across cases that are problematic. Art,” Gear Technology, Vol. 20, No. 6, For example, initial attempts to superfin- November/December 2003, pp. 28–33. ish a much finer-pitched internal gear for 2. Collis, J., and H. Proffitt. “Reduced the Global Hawk UAV resulted in the Total Ownership Cost for Isotropic inadvertent removal of more stock near Superfinished Dynamic Components,” the tip than at the root. Fortuitously, the Joint Council On Aging Aircraft, Aging company was pleased with the outcome Aircraft Conference 2005—The 8th because the biased removal provided Joint NASA/FAA/DOD Conference On needed tip relief. Aging Aircraft, Presentation Number 02- When no bias is desired or can be 0800-Collis, Jan. 31–Feb. 3, 2005, Palm tolerated, another approach is possible. Springs, CA, 46 slides. The gear designer can compensate by 3. Houser D.R., M. Vaishya and J. leaving more stock at the tip than at the Sorenson. “Vibro-Acoustic Effects root. Recently, Sikorsky Aircraft used of Friction in Gears: An Experimental this approach. The company decided it Investigation,” 2001 SAE Noise & wanted to use this superfinishing technol- Vibration Conference & Exposition, ogy to take advantage of its performance Traverse City, MI, 2001-01-1516, April benefits, so it designed its gears to fit the 2001, pp. 1–9. process (Ref. 8). 4. Gangopadhyay, A., E.A. Soltis, and Although skill is needed to select the M.D. Johnson. “Valvetrain Friction and optimum superfinishing parameters, dur- Wear: Influence of Surface Engineering ing the last several years, there have been and Lubricants,” Proceedings of the advances in the areas of media, chemicals Institution of Mechanical Engineers, Part and techniques that simplify the task. As J, Journal of Engineering Tribology, Vol. a result, a reasonably competent techni- 218, No. J3, 2004, pp. 147–156. cian working under commercial condi- 5. Niskanen, P., A. Manesh, R. Morgan. tions can now success fully superfinish

32 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com www.geartechnology.com

• Easy access to all current articles • Latest news, updated as it happens • Improved format buyers guide (free listings now available) A Study on Reducing Gear Tooth Profile Error by Finish Roll Forming

Seizo Uematsu, Donald R. Houser, Sung-Ki Lyu, Long Lu, Ju-Suck Lim

Introduction Measuring position Root Tooth tip This paper deals with the tooth profile error of spur gears on line of action 10 15 20 25 30 that have been finished by roll forming. First, we present � max �� experimental data that confirms that the tooth profile error (mm) � ca Before rolling is a synthesis of a concave error and a pressure angle error After rolling (Refs. 7–8). Since various types of tooth profile errors appear (a) Standard gear ��T in the experiments, evaluation parameters are introduced for Root Tooth tip rolling gears so that profile quality may be objectively evalu- Measuring position 15 20 25 30 35 ated. Using these evaluation parameters, the relationships among the tooth profile error, the addendum modification factor on line of action � max � ca (mm) (A.M. factor) and the tool loading force are verified. �� The character of concave error, pressure angle error and tool ��T loading force of finish roll forming by using a forced displace- (b) Profile shifted gear ( X = 0.52 ) ment method are verified. This study makes clear that the tool loading force of finish roll forming is a very important factor � max: Maximum deformation that affects involute tooth profile error. ��ca : Concave error Evaluation Parameters for Roll Forming ��T� � �� Displacement at tooth tip Figure 1 shows the evaluation parameters for gear rolling. �� Pressure angle error The parameters are maximum deformation δmax, concave defor- Figure 1—Plastic deformation on tooth profile. mation , deformation at tooth tip and pressure angle error δca δT . The solid and broken lines in the figure indicate the tooth δα

profile curves before and after rolling, respectively. δmax is the

Management Summary In recent years, the gear industry is increasingly applying Based on the proposed concept, automotive gear manufac- non-cutting forming methods to the production of toothed work- turers attempted finish rolling larger gears, but could not obtain pieces. Of these, finish roll forming seems to have the widest adequate quality. A great deal of research and development work range of application. Finish roll forming is a manufacturing has been carried out by many companies and researchers to see technology that improves the tooth profile accuracy, pitch accu- if roll forming can be more widely applied to larger gears with racy and surface roughness of a hobbed gear. In this technique, coarser pitches (Refs. 2–6). However, these investigators could a hobbed gear having a finish roll stock allowance contacts not develop a mechanism to generate high quality profiles. under high load with a tool having a high accuracy profile. The In this study, the authors have developed a rack-type rolling high load plastically deforms the surfaces of the teeth, smooth- process in which a rack tool is used to roll gear teeth. The results ing them and making them more accurate. This concept was of the experiment and analysis show that the proposed method proposed by Ford Motor Co. for the finishing of automotive reduces errors. pinions (Ref. 1).

34 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com Dr. Seizo Uematsu is a retired member of the engineering Dr. Sung-Ki Lyu is director of the Regional Consortium Center, faculty at Yamagata University, located in Shimowada, Japan. located at Gyeongsang National University in Jinju, South Korea. In 2002, he retired from the university’s precision engineering The center performs industrial research sponsored by 20 par- department. He’s studied roll forming of gears for more than 30 ticipating companies. Lyu is also a professor in the university’s years, publishing 14 papers on the subject. mechanical & aerospace engineering department. He teaches and researches in the area of gear design. Dr. Donald R. Houser is director of the Gear Dynamics and Gear Noise Research Laboratory (GearLab), located at The Dr. Long Lu is a professor in the mechanical engineering Ohio State University in Columbus. GearLab is an industrially department of the Huaihai Institute of Technology, located in sponsored research consortium with 30 participating companies. Lianyungang, China. He earned his doctorate at Gyeongsang Houser is also a professor in the university’s mechanical engi- National under Dr. Lyu’s supervision. neering department. He teaches and researches in the areas of gear design and gear manufacture. Ju-Suck Lim is a graduate student at Gyeongsang National studying finish roll forming of gears.

value of deformation at the position of maximum deformation when the tooth profile curves are compared before and after Standard tooth Rolling tooth rolling a gear. is the value of deformation at the position δca of the maximum distance from the tangent line to the profile where a tangent is drawn through the tooth tip and tooth root on the profile. A positive value of indicates a concave shape on the δca 30 65 � � � tooth profile, whereas a negative value indicates a convex �

shape. δT is the amount of deformation at tooth tip. A positive Internal diameter External diameter value of δT is the form in which the tooth tip is lower before rolling and a negative value is the opposite form. is the pres- δα sure angle error. Test Gear and Experimental Method 10 5 10 7.5 0 The experiment was conducted on module 5 spur gears as 32.5–0.1 follows: A rack was used for the tool and was driven at a speed Figure 2—Shape of test gear. of 4.5 mm/min. (0.08 mm/sec.). The number of teeth on the gear was 22 and the A.M. factor was 0.52. The specifications of the roll forming tool and the test gears are shown in Table 1. The shape of the test gears is shown in Figure 2 and in Photo 1. The gear on the left side of the photo is a standard gear, and the gear on the right is one of the roll formed gears made in this study. The rolling was performed

Table 1—Speciﬁ cation of Roll Forming Tool and Test Gears.

Tool Test gear Module (m) 5 Number of teeth (z) 11 22 Pressure angle (deg) 20˚ Tooth width (mm) 17.5 10 Coefﬁ cient of proﬁ le shift 0.52 External diameter (mm) 125 Photo 1—Test gear. Material SK5 S45C Hardness HRC 63 HRB 80 Individual pitch (µm) 1.0 7 Cumulative pitch (µm) 1.0 20

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 35 Figure 3—Method of tooth deflection measurement.

Figure 6—Plastic elongation on the tooth center line.

Figure 7—Strain distribution on the tooth center line.

Figure 4—Variation of tooth profile in rolling process.

Figure 5—Plastic deflection of tooth. Figure 8—Variation of tooth profile in rolling process.

36 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com over several teeth and was repeated several times on the same At point C, the plastic deflection grows large at the deden- teeth. The tooth profile and tooth trace curves were measured dum. The deflection of the dedendum at point C is unlike at after each rolling cycle. After rolling, the evaluation parameters point B and is inverted from positive to negative. were compared to those of the standard tooth. While the gear rotates from point B to point C, the heights Deformation Mechanism of contact point on the driven side and the follower side are If the amount of deformation becomes partially negative inverted near the pitch point. Here, the change in the direction on a tooth profile, this phenomenon cannot be explained by of the dedendum corresponds to the tooth profile at point C analytical methods based on the amount of deformation. in Figure 4. When the gear rotates from point C to point E in Therefore, the teeth seem to bend plastically during roll- Figure 5, the tooth profiles at points D and E show very little ing. The formation mechanism of the pressure angle difference from that at point C. error was studied as follows: Since a large portion of the Figure 6 shows the radial elongation δY. The tooth shows no roll stock plastic deformation occurs during the first elongation at point A. The tooth is slightly elongated at point B rolling pass, the remainder of the discussion will focus on and is elongated more on the dedendum at point C. The elonga- results after the first rolling pass. tion does not change when the mating progresses further. For verification, the profile of mating tooth and the dis- Figure 7 shows the plastic strain calculated from the εy placements of lattice point drawn on the side of the tooth were results shown in Figure 6. The strain is nearly zero at points measured at several positions on the line of action. Therefore, A and B and becomes very large at point C. The maximum we stopped the mating gear at several positions on the line of strains are 0.2% and 0.9% when the loads are 9.8 kN and 14 kN, action. During rolling, each measuring position on the line of respectively. These results indicate that the plastic area reaches action was judged by comparing the output from the strain gage the center of the tooth near the pitch point where the heights of at the tool’s tooth root and the analytical mating diagram. Since the contact point on the driven side and the follower sides are the tool driving speed is 0.08 mm/sec., the tool can be stopped inverted. When the gear rotates from point D to point E, the near a target position. strain at these points is nearly zero. Figure 3 shows the lattice points drawn on the tooth side. Figure 8 shows the deformation process in which the A.M. The lattice points are arranged on the mirror-finished side of the factor is zero. Results would likely be similar for values of A.M. tooth using the micro Vickers tester. In the coordinate system on factor up to about 0.4 based on the results of Uematsu (Ref. 7). the tooth side, the Y-axis is positioned on the centerline of the In positions A and B, the tooth profile of the follower side con- tooth side and the origin is positioned 30.5 mm from the tooth tacts the tool, and the amount of deformation on the rolled part tip on the centerline. The X-axis is the direction perpendicular is in the positive direction. In position B, the tooth profile of the to the centerline. The lattice point interval ∆ is set to 1 mm. The driven side has not yet come in contact with the tool. However, components of the displacement of the lattice point are , δX δY in each axis. The plastic strain εy between lattice points on the centerline direction was defined as follows:

εyi = (δyi – δyi–1)/∆ (1) where index i indicates the position of a lattice point from the origin on the centerline. Figure 4 shows how a gear having an A.M. factor of 0.52 is deformed during rolling. The sign ∇ indicates a contact point on the tooth profile. The contact point on the tooth begins from the driven side at tooth tip and ends at the follower side at the tooth root. The load is 9.8 kN. At points A and B, the amount of deformation on the tooth profile contacted with the tool is positive. At point C, the gear rotates slightly from point B and a concave shape of the tooth appears at the pitch point on the tooth profile. Here, it is observed that the deformation of the driven side changes from positive to negative. The tooth profiles Figure 9—Plastic deflection of tooth. at points D and E show very little difference from the profile at point C. Figure 5 shows the plastic deflection . When the load is δX 9.8 kN, and the gear rotates from point A to point B, the plastic deflection is very small.

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 37 D, the elongation in the addendum becomes bigger. When the load is 9.8 kN, the strain becomes more than 0.2%. When it’s 14 kN, the strain becomes 1.2%. As a result, the plastic region spreads near the pitch point on the central part of the tooth. Formation Mechanism of Pressure Angle Error. Plastic deflection and elongation in finish rolling were confirmed by the experimental result described above. Plastic deflection that appears in the addendum is affected by the transfer direction of the contact point on the tooth. The transfer direction of the contact point is decided by the direction of rotation. Therefore, as the tooth bends to the driven side, the amount of deformation on the tooth profile decreases on the driven side and increases on the follower side. The elongation appearing on the addendum decreases the amount of deformation on both tooth sides. The amount of deformation on the tooth profile consists of the components: P , P , cos , sin where P , P is δ d δ f δX θ δY θ δ d δ f the amount of deformation, δXcosθ is the plastic deflection,

Figure 10—Plastic elongation on tooth center line. δYsinθ is the plastic elongation, and θ is the pressure angle. The

total amount of deformation Yd of the driven side and Yf of the follower side will consist as following:

Y = P – cos – sin d δ d δX θ δY θ Y = P + cos – sin (2) f δ f δX θ δY θ

Then, the result of the calculation based on Equation 2 is added to the tooth profile in which the deformation was calcu- Figure 11—Calculated tooth’s plastic deflection based lated, and the pressure angle error is examined. on experimental results. Figure 11 shows the result. The tooth profiles represented by the broken, dashed and solid lines are respectively the tooth the tooth profile has been deformed in the negative direction profile before rolling, the experimental tooth and the calculated before the tooth comes in contact with the rolling tool. tooth. At position C, the tooth profile of the driven side begins to The deformation correction value calculated by Equation 2 contact with the tool, and the negative deformation that appeared is shown by the black circles. The corrected tooth profile and the in position B is disappearing. The tooth profiles on both sides rolled tooth form agree to an accuracy of 1–2 µm. also contact with the tool, and the amounts of deformation on Therefore, the convex shape on the addendum of the driven the driven side have a positive direction. side of the rolled tooth was not verified by the calculation with In position D, the amount of deformation on the driven only the mean deformation being predicted by Equation 2. side decreases and this tooth profile has been deformed more Similarly, the amount of deformation difference on the driven side negatively than before rolling. In position E, the tooth contact and follower side is verified by the calculations using the same has finished on both sides. The amount of deformation on the equation. follower side that appeared in position D again decreases. When the plastic region reaches the central part of the tooth, Figure 9 shows the plastic deflection of the tooth in rolling. the pressure angle error is based on the second and third terms The change of the plasticity deflection corresponds well to the of Equation 2. tooth profile shown in Figure 8. When the tooth contact occurs Tooth Profile Error at Low Load on the tooth profile of one side as shown in positions A and B, In the above, the load was set to 9.8 kN, so that the deforma- the plastic deflection appears on the tooth root, and the elongation may easily appear in the tooth, and the mechanism in which tion in the interval is small. When the tooth contact crosses near the pressure angle error arose was examined. However, the the pitch point as shown in positions C and D, the deflection in conclusion obtained in this experiment may not always apply to the addendum becomes bigger. the case in which the load is set at a lower value. Figure 10 shows the elongation, and the plastic strain Figure 12 shows the results with a 5 kN load. The between points C and D are shown in Figure 9. When the tooth other experimental conditions are the pitch-line velocity of contact crosses near the pitch point as shown in positions C and 8.5 m/min., and the number of total rolling cycles is 30. The

38 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com plastic deflection and plastic strain εy on the center line is shown in Figure 12(a). This deflection is about 3 µm near the pitch point and becomes about 12 µm at the tooth tip. The strain remains at roughly 0.2% from the pitch point to the tooth tip. There is a maximum compressive strain of 0.2% on the dedendum, and the plastic region spreads to the central part of the tooth. The profile of both sides of the rolled tooth is shown in Figure 12(b). The rolled tooth deformed almost uniformly along the hobbed tooth shape; the amount of plastic deformation ranges from 2–8 µm. On the follower side, the concave shape at the pitch point has amplitude of about 30 µm. Conclusion In this paper, we have defined an evaluation method for tooth rolling and have established the formation mechanism of the pressure angle error. Analysis reveals two causes of the Figure 12—Tooth profile error and plastic deflection tooth profile error: under low load rolling. 1.) When the tool approaches the work with a constant load, References the number of mating teeth on the line of action varies, the nor- 1. DeVos, Leon N. “Roll Forming of Gears at Ford Motor mal load on the tooth changes with the number of mating teeth, Company,” Gear Design, Manufacturing and Inspection and the concave type error occurs at the pitch point. Manual, AE-15, SAE International, 1990, pp. 335–343. 2.) When the tooth contact stress is very high near the pitch 2. Terauchi, Y., M. Tahara and N. Wakaoka. “A Study of Rolling point, the plastic deformation extends inside the center of the Finish,” Transactions of the Japan Society of Mechanical tooth and the addendum deflects to the driven side. Engineers, Vol. 43, 1977, pp. 4327–4336. Additional results of this study are as follows: 3. Tsutsumi, S., S. Tanaka and S. Senda. “Cold Rolling of 1.) The pressure angle error that appears in the addendum Zigzag-Toothed Gears,” JSME International Journal, Series C, is the sum between plastic deflection on the addendum and the Vol. 33, No. 2, 1990, pp. 251–255. elongation in the same region and results in the concave shape 4. Ozaki, T., K. Funatsu and I. Fuchi. “Theoretical Analysis of at the pitch point. Finish Rolled Gear Tooth Profiles,” Bulletin of JSME, Vol. 29, 2.) The deflection in the addendum decreases the deforma- No. 255, 1986, pp. 3182–3188. tion on the driven side and increases the deformation in the fol- 5. Vasilchikov, V.M., et al. “The Effect of Gear Blank Throw on lower side (reverse effects). the Accuracy of Gear Rolling,” Russian Engineering Journal, 3.) The elongation in the addendum decreases the amount of Vol. 57, No. 6, 1977, pp. 56–59. deformation in both teeth. 6. Weck, M., W. Kong, J. Goebbelet and G. Bartsch, “Cold 4.) This deflection and elongation arise when the contact Rolling for Processing Involute Gears,” International Symposium point crosses near the pitch point on the right and left tooth on Gearing & Power Transmissions, Tokyo, Japan, A-37, 1981, profiles. pp. 88–93. 5.) The direction of deflection is decided according to the 7. Uematsu, S. “How to Occur Involute Profile Error in Finish transfer direction of the contact point on the tooth surface, and Roll Forming of Spur Gears,” Transactions of Japan Society of the tooth deflects to the driven side regardless of the number of Precision Engineering, Vol. 54, No. 1, 1988, pp. 139–144. teeth and the addendum modification coefficient. 8. Uematsu, S. and M. Kato. “Involute Profile Error in Acknowledgments Finish Roll Forming of Spur Gears-Formation of Pressure This work was supported by grant No. RTI04-01-03 from Angle Error,” Transactions of the Japan Society of Precision the Regional Technology Innovation Program of Korea’s Engineering, Vol. 55, 1989, pp. 1839–1844. Ministry of Commerce, Industry and Energy (MOCIE) and by the NURI Project at Gyeongsang National University.

This paper was presented at the ASME/AGMA 2003 International Power Transmission and Gearing Conference, held Sept. 3–5, 2003, in Chicago, IL, and was published in Proceedings of the 2003 ASME Design Engineering Technical Conferences & Computers and Information in Engineering Conference. It’s republished here with permission from ASME.

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 39 Systematic Tooth flank Tooth root 1 1 σH0 Ft 30° σ F ρ F0 t m Investigations C n Strength related to hardness Strength related to hardness Contact stresses Bending stresses s e s s e s s e s

�C1< �C2< �C3 r mn1< mn2< mn3 t e r s t

t s

o t o on the c r

a �C3 t h n t mn3 o o mn2 o C �C1 �C2 mn1 T Influence of Depth below surface Depth below surface Figure 1 —Basic principles of tooth flank and tooth root stresses Case Depth (schematically).

Eht Eht on the �� 100 mm �� Pitting

Eht� Eht and Bending Eht�� Strength of Case Figure 2—Gear types (pinion) of the test program. Management Summary Carburized High power transmitting gears are nowadays nearly always case carburized and hardened. The value of case depth is one important parameter that has to be specified by the gear designer for the heat Gears treatment process. On the one hand, the available gear load capacity can be reduced with a case depth that is too small. On the other hand, unfavorable influences on the material properties and possible increased distortion by hardening and increased requirements Dr.-Ing. Thomas Tobie for grinding may result from a case depth that is too large. In times Dr.-Ing. Peter Oster of modern and increasingly optimized gear manufacturing, there is a fundamental need for the gear designer to know how to determine Prof. Dr.-Ing. Bernd-Robert Höhn an appropriate case depth for his actual gear application in order to guarantee the required load capacity and taking into consideration the different basic principles in the nature of contact and bending stresses that are most relevant for gear load capacity.

Dr.-Ing. Thomas Tobie is a chief engineer at the Gear Research Centre, a part of the Technical University of Munich, Germany. His research specialties are in the fields of heat treating, gear material and gear load capacity regarding tooth root bending fatigue, pitting and micropitting.

Dr.-Ing. Peter Oster is a chief engineer at the Gear Research Centre and specializes in tribology and load capacity of gears. As a research group leader, he guided the studies presented in this article.

Prof. Dr.-Ing. Bernd-Robert Höhn is head of the Gear Research Centre. The centre’s main research efforts include the examination of load carrying capacity of gear drives, the design of gears and the testing of gears.

40 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com Introduction teristics of the case hardened layer that are In modern gear manufacturing, power- also influenced by the value of case depth transmitting gears are nearly always made were examined. of case carburized steels, which are par- Test Programs and Test Gears ticularly suitable for withstanding high local The investigations have been carried out stresses without sustaining damage. The on several gear types, different in gear size heat treatment process of case carburizing is and gear geometry. Figure 2 shows the test an exceedingly demanding process, requir- pinions of the gear types. ing a high level of technical knowledge From each gear type, several test series and experience. of gears having the same geometry but dif- Gears are case carburized to increase ferent case depth were investigated. Table 1 surface hardness, improve wear resistance shows the complete test program. and achieve high contact and bending strength. The hardness distribution in gen- Test series 1 2 3 4 5 eral is described by the characteristic param- Case depth in mm eters of surface hardness, case depth (Eht) (drawing specification) and core hardness, and is usually seen as an EhtA 0.3 0.6 0.9 1.4 2.0 * * * approach for the strength distribution in the EhtB/B1 0.2 0.4 0.7 1.1 1.6 case hardened layer. While surface and core ** ** ** EhtB2 0.2 - 0.7 - 1.6 hardness are restricted to narrow limitations, Eht 0.2* 0.4 0.7* 1.1 1.6* case depth can be varied in a wide range. C/C1 ** ** ** Thus the value of case depth decisively EhtC2 0.2 - 0.7 1.6 influences the hardness (strength) profile in * only bending fatigue tests ** only pitting fatigue tests the case carburized layer. Table 1—Test Program: Influence of Case Depth on Pitting and Bending Failure modes of pitting and tooth root Strength. breakage are affected by the value of case depth. Whereas the pitting load capacity Nomenclature is a function of Hertzian contact stresses, Eht Case depth at Vickers hardness 550HV1 depending on the square root of applied Eht Optimum case depth for maximum bending strength load and reciprocal of equivalent radius of Fopt Eht flank curvature, the tooth root strength is Hopt Optimum case depth for maximum pitting resistance related to bending stresses and directly to Ft Nominal tangential load the applied load and gear module. SF Safety factor—bending These differences in the nature of con- SH Safety factor—pitting tact and bending stresses result in different Y Case depth factor—bending strength requirements regarding the strength profile Eht for tooth root and tooth flanks of a gear Y… Infl uence factor—bending, according to DIN 3990 (Ref. 4) and have to be taken into consideration ZEht Case depth factor—pitting resistance when choosing an appropriate case depth Z… Infl uence factor—pitting, according to DIN 3990 (Ref. 4) (see Fig. 1). a Center distance Since the costs of a case carburized gear m are influenced significantly by the value of n Normal module case depth, experimentally verified and eas- z Number of teeth ily applicable rating formulas are required to ρc Relative radius of fl ank curvature at pitch point evaluate the influence of case depth in order σF Bending stress number to guarantee required load capacity regard- σ Allowable bending stress number ing pitting resistance and tooth root bending Flim strength of a gear. σH Contact stress number For this purpose, the pitting and the σ Allowable contact stress number bending strength of case carburized gears Hlim were investigated (Ref. 14). Gears of dif- *Further symbols according to DIN 3990/ISO 6336 (Refs. 4, 9). ferent sizes and different gear geometry were included in the test program in order to determine the basic principles for the influence of case depth on the gear load capacity. Residual stress and further charac-

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 41 Tooth root bending strength was inves- rial is shown in Table 4. (Ref. 8). The peak-to-valley roughness Rz in tigated on gear types EhtA, EhtB and EhtC. All gears were hobbed, carburized and the unground tooth root of the bending gears

Essential data for the bending gears are hardened with the carburizing process, is Rz ≈ 5 µm. listed in Table 2. which was varied in order to obtain the Test gears were manufactured accord- Pitting resistance was investigated on desired different case depth values. After ing to industrial practice and fulfill the test series of all gear types but with special heat treatment, the test gears were mechani- requirements for case carburized gears of focus on test series with center distance of cally (shot) cleaned. The flanks of the pitting quality MQ according to DIN 3990/ISO 200 mm. The design parameters for the pit- gears were additionally finished by grinding 6336 (Refs. 4, 9). ting gears are given in Table 3. (MAAG–0°) to surface roughnesses of Ra = Test Conditions

All test gears were made from one batch 0.2–0.4 µm (a = 91.5 mm) and Ra = 0.3–0.5 Each test series repeated single stage of 16MnCr5 steel, comparable to SAE 5115. µm (a = 200 mm), respectively, and a gear- tests in the range of endurance limit and The chemical composition of the gear mate- ing accuracy of 4–6, according to ISO 1328 low- and high-cycle fatigue. Bending fatigue tests were carried out in pulsator test rigs of 100 and 250 kN capac- Parameter Unit EhtA EhtB EhtC ity. The frequency was about 110–120 Hz. Normal module mn mm 8 3 3 The gear teeth were clamped between two Number of teeth z - 24 67 29 contact jaws as shown in Figure 3 and load- Pressure angle α ° 20 20 20 ed in such a way that the load direction was tangential to the base circle. The endurance Helix angle ß ° 0 0 0 limit was assumed to be 6 x106 stress cycles Face width b mm 30 30 20 without breakage. The endurance strength Add. mod. factor x - 0.27 -0.60 0.56 in bending was calculated according to the method in DIN 3990/ISO 6336 (Ref. 9). Tip diameter da mm 212.3 201.0 96.3 Pitting fatigue tests were performed on Table 2—Gear Data of Bending Test Gears. FZG gear test rigs (see Fig. 4). The gear center distances were 200 mm and 91.5 mm, Parameter Unit EhtA EhtB1 EhtB2 EhtC1 EhtC2 respectively. A detailed description of the Center distance a mm 200 200 200 91.5 91.5 test rig is given in Reference 5. The gears Normal module mn mm 8 3 5 3 5 were spray lubricated with refined mineral 2 Number of teeth z1 - 24 67 40 29 17 oil ISO VG100 (viscosity v = 100 mm /s at z2 - 25 69 41 30 18 40°C) with a 4% sulfur-phosphate additive. Face width b mm 18 18 18 12 14 Oil injection temperature was 60°C. All tests Pressure angle α ° 20 20 20 20 20 were performed at rotational speed of 3,000 rpm at the pinion of the driving gear. The Helix angle ß ° 0 0 0 0 0 gears were loaded to various Hertzian stress Contact ratio εα - 1.50 1.50 1.50 1.51 1.38 limits until failure occurred. An endurance Relative radius of limit was considered to be reached when flank curvature ρC mm 19.5 14.3 15.4 9.5 10.0 the test pinion ran for 100 x 106 cycles Table 3—Gear Data of Pitting Test Gears. without damage. Test gears were deemed to have failed when 4% of the active working Element composition wt% flank area of a single tooth was damaged C Si Mn P S Cr Al Ni Mo Cu by pitting. The applied contact pressure and 0.17 0.37 1.20 0.02 0.03 1.17 0.04 0.15 0.04 0.15 Hertzian stresses were calculated according Table 4—Chemical Composition of 16MnCr5 Steel. to the method of DIN 3990/ISO 6336. Test Results—Bending Strength Figure 5 shows the hardness distribu-

tion of bending gears type EhtC. Surface hardness and core hardness of the different test series are comparable. The case depth values are clearly different. Surface hardness of all test gears type

EhtA and type EhtB is also in the same range, 720 +/– 50 HV1.

Core hardness of test gears type EhtA is about 350 HV10 and, due to the larger size, is somewhat less than core hardness of gear Figure 3—Clamping of test gear. types EhtB and EhtC.

42 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com Figure 6 shows test results for the influence of case depth on the bending strength torque indicator of all test series. Each point represents the tooth root endurance limit of one test series as determined by the S-N curve and is related to the maximum bending strength of drive gears each investigated gear type. Results of some former investigations (Ref. 2) are shown. Maximum bending strength was gear wheel achieved for a case depth of 0.1...0.2 · m . pinion lever arm with n temperature sensor weight pieces In the range of case depth < 0.1 · mn, bend- load clutch ing strength strongly decreases with reduced Figure 4—FZG gear test rig for pitting endurance tests. case depth. In the range of case depth > 0.2

· m , the bending strength decreases with 900 n hardness gradient increasing case depth but was more moder- 800 ate compared to the range of too small a 700

case depth. The actual results are in good 1

V 600 550 HV1 H

agreement with those from former investi- ,

s 500 gations. s e

n 400 d

Test results clearly demonstrate that the r a

h 300 bending strength of case carburized gears is s r Bending test gears influenced significantly by the ratio of case e 200 k type Eht :

c C i

depth to gear module. This corresponds V 100 16MnCr5 mn = 3 mm z = 24 with the basic principles for tooth root 0 bending stresses, as a module of a gear is a 0 0.5 1.0 1.5 2.0 2.5 3.0 relevant parameter for the dimension of the Depth below surface, mm critical cross-section in the tooth root area. Figure 5—Hardness distribution of bending test series, gear type EhtC. Increasing the module causes a decreas-

ing stress gradient over the material depth. x t a h E m

, With the same maximum tooth root bending , m m i i l l F F 100 � � � � � � � stresses at the surface, a larger gear will �

t [%] therefore have higher stresses at a given i m i l distance below the surface than a smaller 80 e c n

gear (see Fig. 1). a r u

d 60

Compared to DIN 3990/ISO 6336 stan- n e

dards for case carburized gears, all test o o r mn = 2.3 mm series with a case depth of 0.1...0.2 · m h 40 n t m = 3 mm o EhtA: mn = 8 mm, z = 24 FVA - Nr. 8: n o

t m = 5 mm show a bending fatigue strength equal to or EhtB: mn = 3 mm, z = 67 n . [2] l m = 10 mm

e Eht : m = 3 mm, z = 29 n 20 C n even higher than specified by the DIN/ISO R 0 0.1 m 0.2 m 0.3 m 0.4 m 0.5 m 0.6 m field for allowable stress number σ of n n n n n n Flim Rel. case depth quality MQ case carburized gears. Investigations of material properties, Figure 6—Test results for the influence of case depth on the tooth root bending strength (endurance limit). on the one hand, gave no indication of a relevant influence of carbon content (C 40

approximately 0.65–0.85%) or residual 35 austenite content (< 5–20%) on the test 30 m � � � results for the investigated gears. On the �

n 25 o

other hand, material investigations showed i t

a 20 d

that with increasing case depth and thus i x o

also increasing duration of the carburizing r 15 a l u

process, intergranular oxidation as well as n 10 a r g

grain size of the former austenite increased r

e 5 t n (see Fig. 7). I 0 Residual stress distribution in the 0 0.5 1.0 1.5 2.0 2.5 case carburized layer was determined by Case depth, mm X-ray diffraction. Figure 7—Case depth and intergranular oxidation of bending test gear types EhtA, EhtB,EhtC.

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 43 Figure 8 shows the residual stress dis- It is well known that these influences— tribution for different test series of gear higher intergranular oxidation, larger grain

type EhtC. Residual stress distribution has size, smaller residual compressive stresses the typical form known for case carburized in the tooth root area of a case carbu- and shot cleaned gears. Residual compres- rized gear—may result in reduced bending sive stresses at the surface and in the near strength (Refs. 1, 3 and 6). As all test gears surface area, especially maximum values, were made of the same batch of steel and are smaller for test series with higher case manufactured under equivalent mechanical depths and longer carburizing times than for conditions, results are related to case depth gears with smaller case depths. carburizing time and not separated into individual influence parameters. �� Test Results—Pitting Resistance 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 In former investigations on the influ- 0 ence of case depth on the pitting resistance

� -100 d of case carburized gears (Refs. 2, 11), an �

� optimum case depth to ensure the maximum � -200 � � �

� allowable contact stress number has been

� -300 �

� established as: � �

� -400

� + 10 � e ρc � c EhtGrenz = ± 0.15 mm (1) � -500 25 � Bending gear type Eht � C

� b � The test results are mainly based on -600 a: Eht = 0.27 mm � b: Eht = 0.55 mm smaller gears. In Figure 9, results of inves- -700 c: Eht = 0.75 mm tigations on the influence of case depth on a -800 d: Eht = 0.94 mm pitting resistance (Ref. 14) are compared e: Eht = 1.61 mm -900 with the results from other investigations Figure 8—Residual stress distribution for test gears with different case depth (bend- (Ref. 2). Results are given as allowable ing gear type EhtC). stress numbers, which are derived from the 2000 pitting fatigue limit of S-N curves for the FVA 271 1900 investigated test series of gear types FVA 8 EhtC1 1800 and Eht . The highest fatigue limit was Tolerance range C2 1700 achieved for test series with case depth in the range of optimum case depth Eht . 2 1600 Grenz m Test series with smaller or larger case depth m 1500 / N

than the optimum depth (Eht ) achieved , 1400 Grenz m i l

H lower fatigue limits. Results in Figure 10

� 1300 are based on larger gears (gear type Eht ) 1200 A Gear types EhtC1/2 EhtGrenz from other investigations (Refs. 11, 14). 1100 a = 91.5 mm �c = 10 mm Tendencies for the influence of case depth 1000 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 on the pitting resistance are the same as for Eht 550 HV1, mm smaller gears. However, the highest fatigue Figure 9—Test results for the influence of case depth on the pit- limit was achieved for larger optimum case depth. These findings are also confirmed by ting resistance (gear size ρC=10 mm). the results of the investigations on the test 2000 FVA 271 series of gear type Eht . 1900 B2 FVA 8 Figure 11 summarizes the experimental 1800 Tolerance range results on the influence of case depth on the 1700 pitting resistance for test series of different 2

m 1600 gear types. The achieved contact fatigue m / 1500 N

, limit (surface pitting) of each test series is m i l 1400 H related to maximum fatigue limit of the rel- � 1300 evant gear type for Eht ≈ EhtGrenz. 1200 Figure 11 shows that all gear types Gear type Eht EhtGrenz A 1100 a = 200 mm achieved maximum pitting resistance if case � = 20 mm 1000 c depth was in the range of optimum case 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 depth EhtGrenz as defined in References 2, 10 Eht 550 HV1, mm and 11. An approximately linear decrease Figure 10—Test results for the influence of case depth on the of pitting resistance with the difference of pitting resistance (gear size ρC=20 mm) . 44 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com actual and optimum case depth was found. � � � � � Several guidelines given in literature � � � � � 1.00 ( ) � � � � � (Refs. 12, 13) recommended case depth � � � [-] as a function of module. Comparing test 0.95 t results of gear types Eht and Eht , both i B2 C2 m i 0.90 l

with the same module but different radii e c

n 0.85 of flank curvature, indicates that the gear a r

u Eht = ( � + 10) / 25 module may not be sufficient for choosing d Grenz n 0.80 e appropriate case depth regarding contact g

n a = 91.5 mm, = 10 mm

i C t 0.75 t

fatigue life. Especially for gears with small i a = 200 mm, C = 15 mm p

. ratios of m /ρ , often used in high speed l EhtGrenz a = 200 mm, C = 20 mm n C e 0.70 gears, discrepancy will arise if choosing R 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 case depth as a function of relative radius Case depth Eht 550HV1, mm of flank curvature or if choosing case depth Figure 11—Comparison of test results for the influence of case depth on pitting based on module. resistance for different gear sizes. Compared to DIN 3990/ISO 6336 standards for case carburized gears, test series 1.10 1.10

with case depth in the range of EhtGrenz 1.00 1.00 achieve allowable contact stress numbers as EhtA 0.90 0.90 specified in DIN/ISO standards for quality EhtA % EhtB2 % Eht

C1/2 , , R MQ case carburized gears. Fatigue limits 0.80 R 0.80 C C (pitting) of other test series, in particular 0.70 0.70 Eht with smaller case depth, fell mostly below C1/2 EhtB2 0.60 0.60 the upper limit of the DIN/ISO allowable 0 0.5 1.0 1.5 2.0 1300 1400 1500 1600 2 field for material quality MQ. Eht/EhtGrenz � Hlim, N/mm

Thus, the results indicate that optimum Figure 12—Case depth (Eht), surface carbon content (CR) and achieved pitting case depth for maximum pitting resistance fatigue limit (σHlim) of investigated test series. is a function of the relative radius of flank curvature as described by Equation 1. 300

Accompanying investigations on the 2 200 m 100 m

material properties indicated for most gear /

N 0

types a slight increase of surface carbon , -100 s

content and consequently higher content s

e -200 r t

of residual austenite with increasing case s

-300 l

depth. On the other hand, the investigations a

u -400 d i -500 showed no relevant—and from the value of s e -600 case depth—independent influence of these R specific parameters on the achieved pitting -700 Pitting gear type EhtB2 resistance (see Fig. 12). Only two test series -800 Eht = 0.35 mm -900 Eht = 0.84 mm of gear type Eht with a large case depth Eht = 1.63 mm A -1000 showed a relatively high surface carbon 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 content, but also showed case depth to be Depth below surface, mm the dominant influence on the achieved Figure 13—Residual stress distribution for test gears with different case depth fatigue limits. (pitting gear type EhtB2). Residual stress distribution was measured using X-ray diffraction. Figure 13 shows measurement results for a different

test series of gear type EhtB2. For test series with smaller case depth, relatively high compressive residual stresses were measured in the near-surface region. Larger case depth, especially on test gears with higher surface carbon and higher residual austenite content, caused mostly a reduction of compressive residual stress in the case hardened layer. In some cases, test series with larger case depth and high surface carbon content

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 45 showed even small tensile residual stresses tured surfaces showed that the fracture was below the surface. starting at a small inclusion in the material, The results presented in Figures 9–11 are generally at the transition between the case based on typical pitting failures. Analysis of hardened layer and the softer core material. the damaged gear flanks showed that these These tooth breakages appeared sud- failures originated at the surface or at least denly, often after a high number of load in the near-surface region. The given stress cycles and without any indication of previ- values therefore have to be regarded as sur- ous surface (pitting) damage. Gear type

face contact fatigue limits. EhtB2 and especially gear type EhtB1 are

Test series of gear type EhtB1, and in characterized by a relatively small module some cases also test gears of gear type but a high number of teeth (high relative

EhtB2, failed due to a special type of tooth radius of tooth curvature). Tooth breakage breakage where the fracture occurred above appeared on each of the two test series of

the tooth root, frequently halfway down the gear type EhtB1 with case depths of 0.5 mm tooth tip (see Fig. 14). Analysis of the frac- and 1.3 mm, respectively. As the nature and the mechanisms of this special type of tooth fracture are not fully understood, Loaded gear flank results of gear type EhtB1 were not taken into consideration in results on the influence of case depth on the surface contact (pitting) fatigue. Results of the influence of case depth on the load capacity of the tooth flank agree with the accompanying investigations. These theoretical studies show that the variation of case depth influences the stress as well as the strength distribution over material depth, especially if residual stresses connected with the value of case depth are taken into consideration. Computations demonstrate that adequate case depth, depending on the relative radius of flank curvature and Figure 14—Special tooth breakage on test gear applied load, leads to a peak value of stress/ type EhtB1. strength ratio at or near the surface so that pitting will be initiated in this area. Smaller values of case depth or unfavorable residual stresses due to large case depth can result in 1.0 a higher stress/strength ratio, or a lower load [-] capacity. It may also lead, especially for 0.8 gears with small ratios of mn/ρc to a relocation of the maximum value of stress/strength t h

E 0.6 ratio to a greater distance below the surface. Y Optimum value This relocation may lead to gear damage 0.4 that is initiated below the surface. Results of the theoretical studies have been published

0.2 in detail (Refs. 7, 15). 0 0.1 mn 0.2 mn 0.3 mn 0.4 mn 0.5 mn 0.6 mn Application of the Test Results Rel. case depth Eht 550HV1 on the Influence of Case Depth on Gear Load Capacity Figure 15—Influence factor YEht for the influence of case depth on tooth root bending (endurance) strength. Influence factor YEht for tooth root bending strength. Test results indicate tooth root bending strength is influenced by the ratio of case depth to gear module. Optimum case depth for maximum tooth root bending

strength (EhtFopt) is evaluated as

EhtFopt = 0.1...0.2 · mn

46 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com Gears with case depth in the range of and ZEht may be used to calculate optimum

optimum case depth EhtFopt should certainly case depth for maximum load capacity of achieve the allowable stress number accord- tooth root or tooth flank as well as to deter- ing to standards for material quality (MQ). mine adequate case depth for actual gear For case depth values different from the application if geometry, relevant stresses

optimum (Eht ≠ EhtFopt), achievable tooth and minimum required safety factors are root bending strength is reduced. When known. Consequently, lightly loaded gears evaluating the influence of case depth on will tolerate less case depth. On the other

tooth root bending strength, the influence hand, safety factors SH and S F for a gear

factor YEht, as defined in Figure 15, depends with a given case depth may be calculated

on the ratio of the case depth to the gear by using YEht and ZEht. module. All test results fall into the given Especially for critical gear applications

tolerance field. YEht may be integrated in the and special gear geometries, an optimized standardization calculation method for rat- load capacity may be evaluated by using ing gears according to DIN 3990/ISO 6336, 1.10 shown in Equation 3 (Refs. 4, 9). 1.05

σFlim · YST · YδrelT · YRrelT · YX ·YEht 1.00 SF = (3) σF 0.95

t 0.90 h

Influence factor ZEht for surface con- E Z tact (pitting) fatigue strength. Test results 0.85

show that pitting resistance is influenced by 0.80 case depth. Optimum case depth regarding 0.75 � + 10 the maximum pitting resistance of the tooth EhtGrenz = 25 flank ( ) is a function of relative radius 0.70 EhtHopt -1.0 -0.75 -0.5 -0.25 0 0.25 0.5 0.75 1.0 1.25 1.5 of flank curvature according to Equation 4. Eht = Eht - EhtGrenz in mm

Figure 16—Influence factor Z for the influence of case depth on the pitting EhtHopt = EhtGrenz = ρc + 10 ± 0.15 mm Eht 25 (4) resistance (endurance strength).

Gears with case depth in the range of 4.5 min.....max. Eht should achieve the allowable stress Hopt 4.0 86.. � � ..94 number for case carburized gears of material quality MQ according to DIN 3990/ISO 3.5 Optimized for 74.. � � ..81 tooth flank (pitting) 6336 (Refs. 4, 9). 3.0 61.. � � ..69 Smaller or larger case depth values m m

, 2.5 49.. � � ..56

than the optimum lead to a decrease of pit- m 1 0.15 m

n m ting resistance. Influence of case depth on V 2.0 36.. � � ..44 � H �

allowable contact stress number (pitting) 0 5

is described by the influence factor Z . 5 1.5 24.. � � ..31 Eht

Z is established as a function of the opti- t Eht h 1.0 11.. � � ..19 mum case depth regarding maximum pitting E Optimized for resistance EhtGrenz—that depends on the gear 0.5 tooth root (bending) ..... � ....6 geometry, described by ρ —and the relevant c 0.0 case depth of the actual gear application. 0 2 4 6 8 10 12 14 16 18 20 22 Z may be approximated from Figure 16. Eht mn, mm According to DIN/ISO, the influence of case depth on pitting load capacity can Figure 17—Basic recommendation for simplified determination of “optimized” case depth regard- be taken into consideration by introducing ing maximum load capacity for tooth flank (pitting) and tooth root (bending) of case carburized gears with usual ratio of m /ρ . factor ZEht into Equation 5. n C

σHlim · Zw · ZL · Zv · ZR · ZX · ZEht SH = (5) σH Optimized case depth regarding maximum pitting and bending strength.

Equations 2 and 4 and influence factors YEht

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 47 defined influence factors. By introducing the defined influence Organization for Standardization, 1995. For practical use, easily applicable factors into the standardized calculation 9. ISO 6336, Calculation of Load Capacity guidelines are required. As tooth root and method, the influence of case depth on of Spur and Helical Gears, International tooth flank of a gear cannot be loaded bending and surface (contact) load capacity Organization for Standardization, 1996. independently from each other, an adequate can be taken into consideration if rating a 10. Käser, W. “Beitrag zur Grübchenbildung case depth for a gear has to consider require- gear according to DIN/ISO. an einsatzgehärteten Zahnrädern,” ments for surface contact fatigue (pitting) For practical use, a basic recommen- Dissertation, Technical University of as well as for tooth root bending strength. dation for choosing optimized case depth München, 1977. Often, simple empirical methods that are regarding maximum gear load capacity is 11. Knauer, G. “Grundlagenversuche based on long practical experience—mostly given, applicable for a wide range of stan- zur Ermittlung der richtigen Härtetiefe case depth as a function of gear module— dard gears. bei Wälz- und Biegebeanspruchung— are used (Refs. 12, 13). For a wide range Acknowledgment Ergänzungsversuche zum Größeneinfluß an of standard gears, these recommendations This research project was sponsored einsatzgehärteten Rädern aus 16MnCr5,” also agree with the results of the presented by the Arbeitsgemeinschaft industri- FVA-Forschungsheft Nr. 223, 1986. investigations. Figure 17 shows a simpli- eller Forschungsvereinigungen e.V. (AiF) 12. MAAG-Taschenbuch, Berechnung und fied guideline for practical use in order to by funds of the Bundesministerium für Herstellung von Verzahnungen in Theorie determine optimized case depth for a gear Wirtschaft (BMWi) with an equity ratio by und Praxis. Zürich: MAAG-Zahnräder AG, regarding maximum load capacity for tooth the Forschungsvereinigung Antriebstechnik 1985. flank and tooth root. Given values are based (FVA). The paper was originally printed by 13. Niemann, G. Maschinenelemente Band on test results and with special regard to the ASME at the 2003 Design Engineering II. 2. Berichtigter Neudruck, Springer fatigue limits as stated in the standards Technical Conferences and is reprinted with Verlag, 1965. (Refs. 4, 9). its permission. 14. Tobie, T. “Einfluß der Einsatz här- Choosing case depth according to Figure tungstiefe auf die Grübchen- und 17 requires that module and relative radius References Zahnfußtragfähigkeit großer Zahnräder,” of flank curvature of a gear be within the 1. Anzinger, M. “Werkstoff- und FVA-Forschungsheft Nr. 622, 2001. limits of the specified range. For other gear Fertigungseinflüsseauf die Zahnfuß- 15. Tobie, T. “Zur Grübchen- und Zahnfuß- geometries as well as critical gearing, it is tragfähigkeit insbesondere im hohen tragfähigkeiteinsatzgehärteter Zahnräder,” recommended to evaluate an optimized case Zeitfestigkeitsgebiet,” Dissertation, Dissertation, Technical University of depth with regard to the defined influence Technical University of München, 1991. München, 2001. factors YEht and ZEht. In case of a given gear 2. Börnecke, K., W. Käser and H. Rösch. geometry and a case depth outside the speci- “Grundlagen-versuche zur Ermittlung fication, a decrease of the gear load capacity der richtigen Härtetiefe bei Wälz- und is expected. Biegebeanspruchung,” FVA-Forschungs- Conclusions heft Nr. 36, 1976. The influence of case depth on the 3. Brinck, P. “Zahnfußtragfähigkeit bending strength and pitting resistance of oberflächengehärteter Zahnräder bei case carburized gears was systematically Lastrichtungsumkehr,” Dissertation, investigated in a number of test series with Technical University of München, 1989. different gear sizes and geometries. 4. DIN 3990, Tragfähigkeitsberechnung von Test results show that the case depth Stirnrädern, Beuth-Verlag, 1997. influences both bending and surface (con- 5. DIN 51354–Teil 1, Prüfung von tact) load capacity but in different ways. Schmierstoffen—FZG-Zahnrad- Maximum load capacity is achieved for an verspannungs-Prüfmaschine: Allgemeine optimum value of case depth, but optimum Arbeitsgrundlagen, Beuth-Verlag, 1990. values for maximum tooth root bending 6. Funatani, K. “Einfluß der strength and pitting resistance of a gear need Einsatzhärtungstiefe und Kernhärte auf not necessarily be the same. An unfavorable die Biegedauerfestigkeit von aufgekohlten case depth, smaller or larger than the opti- Zahnrädern,” HTM 25, 1970, Heft 2, pp. mum, leads to a decrease of achievable load 92–98. capacity. 7. Höhn, B.R., P. Oster and T. Tobie. Based on the results, rating formulas “Case Depth and Load Capacity of Case- were derived which can be used to calculate Carburized Gears,” Gear Technology, Vol. optimum case depth for maximum load 19, No. 2, 2002, pp. 31–38. capacity of tooth root and tooth flank of a 8. ISO 1328-1, Cylindrical Gears—ISO gear as well as to determine adequate case System of Accuracy–Part 1: Definitions and depth in order to guarantee required load Allowable Values of Deviations Relevant to capacity. Corresponding Flanks of Gears, International

48 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com ADVANCES FROM AACHEN WZL AND GRC CONTRIBUTE

TO GEAR The WZL Gear Department Staff—Projects sponsored by the Gear Research Circle are performed by the WZL gear department’s staff. Klaus Peiffer, Gleason Corp.’s representative in the GRC, describes the staff as “a source MANUFACTURING of very well educated specialists for the gear industry.”

Borg Warner, Dana, General Motors, Gleason, which is headed by professor Fritz Klocke, and the chair of Klingelnberg, and ZF. These companies are heavyweights machine tools, which is headed by professor Christian Brecher. in the gear industry. They’re international operations with The two chairs share the WZL gear department. GRC work is thousands of employees in offices and factories around done by professors, scientists working toward doctorates, tech- the world—Argentina, Australia, China, England, Germany, nicians and undergraduates in that department. India, Japan, South Africa, and the United States. The research furthers the art of gear manufacturing for GRC But even these companies don’t always have the time members. The advances show up in the form of better machines, and resources to spare for long-term research & development tools and other technologies, which benefit the gear industry. projects to advance gear manufacturing. So they and many “Many of the technologies that we currently use on our other companies, including Caterpillar, DaimlerChrysler, machines have been developed at the GRC,” says Klaus Peiffer, Samputensili and Saint-Gobain Abrasives, come together in a vice president–product development & technology for Gleason consortium: the Gear Research Circle. Corp. Founded in 1956, the GRC consists of 70+ companies Peiffer, Gleason’s representative in the GRC, can easily in the gear industry that jointly sponsor R&D projects. And think of four GRC contributions to gear manufacturing: while GRC companies have international operations, their 1.) better understanding of hobbing, shaping and bevel cut- joint R&D is done in one building in Aachen, Germany. ting through simulations; The city is home to a well-known technical institute, RWTH 2.) development of processes for dry cutting gears with high Aachen University, which houses the Laboratory for Machine speed steel tools; Tools and Production Engineering, probably best known by 3.) improvement of skiving through study of its tool sys- its German acronym: WZL. tems, tool materials, cutting geometry and operating data, like The lab includes the chair for manufacturing technology, speeds and feed rates; and

A Well-Equipped Gear Department • 11 twin-disk test rigs, Research work is done with modern gear manufacturing • four pulsator test rigs, and measuring machines, including: • a Klingelnberg T20 bevel gear tester, and • a Gleason-Pfauter P 300 hobber, installed in 2000; • two spur and bevel gear noise test rigs for single-flanks tests. • a Kapp VAS 55 P gear profile grinder, in 1996; The gear department also has several metrology • a Liebherr LC 122 hobber, in 1997; machines, such as: • a Liebherr LFS 182 gear shaper, in 2003; and • two Zeiss CMMs, • a Sampuntensili K 250 HSC bevel gear cutter, in 2003. • a Klingelnberg P40 gear measuring machine, Besides machine tools, the department has numerous • a Stresstech X 3000 X-ray analyzer test rigs: • a Seifert XRD 2000 X-ray analyzer, • a power train test rig, • a Stresstech Rollscan 300 Barkhausen-noise analyzer, and • a bevel gear power-circulating (PC) test rig, • a scanning electron microscope. • 24 back-to-back test rigs,

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 49 panies gain a competitive advantage over nonmembers. GRC companies also receive the results of the department’s German and European publicly funded projects. The department presents the research results of 16–18 technical papers to GRC members during its annual spring gear conference, which is held at Eurogress, Aachen’s convention center. This August 17–18, the department will give a shorter version of its conference at The Gleason Works in Rochester, NY. This version will consist of the best presentations from the ’05 conference—held in April—and will be for the benefit of U.S.-based member-companies who didn’t attend the Aachen meeting. Members can send employees to either conference. Each Modern Gear Machinery—The WZL gear department includes several mod- attendee receives a copy of the spring conference’s proceed- ern gear machines on loan from GRC companies. The department uses the ings, including a detailed report of each presentation and a list machines to conduct its 25+ research projects, both GRC and non-GRC. of all other literature published by members of the WZL gear department. 4.) better understanding of profile grinding, so grinding Another advantage of membership in the GRC is that burn can be prevented. members participate in many segments of the gear industry, Peiffer adds that the profile grinding research is recent, including machine tools, metrology, cutting tools, abrasives and even ongoing, with its results only now being introduced into coatings. Many R&D partnerships are possible. industry application. “It’s all these partnerships that make a total system work,” Dividing Up the Work Gleason’s Peiffer says. “In the GRC, we can find any kind of The department’s research covers gear design, gear manu- partner in this business.” facture and running behavior. Design is handled by the gear Coming Up with Ideas calculation team. The gear manufacturing team works on hob- Thinking of research projects for 70+ companies is a bing, shaping, shaving, grinding, honing and other manufactur- research project in itself. ing processes. Studies of load carrying capacity and running, “It’s hard to find topics that are of interest to all of them,” stress and noise behaviors of gears are performed by the gear Klocke says. “However, we continuously ask them for ideas and investigation team. their opinions about future challenges, and we consider them in Together, the three teams include some 16 scientists. These our proposals for new projects. mechanical engineers hold diplomas equal to master’s degrees “We have to make sure that larger groups of member-com- in the United States, and most are working toward doctorates. panies can take advantage of the research results.” Undergraduate assistants help perform and evaluate trials. Results Manufacturing engineering students, they work on the teams for Klocke sees the long-term research work as the starting 11–19 hours a week—in addition to their regular studies. GRC companies provide equipment and funding for the department to do its work. The money comes from two sources: a one-time admission fee for new GRC members and an annual membership fee. Each fee ranges from 3,500€–14,500€ (about $4,200–$17,500). GRC annual fees alone make up about 30% of the WZL gear department’s budget. Both admission and annual fees, however, vary depending on a company’s size and what it manufactures. GRC money supports two types of research: common and applied. Common research is funded by groups of companies, and applied research is sponsored by one or very few companies. The third type, pure research, is funded by public organizations. Of the department’s 25+ projects, only some of them are GRC projects. A New Home, A New Test Rig—WZL is expanding its research work to Membership Has Advantages include aspects of the system behavior of transmissions and has taken GRC research results are restricted to members, so the com- steps to prepare for this work. WZL’s new building, though still being constructed, already houses a universal gear test rig in its basement.

50 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com point for advances in gear manufacturing. From the WZL For more information: building in Aachen, the research results are taken by GRC com- Gear Department panies and used in their factories around the world, enhancing Laboratory for Machine Tools techniques for designing and manufacturing gears or becoming and Production Engineering (WZL) improvements or innovations in gear machine tools, cutting Aachen University of Technology tools and materials. Steinbachstr. 53 “It’s up to the technology suppliers to develop a technology 52074 Aachen to industrial relevance,” Klocke says. “Our job is mainly to Germany show the potential.” Phone: +(49) 241-80-27416 Fax: +(49) 241-80-22293 E-mail: [email protected] Internet: www.getriebekreis.de

The WZL gear department is working Gear Shaving on more than 25 projects. • Process Simulation by Means of FEA. The goal: Determine The following isn’t a complete list of them, but it shows loads on tools under specific conditions of the gear shaving projects undertaken by each WZL gear team, both for the GRC process, a very complex process geometrically and techno- and for other organizations: logically. Sponsor: German Research Foundation (DFG) Gear Manufacturing Team Gear Calculation Team Discontinuous Form Grinding Tooth Root Geometries • Potential of new dressable grinding wheels. The goal: Learn • Optimization and generation of arbitrary tooth root ge- the behavior and potentials of modern grinding wheels in ometries in gear manufacturing processes. The goal: Find a relation to grinding burn. Sponsor: GRC way to determine tool geometry based on a given tooth root • Determination of characteristic values to avoid grinding burn. geometry. Sponsor: GRC The goal: Find a systematic way to predict grinding burn in Tooth Contact Analysis discontinuous profile grinding. Sponsor: German Federation • Influence of gear errors on noise emission of gears. The of Industrial Cooperative Research Associations (AiF) goal: Find critical and less critical gear geometry errors in Gear Honing terms of noise emission. Sponsor: GRC • Potential of ceramic tools. The goal: Study the performance • Design of function-oriented, acceptable manufacturing errors of different types of honing tools in the cutting process and for bevel gears. The goal: Determine the effect of different gear in the dressing process. Sponsor: GRC geometry errors on excitation of and contact patterns for bevel • Process simulation by means of FEA. Honing is a grinding gears. Sponsor: Industrial Research Foundation (Stiftung process with very low cutting speeds. The goal: Obtain fun- Industrieforschung) damental information about grinding processes with very Process Simulation low cutting speeds. Sponsor: German Research Foundation • Development of SPARTApro. The goal: Help manufacturing (DFG) engineers optimize the hobbing tool and its process. The soft- Hobbing ware is available only to GRC member-companies. Sponsor: • Potential of cermet cutting tools in hobbing. The goal: Study GRC types of new cermet materials to determine their potential in • Modeling and calculation of chip creation parameters in hobbing. Sponsor: Research Association for Machine Tools bevel gear cutting. The goal: Create a bevel gear version of and Manufacturing Technology (FWF) SPARTApro. Sponsor: German Research Foundation (DFG) • Reconditioning of carbide hobs. The goal: Learn why car- Gear Investigation Team bide hobs in industrial applications do not show reliable wear Noise Behavior behavior and find the solution to this problem. Sponsor: • Noise analysis of a real gearbox. The goal: Learn the influ- Research Association for Machine Tools and Manufacturing ence of bearings and housings on noise emission of a real Technology (FWF) gearbox in addition to noise emission of the gears. Sponsor: Bevel Gear Cutting German Research Foundation (DFG) • High speed cutting of bevel gears. The goal: Study the Load Carrying Capacity effect of process parameters, cutting materials, coatings and • Potentials of PVD coated gears. The goal: Determine the other influence factors on the wear behavior in bevel gear cut- potential of PVD coatings on gear flanks to replace toxic addi- ting. Sponsor: German Federation of Industrial Cooperative tives in the oil. Sponsor: German Research Foundation (DFG) Research Associations (AiF)

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 51 EVENTS

The Machine Tool World, EMO Hannover 2005: All in One Place The World of Machine Tools Dates: September 14–21, 2005 Hours: 9 a.m.–6 p.m. Site: Fairgrounds Hannover, Germany Organizer: The German Machine Tool Builders’ Association (VDW) Web: www.emo-hannover.de Admission Fee Day ticket 25€ Season ticket 45€ Student ticket 10€ Photo: Deutsche Messe AG, Hannover Hall 2 hosts Soon, machine tool users will again be able to visit many gear machine tool exhibitors, including: the machine tool world by going to one place: Fairgrounds Hannover in Germany. • Doimak A57 • Fässler A36 EMO Hannover 2005: The World of Machine Tools • Frenco A73 will open on the fairgrounds Sept. 14 and continue through • Gleason A56 Sept. 21. • Höfler A58 • Kapp B56 One of the world’s largest trade shows, EMO is a chance • Klingelnberg C42 for machine tool users to see a wide range of machinery, with • Koepfer C43 more than 14 buildings featuring equipment, including milling • Lambert A59 machines, lathes, forming machines, machining centers, grind- • Liebherr C42 • Reishauer A72 ing machines, and gear cutting machines. • Samputensili D40 Attendees from the gear industry should find interest- • Wera Werk B59 ing products in the exhibits on cutting, splitting and milling machines; precision tools, diamond tools, and measuring tools; EMO Hannover 2005 will have exhibits on: coolants and lubricants; surface finishing technology and thin- • Machine tools for cutting, splitting and milling film processes; and robotics and automation. • Precision tools, diamond tools, measuring tools Admission prices vary. A day ticket costs 25€, a season • Coolants, lubricants • Welding, cutting, hardening, heating ticket 45€, and a student ticket 10€. • Surface finishing technology, thin-film processes Additional information can be obtained via • CAD/CAM www.emo-hannover.de. • Instrumentation and control technology A symposium, “Cutting Edge Machine Tools for Tomorrow’s • Robotics and automation • Mechanical, hydraulic, electrical and electronic acces Production,” will be held Sept. 15–16. sories for manufacturing technology The discussion will be divided into five themes: “The Future • Industrial electronics, sensor and diagnostic technology of the Machine Tool,” “Micro and Precision Machining,” • Sheet metal, wire and tube working machines, metal forming machine tools “Simulation and Optimization,” “Modularization” and • Machine tools for thermal, electrochemical and other “Automation.” The information is based on research projects processes funded by Germany’s Federal Ministry for Education and • Software for entire manufacturing technology area • Control systems Research (BMBF) and is being held by The German Machine • Components for flexible automation Tool Builders’ Association (VDW) and the Research Centre • Quality management systems Karlsruhe’s production and manufacturing technologies divi- • Material flow and storage technology sion (PFT). • Metal forming machine tools • Machines and systems for tool and mold construction, The symposium costs 95€ for admission for one day, 150€ rapid prototyping, model construction for both days. Its languages will be German and English.

52 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com EVENTS HIGH SPEED Gear Inspection introduces the Model 5823 Gear Inspection Machine for automatic high speed inline gear inspection, offering greater flexibility with 6 axis robot loading and sorting of gears.

MACHINE FEATURES INCLUDE: • Greater flexibility in running complete families of different gears on the same machines. • Part change over is done very quickly requiring no tools or special skills. • Setting masters are stored in quick change trays. The robot automatically selects the setting masters and returns them to the same location after calibration. • Production capability up to 600 Attendees of the free “New Technology Broaching gears per hour depending on the Manufactured in the USA style of the gear. Seminar” will learn about technologies for making parts TURN-KEY SYSTEMS AVAILABLE like these better, faster and cheaper. • Inspecting total composite, tooth- CUSTOMIZED TO YOUR APPLICATION to-tooth action, runout, nicks, BURNISHING + WASHING + INSPECTION DOB size, lead, lead variation, Broaching Seminar taper along with other gear and part geometry measurements For additional information on our full to Attract Leading Experts custom-ized to your particular line of Functional Gear Inspection, n e e d s . and Gear Burnishing, Manufacturers can learn about the latest technologies in visit our website at: broaching by attending the free “New Technology Broaching www.itwgears.com Seminar” being held by Broachman LLC in Dearborn, MI, on October 11. 1104 Hwy 27 West Alexandria, MN 56308 U.S.A. “The seminar will provide attendees with the basics of Ph: (320) 762-8782 Fax: (320) 762-5260 broaching as well as educate them on the newest technolo- E-mail: [email protected] gies that will result in broaching parts faster, better and at a Visit us at Gear Expo 2005, Booth #272 lower cost per piece broached,” says Ken Nemec, president of Broachman. The seminar will include presentations from people at a wide variety of broaching industry companies, including HIGH PRECISION Stenhøj Hydraulik, Broachman LLC, Triple E Manufacturing, Parma Broach, Katexim Broach and Berghaus Broach. GROUND GEARS In addition, many related technologies will be covered by presenters from companies that are involved with materi- • Bevel and Hypoid als, coatings, lubrication, inspection and deburring, including Bohler Uddeholm Specialty Metals, Gold Star Coatings, • Spur and Helical Master Chemical, Balzers, Process Equipment Co. and On-Line Services. • Taper Rack and Pinion “Sharing technologies will be a key to the success of our seminar,” Nemec says. “Our focus will be sharing ideas and • Worms & Wormwheels innovation to reduce costs and improve quality and the bottom line.” • CURVIC® Couplings The seminar, which includes lunch, will be held at the (registered trademark of The Gleason Works) Holiday Inn Fairlane-Dearborn in Detroit, and the organizers ISO-9001: 2000 CERTIFIED are expecting as many as 300 attendees. The format will be 10– ISO-14001: 1996 CERTIFIED 15 minute mini-presentations until lunch, followed by several break-out meetings including question-and-answer sessions. Est. 1944 Registration is available online at www.broachman.com. SIG For more information: Phone: (231) 768-5860 SUDA International Gear Works Ltd. Broachman LLC Fax: (231) 768-4381 www.sudaintlgear.com 16900 Candy Road E-mail: [email protected] Head Office: 119-1 Kumaiden Contact: (North America) LeRoy, MI 49655 Shimizu-cho, Sunto-gun, Shizuoka P.O. Box 4, Pittsford, NY 14534 USA Website: www.broachman.com Japan Fax: +81-55-972-4553 Fax: (585) 385-8537 E-mail: [email protected] E-mail: [email protected]

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 53 Visit us at Gear Expo 2005, Booth #549 �� EVENTS �� Making Bevels and Hypoids Right Requires Training Leading calculation software Machine tools, cutting tools and other needed supplies— that’s the easier part of making bevel and hypoid gears. With for efficient gear box design settings from well designed gears and gear blanks of the right tolerances, the machine tools will do their jobs. The harder part is creating the good designs and figuring the �� right tolerances. That requires understanding from gear engineers, and understanding requires training. Dimensioning and optimization of gearboxes Gleason Corp., however, offers that training via two courses Fast analysis of variants and on designing and manufacturing bevels and hypoids. switched gears The first course, “Fundamentals of Bevel Gear Design,” is Automatic documentation recommended for people currently designing and engineering �� gears. It emphasizes design elements of bevels and hypoids, �� with lectures on gear theory, terminology, selection of gear size, Dimensioning and design tooth design parameters and cutting methods. optimization of machine elements Various unique calculation tools S t u d e n t s Rating according to calculate a ISO, ANSI, DIN, AGMA, gear dimension VDI, FKM Tel: +41 55 264 20 30 [email protected] sheet using http://www.KISSsoft.ch Gleason com- KISSsoft AG puter programs Frauwis 1 8634 Hombrechtikon and evaluate

Switzerland SWISS Quality the resulting stress data. They also learn about gear l u b r i c a t i o n , gear mount- ings, types of failures, gear blank dimen- sions, gear blank tolerances, and calculating gear life. The course includes machine and process demonstrations on Gleason’s latest equipment and software. “At the end of the course, the student will have learned enough of the basics to be able to design a gear set,” says Richard Jaworski, application engineer, customer support–Asia/ Pacific. Jaworski is the main teacher for both bevel/hypoid courses. The first course should be taken after attending Gleason’s more general course on gear process theory. Likewise, people should take the fundamentals course before the second bevel/ hypoid course, “Applied Gear Engineering.” “The applied gear engineering course is an extension of the fundamentals course,” Jaworski says. Attendees of the applied course should be designers of bevel and hypoid gears or be responsible for creating cutting or grinding summaries. According to Jaworski, the applied course promises to provide students with a working knowledge of the theory of tooth contact pattern development and the use of Gleason computer 54 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com EVENTS programs for tooth contact analysis—TCA, undercut checks and machine summary settings. Like in the first course, instructors teach via lectures, discussions and hands-on workshops with Gleason computer programs. Also, students learn about product application testing, software for loaded tooth contact analysis (LTCA) and finite element analysis (FEA), and methods of hard finishing bevels and hypoids. Each 12-student course is taught in the same classroom, which features 12 computer work stations with wireless connec- tions to Gleason’s local training network. In both courses, students can bring specific design problems to discuss with instructors. The problems can be reviewed either in class as a group or individually after class depending on the nature of the problem and the design’s confidentiality. “We take the time to work with the individuals after class on their designs if they wish,” Jaworski says. In the fundamentals course, students bringing problems should make sure their data include horsepower, speed, ratio and torque loads. MIDWEST GEAR CONTACT: In the applied course, they should bring the following for & TOOL, INC. CRAIG D. ROSS their existing or future applications: horsepower, speed, torque 15700 Common Rd. (586) 779-1300 loads and size restrictions. Roseville, MI 48066 [email protected] FAX (586) 779-6790 In both courses, attendees should bring electronic calcula- tors. The remaining sessions for the fundamentals course are Aug. 22–26 and Nov. 7–11, and for the applied course Aug. 29–Sept. 2 and Nov. 14–18. Attendees must submit their registration forms so Gleason receives them 30 days or more before the starting date of the first course. Visit us at Gear Expo 2005, Booth #504 “Usually these classes book within 30–60 days before start of class,” says George Baldwin, manager of Gleason’s customer/dealer training department. The courses are taught at The Gleason Works in Rochester, NY. Attendees can stay at any of nine hotels in the Rochester area. Gleason can reserve hotel rooms for students, or they can make their own reservations. When making them, attendees should ask for the Gleason corporate room rate. Hotel information, including rates and distances to The Gleason Works, is available on Gleason’s website.

For more information: George Baldwin The Gleason Works 1000 University Ave. Rochester, NY 14692 Phone: (585) 256-6688 Fax: (585) 256-6729 E-mail: [email protected] Internet: www.gleason.com

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 55 EVENTS

September 6–9 —9th International Conference on Shot Peening. UMLV, Copernic Building, Paris, France. Focuses on shot peening, deep rolling, laser peening, ultrasonic peening, com- bined and cold work processes. 750€. Fees are reduced to 700€ for members of universities. For more information, contact IIIT International by e-mail at [email protected] or on the Internet at www.icsp9.iiit.com.

September 13–14—Advances in P/M Gear Technology Seminar. Crowne Plaza at Detroit Metro Airport, Romulus, MI. Presents a future outlook for P/M gearing as well as the automotive industry’s changing requirements. Also covers P/M heat treating, gear design, material selection, tooling, manufacturing inspection and applications. For registration before Aug. 12, $825 for MPIF members, $925 for members of APMI and $1,025 for non-members of either organization. For registration after Aug. 13, $925 for MPIF members, $1,025 for APMI members and $1,150 for non-members of either. For more information, contact MPIF by telephone at (609) 987-8523 or on the Internet at www.mpif.org.

September 13–15—Basic Gear Noise Short Course. Department of Mechanical Engineering, Ohio State University, Columbus, OH. Aimed at gear designers and noise specialists who encounter noise and transmission problems. $1,390. For Corrections more information, contact the Gear Lab by telephone at (614) 292-5860 or on the Internet at www.gearlab.org.

In the May/June issue, on page 19, two equations and a September 14–16—International Conference on Gears. number of in-text variables didn’t appear as they should have in the leftmost column. Equation 1 should have Technical University of Munich, Garching, Germany. Keynote appeared as it does below. Also, the arrows somewhat addresses and presentations for manufacturers, developers, engi- above Equation 2 should have been just above its x and x' neers, designers, researchers, users and suppliers of all types of variables. Likewise, the arrows elsewhere in the column’s gears, gear components and gear materials from throughout text should have appeared just above their nearby x, x' the world. The official language of the conference is English, and x variables. 0 although some presentations will be in German. Conference fee   is 980€ and is reduced to 882€ for VDI members or members 2 of sponsoring organizations. For more information, contact ∑ (|xi – x0| – di) Min (1) i the conference headquarters on the Internet at www.vdi-wissens-forum.de. After the position of the TI has been In the May/June Industry News section, Gear Technology September 19–20—14th Annual Gear Failure Analysis Seminar. determined,reported that the Star actualSU consolidated measurement sales with Bourn is & Big Sky Resort, Big Sky, MT. Sponsored by AGMA, this Koch and Winco. In the case of the Winco consolidation, seminar explores various types of gear failure, such as mac- performed.the sales ofDuring each company’s a measurement, tool product line willthe be ropitting, micropitting, scuffing, tooth wear and breakage. probingaffected, system’s not their gear signals, tool product the lines. machine Handouts include a 272-page manual, which has copies of seminar presentations, reference technical papers and an atlas scales and the interferometer length of 36 photographs showing and explaining all failure modes. informationWe apologize are for recorded these inconveniences. simultaneously. $625 for AGMA members, $845 for non-members. Class size is —The Editors limited to 30 participants. For more information, contact The calculation of the improved AGMA by telephone at (703) 684-0211 or by e-mail at  [email protected]. CMM position x' i iss pe performedrformed asas f fol-ol- 56 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com lows: The improved position x' a andnd t thehe  position x rreadead ffromrom tthehe mmachineachine sscalescales are assumed to have a difference of ∆x. Their distances d andand d' fromfrom thethe refer-reference position differ by an offset ∆d. The improved position is also related to the  position x0 of the interferometer: Figure 3—Reduction of the measurement uncertainty of the CMM uCMM vviaia additional length information (measurement uncertainty u ) to the resulting      TI measurement uncertainty of the uncertainty ellipsoid u . x' = x + ∆x, d' = d + ∆d, d' = |x' – x0| (2) res

The coordinate and distance improvements can be found by mathematical optimization with a target function that puts a large weight on the distance measurements d' aandnd a llowow wweighteight on tthehe position x'. The reciprocal values of the estimated uncertainties of the CMM scale

positions uP and of the interferometric

distance ud areare aappropriateppropriate cchoices:hoices:

∆ x 2 ∆y 2 ∆z 2 ∆d 2 + + + 2 2 2 2 Min (3) u p u p u p u d

In principle, the optimization can be performed by any numerical method. As no directional information is drawn from Figure 4—Tracking laser interferometer. the TI measurement, reduction of the As commercial laser trackers (Ref. 5) do has a form error of less than 30 nm. It is uncertainty of the position measurement not achieve distance measurement uncer- mounted on an invar stem to avoid any is achieved only in the direction of the tainties in the submicron range, PTB has displacements due to thermal expansion. straight line connecting the probing sys- developed a new high-precision tracking Atmospheric conditions, such as temper- tem and the interferometer position. interferometer. In its design, the gimbal- ature, barometric pressure and relative If the uncertainty of the original posi- mounted interferometer moves around a humidity, are monitored to numerically tion x iiss aassumedssumed ttoo hahaveve tthehe fformorm of a fixed reference sphere serving only as the correct the laser signal. As the TI is only sphere, the uncertainty of the improved reference mirror for the interferometer 20 cm in diameter and 25 cm in height position x' willwill taketake thethe formform of anan ellip-ellip- (see Fig. 4). Due to this principle, radial and has a weight of only 7 kg, it can be and lateral deviations of the mechanical placed directly on the CMM table. soid ures during a profile measurement, as shown in Figure 3. axes of rotation do not affect the measure- Reference Software Tracking Laser Interferometer ment accuracy. The new evaluation software allows The distance measurement uncertain- The accuracy of the TI length measure- evaluation of the measurement param- ty of the TI is the dominant uncertainty ment depends significantly on the quality eter of the modified flank geometries of contributor of the system in the direction of the reference sphere surface and its product-like artifacts according to the of the beam. The stability of the point of unchanged position in space. To mini- definition of common gear evaluation rotation is of especially great importance. mize its influences, the reference sphere standards and guidelines (Refs. 6, 7 and

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • MAY/JUNE 2005 19 EVENTS TRUE DIMENSION ™ September 27–29—Wisconsin Manufacturing & Tool Expo. GEAR INSPECTION Wisconsin Expo Center at Wisconsin State Fair Park, Milwaukee, WI. Seminars concentrate on metalworking technology for both large and small job shops as well as business +/- .001 mm management practices. New product areas include plastics Repeatability manufacturing and production. $10 for all three days. For more information, contact Expo Productions by telephone at (800) 367-5520 or on the Internet at www.expoproductions.com.

October 10–13—Gear School 2005. Gleason facility, Rockford, IL. A blend of shop time, classroom study and lectures covering fundamentals, high speed steels and coatings, gear cutting and inspec- • 0-12” OD CAPACITY ™ tion. $895. For more information, contact Gleason • 0-9” ID CAPACITY �� Cutting Tools at (815) 877-8900 or on the Internet at • SHAFT CAPABLE • SHOP HARDENED VisitVisit us us atat GearGear Expo 2005,2005, www.gleason.com. • LOWEST COST IN THE INDUSTRY BoothBooth ##648 468 October 18–20—Expo Metalmecanica 2005. Call to use gage for your next machine run off Expo Guadalajara Center, Guadalajara, Mexico. Part of 90 Days at NO CHARGE International Manufacturing Week of Mexico. Product catego- UNITED TOOL SUPPLY ries consist of machinery and supplies; robotics and automation; 8 5 1 OHIO PIKE • CINCINN A TI, OH 4 5 2 4 5 metal joining and assembly; material handling and storage; qual- TOLL FREE: (800) 755-0516 ity control, calibration and testing; software and systems; sur- FAX: (513) 752-5599 • EMAIL: [email protected] face finishing tools and supplies; engineering and maintenance; and plant safety and environmental protection. Registration is free through the pre-registration period, which ends Oct. 11. For more information, contact Roc Exhibitions by telephone Get your Fellows machines at (630) 271-8210 or by e-mail at [email protected]. back in shape October 18–20—Mid-Atlantic Machine Tool Show. Your single source for Fellows Fort Washington Expo Center, Fort Washington, PA. Attendees Your single source for Fellows 10-2, 10-4, 20-4 and 20-5 Gear evaluate machining centers, metalworking equipment, robotics, Shaper Rebuild/Retrrofit prrograms: metal cutting tools, quality control and inspection, among other �� technologies. Attendance is free. For more information, contact �� the American Machine Tool Distributors’ Association by tele- �� phone at (800) 878-2683 or on the Internet at www.amtda.org. ��

1000 University Ave., P.O. Box 22970 Rochester, NY 14692-2970 U.S.A. Phone: 585/473-1000 Fax: 585/461-4348 Web site: www.gleason.com E-mail: [email protected]

��

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 57 INDUSTRY NEWS

Gleason Acquires M&M Philadelphia Gear Precision Systems Appoints Sales Rep Gleason Corp. acquired for Latin America M&M Precision Systems Philadelphia Gear Corp. hired Corp. on June 24. Jorge J. Flores as direct sales According to the compa- representative for Latin America. ny’s press release, Gleason According to the company’s will retain M&M’s exist- press release, Flores will be ing management team. Main responsible for increasing and operations will remain in the developing business with energy- Dayton, OH, area. Under related companies from Mexico Gleason’s ownership, M&M to Argentina. Overall, it requires Jorge J. Flores John J. Perrotti will be renamed Gleason Flores to maintain a solid and M&M Precision Systems Corp. Sales and distribution channels constant presence in the market of the Latin American coun- will be integrated with Gleason’s existing sales offices and rep- tries. resentatives in most markets. Prior to joining Philadelphia Gear, Flores founded “Power John J. Perrotti, Gleason’s president and CEO, said in a Transmission Elements,” a training course for maintenance per- press release, “M&M brings complementary products that fur- sonnel covering the history and basics of power transmission. ther strengthen our ability to serve our global markets. By leveraging Gleason’s leadership in gear technology and our global reach, we believe great opportunities exist to expand sales of M&M’s products.” Knoy Joins American Wera Scott Knoy was hired as vice president of sales by American Wera. Among his responsibilities will be sales and customer service for WERA profilators, tooth rounding and pointing equipment as well as PRAEWEMA honing machinery. Prior to this position, he was employed as a regional sales manager for Gleason Corp. Knoy has worked in the gear industry for the past 12 years. Ikona Launches New Gearing Technology Services Division EMAG Buys Ikona Gear launched a services division that enables clients Jos. Koepfer & Sohne GmbH to leverage advanced finite element analysis services for evalu- EMAG has acquired majority interest in Jos. Koepfer & ating and improving custom gearing solutions. Sohne GmbH. Finite element analysis (FEA) is a technique for modeling Present product lines and personnel will remain, according complex structures used in situations that are difficult to model to the company’s press release. In North America, EMAG of with standard engineering techniques. Farmington Hills, MI, will continue to service customers with FEA helps Ikona Gear verify whether a proposed design will EMAG Production Centers and related machines. be able to perform to the client’s specifications prior to manu- Within the new EMAG group, Koepfer will act as the gear facturing or construction. technology center. In total, the Koepfer group comprises three According to the company’s press release, United Gear & enterprises for the development and building of high precision Machine Works just utilized the new division to evaluate high- gears, cutting tools and high precision parts. Its consolidated end planetary gears purchased from third-party suppliers. sales figures for 2004 were 60 million euros. Laith Nosh, Ikona’s president and CEO, says, “As an EMAG specializes in manufacturing high production turn- industrial gear manufacturer, United Gear requires all gears ing and multifunction production centers. Its consolidated sales from third party suppliers to be of the highest quality and able for 2004 were 350 million euros. to perform under exceptional conditions. By leveraging FEA During EMO 2005, the company will display its first devel- services, the company was able to quickly and accurately opment. The VSC250DUO WF is a multifunctional production evaluate its planetary gears, make recommended alterations to machine that integrates double-spindle turning, hobbing and improve performance, reduce risk of failure and satisfy the end deburring in a single cycle. user’s requirements.”

58 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com INDUSTRY NEWS Do your gears need:

Gleason Appoints More strength? New Sales Management Longer life? Gleason Corp. has appointed John M. Terranova and Shot peening is the answer. Kelvin T. Harbun as vice presidents of sales. To learn more, subscribe to Terranova is vice president of American sales and respon- The Shot Peener. The Shot sible for the sales and marketing of Gleason products, including Peener is dedicated to raising those from the Gleason technical support centers in Novi, MI, the awareness and apprecia- tion for the shot peening and Queretaro, Mexico. He has worked at Gleason in a number process. of technical, sales and manufacturing positions, most recently as head of the implementation team for lean processes at The Magazine Subscription Request Gleason Works in Rochester, NY. � I want a free subscription to The Shot Peener. As vice president of Asia-Pacific sales, Harbun will be Please send it to the address below. responsible for the sales and marketing of Gleason prod- Please print or attach your business card: ucts in Japan, China, Korea, India, Australia and Thailand. Most recently, he worked in Ludwigsburg, Germany, in asso- Name ______Title ______ciation with Gleason-Pfauter and Gleason European sales. Company ______Address ______In Memoriam: City ______State______Zip______Country ______Gear Manufacturer Joseph M. Garfien: Telephone ______Fax ______1909–2005 Email Address ______Fax: (574)256-5222 Joseph M. Garfien, co- Mail: The Shot Peener founder of United States Gear 56790 Magnetic Drive, Mishawaka, Indiana 46545 USA Corp., died May 5 from an infec- The Shot Peener: www.shotpeener.com/EI/tsp/index.html GT tion. He was 95 years old. Mr. Garfien had more than 70 years of experience in the gear industry, starting as a machine �� operator in the late 1920s, when �� he was newly arrived in America, �� and including work for the U.S. �� and Israeli governments. �� An Austrian immigrant, Mr. � Garfien’s journey to the United �� States started with several soccer Joseph M. Garfien games in the United Kingdom. �� In 1928, he was a teenaged player with the Austrian national team and traveled with it to Great Britain. After the games, he �� continued westward, an uncle in Chicago sponsoring his immi- �� gration. “There wasn’t very much opportunity in Austria at the �� time,” Mark Garfien explains about his father’s decision. �� But, arriving in Chicago, Mr. Garfien had no job, no money, no English. He dealt with his first two problems by joining �� Perfection Gear, beginning as a machine operator. He also �� drew a second income from playing soccer. As for English, the Polish-speaking Mr. Garfien learned that over time. Overton Gear and At Perfection, he became a practical, hands-on gear engineer Tool Corporation with an intuitive grasp of gear geometry and manufacturing, a grasp that he made good use of and became known for. By 1941, www.overtongear.com Mr. Garfien was consulting with the U.S. Army to deal with the 630-543-9570 PHONE poor performance of some of its trucks. In ’53, though, he left 630-543-7440 FAX 530 Westgate Drive Perfection to become his own boss, co-founding International Addison, IL 60101 �� Gear. He left that business 10 years later to co-found a second www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 59 INDY NEWS 11/21/03 2:37 PM Page 18

INDUSTRY NEWS INDUSTRY NEWS Philadelphia Gear Quotes Prices Online Potential customers can visit www.philagear.com to quote prices for replacement parts. company,Price quotes U.S. Gear, can withbe provided his son andfor son-in-law,the company’s Don parts Garfield. and Today, U.S. Gear employs 300 people in Chicago and is still equipment as well as parts for gearboxes from other companies. owned and operated by the Garfien family. According to the company’s press release, this system stream- In the late ’60s, Mr. Garfien worked with the Israeli gov- lines the ordering process for the replacement parts. ernment on gear-related projects. In 1967, he helped it reverse engineerFor Philadelphia the gears of Gear Soviet-made gearboxes, tanks customers and trucks must captured submit duringthe model the Sixnumber, Day whichWar. Through is located reverse on the engineering,nameplate in the the gov- box ernmentlabeled “size/type.”could judge Afterthe state entering of Soviet this, gear customers manufacturing gain access and, byto aextension, detailed technicalestimate thedrawing. state of Soviet heavy industry. Also, Mr.Non-Philadelphia Garfien helped set Gear up customersthe Israeli cangear submit manufacturer their technical Ashot Ashkelon.drawing on A thesouvenir Internet of hissite Israeli as well work as hangsother onproduct-specific a wall at U.S. Gear:information a photo that of himselfcan help shaking identify hands the parts. with Golda Meir. Mark Guggenheim, a 17-year employee, describes Mr. GarfienmG as a miniGears likable fellow, Granted a firm boss,MANA but Membership one who cared about his employeesmG miniGears and was North willing America to listen has beento them. awarded membership“Joe in the had Manufacturers’ a lot of longtime Agents employees,” National Association.says Guggenheim, U.S. Gear’s vice president of manufacturing and engineering. MANA, headquartered in Lake Forest, CA, is the world’s “He treated his people with respect. He was loyal to them.” largest association of manufacturing agencies. Outside the Garfien family, several U.S. Gear employees are the mGchildren miniGears, of past of employees. Virginia Beach, Mark VA,Garfien specializes thinks inthis manu- says somethingfacturing smaller-endabout his father cut metalas U.S. and Gear’s powder leader: metal “He gears could and be trusted.”small gear assemblies and actuators. By the late ’90s, Mr. Garfien had ceded day-to-day admin- istration ofNew U.S. Plant Gear Managerto his son, at the Applied company’s Process president, and his son-in-law, its vice president of sales.Mark Still, Steinhe came was in named every workday, except for his last four months,plant managerwhen he cutof Applied back to three days. Process’s heat treating “He wanted to get here every day,facil brightity in and Elizabethtown, early, just to be here,” Guggenheim says. KY. Mark Garfien recalls his father’s lovePreviously, of his family Stein and love was of his country. plant manager at Century Mr. Garfien is survived by his son; two daughters, Barbara Sun Metal Treating in Garfien and Charlene Garfield; nine grandchildren; and three Mark Stein Traverse City, MI, as well great-grandchildren. as metallurgicalGuggenheim, engineer invited aat numberthe same of company. times to Mr. Garfien’s home,Applied says the Process gear manufacturer specializes inloved austempering, to show off ahis high gardens, per- wouldformance buy heat flats treating and flats process of flowers for nonferrous at the beginningmetals. of the season. At his funeral, Mr. Garfien’s family provided baskets of flowerArrow seeds Gear for Offers mourners, In-House asking Designthem to Capabilitiesplant the seeds in memoryArrow to Gear him. Co. introduced a computer modeling system for useAfter in the he design died, aof grandson spur and discovered helical gears. in a desk drawer in Mr. Garfien’sArrow’s home system a tape uses player advanced with acomputer cassette technologyrecording of to “God pre- Blessdict the America.” performance of a gear before a part is machined. These techniquesMichael include Goldstein, loaded a 40-year tooth contact friend analysis,and associate, which learnedis used about the recording at Mr. Garfien’s memorial service and to determine how the gear will be affected in its actual use thought: “God did bless America, He sent us Joe Garfien.” under load. In addition, Finite Element Analysis is used to study the physical stresses on the gear under load so that engineers can modify the design to provide maximum performance.

IonBond and Cline Tool Announce Venture IonBond of West St. Paul, MN, and Cline Tool of Newton,

18 NOVEMBER/DECEMBER 2003 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com 60 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com ADVERTISER INDEX Use this index to contact any advertiser in this issue. ADVERTISER PAGE # PHONE E-MAIL INTERNET

American Gear Manufacturers Assoc. 1 (703) 684-0211 [email protected] www.gearexpo.com American Metal Treating Co. 62 (216) 431-4492 [email protected] www.americanmetaltreating.com Arrow Gear Co. 4, 15 (630) 969-7640 [email protected] www.arrowgear.com A/W Systems Co. 16 (248) 544-3852 B&R Machine & Gear Corp. 21 (731) 456-2636, (800) 238-0651 [email protected] www.brgear.com Broaching Machine Specialties Co. 63 (248) 471-4500 [email protected] www.broachingmachine.com Broachman LLC 29 (231) 768-5860 [email protected] www.broachman.com Ceratizit 27 (800) 334-1165, (803) 736-1900 [email protected] www.ceratizit.com Comtorgage Corp. 10 (401) 765-0900 [email protected] www.comtorgage.com De.Ci.Ma SpA 60 (39) (051) 611-7811 [email protected] www.decimaspa.it Donner + Pfister AG 56 (585) 586-5748 [email protected] www.dpag.ch Eldec Induction USA Inc. 62 (248) 364-4750 [email protected] www.eldec.de Forest City Gear IBC (815) 623-2168 www.fcgear.com Gear Motions Inc. 11, 63 (315) 488-0100 [email protected] www.gearmotions.com Gear Technology magazine 62 (847) 437-6604 [email protected] www.geartechnology.com The Gear Industry Home Page 33 (847) 437-6604 [email protected] www.geartechnology.com The Gear Works—Seattle Inc. 62 (206) 762-3333 [email protected] www.thegearworks.com Gleason Corp. IFC, 57, 63 (585) 473-1000 [email protected] www.gleason.com Gleason Cutting Tools Corp. 63 (815) 877-8900 [email protected] www.gleason.com Insco Corp. 54 (978) 448-6368 [email protected] www.inscocorp.com ITW Heartland 53 (320) 762-8782 [email protected] www.itwgears.com Kapp Technologies 3, 13 (303) 447-1130 [email protected] www.kapp-usa.com KissSoft AG 54 (41) (55) 264-2030 [email protected] www.kisssoft.ch Koro Sharpening Service 63 (763) 425-5247 [email protected] www.koroind.com Marposs Corp. 6 (888) 627-7677, (248) 370-0404 [email protected] www.marposs.com Midwest Gear & Tool Inc. 55 (586) 779-1300 [email protected] Milwaukee Gear Co. 17 (414) 962-3532 [email protected] www.milwaukeegear.com Niagara Gear Corp. 12 (800) 447-2392, (716) 874-9003 [email protected] www.niagaragear.com Overton Gear & Tool Corp. 59 (630) 543-9570 [email protected] www.overtongear.com Paulo Products 55 (314) 647-7500 [email protected] www.paulo.com powertransmission.com 15 (847) 437-6604 [email protected] www.powertransmission.com Presrite Corp. 9 (216) 441-0057 www.presrite.com Process Equipment Co. 63 (800) 998-4191 [email protected] www.gearinspection.com Quality Gear & Machine Inc. 4 (888) 452-7979 www.qualitygear.com Quality Transmission Components 60 (516) 437-6700 www.qtcgears.com Sigma Pool 5 (734) 429-7225 [email protected] www.liebherr.com Schwartz Precision Gear Co. 62 (586) 754-4600 [email protected] The Shot Peener magazine 59 (800) 832-5653, (574) 256-5001 www.shotpeener.com Star SU LLC BC, 63 (847) 649-1450 [email protected] www.star-su.com Stock Drive Products/Sterling Instrument 62 (516) 328-3300 www.sdp-si.com/e-store SUDA International Gear Works Ltd. 53 (585) 385-8537 [email protected] www.sudaintlgear.com Timco Inc. 14 (914) 736-0206 [email protected] www.timco-eng.com United Tool Supply 57 (513) 752-6000 [email protected]

www.powertransmission.com • www.geartechnology.com • GEAR TECHNOLOGY • JULY/AUGUST 2005 61 CLASSIFIEDS GEAR MANUFACTURINGGEAR MANUFACTURING HEAT TREATING PRECISION GROUND SPUR-HELICAL-GEARS- Induction Hardening Specialists in Tooth by Tooth Contour SPLINES-WORMS-WORM Hardening of Internal GEARS-GROUND RACKS- Spur, helical and bevel gears PROTOTYPE OR PRODUCTION Our gear hardening equipment includes 5 MAKE COMPLETE OR NATCO submerged process machines and 5 AJAX CNC-controlled gear scanning OPERATIONAL INCLUDING machines. Tooth by tooth gear hardening GEAR BOXES & ASSEMBLY- from .5DP-10DP, up to 15 tons, 200" diameter. GEAR PUMPS-AEROSPACE- MILITARY-COMMERCIAL- HOBBING-SHAPING-TURNING JIG GRINDING-COMPLETE GRINDING FACILITIES

NITAL ETCH-MAGNAFLUX Breakdown Service Available 24649 Mound Road, Warren, MI 48091 Phone (586) 754-4600 American Metal Treating Company Fax (586) 754-4603 Cleveland, Ohio Email [email protected] Phone: (216) 431-4492 • Fax: (216) 431-1508 Web: www.americanmetaltreating.com E-mail: [email protected]

WHEN IT HAS TO BE RIGHT Be on the Cover • Gear Grinding to 94" of • Industrial Gears to 250" • Turbo Compressor Gears We Use Med. & High Frequency • Custom Drives Gear Technology • Spline Broaching Simultaneous Dual Frequency • Gear Metrology Send us your high-quality • StockStock PlanetaryPlanetary SpeedSpeed ReducersReducers Induction Hardened gear-related images for G our consideration. It's a Custom Gear Services Since 1946 great chance for ISO-9001 FREE publicity. w w w. t h e g e a r wo r k s . c o m Aircraft Gear Contact: If you need this, call us. We sell The Gear Works—Seattle, Inc. Kathy O'Hara 500 S. Portland Street the systems to make it for you! Seattle, WA 98108-0886 1425 Lunt Avenue Phone: (206) 762-3333 Elk Grove Village, IL 60007 Induction, USA, Inc. Fax: (206) 762-3704 Phone: (847) 437-6604 [email protected] E-mail: [email protected] [email protected] 248-364-4750 www.eldec.de

Rates—Line Classified: 1" minimum, $325. Additional lines $45 per line (8 lines per inch). Display Classified: 3" minimum: 1X—$540, 3X—$495 per insertion, 6X—$450 per insertion. Additional per inch: 1X—$255, 3X—$235 per insertion, 6X—$225 per insertion. Color Classified: Add $135 per insertion for color. Gear Technology will set type to advertiser’s layout or design a classified ad at no extra charge. Payment: Full payment must accompany classified ads. Send check drawn in U.S. funds on a U.S. bank or Visa/MasterCard number and expiration date to Gear Technology, P.O. Box 1426, Elk Grove Village, IL 60009. Agency Commission: No agency commission on classified ads. Materials Deadline: Ads must be received by the 15th of the month, two months prior to publication. Acceptance: Publisher reserves the right to accept or reject advertisements at his discretion.

62 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com � �� Class 12/21/04 1:24 PM Page 54 � �� PICK UP AND DELIVERY IN MANY AREAS SPECIALIZED GEAR SERVICES SERVICE Sharpening Service CLASSIFIEDS for hobs, milling cutters shaper cutters, shaving cutters.

SERVICE �� SERVICE WEBSITES � �� Broaching Requirements? � HOB SHARPENING � �� • Eight standard lines of Thin�� film coatings new broaching equipment (763) 425-5247 � �� Class 12/21/04 1:24 PM Page 54 5200� Prairie�� Stone�� Parkway�,�� Suite 100 • New and remanufactured THIN FILM COATINGS Hoffman�� Estates, IL�� 60192�� turnkey broaching systems HSS & Carbide up to 5” Dia. Tel.: (847)� �� 649 -1450�� - Fax:�� (847) 649-0112 Straight Gash, �� •Hydraulic and electro- 2083 W.M-55, West Branch, MI 48661 mechanical drive available Sharpened & Inspected 1-888� ��-�Resharp��1-888-737-4277 � �� Per AGMA STANDARDS Tel.: (989) 345 -2865 - Fax: (989) 345-5660 � �� • Broach Tools Quick Turnaround GLEASON CUTTING TOOLS GLEASON CORPORATION 1580 Progress�� Dr.,� �� Richmond, IN�� 47374 Tel.: (765)CORPOR 935 -7424 - Fax:ATIO (765)N 935-7631 PICK UP AND DELIVERY IN MANY AREAS • Production Broaching Gleason is the world’s most comprehensive SPECIALIZED GEAR SERVICES Services resource for gearSERVICE manufacturing technolo- Gleason Cutting Tools Corporation is the gy. We offer a comprehensive gear cutting leading gear cutting tool manufacturer in Electro-mechanical • Parts and service for all machine program for every gear hobbing, North America. We offer a wide variety of Electinternalro-mechanical table-up types of broaching machines Sharpening Service form-relievingGEAR milling MFG.cutters, hobs, shaper internal table-up milling and grinding application for cylin- CLASSIFIEDS for hobs, milling cutters cutters, shaving cutters and CBN-plated form 25180 Seeley Road drical and bevel gears. To learn more about WHEN IT HAS TO BE RIGHT shaper cutters, shaving cutters. grinding wheels as well as our engineering, Novi, MI 48375-2044 our productsKORO SHARPENINGand services or SERVICEto find key coating, heat treating, metallurgical, tool Phone: (248) 471-4500 contact information,9530 - 85TH see A ourVENUE Web siteNO.. sharpening and reconditioning services. E-mail: [email protected]: (248) 471-0745 MAPLE GROVE, MN 55369 SERVICEwww.broachingmachine.comE-mail: [email protected] www.gleason.com �� www.broachingmachine.com [email protected] www.gleason.com

• CCONTRACTONTRACT MMETROLOGYETROLOGY SSERVICESERVICES Sharpening• BROACH SHARPENING Service • CCURVICURVIC CCOUPLINGOUPLING GGRINDINGRINDING Thin• HOBfor SHARPENING hobs, film milling coatings cutters & IINSPECTIONNSPECTION shaper cutters, shaving cutters. BBEVELEVEL & CCYLINDRICALYLINDRICAL •5200SHAVING Prairie CUTTER Stone Parkway GRINDING, Suite 100 • Hoffman Estates, IL 60192 DDEVELOPMENTSEVELOPMENTS & PPROTOTYPESROTOTYPES Tel.:• THIN (847) FILM 649 -1450 COATING - Fax: (847) 649-0112 • AAPPLICATIONPPLICATION EENGINEERINGNGINEERING SSUPPORTUPPORT & DDESIGNESIGN SSERVICESERVICES • 2083CUSTOM W.M- 55,HEAT West TREAT Branch, SERVICE MI 48661 1-888-Resharp 1-888-737-4277 • HHEATEAT TTREATMENTREATMENT Tel.:• REPLACEMENT (989) 345 -2865 HELICAL - Fax: (989) GUIDES 345-5660 The Gear Works—Seattle, Inc. 500 S. Portland Street • RREPLACEMENTEPLACEMENT HHELICALELICAL GGUIDESUIDES FFOROR FOR SHAPERS, INCLUDING FELLOWS GLEASON CUTTING TOOLS SSHAPERS,HAPERS, I INCLUDINGNCLUDING FFELLOWSELLOWS 1580 Progress Dr., Richmond, IN 47374 Seattle,GLEASON WA 98108-0886 CORPORATION Tel.: (765) 935 -7424 - Fax: (765) 935-7631 Phone: (206) 762-3333 PICK UP AND DELIVERY IN MANY AREAS Gleason is the world’s most comprehensive CORPORATION Fax: (206) 762-3704 SPECIALIZED GEAR SERVICES 5200 Prairie Stone Parkway, Suite 100 resource for gear manufacturing technolo- Gleason Cutting Tools Corporation is the Hoffman Estates, IL 60192 E-mail: [email protected] leading gear cutting tool manufacturer in Tel.: (847) 649 -1450 - Fax: (847) 649-0112 gy. We offer a comprehensive gear cutting Electro-mechanical machine program for every gear hobbing, North America. We offer a wide variety of internal table-up GEAR MFG. form-relieving milling cutters, hobs, shaper 1000 University Ave., P.O. Box 22970 2083 W.M-55, West Branch, MI 48661 millingPRECISION and grinding application GROUND for cylin- � cutters, shaving cutters and CBN-plated form Rochester, NY 14692-2970 U.S.A. WHEN1-88 IT8 Resharp HAS TO1-888- BE737-4277 RIGHT drical and bevel gears. To learn more about Phone: 585/473-1000 Tel.: (989) 345 -2865 - Fax: (989) 345-5660 SPUR-HELICAL-GEARS- grinding wheels as well as our engineering, Fax: 585/461-4348 ourSPLINES-WORMS-WORM products and services or to find key coating, heat treating, metallurgical, tool E-mail: [email protected] 1580 Progress Dr., Richmond, IN 47374 contactGEARS-GROUND information, see our RACKS-Web site. sharpening and reconditioning services. E-mail: [email protected] Tel.: (765) 935 -7424 - Fax: (765) 935-7631 www.broachingmachine.com www.gleason.com www.gleason.com PROTOTYPEwww.gleason.co OR PRODUCTIONm [email protected] www.star-su.com MAKE COMPLETE OR www.gleason.com OPERATIONAL INCLUDING � • CONTRACT METROLOGY SERVICES • BBROACHROACH SSHARPENINGHARPENING GEARINSPECTION.COM GEAR BOXES & ASSEMBLY- GEAR PUMPS-AEROSPACE- • CURVIC COUPLING GRINDING • HHOBOB SSHARPENINGHARPENING & INSPECTION MILITARY-COMMERCIAL- • BEVEL & CYLINDRICAL • SSHAVINGHAVING CCUTTERUTTER GGRINDINGRINDING HOBBING-SHAPING-TURNING DEVELOPMENTS & PROTOTYPES • TTHINHIN FFILMILM CCOATINGOATING JIG GRINDING-COMPLETE • APPLICATION ENGINEERING GRINDING FACILITIES SUPPORT & DESIGN SERVICES • CCUSTOMUSTOM HHEATEAT TTREATREAT SSERVICEERVICE NITAL ETCH-MAGNAFLUX • HEAT TREATMENT • RREPLACEMENTEPLACEMENT HHELICALELICAL GGUIDESUIDES The Gear Works—Seattle, Inc. • REPLACEMENT HELICAL GUIDES FOR FFOROR SSHAPERS,HAPERS, I INCLUDINGNCLUDING FFELLOWSELLOWS 500 S. Portland Street SHAPERS, INCLUDING FELLOWS Seattle, WA 98108-0886 PICK UP AND DELIVERY IN MANY AREAS Phone: (206) 762-3333 GEAR MOTIONS, INC. SPECIALIZED GEAR SERVICES Fax: (206) 762-3704 E-mail: [email protected] Learn about one of the most modern fleets of Gear Grinders, including the CORPORATION new Höfler 700 at Oliver Gear. See the 1351 Windsor Road PRECISION. �� GROUND�� latest Reishauer Gear Grinding technolo- Loves Park, IL 61111 U.S.A. SPUR-HELICAL-GEARS-. �� gy, at ISO 9001-2000 registered Nixon Phone: 815/877-8900 . �� Gear, as well as the latest in CNC Gear Fax: 815/877-0264 SPLINES-WORMS-WORM�� E-mail: [email protected] GEARS-GROUND RACKS- Hobbing and cellular manufacturing. �� www.gleason.com www.gleason.com PROTOTYPE OR PRODUCTION wwwww.gearmotions.co.gearmotions.com MAKE COMPLETE OR www.gearmotions.com www.powertransmission.com •OPERATIONALwww.geartechnology.com INCLUDING • GEAR TECHNOLOGY • JULY/AUGUST 2005 63 GEAR BOXES & ASSEMBLY- GEAR PUMPS-AEROSPACE- MILITARY-COMMERCIAL- HOBBING-SHAPING-TURNING JIG GRINDING-COMPLETE GRINDING FACILITIES NITAL ETCH-MAGNAFLUX ADDENDUM

THE GEAR MIX SIATRO

How To Play: UNDADEMD

Unscramble these five mixed-up words, one letter to each square, to form five gear-related words. Print your answer to the right. CALEHLI

Now arrange the circled letters to form the surprise answer, as suggested by the cartoon below. AKCR For the answers, visit: www.geartechnology.com

RONGHEREBIN

R & D LAB

Fred’s greatest design involved flame heating and ground beef.

“ ”

64 JULY/AUGUST 2005 • GEAR TECHNOLOGY • www.geartechnology.com • www.powertransmission.com

StarSU_chuck_check_ad.qxd 4/5/2005 8:50 AM Page 1

Chuck It... and... Check It

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Or just contact your Star SU salesman. We’re closer to you than you may know.

Star SU LLC 5200 Prairie Stone Parkway, Suite 100 Hoffman Estates, IL 60192 USA Tel.: (847) 649 1450 Fax: (847) 649 0112 See us at AGMA Gear Expo 2005, [email protected] Detroit, MI, in Booth 370.