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October 2013 Our Machines Are Making History OCT 2013 THE ART OF VERSATILITY Machining Gears without Gear Machining GEAR PROFILE Jan Klingelnberg ITAMCO Chips in for Youth Training TECHNICAL ASK THE EXPERT: Worm Gears THE NEXT STEPS FOR GEAR INSPECTION STANDARDS HARMONIC GEAR DRIVES WITH EXTERNAL WAVE GENERATORS MASTERING LUBRICATION BUYING www.geartechnology.com THE JOURNAL OF GEAR MANUFACTURING Samputensili G 250 generating and profi le grinding machine The Samputensili G 250 gear grinding machine has been especially developed for very low cycle times and for top-quality and effi cient mass production of gears with outside diameters up to 250 mm and shafts with lengths up to 550 mm. The machine is based on the dual work spindle concept, which eliminates non-productive times almost completely. By means of this feature, the loading/unloading process of a workpiece is carried out in masked time, while simultaneously the manufacturing process proceeds on another workpiece. Simple design concepts in terms of tooling and dressing technology, fast automation and amazing user friendliness are the strengths behind this innovative machine. Phone: 847-649-1450 • [email protected] 5200 Prairie Stone Pkwy. • Ste. 100 • Hoffman Estates • IL 60192 2013-09_Star-SU_Samputensili_Adv_2pages_us.indd 1 10.09.13 21:58 The G 250 / G 450 can be easily equipped with various automation solutions www.star-su.com/G250geargrinding 2013-09_Star-SU_Samputensili_Adv_2pages_us.indd 2 10.09.13 21:58 contents OCT 2013 22 28 features 22 The Art of Versatility Grinding Technology Dazzles at Gear Expo and EMO. 28 Untraditional Gear Machining Ingersoll and Allied Precision make gears by not making gears. technical 32 The Latest Gear Generation: An Interview with Jan Klingelnberg First of a new series of Gear Technology profiles 50 Ask The Expert: Worm Gears of individuals you should know in the gear 54 Gear Standards and ISO GPS industry. The Next Steps for Gear Inspection Standards. 36 The Halls of Ivy (Tech) Are Humming With Precision (Tooling) 58 Minimal Tooth Number of Flexspline ITAMCO Helping Indiana Students Help in Harmonic Gear Drive with External Themselves. Wave Generator How to Avoid Fatigue Fracture Under 42 Computer-Aided Finite Capacity Alternating Force Exerted by Wave Generator. Scheduling of a FLEAN Machining Cell Achieving FLEAN (Flexible and Lean) with People 64 Purchasing Gear Lubricants: Be Careful First, and IT Next. When Playing the Numbers Game Mastering Lubrication Buying. Vol. 30, No. 7 GEAR TECHNOLOGY, The Journal of Gear Manufacturing (ISSN 0743-6858) is published monthly, except in February, April, July and December by Randall Publications LLC, 1840 Jarvis Avenue, Elk Grove Vil- lage, IL 60007, (847) 437-6604. Cover price $7.00 U.S. Periodical postage paid at Arlington Heights, IL, and at additional mailing office (USPS No. 749-290). Randall Publications makes every effort to ensure that the processes described in GEAR TECHNOLOGY conform to sound engineering practice. Neither the authors nor the publisher can be held responsible for injuries sustained while following the procedures described. Postmaster: Send address changes to GEAR TECHNOLOGY, The Journal of Gear Manufacturing, 1840 Jarvis Avenue, Elk Grove Village, IL, 60007. Contents copyrighted ©2013 by RANDALL PUBLICATIONS LLC. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing from the publisher. Contents of ads are subject to Publisher’s approval. Canadian Agreement No. 40038760. [www.geartechnology.com] 2 GEAR TECHNOLOGY | October 2013 our machines are making history August 2006 NASA begins development on Mars Science Laboratory Rover(MSL)-later renamed Curiosity. December 2008 (date for illustrative purposes only) Critical gears are required for MSL’s 6 wheels. An American manufacturer is chosen to produce these. KAPP VUS 55P is chosen to grind them. November, 2011 Curiosity launches into space from Cape Canaveral Air Force Station, Florida. August 6, 2012 Curiosity lands successfully on Mars. Gears for the Curisoity Rover September 2012 - July, 2013 Curiosity collects first samples of material were ground using the KAPP VUS 55P. ever drilled from rocks on Mars. Analysis shows evidence of conditions favorable for life in Mars’ early history. Gears good enough for NASA. KAPP Technologies 2870 Wilderness Place Boulder, CO 80301 Phone: (303) 447-1130 Fax: (303) 447-1131 www.kapp-niles.com [email protected] contents CNC Continuous Generating Gear Vol. 30, No. 7 Grinding Machines departments Built for long standing performance 06 GT Extras Burri BZ331 & BZ362 And by the Way… Each machine is built on 09 Publisher’s Page the mechanical basis of Opportunity Knocked Reishauer RZ301/RZ362. After a Burri retrofit the 10 Voices machine is technically Bill Bradley Responds to Buzz Maiuri’s “How Gear comparable to the latest Standards are Written.” (Sept. Gear Technology) machine generation. Burri machines are rebuilt to 12 Product News be modern and innova- KISSsoft’s Latest Software Upgrades; tive technology, competitive with today’s expectations for MHI Touts Gear Shaping Technology reduced set-up time and lower costs of gear grinding. 70 Industry News www.machinetoolbuilders.com Gear Technology hosts Presenters, Industry Experts during Gear Expo; Holroyd Precision Invests in local 815.636.7502 workforce 76 Events/Calendar Call MTB: 815.636.7502 or visit www.machinetoolbuilders.com October: Power Transmission and Control 2013 November: AWEA Wind Energy Fall Symposium 78 Advertiser Index Contact information for every company in this issue 79 Classifieds Our products and services marketplace 80 Addendum The Ever-Evolving Apple Parer FROM PROTOTYPE TO PRODUCTION OCT Your Source for High Precision Large 2013 Component Machining and Gear Cutting. THE ART OF VERSATILITY Machining Gears without Gear Serving the Industry for over 65 Years Machining GEAR PROFILE Jan Klingelnberg ITAMCO Chips in for Youth Training TECHNICAL ASK THE EXPERT: Worm Gears THE NEXT STEPS FOR GEAR INSPECTION STANDARDS HARMONIC GEAR DRIVES WITH EXTERNAL WAVE GENERATORS MASTERING LUBRICATION BUYING Gear Grinding on a Kapp Niles www.geartechnology.com machine THE JOURNAL OF GEAR MANUFACTURING www.rmc-BIGCNC.com Tel: 217-546-2249 Photo by David Ropinski [www.geartechnology.com] 4 GEAR TECHNOLOGY | October 2013 Intelligence in Production. Gear manufacturing technology innovations from Liebherr. During development of our innovations, we place particular emphasis on choosing an optimal solution for the respective application. The result: Process stability and an outstanding quality of manufactured components – with the highest level of economy possible. Generating grinding machine LGG 180 / LGG 280 • A single-table solution for gear grinding of workpieces up to Ø 180 mm, or up to Ø 280 mm, and workpiece lengths up to 500 mm • Extremely fast load/unload times of 4 seconds, chip-to-chip, with a single-table • New Palletizing Cell LPC 3400 Gear hobbing machine LCH 180 two Gear hobbing machine LC 180 Chamfer Cut • Multi-cut strategy with roll / press deburr-chamfering • High chamfer quality with one-cut hobbing strategy • Primary hobbing time is done in parallel to the load / unload, • Primary hobbing time is done in parallel to chamfering and roll / press deburr-chamfering, between two cuts – on in a second machining position two work-tables Liebherr Gear Technology, Inc. 1465 Woodland Drive Saline, Michigan 48176-1259 Phone.: +1 734 429 72 25 E-mail: [email protected] www.liebherr.com The Group 2014-503_003_LVT_EMO_aMP_USA_GB 2.indd 1 28.08.13 12:42 GT extras THE GEAR INDUSTRY’S INFORMATION SOURCE www.geartechnology.com RANDALL PUBLICATIONS LLC 1840 JARVIS AVENUE ELK GROVE VILLAGE, IL 60007 (847) 437-6604 FAX: (847) 437-6618 EDITORIAL Publisher & Editor-in-Chief Michael Goldstein GT VIDEOS [email protected] The GT website currently features a video Associate Publisher & Managing Editor on how the MTConnect+Google Glass app Randy Stott works from ITAMCO. For more information, [email protected] visit www.itamco.com/glass.html. Senior Editor Jack McGuinn [email protected] Senior Editor Matthew Jaster [email protected] Editorial Consultant Paul R. Goldstein Technical Editors William (Bill) Bradley Gear Expo Coverage Robert Errichello Octave Labath, P.E. Gear Technology and Power Joseph Mihelick Transmission Engineering hosted Charles D. Schultz, P.E. two successful events during Robert E. Smith Gear Expo. Check out the Gear Expo photo album on our DESIGN Facebook page at https://www.facebook.com/pages/Power- Art Director Transmission-Engineering/109042075794176?ref=hl# . David Ropinski [email protected] ADVERTISING Associate Publisher & Advertising Sales Manager Dave Friedman [email protected] Materials Coordinator Dorothy Fiandaca LinkedIn [email protected] Check out our LinkedIn page for upcoming trade shows, seminars or educational CIRCULATION events like the 12th International CTI Circulation Manager Symposium and its flanking specialist Carol Tratar exhibition aimed at people seeking Stay Connected [email protected] the latest developments in automotive transmissions and drives for passenger Follow us on Twitter RANDALL STAFF and commercial vehicles. twitter.com/#!/Gear_Technology President Michael Goldstein Accounting Connect with us on LinkedIn Luann Harrold E-Newsletter www.linkedin.com/groups/Gear-
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