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

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- Upcoming E-News topics for Gear Technology-Magazine-3893880 Technology include the following: November—Cutting Tools Subscribe Online www.geartechnology.com/ December—Gear Metrology subscribe.htm Contact [email protected] with editorial ideas.

[www.geartechnology.com] 6 GEAR TECHNOLOGY | October 2013 Hunting For High Quality Gears? Forest City Gear Leads the Way

US Navy MH-60S Seahawk helicopters patrolling for mines out ahead of surface vessels use a powerful and precise Carriage Stream Tow and Recovery System (CSTRS) to quickly raise and lower mine-hunting and destruction equipment. Very high-precision gears from Forest City Gear help to ensure that the mission goes as planned. In this and many other aerospace and defense applications, Forest City Gear is helping customers meet their gear challenges – no matter how difficult to detect.

Don’t let gear challenges go undetected. Visit www.forestcitygear.com.

11715 Main Street, Roscoe, IL 61073 815-623-2168 Our Technologies, Your Tommorow

The E f ﬁ c i e n c y of Process Integration

Maximize Production and Profi ts With Mitsubishi’s Multiple Process Capabilities Machines. When you reduce steps you reduce costs. With that in mind Mitsubishi developed its Process Integration platform. It allows various operations, such as chamferring, deburring, inspection, timing and meshing, to be incorporated into our existing gear machines. The advantage is clear. It’s simply more effi cient to have one machine completing two or more processes. With numerous options and confi gurations available you can customize our shaping, grinding or hobbing machines to incorporate the additional services that precisely meet your needs—and maximize your effi ciencies, production ZE40A and profi ts. To learn how you can leverage all the possibilities of Process Integration visit www.mitsubishigearcenter.com PROCESS+integration or contact sales at 248-669-6136.

Inspection Device Dress Automation

MHIA_Service Int ad.indd 1 11/8/12 4:27 PM publisher's page Opportunity Knocked

Our Technologies, Your Tommorow For anyone involved in gear manufacturing, Gear Expo is an absolute treasure. Publisher & Editor-in-Chief In 2013, it was bigger Michael Goldstein and more varied than it’s been in a decade. With 226 exhibitors covering every conceivable gear-related technology, Gear Expo offered visitors unparalleled opportunities to interview poten- tinues to inform the gear industry through their research and tial new suppliers. More importantly, many exhibitors were writing (see our news item on pp. 70 for a full list of attendees). showing new technology—in some cases, game-changing tech- The dinner was a great opportunity for our staff to get to The E f fi c i e n c y nology with the potential to improve your productivity, not just know many of these contributors on a more personal level, and incrementally, but by an order of magnitude. 3M’s Cubitron II to learn more about the work of these important individuals. In and Gleason’s power skiving were just two examples. addition, by fostering and developing these relationships, Gear Gear Expo was equally impressive from a gear buyer’s per- Technology will continue to provide the most relevant, accurate of spective. With more than 50 of the world’s leading suppliers of and significant technical articles available for your educational Process gears and gear drives exhibiting, gear buyers had a wide variety benefit. of potential suppliers to visit, including manufacturers of plas- Our sister publication, Power Transmission Engineering, held tic, powder metal and cut steel gears for aerospace, industrial, a marketing seminar and breakfast for gear manufacturers, in automotive and many other industry sectors. which some of the key concepts of branding that help differ- Integration On top of all that, the exhibition was once again co-located entiate one gear manufacturer from another were explained. with ASM’s Heat Treating Conference and Exposition, as well as The seminar was extremely well attended, with more than 50 in AGMA’s Fall Technical Meeting, providing even more learning the audience and the crowd spilling into the aisles around our opportunities for visitors. booth. If you’d like more information about the presentation, The folks over at AGMA put on quite a show, and over- contact Associate Publisher/Advertising Sales Manager Dave all attendance was up considerably. The final tally was 3,466, Friedman via e-mail at [email protected]. according to Jenny Blackford, AGMA director of marketing Finally, our booth included a wide-screen TV with a display communications. This is up nearly 12% compared to the show of video recordings “starring” Gear Technology readers, who in Cincinnati two years ago. talked not only about what they do and how they’re involved in Although some exhibitors expressed concern that the foot the gear industry, but also about what Gear Technology means traffic is still light, many were pleased with the quality and to them. The video presentation included many of the lead- motivation of the attendees who came with projects in hand ing manufacturers in our industry, and we thank them for their and intentions to buy. We saw visitors from companies like participation. The video was so well-received—and our read- Maximize Production and Profi ts With Mitsubishi’s General Motors, Chrysler, American Axle, Caterpillar, Eaton ers so enthusiastic about what we do—that several visitors vol- Multiple Process Capabilities Machines. and so forth—the types of visitors that exhibitors like to see. unteered to have their own videos recorded right there on the When you reduce steps you reduce costs. With that in mind Mitsubishi And although they didn’t come in large groups, they came with spot. developed its Process Integration platform. It allows various operations, such specific needs. Thank you to all who came and visited us during the show. as chamferring, deburring, inspection, timing and meshing, to be incorporated So overall, Gear Expo 2013 was a very good show. I just wish We appreciate your support and feedback, and we promise we’ll into our existing gear machines. The advantage is clear. It’s simply more more of you had been able to take advantage of it. It continues keep working on ways to improve Gear Technology to suit your effi cient to have one machine completing two or more processes. With to amaze me that this show doesn’t attract far more visitors. needs even better than we’ve done so far. numerous options and confi gurations available you can customize our As for us at the Gear Technology family, we considered Gear We look forward to seeing even more of you at Gear Expo shaping, grinding or hobbing machines to incorporate the additional services Expo 2013 to be a resounding success. As has become our cus- 2015. that precisely meet your needs—and maximize your effi ciencies, production tom over the last several shows, we transformed our booth into ZE40A and profi ts. To learn how you can leverage all the possibilities of Process a gourmet coffee bar with freshly made espresso, cappuccino Integration visit www.mitsubishigearcenter.com and latte drinks served to visitors and exhibitors alike, many of PROCESS integration or contact sales at 248-669-6136. + whom came back for seconds or thirds and told us we had “the best coffee at the show.”

Inspection Device Dress Automation We also expanded on an idea we started two years ago hosting a dinner for our technical editors; this year we also broke bread with a number of authors who have been significant contributors to the magazine over the years. In attendance were some of the leading minds in gear technology, whose work con-

October 2013 | GEAR TECHNOLOGY 9

MHIA_Service Int ad.indd 1 11/8/12 4:27 PM voices To Be Emphatically Clear —The Devil (and the Standard) is in the Details Bill Bradley

I read with great inter- is balloted within the whole organiza- est Buzz Maiuri’s article in tion — be it ANSI/AGMA or ISO. the September 2013 issue of Also, the ballot comment resolution Gear Technology — “How Gear process is extremely important. The Standards are Written.” AGMA procedures require that all com- I feel Buzz did a good job of ments be addressed and resolved by the outlining the process. There developing committee. An extremely are a couple of things where important AGMA requirement is that if I would like to add emphasis. the resolution of a comment results in a SEP The committee membership substantive change in the standard, the Gear Expo 2013 and the ballot comment res- draft must be re-balloted at either the olution process are extreme- committee comment or general ballot 2013 Issue ly important for developing stage. The procedures require a 75 per- • Gear/ASM Exhibitor Interviews • Showstoppers Advertising Section good standards. cent approval of all those voting at each • Show Map/All Booth Listings The committee member- stage. These requirements help assure STEM: The New 3 Rs? ship needs to be made up of the development of a consensus stan- How to Inspect a Gearbox competent and knowledgeable dard. individuals that represent all The ISO ballot comment resolu- aspects and views that are cov- tion requirements are different. The TECHNICAL ASK THE EXPERT: ered by the scope of the pro- ISO/IEC directives allow for the reso- Lubrication Education NEW-FORMULA ACETYLENE posed standard. They must be lution of comments to be proposed by ENHANCES LPC PLANETARY GEAR able to find compromise. If not, the Secretariat “in consultation with the TRANSMISSIONS GO LITE the standard may end up being biased to a agma voices segment of industry, a www.geartechnology.com How Gear Standards are Written company, or misleading T.J. “Buzz” Maiuri, Sr. Product/Project Manager, The Gleason Works THE JOURNAL OF GEAR MANUFACTURING prise proven, reliable information. attends the meetings, as does the AGMA- Information sheets, however, often con- in its application. The Several years ago my friend, colleague chairman of the board. The new chair tain material that is still being tested and and past Technical Division Executive man is Lou Ertel of Overton Chicago proven. Information sheets are also a Committee (TDEC) Chairman Doctor Gear Corporation, and the chairman forum for setting new material before committee membership Phil Terry (retired chief metallurgist, emeritus is Matt Mondek of Reliance the industry so that they can be used and Lufkin Industries and now owner of P. Gear Corporation. refined. ANSI/AGMA standards require Terry and Associates) wrote a very good Each member of the TDEC is also the- balloting before the entire membership is perceived as being “the article titled “Raising the Standards” liaison to several of the technical com of AGMA, as well as any other interested about the AGMA Technical Division mittees. As the liaison, he helps the com- parties. An information sheet requires- and the AGMA TDEC. Doctor Phil’s mittee chairman evaluate new projects only approval of the technical commit words are still applicable today, and I’d experts” in the technology and, and prepare proposals to the TDEC for- tee that prepared it, and permission to like to revisit some parts of the article the committees, as well as submit prog publish from the TDEC. One advantage with a few updates, as well as explain the ress reports, completed work and com- to preparing an information sheet is that therefore, are not generally chal- AGMA Standard and Information Sheet mittee problems to the TDEC. - it can be published more quickly, since- writing process. The technical committees are respon it does not go through the general bal The AGMA mission statement is “To - sible for the timely development, main- lot process. However, information sheets lenged when a committee draft help members compete more effec tenance and theoretical accuracy of the are not standards and do not carry the tively in today’s global marketplace.” A technical publications of AGMA. Each authority of consensus standards. large part of that mission has to do with committee has a chairman and vice New standards and information- the standards and information sheets chairman. sheet projects can originate from with created by the 26 committees in the Several of the technical committees in an AGMA technical committee, the Technical Division. also serve as the United States Technical AGMA Business Management Executive The Technical Division of AGMA is Advisory Group to programs within ISO Committee (BMEC), from AGMA overseen by the TDEC. The TDEC has- TC 60 and ISO TC 14 (International membership, or from sources outside of the responsibility to supervise the devel Organization for Standardization – AGMA. opment and maintenance of AGMA- Technical Committee). The scope for The whole process from the proposal Standards and other technical publica ISO TC 60 is the standardization in- of a new standard or information sheet tions, as well as supervising the division’s the field of gears, including terminol to its publication will take some time, activities and coordinating them with ogy, nominal dimensions, tolerances and and there are a number steps along the the Administrative Division. The TDEC tools for manufacturing and control. The- way. AGMA headquarters with the guid- also organizes and conducts the annual scope for ISO TC 14 is the standardiza ance of the TDEC has prepared a docu- Fall Technical Meeting. tion in the field of shafts for machines,- ment titled “Operating Instructions for The TDEC consists of a chairman their keys and keyways, splines and ser AGMA Committee Chairmen and Vice- (myself – T.J. “Buzz” Maiuri of The rations and their accessories such as cou- Chairman,” which outlines the proce- Gleason Works) and 7 voting members: plings, flanges, etc. dures for writing standards and infor John B. Amendola, Sr. of Artec Machine - AGMA is the secretary of ISO TC 60- mation sheets. As an example, the docu Systems; Terry Klaves of Milwaukee and procedurally oversees all the stan ment contains an extensive flow chart as For Related Articles Search Gear Company; Bob Wasilewski of dards programs that are undertaken. well as a checklist with 30 task items for Arrow Gear Company; Dan Phebus of All AGMA standards have the status standards development. In addition, the- Fairfield Manufacturing Company; Todd of being American national standards manual contains other useful informa Schatzka of Rexnord Corporation; Todd as defined by the American National tion in the “Policy and Practice Guide” Praneis of Cotta Transmission Company Standards Institute (ANSI). To maintain portion of the document. (Note that standards and Bill Hankes of A-C Equipment this status, AGMA’s Technical Division the TDEC is in the process of reviewing Services. We meet face to face two to operations are audited by ANSI every the document for necessary updates to three times a year, once online via Web- five years to ensure compliance with reflect current procedures.) at www.geartechnology.com Ex. As necessary, we use conference calls our own policy and practices, and with In brief, the process for a proposed and e-mails throughout the year to take ANSI’s requirements. The next audit will standard will go something like this: care of any business that needs to be be in 2014. - If the proposed standard originates addressed between meetings. There are currently 53 AGMA stan from within a Technical Committee, the All TDEC meetings are attended by dards and 30 information sheets. - proposal will contain a written scope AGMA headquarters personnel Charlie Information sheets are similar to stan and justification for the standard. It Fischer – VP Technical Division and dards, but are different in a few major- Amir Aboutaleb – staff engineer. Joe ways. ANSI/AGMA standards com Franklin Jr. – president of AGMA also [www.geartechnology.com]

| September 2013 12 GEAR TECHNOLOGY

[www.geartechnology.com] 10 GEAR TECHNOLOGY | October 2013 Chair of the technical committee or sub- or IEC standard than an ANSI/AGMA committee and, if necessary, the proj- standard — especially if there is no polic- ect leader, for proceeding with the proj- ing of the decisions by committee lead- ect.” This can result in unilateral resolu- ership. (Note: While the U.S. [AGMA] tions. The directives require committee has been the Secretariat of the ISO/ resolution of comments only if two or TC60 Committee for Gears, all bal- more participating countries file a time- lot comments on TC60 standards, by ly objection (within two months) to the agreement in 1994, have been resolved leadership’s proposals. Also, the direc- by the developing working group(in tives only require two-thirds acceptance order) to promote consensus.) and less than one-fourth rejection of One last comment is that a standard Bill Bradley, a participating countries to become an should be short in volume, with spe- longtime, distinguished AGMA member — and ISO or IEC standard. In addition, in a cific requirements, (and shall) contain former vice president 2013 directive change, committee draft few recommendations (should doing of the AGMA Technical ballots may be skipped if a committee so) tend to make compliance difficult Division — was in 2006 awarded AGMA’s so decides on the recommendation of to discern. The recommendations or Lifetime Achievement the developing working group. Although textbook statements belong in AGMA Award. He has, over the years, also graciously there is some rhetoric paid to developing Information Sheets or ISO Technical volunteered his time and expertise to serve as consensus, it is easier to develop an ISO Reports. a Gear Technology technical editor.

High precision Gears and Components. Short lead times for any volume environment. Latest technology for high efficiency and competitiveness.

PreSenCe in all SeCtorS: · Marine · Highway and Off-Highway · Industrial · Railway · Aerospace

www.gruposdiferenciales.es Portal de Bergara 32, 01013 Vitoria-Gasteiz (Álava) Spain Phone: (+34) 945 260 100 Fax: (+34) 945 261 446

October 2013 | GEAR TECHNOLOGY 11 product news KISSsoft OFFERS LATEST SOFTWARE UPGRADES

KISSsoft covers a broad range of applications in a single software package. The latest release of KISSsoft (Version 03/2013) incorporates the newest advances in contact analysis for both cylindrical gearing and planetary geared systems as well as fine sizing for worm wheels and crossed helical gears. Fine Sizing for Worm Wheels and Crossed Helical Gears For the calculation of worm wheels and crossed helical gears, fine sizing modules are now available (module ZD5 and ZE6). The KISSsoft fine sizing is applied to gear optimizations of all kinds — from static strength to noise optimization. Thereby, the macro geometry is varied in desired areas and the optimal solution according to various criteria is selected from the calculated variants. Plastic helical gears can be directly calculated according to the new draft of VDI 2736. After the cylindrical and bevel gears, Evaluation of Gear Modifications displayed in the 3-D system, ensuring these fine sizing modules complete the in the Radar Chart maximum clarity. This provides a pow- sizing process for all teeth. Another highlight in the KISSsoft Release erful analysis tool for the planet system. 03/2013 is the extended settings and New dimensioning suggestions are now Configurable Manufacturing evaluation options for optimizing modi- calculated for modifications, especially Drawings for Cylindrical Gears fications of cylindrical and planet gears. for planetary gear units (module ZA5). For all cylindrical gears, custom configu- A new feature is that the face load factor This ensures that tooth trace modifica- rable manufacturing drawings are now KHβ can now also be calculated. This tions can be specified accurate- available in KISSsoft (module ZPK). The therefore reveals the direct influence of ly, on the basis of the planet gear data and a range of different graph- the tooth trace modification on the safe- carrier torsion and sun gear ics−such as flank modifications, etc.−can ties of the classic tooth root and flank deformation. now be displayed in one graphic, output load capacities. For more information: to screen or paper, and sent to the gear Modifications are evaluated in the KISSsoft AG manufacturer. At the same time, graphic radar chart, which also provides a very Phone: +(41) 55 254 20 50 www.kisssoft.ag position and scale can be set by the user clear comparison, especially within dif- on his own. Now gear data can be eas- ferent partial loads. ily arranged and placed on the graphic. The settings are saved in a separate file Contact Analysis for Planetary and thereby adopted for all gears. This Units approach favors also the definition of The contact analysis has been greatly company standards. Those interested extended for planetary gear units (mod- can look at the manufacturing drawing ule ZA30). It is now possible to take examples in a KISSsoft test license by into account the exact deflections of the e-mailing [email protected]. shafts on the sun, the planet, and the internal gear. The planet carrier position is also determined by a shaft calculation, or can alternatively be specified as a displacement. The results are finally

[www.geartechnology.com] 12 GEAR TECHNOLOGY | October 2013 MHI TOUTS GEAR SHAPING TECHNOLOGY

Mitsubishi Heavy Industries, Ltd. (MHI) 500 strokes per minute to 600, enabling demand for a broader range of optional has completed the development of a new high-speed cutting with a focus on pro- devices and functions, and enhanced gear shaping machine, the ST40A, capa- ductivity. Stroke speed when machin- operability, safety and energy savings. ble of cutting a broad array of gears, ing at lower speeds meanwhile has been The company intends to market the including helical and cluster gears, with reduced by 50 percent, from 60 strokes ST40A for a wide spectrum of gear cut- one system. The ST40A’s significant- per minute to 30, enabling secure cutting ting applications for various products ly expanded range of cutting applica- of hard workpieces. The new machine is including automobiles, construction tions derives from the first application also capable of tapering up to 0.3 degrees machinery and aircraft. in Japan of NC programming technol- without use of a tilt table. In these ways, For more information: ogy to the relieving motion that prevents the ST40A has been designed to fully Mitsubishi Heavy Industries America interference between the cutter and the address diverse user needs, including Phone: (248) 669-6136 www.mitsubishigearcenter.com workpiece. The machine made its international debut in the United States with a live demonstration of its capabilities at Gear Expo 2013, in Indianapolis. The ST40A is a totally upgraded version of the ST40, a helical gear shaping machine requiring no helical guide for each workpiece. The ST40A has extended the ST40’s cutting flexibility even further by incorporating Japan’s first NC-programmable relieving mechanism and making all seven of the machine’s axes fully NC-programmable. This new precise cNc measuremeNts taKes mOre tHaN a great cmm. capability enables the ST40A to accom- it taKes valued service aNd suppOrt. modate various high-precision cutting applications such as crowning and tapering. In addition, stroke speed has been increased by 20 percent, from the earlier

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cmm • vision • form and finish • precision tools and instruments • data management

October 2013 | GEAR TECHNOLOGY 13 product news Sandvik Coromant EXPANDS GEAR MILLING FAMILY

The CoroMill 172 range was recently extended on October 1st. This disc cut- When Weeks ARE ting concept adapted for gears, splines and racks will now be available in mod- 172 is designed to be able to hold a range Just toO long ... ule 3-10 (DP 8.467-2.540) with gear of inserts, offering flexibility for custom- profiles in accordance with DIN 867 ers producing gears and splines of close WE SHIP In as fEW as 5 days for gears and DIN 5480 for splines. module size and similar tooth profiles. CoroMill 172 disc cutters offer a versa- CoroMill 172 is an attractive alterna- By combining the latest in ring tile and time saving solution for milling tive for milling of high-precision pro- rolling technology with experienced of high-quality gear profiles. Thanks to files in a wide range of applications. people, McInnes delivers the best the new indexable carbide insert tech- Diameters range from 2.480-10.000 in. value in carbon, alloy and stainless nology and powerful iLock interface, the (63 to 254 mm). steel rolled rings. component can be machined in flexible, For more information: non-dedicated machines, such as multi- Sandvik Coromant task machines and machining centers, as Phone: (800) SANDVIK www.sandvik.coromant.com well as in hobbing machines. CoroMill Saint-Gobain INTRODUCES NORTON FINIUM FILM ROLLS

Saint-Gobain Abrasives, Inc. has introduced Norton Finium abrasive microfinishing film rolls for precision applications. Norton Finium products are designed with a new, patented topside resin system alongside two new backing types and an innovative grit size color coding. This combination is specifically engineered to deliver high material removal and exceptional surface finish uniformity, while positioning Norton Finium film products as the most advanced in the market. The new Norton Finium line, des- ignated Q351R and Q351S, features either a Rough (R) back or Smooth (S) back film, to meet any application requirement and equipment type. These microfinishing film rolls are used in powertrain polishing operations in the automotive, truck, marine, small engine, and very large engine manufacturing operations around the world. Film rolls are made in extremely fine grit sizes, available in 80 – 9 micron/μ or 180 – 1,000 grit of straight and scalloped edge. The micron size is so fine that it can be difficult to distinguish visibly one from the other, which is critical in selection process. “We have added a color code by grit size as visible identity verification to simplify selection to avoid mistakes inside our customers manufacturing plants,” says Alexandre Pecora, product manager for film for Saint-Gobain. For more information: Norton (Saint-Gobain) Phone: (508) 795-2833 Carbon · alloy www.nortonabrasives.com stainless steel Rings · 4˝- 144˝ OD

www.McInnesRolledRings.com 1.800.569.1420

[www.geartechnology.com] 14 GEAR TECHNOLOGY | October 2013 Siemens ENHANCES PLM SOFTWARE

Siemens recently introduced a new series customers. By embedding that knowl- from the latest technology as soon as it of industry-specific offerings at its annu- edge and experience in each offering, becomes available.” al PLM Software Analyst Conference our customers will not only experience Over the past several years, most orga- in Boston. The Industry Catalyst Series accelerated PLM implementations, but nizations have come to appreciate how offerings consist of a pre-packaged com- those implementations will be tailored PLM technology and processes can help bination of industry best practice guides, to each company’s business in a way that them increase productivity and efficien- templates and software aimed at accel- facilitates the adoption of new technol- cy. At the same time, however, many of erating PLM deployment and tailor- ogy. The result is more business value, these organizations have been slow to ing the system to the needs of specif- faster ROI, and the ability to benefit implement a full-scope PLM solution, or ic industries. The series is designed to increase a company’s overall return on its PLM investment, as well as the speed at which ROI is realized. The new offerings will also make it faster and easier to adopt, and gain value from, the latest PLM technology. The Industry Catalyst Series will work with one or more Siemens PLM Software offerings and – in accordance with the company’s open business model – in combination with third party PLM solutions. Individual Industry Catalyst Series offerings will be announced over the next several months. “Two years ago we began our transition from a product-focused organization to one focused on the unique requirements of industries,” said Chuck Grindstaff, president and CEO, Siemens PLM Software. “This announcement represents a pivotal step forward in that transition. Each offering in the Industry Catalyst Series will be built around a specific industry’s best practices, based on in-depth knowledge we have collected over more than 30 years of working with

October 2013 | GEAR TECHNOLOGY 15 product news

to adopt the latest technology for their a Siemens PLM Software customer. existing PLM system. This often stems “Over the past several years, Siemens from concern about costs and business has evolved its PLM software solutions disruptions associated with the need to to minimize these efforts by allowing customize standard PLM technology to us to configure the system to our needs their specific processes, data structures rather than developing custom software. and workflow. This has already helped us reduce our The Industry Catalyst Series minimizes total cost of PLM ownership by 25 to 35 that disruption by delivering an indus- percent. Now with the introduction of try-tailored deployment more quickly. the Industry Catalyst Series, we see the As the name implies, each individual potential to implement new PLM tech- Industry Catalyst Series offering will nology even faster and reduce costs even work like an industry-specific “agent” to further.” accelerate a PLM implementation. For more information: “Building interfaces and custom cod- Siemens PLM Software ing can add significantly to the cost of Phone: (800) 498-5351 www.plm.automation.siemens.com a PLM system,” said Georg Vogl, executive program manager PLM at BSH,

Northfield Precision INTRODUCES MODEL 1025 AIR CHUCK

Northfield Precision Instrument Corporation, a designer and manufacturer of precision workholding chucks, introduces their Model 1025 air chuck. This chuck is used to grip on the pitch diameter of a large ring gear. A pin cage with integral axial locator is mounted to the chuck face as a subassem- bly. When accomplished, the jaws push the pins inward to grip the gear’s pitch diameter. Northfield Precision designs and manufactures accurate air chucks for any lathe, boring machine, grinder or VMC. Models include through-hole, high-speed and quick-change. Chucks are available in SAE or metric, in sizes from 3" (76 mm) to 18" (457 mm). Accuracies of 0.001" to 0.00001" (0.254 m) are guaranteed. Custom workholding chucks and jaws are available, and free engineering assistance is offered. For more information: Northfield Precision Phone: (800) 810-2482 www.northfield.com

[www.geartechnology.com] 16 GEAR TECHNOLOGY | October 2013 Blaser Swisslube RELEASES BLASOCUT BC935SW

Blaser Swisslube Inc., a manufacturer of Swiss quality metalworking fluids, is pleased to announce the release of Blasocut BC935SW. Blasocut BC935SW is formulated with the latest in state-of- the-art metalworking fluid components. Blasocut emulsions provide excellent bio-chemical stability and long sump life. This is due to the unique bio-concept of Blasocut emulsions and is accomplished without the use of bactericides, while maintaining a high level of environmental health and safety. Blasocut BC935SW is chlorine free yet provides high cutting performance and long tool life in cast iron, steel, aluminum and exotic alloys and is formulated for use in machining applications over a wide range of materials. Blasocut BC935SW has excellent washing action and low misting properties, thus providing a high level of machine and shop cleanliness. Blasocut BC935SW exhibits suitable bio and chemical stability and is formulated for use in water with a maximum hard- ness of 140 ppm. Blasocut BC935SW provides foam control in moderate to high coolant pressure applications. For more information: Blaser Swisslube Phone: (845) 294-3200 [email protected] www.blaser.com

October 2013 | GEAR TECHNOLOGY 17 product news Hardinge OFFERS C-SERIES COLLET AND COLLET STOPS

Hardinge Inc., a manufacturer of spindle tooling, began production of collets in the 1890s for use on bench lathes making parts for the watchmaking and lens industries. It is believed that the “C” des- ignation for their first 5C collets came from the name of the Cataract water- falls that could be viewed from the factory grounds of the Hardinge Brothers Company in Chicago, Illinois where they manufactured precision Cataract bench lathes. Incredibly, the Hardinge C-series design has not changed since the early use in the 1890s, even in light of the rapidly changing technology in machine tool design. A collet has the capability to accurately grip a workpiece or a tool, resisting both rotational forces and body is spring tempered to assure accu- permit the use of Hardinge positive multi-directional cutting loads with the racy and durability. Hardinge C-series solid and ejector stops. The Hardinge ability to rapidly release the workpiece collets are available in fractional sizes stops are threaded into and positively or the tool. A collet has the capability to of round, hexagon and square to capac- locked against the end of the collet and amplify the actuation force, converting ity. In addition, many round collets are are adjustable and machineable for the it into workpiece gripping or tool grip- stocked in metric, decimal, letter and desired part length to accommodate a ping with the ability to operate at high number sizes. Most of the popular sizes wide variety of chucking work. Once repetition levels without loss of accuracy of round serrated, taper hole and regular locked in place, the stop cannot move or material failure. It also has the ability collets are available from stock. Special even under heavy drilling or other end- to operate at a wide range of rotational accuracy 5C collets with a guaranteed working pressures. Universal stops are speeds with minimal loss of gripping maximum TIR of .0002" are available. available for 5C collets and 16C spin- force. Collet variations include emergency col- dles. A variety of Hardinge Dead-Length Hardinge C-Series collets, in sizes lets, step collets, extended-nose collets, systems are also available for produc- ranging from 1C up to 25C, are used in step chucks (stepped out collets that hold ing consistent work pieces, including manual and CNC lathes, mills, grind- larger diameters), and Dead-Length col- through-hole style for bar work. ing machines, collet blocks and closers, let systems for controlling workpiece For more information: indexers, rotary tables and tool holders. lengths. Hardinge Inc. The Hardinge collet is manufactured to The standard Hardinge 5C-series col- Phone: (607) 734-2281 www.hardinge.com exacting standards from special alloy let, with an order hole of .9843" or less steel. Threads are heat treated and the includes precision internal threads to Dillon Manufacturing INTRODUCES HPG500 LUBRICANT

Dillon Chucks and Jaws introduces HPG500 – a boundary lubricant that prevents metal-to-metal contact under high load and slow speed conditions for either high-end manual chucks or power chucks. This premium, high-performance NLDI Grade 2, lubricating grease has suitable mechanical stability, very high load carrying capacity, and water and moisture resistance. It has a water washout rating of less than three percent. Plus, its unique formulation gives it rust and corrosion resistance, even in the presence of a synthetic and oil based coolant environment. This chuck lubricating grease handles high loads, and provides long term corrosion protection under the most hostile conditions.

[www.geartechnology.com] 18 GEAR TECHNOLOGY | October 2013 OVERTONCHICAGOGEAR PROCESS-DRIVEN PRECISION

NSID ’S I E T TH A A H As wind turbines T get larger, gear reliability W C becomes even more crucial. S Overton Chicago Gear is one of the O ’ few companies in the U.S. with the

T machining and heat treat capabilities to

I meet the close tolerances and high N standards of this growing industry.

Today, we supply gearing for most of T the top manufacturers of turbine S gearboxes. Because we know it’s what’s on the inside that counts.

• • 125 years of precision gears Chicago Addison Lombard for the most demanding gear applications. (630) 543-9570 | www.oc-gear.com | [email protected] product news

The environmentally friendly formu- ings, slides, pivots, tracks, etc., — all ing set, consisting of a grease gun, 2 lation contains no heavy metals or other important engineering components of tubes of grease and one grease adaptor environmentally undesirable materials manual and power chucks. It is recom- fitting, is also available. HPG500 is also such as compounds containing antimo- mended wherever high lubricity, EP safe to use in your machine centers that ny, barium, lead, chlorine, phenols, or (Extreme Pressure) properties, mechan- require EPI grease. phosphorus. This lithium-free formula ical stability, rust and corrosion pro- For more information: does not react negatively when contact- tection, water washout protection, and Dillon Manufacturing, Inc. ing the water contained in water based good oxidation stability are required. Phone: (800) 428-1133 www.dillonmfg.com coolants – as opposed to lubricants with Essential for the safe operation, and lithium which cause lithium build-up on maintaining maximum gripping pres- the internal workings of the chuck. sure of chucks, HPG500 is available in An all-purpose industrial lubricant, 14 oz. tubes. It can be purchased by the Oelheld HPG500 can be used in bearings, bush- tube, in cases of 10 or 50 each. A greas- INTRODUCES NEW FLUID LINES

Oelheld U.S. introduces IonoGrind, a multifunction fluid that is equally suitable for spark erosion and as a grinding FORGED oil. It has been designed for the use in combination machines (two-in-one systems). IonoGrind combines the advan- NET and tages of a high-performance dielectric allowing for high rates of metal removal NEAR-NET with suitable surface quality and that GEARS of a high-speed grinding oil which dis-

• Save Time and Money

• Dedicated State-of-The-Art Net and Near-Net Gear Manufacturing Facility

• .008 - .060 Stock Allowance on Gear Flanks plays low foaming and misting proper- • ISO 9001:2008 ties. Additionally, Oelheld U.S. has introduced DiaCut CP, a new line of punch- • TS 16949:2009 ing oils which have been developed especially for fast punching machines. They effectively prevent the formation of built-ups and allow for punching without burrs. DiaCut CP punching oils are rolled or sprayed onto the workpiece. Finished parts are practically free of resi- due. DiaCut CP punching oils contain no chlorines and heavy metals and are practically free of aromatic compounds. For more information: Presrite Corporation Oelheld U.S. Phone: (216) 441-5990 Phone: (847) 531-8501 www.presrite.com www.oelheld.com

[www.geartechnology.com] 20 GEAR TECHNOLOGY | October 2013 PRS-029 GearAd-GearTech2.indd 1 12/22/11 9:50 AM

feature The Art of Versatility Grinding technology on display at Gear Expo and EMO Matthew Jaster, Senior Editor

For Related Articles Search grinding Whether you spent time at at www.geartechnology.com Gear Expo in Indianapolis or EMO in Hannover, there was certainly new technology attracting attention. Machine tools are faster, more efficient and can integrate numerous functions in Klingelnberg Viper 500 Series a single setup. Grinding technology The Höfler Viper 500 series from Klingelnberg offers pre-finishing and fin- is turning science upside down and ishing of complex gears including process design, cutting, measuring, deburr- inside out with high-speed removal ing, grinding and quality control. “We offer three machining configurations rates and increased throughput. The including the Viper 500 (profile and internal grinding), Viper 500 K (profile, mad scientists (engineering wizards) internal grinding and spindle option K) and Viper 500 W (profile, internal have been hard at work in their labs and generating grinding),” says Ralf-George Eitel, managing director, sales and to make gear production more flex- service at Klingelnberg. “These machines are highly adaptable, offer a quick ible in the coming years. The future of changeover, low maintenance and optimal energy efficiency.” some of this technology is just getting The Viper 500 series can go from generation grinding to profile grinding by started. How fast and efficient will swapping out the grinding wheel, grinding wheel flank and dressing wheel in gear grinding become in the coming less than five minutes on the 500 W (which was on display during Gear Expo). years? How will gear manufacturers “We’re offering the customer high productivity with the lowest possible cost per adapt to some of these new technolo- piece,” adds Eitel. “This is made possible with our comprehensive service offer- gies? While we don’t have the answers, ings and the technical expertise and support from the Klingelnberg engineers.” it’s safe to say productivity is defi- Eitel is also proud of the energy efficiency highlights on the machine includ- nitely increasing and the versatility in ing cooling units, optimal axis weight compensation and energy-optimized machining processes continue to add grinding oil nozzles. This overall modular approach gives gear manufacturers value for both job shops and OEMs. the tools necessary to succeed in areas like agriculture, mining, material handling, aerospace, wind power and maritime propulsion technology, Eitel says. Overall, the Viper series allows optimized five-axis machining of an entire range of modifications in the shortest possible grinding time. The pro- prietary GearPro software offers routine operation for the attendant even when the applications are complex. GearPro includes many module options for best-fit, high-speed and adaptive grinding as well as dressing to enable significant reductions in production times.

[www.geartechnology.com] 22 GEAR TECHNOLOGY | October 2013 Gleason Presents Titan 1200G The concept behind the Titan 1200G “In conventional grinding there is was set up to manufacture a sun shaft of began when engineers toyed with the always a compromise when selecting the a planetary gearbox with two gear sets. idea of combining multiple grinding grinding wheel specification to match “We wanted to demonstrate to attend- configurations to increase productivity the opposing requirements of rough- ees how the machine concept worked and throughput. “Let’s combine some of ing and finishing stroke,” Türich says. when you needed two different grinding the established grinding technologies “I compare it to tires on your car; you wheels. The process is quite simple. We like profile grinding, known for its excel- need certain tires for driving in the sum- exchanged the wheel without interfer- lent quality and threaded wheel grind- mer and certain tires for managing harsh ence and it produced excellent surface ing, known for its high productivity. winters. The same can be said about finish qualities.” The combination of both is what we call grinding wheels. Some are better for Power-Grind to provide more flexibility one process than another. With the tool and productivity to our customers,” says changer we are now able to Dr. Antoine Türich, director of prod- solve the conflict in the wheel uct management, grinding solutions at selection and use a dedicated Gleason. “This is now possible with our grinding wheel specification new Titan 1200G including a fully-auto- for the roughing operation matic tool changer, something that is not and another smoother new in the general machining industry specification for the but is totally new to the gear industry.” finishing operation. The Titan 1200G offers a high sur- Of course the Titan face finish quality combined with high 1200G can run with- productivity utilizing the automatic tool out the tool changer changer. The machine can be individu- as well, becoming a ally configured to suit customer require- conventional profile ments and provides maximum produc- grinding machine.” tivity, flexibility and quality. Türich adds that the Titan 1200G exhibited during EMO

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DTR. Your best choice for high quality gear cutting tools. DTR is a world class supplier of the finest high performance long-life gear manufacturing tools, for small and large gear cutting applications. Established in 1976, we are one of the world’s largest producers of cutting tools, shipping to over 20 countries. DTR offers a full line of gear cutting tools including: • Hobs • Chamfering and Deburring Tools • Carbide Hobs • Broaches • Shaper Cutters • Master Gears • Milling Cutters We can produce virtually any tool you need for auto, aerospace, wind, mining, construction and other industrial gears. Every tool is precision-made utilizing high speed steel, premium powder metal or carbide and the latest in coatings, to achieve superior cutting and long life. DTR uses top of the line equipment including Reischauer CNC grinders and Klingelnberg CNC sharpeners and inspection equipment. Learn more about our outstanding quality tools at www.dragon.co.kr. Call us at 847-375-8892 for your local sales representative or Email [email protected] for a quotation.

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U.S. Office Location (Chicago) Headquarters Email inquiries to: [email protected] 36B-11L, Namdong Industrial Complex, Namdong-Gu, Incheon, Korea (formerly Dragon Precision Tools) 1865A Hicks Road, Rolling Meadows, IL 60008 PHONE: +82.32.814.1540 WWW.DRAGON.CO.KR PHONE: 847-375-8892 Fax: 224-220-1311 FAX: +82.32.814.5381

October 2013 | GEAR TECHNOLOGY 23 feature THE ART OF VERSATILITY

“Besides the mechanical develop- ods can require significant time to components and reduced sizes wher- ment of the new Titan 1200G machine, manually align the workpiece,” Türich ever possible without a loss in machine we have made some significant improve- adds. “This technology was first used performance. In addition the machine ments in the grinding technology as well,” on gear inspection machines. In some requires much less floor space, for which says Türich. “Our new infeed strategies— cases, we’ve reduced the alignment pro- our customers thank us.” called: A(X) and degressive infeed—allow cess from one hour to five minutes using The Titan 1200G was a key point a much better and intelligent partitioning wobble compensation.” of interest for our customers at EMO. of the total stock removal into the differ- Sustainability, an important aspect of “Overall, we had 20 percent more visi- ent grinding strokes, resulting in a much manufacturing, remains a priority with tors to this show than the last EMO,” shorter cycle time and a higher process Gleason. The Titan 1200G consumes Türich says. “We collected leads from reliability.” up to 40 percent less energy than older every customer, took some machine Additionally, the Titan 1200G includes machines and is 35 percent smaller in orders and we’re extremely happy with wobble compensation, requiring less footprint. “During setup the machine our presence and with the customer time to align large and heavy workpiec- can be set into a standby mode in order experience we provided this year.” es while improving quality and reduc- to save energy, for example,” Türich says. ing fixture costs. “Conventional meth- “We’ve reviewed all energy consuming Star SU/Samp Gear Grinding Technology Based on established concepts from pre- priate cycle times, and the G 250 is suit- an extremely precise and rigid position- vious Samputensili models, the G 250 ed for future developments in the grinding, which is of fundamental importance is an innovative, compact and extreme- ing tool sector. The profile dressing unit in order to obtain an excellent result. ly flexible gear grinding machine. It consists of a standard profile diamond The dressing movements are actuated by has been developed for very low cycle dressing roll mounted on a dedicated the interpolation of the axes. The pos- times and for top-quality and efficient spindle, which is located on the rotating sibility to use generic profile dressing mass production of gears with outside table structure. An optional diamond rolls on the machine allows you to save diameters up to 250 mm and shafts OD dressing stick can be mounted on money and guarantees a fast supply of with lengths up to 500 mm. The dual the dressing unit structure, in order to dressing tools. You may employ both work spindle concept efficiently elimi- have the necessary flexibility to dress the single- and double-flank dressing rolls, nates non-productive auxiliary times. OD of the grinding wheel. as well as multi-rib type. Additionally, the loading/unloading If the tooth root diameter must Non-productive dressing times can be process of a workpiece is carried out in be ground as well, a tip radius dress- reduced considerably by dressing via a masked time, while the G 250 manufac- ing roll is applied to create the required diamond-plated dressing gear. With its tures another workpiece simultaneously. tip radius on the grinding tool. When total length in contact and its ten times The grinding spindle allows the use required, the dressing unit is automati- larger diamond-plated surface, the dress- of long grinding worms to raise the tool cally brought into the working position ing gear dresses a lot faster and with less life of single or combination worms. The by the rotating movement of the workta- wear, thus much more productively than extremely high rotational and linear ble. This guarantees a single dressing roll. Moreover, dress- accelerations offer appro- ing tool changes are reduced as well. For the dressing cycle, the dressing master is transferred like a workpiece from an external station into the work area. Consequently it always stays clean and is not affected by swarf or heat. Depending on your application, the G 250 machine can be easily equipped with various automation solutions to produce parts in small and large quantities, with shorter lead times, preserving high quality at lower costs. The G 250 can be linked, for example, to a robotic arm, which is normally installed next to the machine and manages the loading and unloading process of workpieces. Optionally a pallet storage solution can be integrated for a continuous workflow without any interruptions.

[www.geartechnology.com] 24 GEAR TECHNOLOGY | October 2013 Liebherr: Short Grinding Times with High-Production Quality The newly designed gear grinding machine LGG 180 for profile and generating grinding offers compact dimensions and is suited to handle the high production demands of vehicle and transmission manufacturers. “The advantage is higher quality throughout the entire production. It gives users fast processing combined with the advances of a one-table solution,” says Dr.-Ing. Andreas Mehr, grinding and shaping technology development and consultancy at Liebherr. The machines for 180 mm and 280 mm contain the same dimensions, making it easy to develop a complete high quality production line in which all the gears are produced using a one- table solution. Manufacturers can Luren Looks to Job Shops with Universal Grinding Machines ground planetary and sun gears, bore- Luren Precision established itself in of specifications and software capabili- type gears as well as drive and pinion the industry for manufacturing and ties for multifunctional machining.” shafts with lengths of up to 500 mm. engineering gear cutting tools but has In addition to the LUG-3040, Ditzler New features on the LGG 180 include expanded in the market to provide gear says the LWT-3080 attracted interest a new grinding head, (speeds up to grinding machines. “The LUG-3040 is a during Gear Expo. “This is our best- 10,000 rpm and a spindle power of great example of Luren’s machining ver- selling machine in the States, thanks to 35 kW), a thermally stable machine satility,” says Darian Ditzler, sales and its competitive price and the direct drive bed and reserve capacities for future service manager at Luren. “This machine motor and linear motor.” Luren’s Smart grinding developments. The LGG 180 is perfect for job shops. It utilizes a Dialogue software offers flexibility as can also utilize the abrasive Cubitron Fanuc controller and direct drive motor well as management of the grinding/ II from 3M. for the workpiece spindle and a built-in dressing cycle without the need for the In addition, the machine will enable motor for grinding. It offers a wide range external PC. undulations to be applied specifically The company plans to bring to gear wheel flanks for noise optimi- more machines to the States zation purposes for the first time. The that are being utilized in Asia ability to produce sub-µ range wavi- in the near future. Currently, ness cost-effectively gives designers a Luren offers hob sharpening, whole new range of options. Features worm thread grinding, horizon- under consideration include twist-free tal and vertical grinding, and grinding, grinding of stimulus-opti- CNC universal gear tool grinding mized corrections (amplitude, wave- machines. length, phase, orientation), trueing up Ditzler was happy with the of lines and grinding of conical gear concentrated traffic that visited teeth (beveloids). The newly designed Luren’s booth during Gear Expo user interface is individually configu- in Indianapolis. “We’ve received rable, enables intuitive operation via some great feedback this week. touch panel, and allows for mathemat- We’re walking away with a cou- ical analysis of waviness and twist. It ple of prospects for our univer- also provides user guidance for pro- sal grinding machine. While it’s cess cycles and conversion cycles. a small show, it’s a much better focus than you’ll find at IMTS or the larger trade shows. I think we’re going to get a larger booth in Detroit in two years and focus on bringing more engineering personnel to talk about our increasing machine capabilities.”

October 2013 | GEAR TECHNOLOGY 25 feature THE ART OF VERSATILITY

3M Offers Grinding Strength and Precision with Cubitron II Made of precision shaped grain (PSG), the Cubitron II offers a more uniform Erwin Junker Promotes Grinding Flexibility at EMO surface finish, no grinding burn (if used Erwin Junker provided several grind- with corundum or CBN. The Junker properly) and can cut production time, ing technologies during EMO, includ- CBN high-speed technology enables dressing amounts and dressing cycles ing the Lean Selection series and the high grinding performance with a in half. It was also widely discussed on Jupiter series. The Lean Selection simultaneous, long grinding wheel the exhibition floor during Gear Expo. all-round, with a grinding length service life and provides consider- Walter Graf, 3M, invented this gear of 800 mm and a center height of able production advantages for high- grinding technique and plans to contrib- 150 mm, is designed for the complete volume applications as well as smaller ute more information to Gear Technology grinding of workpieces used in proto- lot sizes and a broad range of variants. magazine in future issues. What we do type production, mold and tool mak- The high axial feed rate, with through know is that Cubitron II has been dem- ing, pneumatic and hydraulic appli- grinding, makes the process remark- onstrated on some of the latest and most cations, precision mechanics, gear ably fast and delivers exceptionally advanced gear machine tools. Those manufacture and medical technol- high output performance. The Jupiter involved in the demonstrations agree ogy. The machine makes short work machines enable straight infeed that the abrasive offers great potential of wide-ranging different workpiece grinding for the centerless grind- to reduce machining time, the number geometries, including cylindrical ing process, in addition to angled of passes can be significantly reduced diameters, tapers and radii, shoulders infeed grinding made possible by the using angular infeed grinding, OD Jupiter 125. The Jupiter 125, 250 and and ID threads as well as punches. 500 machines offer a large number of The machine can be equipped with functions, which considerably reduc- corundum, CBN or diamond grind- es the effort required for set-up and ing wheels and lends itself to a wide conversion as well as overall produc- variety of uses. The multifunctional tion time. The settings on the patent- OD and ID grinding machine is flex- ed height-adjustable supporting rail ible for small batch runs through to are automatically calculated by a soft- large-scale series, and is used pre- ware tool. While the regulating wheel dominantly by small and medium- is worn down, both the position of sized enterprises. As it offers scope the regulating wheel and supporting for individual automation, it can also ruler are automatically adjusted by and the possibility of soft/green gener- be used in production lines. the patented height adjustment of the ating grinding will be examined in the With the Jupiter series, grinding ruler. The Junker control electron- future. Graf presented a technical paper means centerless cylindrical grind- ics compensate this change in posi- titled “Precision Shaped Grains Turn ing — depending on the application tion with corresponding tracking of the Concept of Gear Grinding Upside Down” during the AGMA Fall Technical Meeting (FTM). Meanwhile, 3M grinding solutions were also exhibited at EMO, including a full range of the Cubitron II abrasives. These are used for the profile grinding of gears as well as for the continuous rolling and bevel gear grinding. According to a company press release, 3M also exhibited prototypes for the external and internal cylindrical grinding of automotive and industrial bearings. Application testing in industrial production has shown that the processing time can be reduced by up to half using these products — and at the highest surface quality. The lifetime increased to three to four times without risk of burning. Initial calculations show that in the future about a quarter of the production costs can be saved when using this innovative abrasive.

[www.geartechnology.com] 26 GEAR TECHNOLOGY | October 2013 the grinding and regulating wheel, ensuring precise, constant grinding at all times. Following each dressing process, the position is automatically re-calculated and the grinding wheel is immediately corrected. The quality of the concentricity remains constant while requiring less time to adjust the centerless grinding process without compromising performance. Depending on the workpiece requirements, the Jupiter series can be offered with an internal or external loading system. The loading systems can be combined with various feeding and discharge systems, such as conveyor belts, vibration convey- ors or systems adapted to customer- specific requirements. The measuring systems are individually adapted to the workpieces and customer specifications. Junker offers a wide range of options for the Jupiter series, such as retrofitting for CBN grinding.

Gear Grinding 2014 The quality and precision of our As mentioned earlier, many of these Broaches, Shaper Cutters and Gears new grinding concepts are in early have won customers world-wide - production runs and will continue from the smallest gear shop to to add capabilities and features in NASA and the Mars Rover. the near future. Gear Technology will check back in around IMTS next year to see how these gear grinding technologies continue to evolve. For more information: Erwin Junker Machinery Inc. Phone: (847) 488-0406 www.junker-usa.com Gleason Corp. Phone: (585) 473-1000 • Broach & Shaper Cutter www.gleason.com manufacturing & repair Klingelnberg America, Inc. • Gear & Spline— Phone: (734) 470-6278 prototype to production www.klingelnberg.com Master Gears & Gages Liebherr Gear Technology, Inc. • Phone: (734) 429-7225 • Small & fine pitch www.liebherr.com Precision. Performance. Perfection. Luren Precision The First time and every time. Phone: (847) 882-1388 TY T LI OO A www.lurenchicago.com L U S Q Star SU The Broach Masters, Inc. & Phone: (847) 649-1450 S E “DEDICATED TO EXCELLENCE” www.star-su.com ERVIC 1605 Industrial Drive 3M Auburn, CA 95603 Phone: (888) 364-3577 Phone: (530) 885-1939 www.3M.com/cubitron2/geargrinding Fax: (530) 885-8157 Web: www.broachmasters.com Email: [email protected]

October 2013 | GEAR TECHNOLOGY 27 feature Untraditional Gear Machining Ingersoll and Allied Precision Make Gears by Not Making Gears Doc Ardrey, Ardrey Inc. “Long story short: the company dramatically improved the material removal rate and yield while reducing Look beyond the obvious, and you may well find a better way to machine a part, fixture cost and delivery lead time on a family of gears and serve your customer better. That’s by not treating them as gears.” the lesson illustrated in a gear machining application at Allied Specialty Precision Inc. (ASPI), located in Mishawaka, Indiana. machining the web, hub and stepped shaft bore—seven opera- Long story short: the company dramatically improved the tions in all—than just cutting the teeth. Now we grab the part material removal rate and yield while reducing fixture cost and once and complete all seven.” delivery lead time on a family of gears by not treating them as gears. First, they moved the tooth forming operation from Done-in-one machining a traditional gear shaper to a CNC multitasking center. Next, The sector gear, machined from solid 17-4 PH bar stock, looks they treated the tooth throat as a short slot rather than the like half a gear with a lever arm attached. Measuring about 3½ usual tooth throat, using a form-matched Ingersoll Chip-Surfer inches diameter with 46 teeth over a 180o arc, the gear goes into replaceable-tip carbide slotting tool. helicopter flight controls. Annual volume for the earliest orders was just 100 pieces, all similar. Back in 2008, ASPI moved strongly toward the “done-in- one” approach on a plant-wide basis. To that end, the company moved the job to a new Mazak Integrex CNC multitasking center with all available auxiliary axes. “In effect it’s a nine-axis machine,” says Stoddard.

Although it’s a gear in the spindle, Allied Specialty Precision Inc. treats this part as something else to achieve “done-in-one” production from 17-4 PH cut-off bar stock, to deliver sooner and to cut machining costs (all photos courtesy of Ingersoll and Allied).

Step one enabled “done-in-one” machining, which led to simpler in-process parts handling and shorter delivery lead times, as well as reduced total machining cycle time by more than 2 to 1. Step two streamlined the tooth-cutting operation itself, the longest operation on the part, by about 3 to 1. Running 24/6 with 60 employees in the shop, the company has earned a reputation as, in the words of CEO Pam Rubenstein, “the ‘go-to’ guys for challenging manufacturing projects.” Because of its location and that reputation, ASPI has become a preferred supplier for aerospace manufacturers. “When you see a gear, you naturally think of a stroker-type gear shaper, equipped with the familiar single point high- speed steel form tool,” says Todd Stoddard, ASPI manufactur- Modified standard Chip-Surfer slotting tool forms teeth in just two ing engineer. “But completing this particular part is more about passes, shaving 20 minutes off tooth-forming cycle time for this sector gear at by Allied Specialty Precision.

[www.geartechnology.com] 28 GEAR TECHNOLOGY | October 2013 Originally on the new Integrex, teeth were formed with a two-inch high-speed steel (HSS) gear gasher – essentially a slitter with form-matched teeth. It completed the teeth in two roughing and one finishing pass. Total cycle time for tooth machining was 28 minutes, the same as before on the shaper. The big savings were in the other operations and in less part handling. Orders for the sector gears started to increase in 2011, and expanded into a family of about a dozen different part numbers. Total annual volume grew to around 500 pieces. The parts varied in diameter, arc, number of teeth and extra features like linkage arms, but used just two different tooth forms. In other words, the job became a big enough piece of business to war- rant some additional optimizing. Tooth formation, the most time consuming of the seven operations, naturally became a prime target. Stoddard reached out immediately to Ingersoll’s Andy ASPI’s CEO Pam Rubenstein and Todd Stoddard (far right) explore Thornburg, who, in Stoddard’s words, “knew more about gear fresh ideas for faster gear production with Ingersoll’s Andy Thornburg (center). “Andy knows more about gear machining than we do,” says machining than I did—especially non-traditional gear machin- Stoddard, “so his application support is invaluable.” ing. It’s a pretty specialized area.” Faster machining Teeth as slots During trials, Stoddard and Thornburg worked together to Thornburg suggested treating the teeth as short slots and optimize parameters for the new process. Conclusion was to machining them with a one inch form-matched Chip-Surfer T quadruple the surface speed and double the feed rate, and to slotting mill oriented like a slitting tool. The cutter features a take just one roughing and one finishing pass. Final settings for small replaceable tungsten carbide tip mounted on a threaded the 1 inch tool are 1,500 RPM, 0.060 in. depth of cut for rough- carbide shank. By itself, moving from HSS to carbide would enable much higher machining rates and extend edge “In one recent case here in the United States, an life, Thornburg reasoned. The replace- Ingersoll one-start indexable carbide insert (ICI) able tip design, moreover, would mini- hobber has reduced “from the round” tooth-generation mize the amount of carbide used and enable in-spindle tip replacement. The cycle time from 34 hours to five on big 8 AGMA shaft carbide shank, which was reusable, gears for mining equipment while actually improving would stiffen the cutting system for a surface finish.” better finish on the wear surfaces of the teeth. ing and 0.010 in. for finishing. This process change reduced cycle time for the teeth from 28 minutes to eleven. Once the new process went operational for a couple of months, tool life could be compared. The Chip-Surfer tips typically last through 50 pieces in this application, while the gear gasher needed a regrind every 10-20 pieces. “So ASPI reduces stoppages for tool replacement and cuts tool inventory costs as well,” says Thornburg. Even though it is form matched, each Chip-Surfer tip costs about $125, the same as one regrind on the gasher. Keeping spares is much more economical, too, since a single gasher can cost more than $400 to buy and $100 a pop to regrind, and can take weeks for delivery. Bottom line: tooling cost per part dropped from $20 to $2.56, an 8 to 1 reduction Slotting tool, close up The improvement in throughput stems from the proven capability of carbide over HSS, plus the Chip-Surfer’s free-cutting presentation geometry that enables higher feeds and speeds ASPI’s gear tooth tooling typifies the many Ingersoll Chip-Surfer without chatter, according to Thornburg. The Ingersoll Chip- modified standard slotting tools in service today. Ingersoll stocks the Surfer mill features a replaceable carbide chip that screws onto standard blanks (left) and simply grinds them to required form.

October 2013 | GEAR TECHNOLOGY 29 feature UNTRADITIONAL GEAR MACHINING a threaded shaft with 0.0002" repeatability to datum. Tips can be swapped out right in the spindle. The shaft can be either alloy steel or carbide depending on stiffness requirements and impact loads. “Even with the carbide shaft, the only throwaway carbide is the tip,” explains Thornburg. Ingersoll custom-grinds a standard Chip-Surfer T-Slot tip to match ASPI’s required form. Modified Standards What about the supply-chain risks of depending on a “special” tool? “Virtually all gear tooling is a special anyway,” says Stoddard. “The lead time on the previous slitter was weeks or months. And here, the customization is so simple that we regard it as a modified standard tool, not a full special. We can get them in a couple of days.”

“When you see a gear, you naturally think of a stroker-type gear shaper, equipped with the familiar single point high-speed steel form tool,” says Todd Stoddard, ASPI manufacturing engineer. “But completing this particular part is more about machining the web, hub and stepped shaft bore—seven operations in all— than just cutting the teeth. Now we grab the No more of the tooling baggage usually associated with gear-tooth part once and complete all seven.” machining. No swapping out gear gashers or dealing with regrinds. Operator simply changes tips in seconds and starts up again.

Ingersoll national milling product manager Konrad Forman ICI Tooling wins gearmakers’ trust adds that modified standard Chip-Surfers are very common for The ASPI application typifies a global trend toward index- slotting and T-slotting and die and mold applications. “As in the able carbide (ICI) tooling in gearmaking, according to Frank ASPI case, it’s a simple matter of a custom grind on a standard Berardi, Ingersoll product manager for gear machining. Chip-Surfer T-slot tip, which is always available off the shelf.” “Gearmakers have always recognized the potential of ICI tooling to outproduce and outlast high speed steel by wide margins, but were deterred by concerns about repeatability in multi- tooth compound cutters and hobbers,” he says. In one recent case here in the United States, an Ingersoll one- start indexable carbide insert (ICI) hobber has reduced “from the round” tooth-generation cycle time from 34 hours to five on big 8 AGMA shaft gears for mining equipment while actually improving surface finish. Now the surface reads 80 RMS all the way to the root, vs. 135 RMS partway down before. The company, a familiar name in off-road equipment, has also standardized on Ingersoll ICI hobbers for a host of whip gears, where surface quality is more critical. “Several European gear manufacturers report similar success- es with both one- and two-start ICI hobbers,” Berardi added. “ICI tooling technology is definitely winning converts in gear- m a k i n g .” For more information: Allied Specialty Precision Phone: (574) 255-4718 Sector gear, machined from solid 17-4 PH bar stock, looks like half a gear [email protected] with a lever arm attached. Measuring about 3½" (89 mm) diameter with 46 www.aspi-nc.com teeth over a 180° arc, the gears produced by ASPI go into helicopter flight Ingersoll Cutting Tools controls. Phone: (815) 387-6600 [email protected] www.ingersoll-imc.com

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Interview withJan Klingelnberg

This the first of a new series ofGear Technology profiles of individuals you should know in the gear industry.

:Tell us a little bit about the his- :For historical perspective, please tory of Klingelnberg. When was describe the significance of the QKlingelnberg originally founded? QKlingelnberg cyclo-palloid tooth When and why did the company form and its development; i.e., get involved in the gear industry? why was it developed, how does it ing in very geometrically precise fit in the overall scheme of spiral gears to meet the highest quality :Klingelnberg was founded in bevel gear production, and, histor- demands. 1863 — originally as a metal trad- ically, how has it competed with : Aing company. We have been locat- other tooth forms? What were the significant technol- ed in Hückeswagen, Germany ogy contributions of Oerlikon, and Qhow does that technology fit with since 1916. Having started with :First of all, cyclo-palloid is a wide- the production of tools and ly used, universal gearing prin- today’s operations? machine knives in 1908, the com- Aciple. The cutting tool is not spe- : pany moved to Hückeswagen and cifically designed for a dedicated Klingelnberg has always been very eventually became involved with gear set. Rather, it is applicable strong in the market of univer- Asal applications in industrial gear gearing technology. Consequently, for any ratio in a defined module in the 1920s we started designing range. This makes cyclo-palloid boxes. But decades ago, on the and producing machines for bevel profitable and thus competitive, other hand, Oerlikon introduced gear manufacturing based on the especially when the customer has the face hobbing principle to pro- palloid system. small batch sizes and a high vari- duce gears for automotive applica- ety of gear designs. tions. This latter process provided :Please describe how Heinrich significantly higher productiv- Schicht invented Klingelnberg :From a gear design perspective, ity, but every individual design Qgearing and the challenges he cyclo-palloid always creates par- required a dedicated tool. originally faced with his invention. Qallel tooth heights. This is impor- Oerlikon has been the market tant to mention since there are leader in lapping technology :Heinrich Schicht converted the other gearing systems that apply a from the beginning of the 1990s. basic principle of hobbing from tapered tooth height. The length- Since bevel gears for industrial Acylindrical gears to spiral bevel wise shape of the teeth, combined gear boxes are mainly ground or gears. Instead of a cylindrical with the optimal tool diameter, skived, Klingelnberg did not ini- hob used for cylindrical gears, he provide the best conditions for tially have enough expertise in applied a conical hob for bevel maximum strength of a cyclo-pal- the area of high-volume products gears. His idea remains the basis loid gear. and lapping. But, by combining for all further developments in Oerlikon’s market knowhow and this industry. The patent for his :One important feature of cyc- Klingelnberg’s experience in CNC idea was applied for in 1921. It lo-palloid is the hard finishing machine design, the group became allowed the company to grow and Aoption. The machine executing a full-service supplier for bevel go global from that point on. the soft cutting operation is able gear manufacturing in the auto- to perform a hard cutting process motive industry. called “HPG skiving” — result-

[www.geartechnology.com] 32 GEAR TECHNOLOGY | October 2013 :What are the keys to success for provide all gear technologies as a wide gear manufacturing commu- a family-run business (now in its one-stop shop. nity? Qseventh generation) operating on a global scale? :What synergies have been :The development of electric drives achieved in the takeover of vs. combustion engines in auto- :There are some valuable, inherent QHöfler? Amotive engineering will have a advantages to being a family-run growing impact on our industry, Abusiness. Time, for example, is one :Of course we benefit from certain for sure. Other than that, efficien- key factor:we take our time — in technological expertise, and the cy, noise reduction, unit costs and both marketing new developments Acomplementary product range of stable manufacturing processes and patiently striving for conti- the two partners. Höfler’s strong will be the focus of development nuity — even in tough periods. On R&D focus is a major asset to our work — both for us and our cus- the other hand, our independence company. tomers. allows us to make quick decisions, even concerning strategic mat- :What regions of the world are :What are your goals for the ters. Another factor that must not showing the most promise for Klingelnberg group over the next be underestimated is our commit- Qgrowth in gear manufacturing, and Qfive years? Can you discuss your ment to our local community and why? expansion plans in Germany? Do our heritage — important values you have plans to expand manu- that contribute to our staff’s iden- :One main factor that drives facturing outside of Germany? tification with the company. demand in the industry is, of Acourse, the growth of the auto- :Certainly one important :How has the gear industry evolved motive sector in certain countries step is relocating our site in since you took over as CEO in such as Russia, India, China and AHückeswagen to new, nearby facil- Q2004? Brazil. This is nothing unique to ities; this will take place gradually gear manufacturing, of course, as during the next decade. In gener- :With regard to the markets in it applies to several other indus- al, we will keep striving to deliver general, what stands out is the tries as well. product innovations, just as we Aincreasing quality demands for have been doing in the past or at gears, especially in the automotive :What innovations, changes or an even higher level. industry. For us as a company in trends do you see in the coming particular, it is the transition from Qyears that will impact the world- machine tool supplier to solutions provider for technology partnerships. Application support along the entire process chain is what customers demand today.

:Why was the recent acquisition of Höfler important for QKlingelnberg?

:Put simply, it was the logical completion of Klingelnberg’s prod- Auct range, adding cutting and grinding machines for cylindrical gears — both in terms of application areas and customer industries served. The addition of Höfler Maschinenbau allows us to significantly advance in reaching our strategic goal of being able to

October 2013 | GEAR TECHNOLOGY 33 gear profile JAN KLINGELNBERG

:How have your customers’ plex technologies. With our cus- :We have established new sales demands changed in recent tomers being globally active, they capacities and have expanded our Qyears? need to rely on reproducible qual- Anetwork through Höfler based on ity worldwide — no matter who their already strong presence in :What sticks out is the ever-grow- operates the machine. Easy opera- the USA. ing demand for more efficiency tion of our machines minimizes Ain production. For this reason we costly human errors and, in the :Describe the importance of introduced our trademarked 2 E final analysis, reduces costs per Klingelnberg’s unique gear manu- efficiency label. The label stands unit. Qfacturing capabilities. (Specifically, both for high-performance and regarding delivery time; quality; energy-efficient machines. In this :What is Klingelnberg doing price; materials; new-application context we are an active mem- to accommodate those designs, etc.) ber of the sustainability initiative, Qdemands? Blue Competence (Ed.’s Note:The :Customer satisfaction is the result Blue Competence machine tools :We listen to the markets and of the optimal interplay between initiative increases awareness and develop our solutions accordingly. Afactors such as delivery time and knowledge of sustainability and AThis is, in our view, the only viable reliability, quality of materials and raises the energy efficiency bar in way to develop products that help service, and pricing. We are con- the European machine tools indus- customers reduce cost-per-unit vinced that cheap “solutions” go try. The initiative offers a com- and at the same time provide high against this interplay and thus mon platform to European machine quality — certainly two of their against customer satisfaction. tool companies and coordinates main goals. Furthermore, our team of innova- efforts for the development of energy tive engineers lays the ground- and resource-efficient solutions). :How has your North American dis- work for refined solutions and new Another important factor is mak- tribution, sales and service organi- developments. ing our machines easy to operate Qzation changed over the last sev- while providing ever more com- eral years? :Given your reputation for recruit- ing and retaining skilled workers, Qdo you have any concerns in that regard?

:In this context we find two trends especially important:first, we Acooperate closely with local and regional schools and universities; second, we continuously invest in internal training and further education to strengthen our staff. This is something that will be of grow- Careers geared to succeed. ing importance in our market, so GLOBALGlobal GEARopportunities ENGINEERING available. OPPORTUNITIES AVAILABLE we are well-prepared for future developments. Moog’s motion control technology and products are found around the world For more information: from helicopters to fighter planes and deep sea drills to syringe pumps. We Klingelnberg GmbH foster an environment where our 11,000 engineers and technologists feel Peterstrasse 45 empowered and inspired to achieve remarkable things. The work we do matters, D-42499 Hueckeswagen Phone: +49 2192 81-0 as does every single person who works with us. Fax: +49 2192 81-200 [email protected] We’re looking for talented engineers with at least seven years of experience www.klingelnberg.com in gear manufacturing to join our business in Baguio City, Philippines, Torrance, California and Wolverhampton, United Kingdom. If you are interested in joining our team in the Philippines, but are not a resident there, you will receive housing benefits and travel allowance.

To apply, please send your resume to [email protected] or visit moog.jobs

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If you’ve been following this “We are continually trying to raise the bar of space with any regularity, you excellence at our company to better serve our know that grassroots efforts customers. We decided to help launch this program among industry and academia so that we could get students excited about are springing up around the manufacturing, give them a solid technical skillset, country to help win the hearts, minds and talents of young peo- and ultimately develop future employees.” ple in nudging them towards a Mark A. Neidig II career in manufacturing. Add another partnership to the list. Students at Indiana-based Plymouth Marshall County area communicat- instructor able and willing to teach the High School (PHS) — with a generous ed to both Ivy Tech and the Plymouth course. And Jerry Hollenbaugh, direc- boost up by ITAMCO, the machining Community School Corporation the tor of the North Central Area Vocational services, open gearing and large-part desire to partner with us to provide Cooperative (NCAVC), put together an assembly company — now have avail- training opportunities to high school advisory committee of local manufactur- able to them the opportunity to pur- students that will lead to jobs immedi- ers and educators to help establish the sue “precision tool manufacturing train- ately after graduation.” curriculum.” ing courses.” ITAMCO, also based in Readers familiar with these kinds of In addition, pre-engineering STEM the Hoosier state, has partnered with partnerships also know that it requires courses are already available at PHS, Ivy Tech Community College (ITCC) a good deal of heavy pulling to make courtesy of the nationwide Project Lead and the Plymouth Community School it happen. Just ask ITAMCO’s Mark A. the Way program (http://www.pltw.org/ Corporation in the creation of “dual Neidig II, purchasing manager for the about-us/who-we-are). This affords stu- credit” manufacturing courses intended family-owned business. dents the luxury of attending egg-head- to help and inspire students to continue “There were a lot of moving parts with ed STEM classes and then heading over their post-high school education. having multiple partners engaged,” he to ITCC for some hands-on precision As Ivy Tech North Central Chancellor acknowledges. “Plymouth High School machining experience. Thomas Coley puts it, “Ivy Tech’s role had to get school corporation board Since the program began in August, in training a skilled workforce is vital- approval for budgeting the funds and the outcome has been “terrific,” accord- ly important to the economic stabili- executing the building renovations for ing to Neidig. And that is despite the fact ty of our region. Manufacturers in the the host site. Ivy Tech had to find an that, says Neidig, “The program was not officially advertised, because we weren’t sure if the facility and equipment would be ready on time.” Speaking of equipment, ITAMCO contributed $100,000 worth of machinery for the venture, as well as invaluable technical assistance. As for the program’s scope, Neidig says that “While any student in the state may attend, we’re target- ing students in 12 area high schools that participate in the North Central Area Vocational Cooperative” So why now? What inspired ITAMCO to help spearhead this program? When you think about it, and if you own a manufacturing company, by now the answer should become obvious. “Ultimately, (the reason) was our customers, Neidig says. “We are continually ITAMCO donated $100,000 in machinery for the new Ivy Tech dual credit program (all photos trying to raise the bar of excellence at courtesy NCAVC).

[www.geartechnology.com] 36 GEAR TECHNOLOGY | October 2013 our company to better serve our customers. One barrier to doing so was the time it would take us to bring new employees up to technical competence. We decided to help launch this program so that we could get students excited about manufacturing, give them a solid technical skillset, and ultimately develop future employees.” But remember—these things take time. Says Plymouth Community School Corporation Superintendent Daniel Tyree, “Marshall County Industrial Corporation Association has been working on this for over a year now. We are excited to finally be seeing the course offering come to fruition. Not only will high school students be able to earn a The Ivy Tech program offers students dual-credit manufacturing courses to motivate them to valuable skill and get college credit for continue their post-high school education. their work, we will be helping our existing manufacturing firms fill much-need- uates with solid STEM knowledge is honest with ourselves, we know where ed jobs.” important.” the blame lays. As Neidig points out, Adds Neidig, “I see this program as Of course the skills gap dynamic has two of the reasons are “School budgets being critical in sparking an interest been with us for longer than we care getting tighter and a lack of industry with students for manufacturing, and in to admit, making insidious and large- engagement with local high schools. turn accelerating their interest in STEM ly unremarked “progress”—from grade When schools started cutting their voca- courses. Getting more high school grad- school to grad school. And if we are tional budgets, manufacturing compa-

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October 2013 | GEAR TECHNOLOGY 37 feature THE HALLS OF IVY (TECH) nies did not step up and say how important the training was or try to find more innovative solutions to bridge the funding gaps.” Another is the now outdated man- tra embedded in kids’ brains that without a college degree, you’re toast. You’ll be parking cars or wrangling burgers or worse. Which begs the question: a degree in what? It can be safely stipu- lated that countless kids go off to college each year with absolutely no clue to what they are going to do if or when they graduate. But what about kids who like working with their minds and their hands? Short of being a surgeon, college doesn’t offer much. Or as Neidig states, “I think the para- The Precision Tool Manufacturing Training Center is an outlet for high school students to earn digm of ‘college vs. vocational trade’ is a valuable skill and get college credit for their work, while also benefiting manufacturers in outdated and doesn’t reflect reality. The Indiana. reality is that college is very expensive For more information: and learning a skilled trade early in life If you’d care to help out in any way, by Mark A. Neidig II Purchasing Manager is a great way to earn a living. It also volunteering your time, expertise, cash, ITAMCO gives students who are pursuing engi- etc., please see right. 6100 Michigan Road neering or management careers a practi- Plymouth, IN 46563 Phone: (574) 936-2112 cal, skills-based foundation.” For Related Articles Search Fax: (574) 936-7224 training www.itamco.com at www.geartechnology.com

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For Related Articles Search lean JOB at www.geartechnology.com SHOP

Ed’s Note: This is the sixth article in an eight-part “reality” series on implementing Continuous Improvement at Hoerbiger Corporation. Throughout 2013, Dr. Shahrukh Irani will report on his progress applying the job shop lean strategies he developed during his time at The Ohio State University. These lean methods focus on high-mix, low-volume, small-to-medium enterprises and can easily be applied to most gear manufacturing operations. LEANClement Peng and Shahrukh A. Irani, Hoerbiger Corporation of America, Inc.

Computer-Aided Finite Capacity Scheduling of a FLEAN Machining Cell

Background will need to be trained to operate multi- FLEAN manufacturing cells with each An earlier column (Gear Technology, ple machines in a cell and suitable group cell dedicated to a product family and August 2012) described the process incentives put in place to ensure that (2) Another area being a “remainder job shown in Figure 1 that is followed for the cell’s team becomes autonomous) or shop” that produces the “cats and dogs” implementing Job Shop Lean in a com- can’t be broken (Example: Heat treat- (parts with low volume, low value, and prehensive manner in any high-mix, ment furnaces cannot be placed inside a infrequent demand) in the product mix, low-volume discrete manufacturing cell next to a CNC grinder). spare parts, prototypes for emergent facility, such as machine shops, forge Typically, after several iterations of business and one-off orders. By divid- shops, fabrication shops, mold shops, the process in Figure 1, a job shop will ing the job shop into these two areas, the etc. At the core of this iterative approach end up being divided into at least two following benefits are gained: (1) The is the expectation that (i) a job shop will areas: (1) One area consisting of several FLEAN cells provide unquestionable utilize production flow analysis and/or group technology to identify the stable part families in its product mix, (ii) will implement a FLEAN (Flexible+Lean) manufacturing cell to produce each part family that has a stable demand and (iii) utilize finite capacity scheduling to schedule each cell on a daily shift-by- shift basis. In theory, every time that one loop of the process shown in Figure 1 is completed, it will result in the implementation of a stand-alone FLEAN manufacturing cell dedicated to producing a family of parts whose manufacturing requirements are completely satisfied by the cell, except for vendor processes that simply could not be brought in-house. In reality, numerous constraints will either need to be broken (Example: Operators Figure 1 Comprehensive approach for implementing Job Shop Lean.

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dmori1470-08 October Ads_mDays_GT.indd 1 8/29/13 10:01 AM feature JOB SHOP LEAN quick response, high quality, teamwork execution system), FactoryViewer, which the following “What if?” scenario for and other benefits that are guaranteed then publishes twice daily a machine-by- the MP cell: If the daily schedule that was with flexible cellular manufacturing and machine sequence for producing orders issued to the cell at the start of the day (2) Instead of the entire business being loaded on every machine in the facil- was subject to change due to one or more managed as a complex job shop, only the ity. Since every machine’s operator must reasons, such as changing order priorities, smaller non-cellular portion of the shop record the start/stop times for each order machine breakdowns, rush orders, opera- now remains a complex job shop. processed on his machine, the MES clos- tor taken sick during the shift, due date es the loop between the daily sched- changes forced by customers, etc., could What Follows the Layout Design ule and the real-time execution of that we rapidly revise and re-generate a new of a FLEAN Cell? schedule. schedule for the cell? Having implemented a new layout for a FLEAN cell, it is then necessary to Scheduling a Single High-Mix, Why Schedlyzer Lite was Chosen schedule daily operations in the cell. In Low-Volume Cell – But Why? over Preactor for this Project this column, I will support the imple- The MP cell in our HCA-TX (HARP) Like all other ERP systems on the mar- mentation of finite capacity scheduling facility is essentially a small job shop. ket, our ERP system (SAP) uses MRP software. Depending on the complexity Therefore, effective scheduling would (material requirements planning) for of the part family and the demand pat- improve its performance and employee production planning and operations terns for the parts produced in a cell, a utilization. The complexity of scheduling scheduling. MRP uses assumptions of manual/visual system of pull scheduling even a small job shop with four or more infinite capacity, backward scheduling just could suffice. For example, I know of machines used in various combina- from customer due dates using fixed at least one precision machine shop that tions makes its schedule hard to gener- lead times, batch production, etc. So it uses a DBR (drum-buffer-rope) schedul- ate, revise and maintain it manually. Ask was decided not to use SAP for scheduling tool. One of our own cells, the QRC, any IE graduate who has taken a course ing the MP cell. makes do with a manual scheduling in scheduling about how much time it Although Preactor is being used suc- board that is populated with orders by took him/her to produce the schedule cessfully in our Pompano Beach facil- an office manager who can guesstimate for a job shop consisting of just three ity, our current license and implementa- work content and overall cell workload. machines producing four parts with dif- tion there is for a factory-wide installa- Possibly even an ERP system’s schedule ferent routings. Similarly, in the case of tion. Due to time constraints, it was dif- adjusted by experienced cell operators the MP cell, it has different equipment ficult to obtain a stand-alone license for who can eyeball capacity requirements types, and in some cases, two machines the MP cell that would run on a desk- by just looking at the queue of parts. of the same type that are unique, yet top computer dedicated to the cell. Also, capable of processing the same parts if our director of manufacturing systems, Why Computer-aided Cell the tools and fixtures are available. In Paul Mittendorff, who is the architect of Scheduling? order to complete the implementation the Preactor+FactoryViewer integrated Personally, I just do not wish to learn of the Job Shop Lean process shown in system that we use in Pompano Beach, and implement questionable ad-hoc Figure 1, we undertook an exploratory had prior commitments that made him manual cell scheduling strategies when proof-of-concept project to demonstrate a solution of the future was already being successfully used in one of our sister facilities in Pompano Beach, FL, prior to my joining HCA. Especially if there are other cells that share resources with this cell, then the schedules of those cells (and outside vendors too), must be coor- dinated with this cell’s schedule. Nor is visual management sacrificed at all. The complete daily schedule for a shop can be visualized using a Gantt chart, such as the one shown in Figure 2 which was produced by Preactor (www.preactor. com), the FCS (finite capacity scheduling) tool that is used by our sister facility in Pompano Beach, FL. The firm orders and their due dates quoted to customers are downloaded from SAP (which is our ERP system) into Preactor. After the schedule is generated by Preactor, it is input to our MES (manufacturing Figure 2 Gantt chart representation of a production schedule for visual management.

[www.geartechnology.com] 44 GEAR TECHNOLOGY | October 2013 unavailable during the period when we wanted to do this project. Therefore, we decided to work with another FCS vendor, Optisol Inc. (www. Optisol.biz) and use their Schedlyzer Lite tool for the project. Schedlyzer Lite is easy-to-learn and allows a user-friendly VBA (Visual Basic) interface to be developed for shop floor employees. Its price tag easily makes it affordable to purchase a single license for a computer that will be dedicated to a cell. It is well-supported by a local vendor resident in Bryan, Figure 3 VBA interface between SAP and Schedlyzer Lite. TX, who boasts a track record of successful implementations in several job shops. Figure 3 shows the VBA interface between SAP and Schedlyzer Lite that was developed by Clement Peng, the graduate intern we hired to work on this project. Since SAP query authorization was not allowed for our project, a macro in SAP was adapted to automatically generate data for daily orders. First you would click on the button highlighted in red then click on the button highlighted in yellow. Voila, the input data file for Schedlyzer would be ready with data extracted from SAP. Next, as shown in Figure 4, we would open the input data file for Schedlyzer that was produced from SAP and, with one click on the “Schedule” button, we would schedule all jobs for production Figure 4 Schedlyzer screen for data input. in the MP cell. By default, Schedlyzer Lite releases all jobs to complete by earliest due date (EDD) subject to labor and machine capacity constraints. Queues of jobs at individual machines are pri- oritized using the same dispatching rule (EDD). Figure 5 shows the cell schedule summary screen in Schedlyzer Lite with detailed information on every job (Job ID, Job Start Time, Job Finish Time, Relative Earliness/ Lateness compared to Due Date, etc.). In the case of our pilot project, 30 jobs and 139 operations were scheduled to minimize the average # of in-process jobs to 8.2 orders. Some immediate benefits of this report are (i) it would help customer service to decide whether a new order can be done by its customer-specified due date and (ii) when the shipping department can expect the order to begin packaging it for shipment. Figure 5 Cell schedule summary.

October 2013 | GEAR TECHNOLOGY 45 feature JOB SHOP LEAN

Figure 6 displays the schedule for a particular machine. This is the preferred sequence in which jobs should be worked on by that machine on any given day. For each job, its Job ID, Material Number, Operation # (with its expected Operation Start Time and Operation End Time), etc. is displayed. Thereby, the machine operator cannot have a doubt as to which jobs absolutely must be ready to run before/after another job. Like the powerful beam that emits from a lighthouse that can be seen by far- away ships, this schedule is the “beat” to which everybody (such as the machine operator, material handler, the cell leader, office manager, etc.) walks. Every vio- lation of this daily sequence would be noted and become a kaizen that the continuous improvement team could solve Figure 6 Schedule for a specific machine. by first asking, “Why? Why? Why? Why? Why did this happen?” This is a how the FCS does Facilitate Waste Who Will Implement, Deploy and core problem-solving tools of lean are Elimination, Too Manage your Implementation of essential even in an IT-aided FLEAN Scheduling using Schedlyzer, or any FCS? manufacturing cell. good FCS tool for that matter, would In Preactor (www.preactor.com), like Schedlyzer can also generate the com- help to reduce WIP, minimize job wait- Schedlyzer (www.optisol.biz) and Tactic plete schedule for all active jobs run on ing, plan on-hand inventories of raw (www.waterloo-software.com), high-mix, all machines in the cell, either in a stan- materials, anticipate short-term over- low-volume job shop-like manufactur- dard Gantt chart format or produce an time needs, etc. for any cell. For exam- ers have a choice of powerful, widely- Excel spreadsheet version for that chart. ple, in this pilot project involving the used and well-supported FCS tools. For Although not as visually pleasing, the MP cell, the Schedlyzer schedule pro- example, in the case of Schedlyzer Lite, spreadsheet showing the sequence of jected that we could reduce the WIP of Dr. Prasad Velaga, president of Optisol jobs, start/finish times, waiting times, in-process orders from 59 orders to 15, Inc., ensured that being able to use his etc. is more effective for use by shop which was equivalent to about $12,000 software was never a bottleneck during floor employees, the plant manager, or based on the prices of those orders. the execution of our project. even the president of the company. Why? Because a schedule based on finite However, besides its weaponry, a good Here in our Houston, TX, facility capacity constraints automatically defers army needs a good general and many we have a pilot implementation of the pre-mature release of orders that will good soldiers, too. I will unequivocally Preactor+FactoryViewer (FV) integrated simply end up in queue in front of the state that the success of this pilot project system in the PoR Cell. The cell oper- bottleneck machine when it is NOT the can be attributed to Clement Peng, the ators are familiar with the FV screen first machine being used to process the graduate intern from the Department to guide schedule execution and on- orders. Similarly, there are additional of Industrial and Systems Engineering time delivery tracking. The FV screen is benefits of effective scheduling using an at Texas A&M University. He sin- superior to a simple tabular version of a FCS tool that are prominently displayed gle-handedly did this project in part- Gantt chart. on any vendor’s website or listed in text- nership with Dr. Velaga, the software For those readers who are famil- books. But beware the hidden pitfalls vendor. His computer-skills, prior IE iar with the takt time counters that are and dangers of wanting to have those coursework related to scheduling, work mounted above assembly lines, the Gantt benefits without investing in the person- ethic, ability and willingness to learn chart, or equivalent display, of the sched- nel and support systems essential for the SAP and Schedlyzer on his own, driv- ule for a high-mix, low-volume job shop success of FCS and MES. en nature, determination to make an cell is equivalent to the “pacemaker” in idea work in practice, desire to learn an assembly line. real-world implementation of Job Shop Lean using computer tools like PFAST and Schedlyzer — he made the difference! As is the case with any lean imple-

[www.geartechnology.com] 46 GEAR TECHNOLOGY | October 2013 mentation, people like him will make the duce garbage output if it receives garbage implementation of FCS a success in any input, aka GIGO (garbage in, garbage company like ours. out). Finally, we will need to engage our IT Now the Hard Work Must Begin staff to develop a professional commu- In order to take the next step towards nication interface between Schedlyzer computer-aided daily scheduling of each (preferably Preactor) and our MES of our cells, we must now undertake the (FactoryViewer) to standardize how our following essential tasks: schedules and employees interact. We must implement the new layout that we proposed for the cell. The Achieving FLEAN (Flexible and new layout will co-locate almost ALL Lean) with People First, and IT the machines and their operators who Next will be responsible for completing orders Lean, IT and flexible automation will loaded on the MP cell. In my experi- co-exist with a motivated, talented and ence, not a single high-mix, low-vol- well-trained workforce in the Hoerbiger ume facility that I have assisted has ever Production System (HPS). The HPS is in been designed correctly. Due to poorly- its infancy but it is intended to become designed layouts, even in the case of an a viable production system model for individual cell, whenever there is a dis- high-mix, low-volume manufacturing tance of separation between two con- environments. Despite the incorpo- secutive operations that exceeds three ration of computer-aided data analy- feet, the inter-operation transfer delays sis and systems optimization, flexible can, and will, destroy the best sched- automation, IT-aided production plan- ules generated by an FCS software resi- ning and control, etc., people and the dent on someone’s computer in an office standard lean tools are going to be the removed from the shop floor. foundation of the Hoerbiger Production Next, we must conduct time studies System. In fact, IT-enabled production (else rely on pre-determined standard systems demand an even greater reli- times based on group technology) to ance on employees and managers who populate the routers in SAP with reason- can undertake continuous improvement ably accurate setup and machining cycle projects to eliminate the myriad prob- times for all the unique parts produced lems that arise when, say, computer- in the MP cell. Any software, be it an aided demand forecasts and daily shop ERP system, FCS tool or MES, will pro- schedules are disrupted by the vagaries

Figure 7 Detailed machine schedule output.

October 2013 | GEAR TECHNOLOGY 47 feature JOB SHOP LEAN of the dynamic shop floor. For exam- For Further Information on HCA’s ple, if a machine operator needs to take Projects Related to Scheduling a restroom break, do you forbid him/ Joshi, P. & Irani, S.A. A Tutorial on Job Shop her because the schedule generated by Scheduling (JSS) using LEKIN Academic Scheduling Software. Presentation made at the Preactor shows that he/she should be First Lean and Flexible Conference in Houston, running Job X at that time? TX, on April 1, 2013. Further, no ERP, FCS or MES sys- Mittendorff, P. The Water Strider: How To Get the tem could ever match the flexibility Right Material to the Right Machine at the Right Time per the Daily Schedule. Presentation made and response time that good cell operat the First Lean and Flexible Conference in ators can provide when any number Houston, TX, on April 1, 2013. of unscheduled disruptions (machine Irani, S.A. What are the Wastes created by a breakdowns, missing tools, defective Jobshop’s ERP System? Presentation made at the First Lean and Flexible Conference in Houston, parts requiring rework, scrapped parts, TX, on April 1, 2013. vendor delivery failures, etc.) render the Ellis, M. & Mittendorff, P. Integration of MES (Manufacturing Execution System) with Material current computer-generated schedule for Zhiyuan (Clement) a cell useless. Will the computer be will- and Inventory Management. Presentation made at the Second Lean and Flexible Conference in Peng is a graduate ing to report to work on a Saturday to Houston, TX, on September 5, 2013. student at the Texas A&M get a rush order done and shipped to a Irani, S.A. & Velaga, P. Revisiting Time and Motion University, where he is pursuing his Master’s Studies: Implementing Lean Improvements for a key customer? degree in industrial High-Mix Low-Volume Flexible Manufacturing Sure, Preactor or Schedlyzer could engineering (IE). He is Cell. Presentation made at the Second Lean currently working as an quickly generate a new schedule but it and Flexible Conference in Houston, TX, on industrial engineering intern at Hoerbiger September 5, 2013. would still have to be the cell leader who Corporation of America (www.hoerbiger.com). would provide it the data to accommo- In his current job, he is supporting continuous date and/or override the existing sched- Please e-mail either Paul.Mittendorff@ improvement and inventory control projects ule! Specifically, our director of manu- hoerbiger.com or Shahrukh.Irani@hoer- in the shipping department and designing a new layout for that department. Previously, facturing systems, Paul Mittendorff, has biger.com to receive electronic versions he worked as a quality engineering intern teamed with our plant managers – Mark of these presentations, subject to permis- in TPT Electronics to apply six sigma skills Ellis (Plant 3) and Christoph Magnet sion from our higher-ups. to increase product quality. His other areas (Plant 1) – to stress to the shop floor of expertise are data-driven justification of projects related to lean manufacturing, that the dispatch lists that FactoryViewer inventory control, and quality control. In the presents them at their machines must be true spirit of continuous improvement, he followed, that cherry-picking jobs out of continues to develop his expertise and work experience in other related areas. the global schedule is not allowed. This teaming partnership has already pro- Dr. Shahrukh Irani is the Director of Industrial duced results in Pompano Beach. Engineering (IE) Research at Hoerbiger Corporation of America (www.hoerbiger. com). In his current job, he has two concurrent responsibilities: (1) To undertake continuous for improvement projects in partnership with Hungry More employees as well as provide them on-the- job training relevant to those projects and (2) To facilitate the implementation of Job Shop ? Lean in HCA’s U.S. plants. Previously, he was an associate professor in the Department of Integrated Systems Engineering at The Ohio

® State University (OSU). There his research focused on the development of new IE methods to adapt and scale lean for use Everything you need to be a world-class by high-mix, low-volume SMEs (small and gear manufacturer—the suppliers, the medium enterprises). His research group created PFAST (Production Flow Analysis technical information and the market and Simplification Toolkit) which is software intelligence—can be found online for material flow analysis and facility layout to implement Job Shop Lean. At OSU, he received the Outstanding Faculty Award for excellence in teaching from the graduating classes of 2002, 2003, 2004, 2005, 2006 and 2009. In 2002, he received the Charles E. www.geartechnology.com MacQuigg Student Award for Outstanding Teaching from the College of Engineering. He is a member of IIE.

[www.geartechnology.com] 48 GEAR TECHNOLOGY | October 2013 Gear Grinding in Swiss Precision

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Gear Technology_EN_203x273+3_SeptemberProposal.indd 1 13.08.2013 08:36:32 ask the expert

Worm Gears Email your question—along with your name, job title and company name (if you wish to remain anonymous, no problem) to: jmcguinn@ geartechnology.com; or submit your question by visiting geartechnology.com. QUESTION #1 How does one determine the center of a worm and a worm wheel?

First response provided by Joe pattern is to be from the nominal cen- have generally been applied with few Mihelick, Gear Technology Technical ter of the worm gear towards the leav- problems. Editor: ing side of the worm gear as deter- While each manufacturer will tout The center of the single enveloping mined by the direction of the worm their particular tooth design as hav- worm is straightforward, as it is at a rotation. ing performance advantages, the key plane passing through the axis of the factor in power capacity remains worm at its outside diameter. The cen- Second response provided by the physical size of the parts and the ter of a double enveloping worm gear Charles D. Schultz, PE, Chief mechanical properties of the materi- is a bit more involved. It is nominal- Engineer for Beyta Gear Service, and als used to make them. Worm gears ly located at a plane passing through Gear Technology Technical Editor have some unique capabilities that can the worm gear at its root diameter. If ([email protected]): be used to good advantage in machin- the worm gear is throated, the loca- Short answer: It depends upon who is ery design. They are the only gear sys- tion of the minimum diameter of the asking and what the intended applica- tem where gear ratio does not affect throat will locate the nominal center of tion is. If you are specifying an off-the- the outside diameter of the rotating the worm gear. This is more useful for shelf solution, you can rapidly deter- parts; this means a machine can eas- the manufacturing process but is less mine the appropriate size from sup- ily be supplied with a wide range of important in the successful operation plier catalogs. Commercially supplied ratios — say 5:1 to 70:1 — without a or the worm – worm gear pair. The worm gear speed reducers are avail- center distance change or multi- successful operation of worm gear- able in a wide range of sizes, ratios and ple reductions. Another capabili- ing involves the actual contact pattern assembly configurations — from both ty — self-locking — can be a boon or between them. The observed contact U.S.-based and off-shore companies. a bane, depending upon your goals. Worm gearing is not as Understanding these aspects of worm standardized as spur, heli- gearing can be a lifelong project, but cal and bevel gearing. users should ask the suppliers about it Several different ‘systems’ before ordering. coexist in the marketplace, The long answer: Many ‘systems’ and each has its propo- have been developed for worm gear- nents. In the smaller gearing over the past 100 years. Each of box sizes (less than 4-inch them has its proponents and, oddly center distance), exterior enough in the normally polite world and mounting dimensions of gear engineering, opponents. If off- have become ‘standard’ and the-shelf components won’t work for users can easily interchange your applications, you have to pick one between brands. Larger of these competing systems and wade units have no such com- through the often confusing recom- monality, and users are well mendations to develop your gear set. advised to carefully consid- Custom-made tooling is expensive and er all factors of supply (ini- takes critical lead time to obtain, so tial cost, availability, service designers are encouraged to use exist- factor and after-sales sup- ing hobs and fly cutters. I recommend port) before selecting a ven- the design system found in Daryl dor. Published ratings can Dudley’s Gear Handbook, along with be based on AGMA, DIN, the worm hob charts on Ash Gear and The study of worm gears has come a long way: 16th century ISO or other methods, and Supply’s web site. AGMA’s standards worm gear illustration (courtesy Leonardo daVinci).

[www.geartechnology.com] 50 GEAR TECHNOLOGY | October 2013 QUESTION #2 A gear handbook in my possession states: The ZI worm is identical to an involute helical gear whose tooth number is the number of worm threads. Equations of tooth surfaces of an involute helical gear are the same as for an involute worm. Knowing that a ZI hob cutter is identical to a ZI worm, I conclude that the mesh of the ZI worm and involute helical gear is identical to a cross involute helical gear mesh; and even identical to the hobbing process of an involute helical gear with a ZI hob cutter. I would like to know whether I am correct and what is their difference.

Response provided by Hermann J. Stadtfeld, vice president - bevel gear are the most reliable rating method for technology - R&D for Gleason Corporation. the independent designer. If your requirement is for instru- Worm Gear Generation and their Manufacturing Tools ment gearing or plastic gearing, it is The question will be answered considering the different possibilities in profile form, recommended that you work with a kind of mesh, and type of tools. Figure 1 contains the general nomenclature used to supplier of such parts or an experi- define the geometry parameters. enced design engineer. Tooling costs Worm gear drives can be separated in three categories: can be very high, and the performance Case A. Crossed helical worm gear drives of prototype sets can vary depending Case B. Cylindrical worm gear drives upon manufacturing method. Molded Case C. Double-enveloping worm gear drives plastic teeth do not have exactly the Cylindrical worm gear drives “B” are the most common form. Their tooth pro- same topography as cut gears; veteran files of the worms depend on the manufacturing method. The different profile forms suppliers of plastic gearing understand according to DIN 3975 are: the changes needed to make sample ZI: Tooth profile in face section is an involute; manufactured, for example, by hobbing, parts that will work reliably without like a cylindrical pinion. The hob for the worm gear manufacturing is a “dupli- skewing test results. cate” of the worm (however serrated and considering clearance and backlash). Worm gearing design is an itera- ZA: Profile is a trapezoid in an axial section; manufactured, for example, by turning. tive process which can be frustrating ZN: Profile is a trapezoid in a normal section; manufactured, for example, by turning the first few times you work through with cutting blade tilted to lead angle of worm. it. Standard worm hobs may not con- ZK: Profile with crowning. Tool is disk cutter with trapezoidal profile, which is tilted verge on the solution you would pre- to lead angle of worm. Profile crown generated depending on disk cutter diameter. fer. Some suppliers can make worm ZH: Disk cutter with convex cutting edges, causing hollow flank profiles in axial gears using ‘fly tools’ — a custom sin- section on worm teeth. gle-point cutter that allows more flexi- Disk cutter axis is par- bility in design than the standard hobs. allel to worm axis (not The cutting process is, by necessity, tilted like ZK). much slower than hobbing, but for A. Crossed helical worm one-off or low-volume requirements gear drive. This is a spe- it is often the best solution. Regardless cial case of crossed helical of the tooling ultimately employed, gears, where the worm is a custom worm gearing design requires helical gear with one to six compromises on center distance, face teeth, and the worm gear width and numbers of teeth/threads. has a high number of teeth More than any other gear type, ‘your (e.g., above 30). The pitch results may vary’ is an appropriate dis- elements of a crossed heli- claimer. cal worm and worm gear are cylinders (Fig. 2). Both members—worm and worm gear—are manufactured like helical gears, with stan- For Related Articles Search dard hobs, for example. The worm gears profile of both members is involute. The hobbing tool at www.geartechnology.com in Case A is not identical to Figure 1 Worm gear drive nomenclature, single-throat example (graphics courtesy of Gleason)

October 2013 | GEAR TECHNOLOGY 51 ask the expert the worm. The two members have line contact, which appear instead as point or small contacting zones. B. Cylindrical worm gear drives (single-throat worm gear drives). A typical worm gear drive; here the worm also has one to six teeth (starts), and the worm gear has a high number of teeth (e.g., 30 to 300). The pitch elements of a single-throated worm and worm gear are shown in Figure 3. The worm is manufactured on a lathe or with a disk milling cutter. The profile is not a generated involute but a straight line. The geometry of a cylindrical worm therefore is similar to an ACME screw. The worm gear is manufactured with a hob and the hob’s enveloping surface is identical to the mating worm. This enveloping surface generates the same involute profile on the worm teeth as seen in Case A. However, the tooth thickness of the hob is thicker by the desired backlash amount. The difference in the gear in Case A is the shape of the pitch element, which in Case B has a hyperbolic form known as “throat.” The throat is formed merely by plunging the hob cutter at the center of the face width. The two members have line contact that appears on the worm gear member like slim ellipses with a major orientation (if projected in an axial plane) parallel to the worm gear axis. C. Double-enveloping worm gear drives (double-throated worm gear Figure 2 Pitch elements of crossed helical worm gear pair. drives). These are special types of worm gear drives with a very high contact ratio and high torque transmission abilities. Again, here the worm has one to six teeth (starts) and the worm gear has a high number of teeth (e.g. 30 to 300). The pitch elements of worm gear and worm have a hyperbolic appearance which is why Case C is called “double-throated” (Fig. 4). The worm is manufactured on a lathe, where the cutting blade profile rotates around a center point while it moves along the face width. The distance between the cutting blade pitch point and the center of blade rotation is identical to the pitch radius of the worm gear. The profile is not a generated involute, but in a straight line. The worm gear is manufactured with a hob that has the pitch diameter of the worm at the center of the throat and the same number of starts, unlike the number of worm teeth. Also, here the worm gear is cut (as in Case B) by plunging with the hob cutter at the center of the worm gear’s face width. The two members have line contact that appears even under light load, as with large elliptical zones—even in single angular positions. It should be mentioned that in Case B, where the worm gear tool resem- bles the mating member within the flank surfaces, there remain several differences. The tool face is extended in order to machine sufficient top- root clearance, and the top-land corners to the flanks are rounded with Figure 3 Pitch elements of single-throat worm gear pair. the desired root fillet radius. The dedendum depth of the tool is equal to the addendum of the worm, plus an excess amount to prevent any cutting action at the worm gear top-lands. The short answer to all conclusions the questioner has posed is “yes.”

Hermann J. Stadtfeld Figure 4 Pitch elements of double-throat worm gear pair.

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For Related Articles Search Gear Standards and ISO GPS standards Michele Deni at www.geartechnology.com In today’s globalized manufacturing, all industrial products having dimensional constraints must undergo conformity specifications assessments on a regular basis. Consequently, (standardization) associated with GD&T (geometrical dimensioning and tolerancing) should be un-ambiguous and based on common, accepted rules. Of course gears — and their mechanical assemblies — are special items, widely present in industrial applications where energy conversion and power transmission are involved.

The ISO (International Standards puterized, electronic metrology devices tools (CMMs, GMMs); i.e., where the Organization) GPS (geometrical prod- (GMMs, CMMs, etc.). dimensional characteristics of measured uct specifications) standard is a new Soon upon (the new devices’) imple- parts are derived by reversing the math- approach to providing the basic tools mentation came the realization that the ematics of analytical geometry (from and developing a common language sup- traditional design specification methods points to mathematical synthesis of geo- ported by mathematical formalisms for (ISO1101, et al.) were no longer suffi- metrical features), and not comparing an acceptance in: cient, and now operative only for the old- artificial feature (artifact, reference frame, • Design geometrical definitions metrology tools like dial comparators, etc.) with a real one, as done in tradition- • Specification limits for (tolerancing) gauges, etc. al metrology. classification And so 1968 presented major problems But despite some uncertainty over • Inspection methods for (manufacturers) like myself and oth- new processes of product develop- • Conformity assessment rules for accep- ers who were involved in the design and ment, (I found that) the uncertainty will tance manufacturing of those new measuring diminish if: Upon general consensus between experts, the following basic, GPS-related documents should be considered in the future development and revision of gear standards: • ISO/TR 14638 • ISO/TS 17450–1 • ISO/TS 17450–2 • ISO/14253–1 • ISO/TS 14253–2 The need for a GPS standard became apparent near the end of 1992, about the same time that the newest-generation tools were becoming available in the field of industrial products design. The development chain was going to be increasingly based on “virtual development” — right up to the physical realization of the single parts constituting the final product. In this chain are involved: • Basic design idea • CAD implementation of drawings Figure 1 Gears are special items — widely present in industrial applications where energy • CAM programming for machine tools, conversion and power transmission are involved. robots, etc. • CNC machining At this stage, everything is “virtual” (i.e., numbers, codes) until the “physical” part is realized. There is then need of an interface able to compare the “real part” with the “virtual data,” — thus capturing feedback for eventual modifications, corrections and final acceptance. This “interface” is the aforementioned, modern measuring tool-set, possessing a Figure 2 With ISO GPS, the manufacturing process is based increasingly upon “virtual certain degree of “intelligence”; e.g., com- development” — right up to the physical realization of the single parts constituting the final product.

[www.geartechnology.com] 54 GEAR TECHNOLOGY | October 2013 ture “extracted” from the workpiece by means of the measuring procedure (prob- ing or scanning points on the part). The parameters of this “substitute feature” can be compared with those represented in the drawing, and hence be able to reveal errors of size, deviation and position; but not form errors — they are not contained in the “substitute feature.” This approach is possible only in the case of what I call “metrology in pre- defined geometry,” as the mathematical formalization of the measured part must be known “a priori” and constitutes a “target feature” for the “best-fit” mathematical algorithm that will produce the aforesaid substitute geometrical feature. From this situation derives one of the most important principles of GPS — the “independency principle” — or ISO/8015 ISO/14659. Figure 3a and 3b (GMM 70) This “interface” is the aforementioned, modern measuring tool-set, possessing a certain degree of “intelligence”; e.g., computerized, For this principle, any tolerance speci- electronic metrology devices (GMMs, CMMs, etc.). fication reported in a drawing must be independent of all other specifications. The GD&T (geometric dimensioning for the creation of different geometrical So if the substitute feature is introduced, and tolerancing) specifications imple- features. The aim is to define the fun- eventual form errors must not influence mented in the CAD drawings have the damental concepts for the geometrical the size, deviation or position errors. In best “correlation” with the final function- specification of a part (workpiece), and my experience I have seen this principle ality of the product, or “low correlation provide a mathematization of those con- violated very frequently in many blue- uncertainty.” cepts in order to have common, stan- print specifications; e.g.: size tolerance • The GD&T specifications are self-con- dardized rules for CAD users, developers specifications smaller than the admit- sistent with an intrinsic low “specifica- of metrology algorithms, and conformity ted — or practically achievable — form tion uncertainty.” verification methods. errors. All of the concepts and definitions • The adopted verification method is at Some observations and perspective are reported in this document are operative least “compliant” with the specifica- necessary in order to better understand in the practice of the design and toleranc- tions in the drawing, or “compliance uncertainty.” the philosophy of this ISO/TS. With the ing specifications of gears. • The conformity assessment for accep- advent of new design tools like CAD, The designer first defines a part of per- tance is based on “traceable” measure- CAM, CNC and coordinate metrology, fect ideal form with shape and dimen- ments. there was the need to change a way of sions, and with tolerance specifications • Following are some tecnical reports thinking. The parts designed in a draw- that best fit the functionality of the final and technical standards containing ing represent an assembly of ideal geo- product. Let’s call this defined part the conceptions of GPS systems: metric features, and the GD&T is related “nominal model.” ISO/TR 14638.This technical report to the geometric parameters that define It is evident that the final realization of contains the “master plan” of the hier- those features. So in the drawing we have this part may not fit completely the ideal archy in which the GPS standards are dimensions and tolerances relative to ide- requirements of funcionality. This will be, organized, consisting of the fundamental, al-perfect, geometrical elements. in the end, an economic factor pertain- global, general and complementary stan- The machined parts derived from the ing to the realization of the product. This dards containing the basic principles and same drawing are imperfect, with errors economic factor is the “correlation uncer- general tenets. relative to size, form, deviation and posi- tainty” in the GPS system. It is only the ISO/TS 17450–1.This technical specifi- tion. Here we have the problem of how first step in the complete process of con- cation, which is part of global GPS docu- to get a set of parameters for each fea- formance assessment for the acceptance ments, contains the model for geometrical ture present on the workpiece that might of the product in terms of economic final- specification used in the design of assem- be comparable to the “ideal” ones on the ization, evaluation of risk in case of accep- blies and individual parts that will deal drawing. tance or rejection, quality assurance and, with compliant measurement procedures. Utilizing coordinate metrology, the not the least, security conformance. These tools are based on the charac- problem was solved with the introduc- In this document (ISO/TS 17450–1) teristics of features, on the constraints tion of a new “substitute geometrical all the definitions related to geometrical between features, and on operations used feature.” This is another perfect ideal fea- features and their geometrical character-

October 2013 | GEAR TECHNOLOGY 55 technical istics are reported. It must be said that the We think that there are more defini- there are no problems (principle of com- majority of those definitions are pertain- tions that may occur in the future devel- pleteness). On the other side there are ing more to specification and verifica- opment or revision of gear standards. metrologists (GPS) that think this is not tion of pre-defined, geometrical features ISO/TS 17450–2. This TS is another the case and specifications are incomplete like line plane, cylinder, etc., and leave global GPS document and contains the (principle of incompleteness). it to the tools to compare the real with basic issues for the development of the The problem is that for every specifica- the ideal geometrical characteristics, thus overall system that is based on the four tion there must be a verification — with a avoiding the form errors. tenets listed as A,B,C and D. preventive measurement at the final stage But this may not be the case of a gear’s A. Simply states that GPS specifications of assembly or at the stage of functional- characteristics where the form error is on a drawing and functionality of the ity proof. relevant and best-fit algorithms for gear final product derived from those spec- So it can be stated that a specification surfaces, where “transcendent” mathe- ifications are correlated at a certain is complete only if all the intended func- degree (correlation uncertainty). matical geometries are involved, are at tions are perfectly described and con- B. If a product is realized using a prod- present in an early stage of develpment, uct documentation (blueprint) where trolled with the specified characteris- and, sometimes, cannot be applied. GPS geometrical characteristics are tics. Unfortunately, most of the specifi- The GPS may well need in the near reported, this product is acceptable cations will be incomplete because some future a contribution from the “gear peo- if GPS specifications are fulfilled and funcions are imperfectly described and ple” with an international project tasked measures are compliant, at a certain controlled — and sometimes not at all. to the “fusion” of the two cultures. Some degree, to the same specifications The consequence is that there may be a terms and definitions of this TS are par- (compliance uncertainty). The GPS more or less good — or bad — connec- ticularly useful for the future work, like: specification itself may be “incom- tion, between the function and the rela- • Feature. Geometric feature: point, plete” (leading to bad functionality or tive specification. Correlation uncertainty line, surface (involute, helix, worm and difficult assembling), so an eventual refers to the case of imperfect control, specification uncertainty has to be bevel in our case) while specification uncertainty implies accounted for regarding acceptance or • Ideal feature. Feature defined by a absence of control. Consequently, we can parametrized equation rejection purposes. say that a measurement with low uncer- • Characteristic. Single property of one C. Here the document points out that the or more features expressed in linear or process of realization of the product is tainty is of little value when correlation angular independent from the GPS specifica- or specification uncertainty is large. For • Specification. Expression of permis- tion, and the GPS specification does metrologists the GPS is a good thing, as sible limits on a characteristic not deal with the choice of the verifi- finally the responsibility of designers will • Deviation. Difference between the cation operator (measurement meth- be strongly accounted for in the produc- value of a characteristic obtained from od). The lowest specification and mea- tion process. the non-ideal surface model (skin) and suring uncertainties obtainable dic- The specfication process is step one, the corresponding nominal value tate the best choice: ISO/TR 14253–2 and is the responsibility of the designer. PUMA method. • Extraction. Operation used to identify The verification process follows the D. Here the document states that the specific points from a non-ideal surface specification and is done by implement- • Filtration. Operation used to create the implementation of the best selected ing the actual specification operator in an non-ideal feature by reducing the level verification process always leads to of information of an extracted non- imperfections, and the implementa- actual verification operation. ideal feature tion uncertainty has to be accounted Some definitions: • Association. Operation used to fit ideal for (compliance uncertainty). Operator-ordered set of operations : features to non-ideal features according • Specification operations. Operation to a criterion (metrologic operator) (Author’s Note: In offering justifica- formulated using only mathematical • Associated feature. Ideal feature estab- tion for this way of thinking in the GPS and/or geometrical expressions and/or lished from a non-ideal surface model environment,a philosophical approach algorithms (skin model), or from a real surface contends that in the community of metrol- • Specification operator. Made up of specifications operations through an association operation ogists recently, two schools of thinking have • Verification operator. Operator made A practical consequence of these defi- evolved, similar to what happened at the up of verification operations (derived nitions is the “conformity assessment” beginning of the last century for the com- from specification operator) procedure, normally adopted for a munities of logicians and mathematicians. machined part, that follows five steps: Of the two schools, one accepted the postu- ISO/14253-1. This standard is now 1. Partition late of “completeness” posed from Hilbert, well known by experts, and will soon gain 2. Extraction the other one, by contrast, belived in the in global importance and acceptance in 3. Filtration Godel theorem of “incompleteness.”) the industrial environment, as the rules 4. Association Thus on one side we have metrolo- for the conformity assessment become 5. Evaluation gists that believe that specifications on clearly defined. the blueprint are self-evident, and if those The role of uncertainty as an eco- specifications are completely fullfilled nomic factor is evident, and the decision

[www.geartechnology.com] 56 GEAR TECHNOLOGY | October 2013 rules for who is going to pay are clear. The uncertainty contributions are introduced at different levels of the conformity assessment, going from the final level of the measurement uncertainty up to the level of the correlation uncertainty finalized to the functionality proof, passing through the specification uncertainty. ISO/TS 14253–2. This technical specification provides a general rule of how to find the best specification and verification operators, known as the “PUMA” method. Conclusion In the future development and revision of existing standards dealing with technical specifications for gears, it should be man- datory to consider that any specification tool must be uniquivically associated to a Figure 4 The verification operator is the basis for the conformity assessment procedure. corresponding verification operator. Unfortunately, it seems that, given a particular specification, there is not much freedom for implementing a verification procedure that must be, at best, compliant witrh this specification, if relevant economic fallouts are to be avoided in a global production environment. It is also suggested to take in account the following normative tools: • The “VIM” for basic terminology. (Editor’s Note: This document gives guidance on the concepts and terms used in various approaches to measurement). • The GPS principles for specifications and verification items Figure 5 Uncertainty—cost unknowns—present at different levels throughout conformity • The “GUM” for measurement uncer- assessment—from measurement uncertainty to correlation uncertainty, and finalized at tainty evaluation . (A series of docu- functionality proof level. ments establishing general rules for evaluating and expressing uncertainty in measurement that can be followed at various levels of accuracy and in many fields — from the shop floor to fundamental research for measurement uncertainty evaluation). • The ISO/14253–1 for conformity acceptance, activities.

Dott. Ing. Michele (Mike) Deni is a designer and manufacturer of gear measuring machines (GMMs) and coordinate measuring Figure 6 ISO/TS 14253–2’s general rule—the “PUMA” method—shows how to find the best machines (CMMs). Based specification and verification operators. in Italy since 1968, Deni is also an ISO TC213 and ISO TC60 expert. He is a member of ASPE (American Society for Precision Engineering) and associate editor of the Journal of Precision Engineering (Elsevier) and co-founder of EuSpen (European Society for Precision Engineering).

October 2013 | GEAR TECHNOLOGY 57 technical Minimal Tooth Number of Flexspline in Harmonic Gear Drive with External Wave Generator Hai-Lin Zhu, Hong-nen Wu, Min Zou, Xing-pei Qin, Pei-yi Song and Jun Pan

Wave generators are located inside of flexsplines in most har- three basic components: a non-rigid “flexspline,” a rigid “circu- monic gear drive devices. lar spline” and an elliptical “wave generator.” The wave genera- Because the teeth on the wheel rim of the flexspline are dis- tor produces and controls the deformation of the flexspline. It is tributed radially, there is a bigger stress concentration on the called the harmonic drive since the wave form presented in the tooth root of the flexspline meshing with a circular spline, flexspline is a simple harmonic wave which is symmetric by and where a fatigue fracture is more likely to occur under the alter- large (Refs. 1 and 2). nating force exerted by the wave generator. Harmonic gear drives have advantages that other drives do Our solution to this problem is to place the wave generator not, such as simpler structure; higher drive ratio with a wide outside of the flexspline, which is a scheme named harmonic range of variation, which is capable of producing speed ratios gear drive (HGD) with external wave generator (EWG). A for- up to 300 in a single stage (Ref. 2); larger load-carrying capac- mula to calculate the minimal tooth number of a flexspline that ity resulting from more teeth meshing and supporting load satisfies the requirement in fatigue strength for the flexspline is simultaneously; tooth contacts of about 10-30% of the total derived in this paper. tooth number (Ref. 3); and smooth transmission with no impact between gears. Because of these advantages, HGD has prom- Nomenclature ising applications in fields such as aerospace, machine tools, ZR Tooth number of flexspline instruments, electronic equipment, mining equipment, trans- ZG Tooth number of circular spline port and communication facilities, hoisting machinery, petro- m Module of flexspline and circular spline (mm) chemical machinery, textile machines, agricultural machinery, rm Radius of middle circle in flexspline (mm) medical apparatus and instruments (Refs. 1–3). dm Diameter of middle circle in flexspline (mm) A flexspline in operation undergoes alternating stress; its life dR Diameter of reference circle on flexspline before its determines the service life of the entire harmonic gear device. deformation (mm) The wave generators are mostly located inside of flexsplines in dG Diameter of reference circle on circular spline (mm) current HGD devices. Because the teeth of the flexspline are dis- h Dedendum of flexspline tooth (mm) fR tributed radially on the gear rim, the mouth of the tooth sock- h* Coefficient dedendum for flexspline fr et in the flexspline meshing with the circular spline will open d Wall thickness of the flexspline’s rim (mm) wider under the action of wave generator. Higher stress con- E Material elastic modulus of the flexspline (MPa) centration is caused in the tooth root of the flexspline, where I Moment of inertia for cross section in the flexspline to mid-axis (mm4) a fatigue crack occurs easily under the periodically alternating B Axial width of the flexspline (mm) force of the wave generator. If the wave generator is set outside of the flexspline — known W0 Radial maximum deformation of the flexspline (mm) b Length of short semi-axis of elliptic mid-layer (mm) as an HGD/EWG (harmonic gear drive with external wave gen- a Length of major semi-axis of elliptic mid-layer (mm) erator) — the teeth on the rim of the flexspline are distributed in ns Safety coefficient under bending normal stress a form of convergence on this occasion. The stress concentra- nτ Safety coefficient under torsional shear stress tion in the tooth root of the flexspline is lightened, thus enhanc- [n] Permissible safety coefficient ing the strength of the flexspline and, in turn, prolonging the σ-1 Fatigue strength limit in bending for flexspline’s material service life of the device. (MPa) The structure size of two key gears — the flexspline and the Kσ Factor of stress concentration in the gear’s root influence of circular spline — must be determined first in order to design an average stress on fatigue strength HGD mechanism with EWG. Unfortunately, HGD-with-EWG

ψσ Influence of average stress on fatigue strength is rarely discussed in mechanical design literature, nor mentioned in reference material. Introduction In an attempt to address the problem, this paper presents a It is via the elastic deformation of the flexspline that a harmonic formula to calculate the minimal tooth number of flexspline gear drive (HGD) transfers motion and power. Unlike a conven- in double-wave HGD-with-EWG. The formula is rooted in the tional gear drive, which is based on the concept of rigid bod- concept of a mid-layer in the flexspline and the analysis of the ies, HGD, operated by the elastic theory, is mainly composed of radial deformation of the mid-layer, section stress and fatigue

[www.geartechnology.com] 58 GEAR TECHNOLOGY | October 2013 strength of the flexspline under the action of EWG. The tooth number of the circular spline can then be settled; if its tooth number is determined, a theoretical foundation is thus laid for structural design and strength analysis on a harmonic gear device with EWG. Principle of HGD-with-EWG An HGD mechanism with EWG (Ref. 4) is also composed of three basic parts: 1) flexspline; 2) circular spline; and 3) wave generator (Fig.1). The circular spline is an external gear; the flexspline is a thin-wall gear ring with internal teeth, and its tooth number is slightly more than that of the circular spline. Most harmonic gear devices are of double waves, and, in this case, the tooth number of the flexspline is usually two more than that of the circular spline. Initially, the profile of the flexspline is circular in shape (Figs. 1 and 2) before the flexspline is compressed by the EWG. The inner side diameter of the wave generator is slightly less than the outside diameter (equal to 2rm) of the flexspline before it is deformed. The flexspline is squeezed into an oval under the action of EWG, which contacts with the flexspline. Teeth near Figure 1 Generalized drawing of HGD with EWG. both ends of the minor axis of the ellipse for the flexspline mesh completely with the teeth in the circular spline, and the teeth near the major axis of the ellipse separate completely from those in the circular spline; teeth on other segments are in transition states of coming into or out of mesh gradually. The circular pitches for the two gears are the same. In the pitch circle of the circular spline, the meshing process for teeth of the flexspline and circular spline looks like two pure rolling (no sliding) rings. The arc length rolled in the pitch circle must be equal at any moment for two gears. The deformation position on the flexspline is ever changing; EWG turns continuously as the teeth of the two gears are in mesh, and then out of mesh; in turn, the engagement transmission is thereby realized. Radial Deformation of a Flexspline The concept of mid-layer in flexspline. Elastic deformation of the flexspline emerges periodically under the action of EWG. The deformation of the flexspline is usually represented by the deformation of the mid-layer. The so-called mid-layer, a hypothesis in material mechanics (Ref. 5), refers to the middle layer in the interior of the flexspline’s rim, which is neither elon- Figure 2 Shape change of mid-layer in flexspline — from circle to ellipse. gated nor shortened while the flexspline is undergoing bending deformation. The middle face through the rim thickness of the tooth hfR = mh*fR, coefficient of dedendum h*fR = 1.35 ring-flexspline is usually considered as the mid-layer because (Ref. 7) for the normal tooth of the flexspline with a the degree of bending deformation for the flexspline is less (Ref. pressure angle of 20 on the reference circle according to 6). The line intersection of mid-layer and cross-section is called the standard of involute tooth profile in harmonic gear the neutral axis; i.e. — a line on the cross-section connecting universally. every point where its normal stress is zero. The elliptic mid-lay- Bending moment on section in flexspline. The flexspline in er in the flexspline will rotate as EWG turns. Figure 1 — a cylindrical shell with teeth inside — is an ortho- The mid-layer of the flexspline before it is deformed is a tropic anisotropic shell (for the flange or rim of the flexspline) circle, or middle circle. If the flexspline is a standard gear (no in structure. There exist structural nonlinearities, since the teeth addendum modification), the radius of the middle circle in the on the rim are equivalent to longitudinal reinforcing ribs, and flexspline (Figs. 1 and Fig. 2) is determined by the equation: geometric nonlinearities of large deflection because the ratio (1) of radial maximum deformation to rim’s wall-thickness of the rm = 0.5dR + hfR + 0.5δ flexspline is bigger than 0.2. It is therefore difficult to obtain an where: the diameter of the reference circle on the flexspline before exact solution in internal force, deformation and stress distribu- tion on the flexspline’s rim under the action of EWG. its deformation dR = mZR, the dedendum of flexspline

October 2013 | GEAR TECHNOLOGY 59 technical

Some simplification is necessary in order to study the inter- The length of vertical diameter AB for the ring-flexspline will nal force and strength of the flexspline. Influence of a flexspline’s surely be elongated when the length of horizontal diameter CD teeth could be left out first, so that the flexspline is simplified as becomes shorter. According to Equation 2, applying Moore’s a smooth, thin-walled cylindrical shell with a rim thickness δ, theorem (Ref. 5) again along the entire circle of the ring, the since it is far less than rm, the radius of the middle circle (Ref. 8). amount of elongation δAB for diameter AB can also be obtained: After obtaining the deformation and stress of the flexspline shell (4) using the shell theory in elastic-plastic mechanics, the influence 3 2 – 1 Frm ( π 2 ) of teeth on stress in smooth shell is then considered and reflect- δAB = ed in the calculation formula as a tooth influence coefficient EI

(Ref. 9). It can be seen that δCD > δAB from Equations 3 and 4 means Assuming that the EWG exerts concentrated forces on the that the maximum radial displacement among points on the flexspline, a mid-layer ring of flexspline which bears a pair of mid-layer appears in the short axis of ellipse; i.e., in the direc- equal pressures F in opposite directions is taken as a research tion of extruding forces. model. As shown in Figure 3a, it is a statically indeterminate From Figure 2, it is directly seen that the radial maximum structure (Ref. 5). deformation (5) Just one-quarter of the ring-flexspline (Fig. 3b) need be stud- δCD ied, considering the symmetry of the ring’s geometry and load. W0 = 2 There is only axial force and moment on section B because of the symmetry. The axial force is equal to 0.5 F using equilibrium To simplify the discussion, assume that the flexspline and cir- condition, and bending moment Mx is a redundant constraint cular spline are two standard gears. From the point of view for to be solved. Since the turn-angles on sections B and D are proper meshing between two gears, the reference circle on the zeroes, section D could be regarded as a fixed end, and the zero circular spline should coincide with the reference line near the turn-angle on section B is taken as deformation coordination short axis of the elliptic mid-layer of the flexspline (Fig. 1). In condition. Thus a force-method based canonical equation (Ref. other words, the length of short semi-axis b should satisfy the 5) can be written (the derivation process is omitted here due to following relationship: (6) limited length of this article), redundant constraint (bending b = 0.5 dG + hfR + 0.5δ moment) Mx = F (0.5-1/π) is then gotten, and from which the rm where: bending moment on any section for the ring-flexspline is deter- the diameter of the reference circle on a circular spline d = mZ . mined by the formula: G G (2) The thickness of the flexspline’s rim δ = (0.01 ~ 0.015) dR Mx = Frm (0.5 cos (φ)-1/π) is generally taken (Ref. 9). where: F is the extruding force pressed on the ring-flexspline by EWG; Obviously, W0 = rm-b (Figs. 1 and 2). We obtain rm-b = 0.5m φreflects the position of the ring section starting from (ZR-ZG) by subtracting Equation 6 from Equation 1. Parameters vertical section B, φ = 0 ~ 90, and the counterclockwise of W0, m, ZG and ZR must obey the following expression: angle is considered positive. (7) W0 =0.5mΔZ Radial deformation of mid-layer in the flexspline. Radial where: deformation in major and short axes of elliptic mid-layer on the DZ is the tooth number difference of the flexspline and the flexspline has the greatest influence on meshing quality between circular spline; DZ = (ZR-ZG). the flexspline and the circular spline, so the fluctuations in length must be analyzed for vertical diameter AB and horizontal Stress on Cross-Section in the Rim of a Flexspline diameter CD on the mid-layer (Figs. 2 and 3). The scholar М. Н. Ivanov considered that HGD is one having The length of horizontal diameter CD on the ring-flexspline initial pre-stress (Ref. 8). After the wave generator is assembled will be shortened under a pair of extruding forces F. From outside of the flexspline, the flexspline is force-deformed and Equation 2 we apply Moore’s theorem (Ref. 5) and integrate subjected to preliminary load because of the extrusion effect by along the entire circle of the ring, the reduction of diameter CD EWG — thus pre-stress occurs in the cross-section of the flex- that is the relative displacement δCD between C and D on which spline’s rim. the forces F act can be obtained: The maximum and minimum stresses in section of flexspline. (3) It is known (Eq. 2) that the biggest bending moment occurs π 2 3 – on sections D of φ = 90 in the ring-flexspline (Fig. 3); its value Frm ( 4 π ) δCD = M = -Fr /π (minus sign means that this bending moment EI max m decreases the curvature of the elliptic mid-layer). The stress where: at the outermost end (away from the center of the middle cir- E is material elastic modulus of the flexspline; I is the moment cle) on section D is the maximum compressive stress in cross- of inertia for cross-section in the flexspline torus to 3 sections of the ring-flexspline, its value σ = 0.5 M δ/I = - mid-axis I = B /12; B is the axial width of the flexspline; max max EI means flexural rigidity of the torus, which reflects 0.5Frmδ/(πI). The maximum compressive stress could be calcu- material’s ability of resistance to bending deformation. lated from Equations 3 and 5:

[www.geartechnology.com] 60 GEAR TECHNOLOGY | October 2013 (8)

W0 Eδ σmax = -8.5580 2 dm Here the minus sign indicates a compressive stress; the diameter of the middle circle in the flexspline is dm = 2rm. Also from Equation 2, it is obvious that the minimal bending moment appears on sections B of φ = 0 in the ring-flexspline; its value is Mmin = Frm (0.5-1/π). The stress at the outermost end (away from the center of the middle circle) on section B (it is a tensile stress) σmin = 0.5 Mminδ/I = 0.5 Frm (0.5- 1/π) δ/I, which is also the minimum tensile stress of all sections in the ring-flexspline. Figure 3 Force analysis on mid-layer of flex-spline. The minimum tension stress can be calculated as follows: Usually, the influence of normal bending stress is only con- (9) sidered in approximate calculation, since it is quite small for the W0 Eδ 2 influence of torsional shear stress on the fatigue strength of the σmin = 4.8849 d m flexspline (Ref. 8). That is, the following equation on safety coef- Cycle characteristic of alternating stress on section in ring- ficient in fatigue strength of flexspline should meet: (13) flexspline. As mentioned above, the stress at outermost end on σ-1 section D (Fig. 3) in the ring-flexspline is biggest (maximum nσ = ≥[n] K σ + ψ σ compressive stresses), and smallest on section B (that is, mini- σ a σ m mum tensile stresses). Therefore, the stress on the ring’s section where: is an alternating stress in an asymmetric cycle, which is a reason the factor of stress concentration in the gear’s root Kσ = 1.8 ~ 2.0, leading to fatigue failure for the flexspline. influence factor of average stress on fatigue strength ψ = 0.10 ~ 0.15 are reasonable ranges (Refs. 6 and 8). Combining Equations 8 and 9, and considering the influence σ of teeth in the flexspline on stress, will derive a general formula The minimal tooth number of a flexspline satisfying the to calculate the average stress in sections of flexspline in one requirement in fatigue strength is then obtained from equations cycle. 1, 7, 10, 11 and 13. (10) In general, let’s take Kδ = 1.07; Kσ = 1.9, ψσ = 0.12; δ = 0.012; σ + σ K W Eδ σ = max min = 1.8366 δ 0 d = 0.012 mZ in the recommended ranges. Substituting rel- m 2 d 2 R R m evant data into Equations 1, 7, 10, 11 and 13 yields the following where: relationship: (14) Kδ is a factor reflecting the influence of teeth in flexspline on σ (Z + 2.668)2 stress (Ref. 9), Kδ = 1.05 ~ 1.10, in most cases. n = 12.2795 -1 R σ K σ + ψ σ ≥[n] Alternating stress amplitude, namely, the difference of maxi- σ a σ m mum and minimum stresses on the ring’s section, is: Equation 14 is the condition under which the tooth number (11) of the flexspline should be satisfied. And ΔZ, the tooth number σ + σ K W Eδ σ = max min = 6.7214 δ 0 difference for two gears, should be integral times of the wave m 2 d 2 m number for HGD (Refs. 8 and 9). Double-wave HGD with a tooth number difference of two has been widely used at present, Determining Minimal Tooth Number of Flexspline and double-wave HGD with a tooth difference of four also has The performance of the flexspline depends on its fatigue application on specific occasions; thus ΔZ could be 2 or 4 in dif- strength. Stress on a section in a ring-flexspline is in cyclical ferent applications. change (an asymmetric cycle), as described. We thus must cal- Tooth number ZG of the circular spline could then be calcu- culate the fatigue strength of the flexspline (Ref. 6). lated using the formula: (15) According to Refs. 5 and 8, the safety coefficient n in fatigue strength under alternating stress of the combination of bending ZG = ZR – ΔZ and twisting is: (12) where: if the tooth number ZR of the flexspline and tooth number nσnτ n = 2 2 ≥[n] difference ΔZ of two gears are determined. √nσ + nτ where: Example: Suppose we are to design a double-wave harmonic the permissible safety coefficient [n] = 1.3 ~ 1.5 (Refs. 8 and 9), gear assembly with EWG. A steel 30CrMnSiA, quenched and as a rule. nitrided, is selected as material for the flexspline; its bend- 5 ing fatigue limit σ-1is 625 MPa; elastic modulus E is 2.1 10

October 2013 | GEAR TECHNOLOGY 61 technical

MPa. Let [n] = 1.4 and ΔZ = 2; solution of inequality (Ref. 14) is References 1. Musser, C.M. Gear Mechanism — U.S. Patent No. 3 178 963, April 20, 1965. ZR ≥ 71.2765; it means that the tooth number of the flexspline should be at least 72, a satisfaction of condition n ≥ [n] guaran- 2. Kayabasi, O. and F. Erzincanli. “Shape Optimization of Tooth Profile of a σ Flexspline for a Harmonic Drive by FEM,” Materials & Design, 2007, 28 (2): tees that fatigue strength of the flexspline is enough. If ΔZ = 4 is 441–447. taken, the result from inequality 14 is ZR ≥ 148.0406; the tooth 3. Su Jeon, H. and S. Hoon oh. “A Study on Stress and Vibration Analysis of a number of the flexspline should be more than 148. In this case, Steel and Hybrid Flexspline for Harmonic Drive,” Composite Structures, 1999, the flexspline could meet requirement for fatigue life. 47: 827–833. 4. Zhu, H.L. and M. Zou. A Gear Pump Having New Internal Gear Ring — China Patent No. 201020022956.9, Jan. 5, 2010. Conclusions 5. Gere, J.M and S.P. Timoshenko. Mechanics of Materials, Second SI Edition, Stress concentration near the tooth root of a flexspline is alle- New York, Van Nostrand Reinhold, 1984. viated in HGD-with-EWG. The strength of the flexspline is 6. Insburg, E.G.G. Harmonic Gear Drives: Principle, Design and Process, Beijing: National Defense Industry Press, 1982. improved and service life of the device can thus be extended, 7. Fan, Y. and B. Cao. Manual of Harmonic Gear Transmission Technology, compared to HGD with built-in wave generator—today’s accept- Beijing, National Defense Industry Press, 1995. ed system. Therefore foundational study on HGD-with-EWG 8. Ivanov, М.Н. Harmonic Gear Drives, Beijing, National Defense Industry has both theoretical and practical significance. Press, 1987. 9. Rao, Z. Planetary Transmission Mechanism Design, Second Edition, Beijing, The basic features in HGD are that the flexspline bends peri- National Defense Industry Press, 1994. odically and repeatedly under the action of the wave generator, and is in a working condition of alternating stress. HGD failure is thus mainly caused by fatigue fracture of the flexspline. Many of the benefits of HGD — such as reliability, kinematic accura- Jun Pan studied at the Huaihai Institute of Technology, China, where he received his BD cy and bearing capacity — are chiefly affected by the flexspline. in 2011. He has since then been doing post- Striking that delicate balance between flexspline strength and graduate study at the School of Mechanical elasticity has been the focus of HGD research for a long time. Engineering, Changzhou University. Pan’s area of research is hydraulic transmission For HGD-with-EWG, the flexspline is also the weakest link; its and control. deformation and stress have critical impact upon transmission precision and the life of the entire device. Xing-Pei Qin received her BD (2011) at Changzhou University. The innovative The authors analyzed the radial deformation of the mid-lay- design of mechanical transmission and the er and section stress of the flexspline under the action of EWG computer-aided design of gear pumps are based on the research model of a smooth cylindrical shell. It her major fields of study. Qin has since 2011 been doing graduate work at the School of showed that the stress in the flexspline at work is an alternat- Petroleum Engineering, Changzhou University. ing one of asymmetric cycle; the stresses of cross-sections in the flexspline’s rim are larger at major axis and short axis of ellipti- Hong-Neng Wu received his BD (2011) cal mid-layer; those between the major axis and short axis are at the University of Technology Shandong, China. The mechanical design and smaller; and the stress in the short axis is bigger than that in the manufacturing, development and optimization major axis. The most dangerous section, vulnerable to damage, of harmonic gear pumps are his major is the contact zones (sections C and D, Fig. 3) of the wave gen- fields of study. Since 2011, Wu has been studying as a graduate student at the School erator and the flexspline. of Mechanical Engineering, Changzhou The strength of the flexspline is closely related to its structure University, China. parameters — especially to its number of teeth Dr. Prof. Hai-Lin Zhu received his Determination of tooth number of the flexspline must com- PhD (1996) at the University of Science & prehensively consider such factors as the deformation, fatigue Technology in Beijing, and his MD (1988) and strength of the flexspline and its proper gearing with the circular BD (1984) at Anhui University of Science & Engineering, Anhui, China. The innovative spline. design of mechanical transmission, The formula on the minimal tooth number of the flexspline development of gear pumps and reliability- derived in this paper provides a basis for tooth number selection based optimization are his major fields of and structure design on the flexspline and the circular spline in study. HGD-with-EWG and engineering application of this kind of Zhu is a senior fellow of the Chinese Mechanical Engineering device, which changes the present situation that little research Society and a member of the Council for China gray resource engineering of the International Institute of General Systems. is done on relationship between the strength of flexspline and Zhu has been working at the School of Mechanical Engineering, its tooth number, and remedies a shortage in reference to devise Changzhou University, China since 1997, and was named full HGD device with EWG. professor there in 2003. He has to date published two books and Acknowledgment. The authors wish to acknowledge the finan- ninety-three technical papers. cial support of the National Natural Science Foundation of P.R. Min Zou received her BD (1984), MD China under Contract No. 51075046. This project is supported by (1987) and PhD (2007) at Nanjing University of Science & Technology, China. She is the National Natural Science Foundation of China No. 51075046. a professor at the School of Mechanical Engineering, Changzhou University. She is a professor at the School of Mechanical Engineering, Changzhou University.

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4630 Freedom Drive • Ann Arbor, MI 48108 • 734.973.7800 • fax 734.973.3053 • www.gmtamerica.com technical Purchasing Gear Lubricants: Be Careful When Playing the For Related Articles Search lubrication Numbers Game at www.geartechnology.com John Sander

Introduction available to provide specific functions. the base fluid. Automotive gear oils are When it comes to purchasing gear lubri- As seen in Figure 1, gear oils are catego- then broken down into a final set of sub- cants, many people on both the sales and rized first based upon the application, categories that describe the application in purchasing side decide to play the num- as either an open gear lubricant or an which it will be used, while industrial oils bers game. The person with the most enclosed gear lubricant. As these names are subcategorized based upon the type numbers, or the biggest numbers, or the would suggest, an open gear lubricant is of additives used in the formula. lowest numbers, must have the best prod- not enclosed in a gearbox or oil sump. uct — right? Wrong; gear oil selection is As such, open gear lubricants are gener- 10-Step Gear Oil Selection not a game, and numbers alone cannot ally formulated as either high-viscosity Process determine the right product for an appli- fluids or greases. This paper will focus on For years, many have stated that when cation. Too much information can be enclosed gears only. selecting a gear lubricant — or any lubri- just as much a problem as too little. A Enclosed gears are generally contained cant for that matter — one need consider purchaser can be tricked into selecting within a gearbox or some other device in only temperature, speed and load. More the wrong oil if he does not completely which the gears can be bathed or show- recently, however, this advice has been understand what the numbers mean. ered with a coating of fluid lubricant. expanded to include environment. An As the old saying goes, “Figures don’t Enclosed gear oils are categorized next easy way to remember this is L-E-T-S, lie, but liars do figure.” This is not to sug- as either automotive or industrial gear i.e.: load, environment, temperature and gest that gear lubricant sales representa- oils. Both types can be subcategorized as speed. While this advice is simple and tives are liars, but rather that too often synthetic or mineral oil, which describes easy to remember, it still doesn’t provide neither the sales rep nor the purchaser completely understands what the num- Table 1 Gear oil ingredients Ingredient Function bers on a technical sheet or price list real- Base Fluid Mineral oil or synthetic fluid (PAO, ester, PAG) makes up 50-98% of the formula. ly mean. An attempt will be made here to Viscosity index improvers or polybutene polymers used to increase the base fluid Viscosity Modifiers viscosity; becoming very common today to replace high viscosity bright stocks often explain what you should consider when used in gear oil formulas. choosing a gear lubricant for a specific Rust inhibitors coat metal surfaces to protect against rusting. Oxidation inhibitors defend Rust & Oxidation Inhibitors the oil against degradation due to reactions with oxygen in the air when the lubricant is application and to show why choosing (R&O) exposed to elevated temperatures. based solely on the numbers is not the Gear systems can contain some yellow, copper-containing metal elements that can be Copper Deactivators best bet. tarnished by gear oil ingredients. These additives protect the metal. Some gear applications operate in the mixed film lubrication regime, meaning slight metal-to-metal contact. The base fluid isn’t sufficient to protect the surfaces from Anti-wear Additives (AW) Background wear, so additives are included to form a sacrificial surface that decreases the friction Gears are a unique application for lubri- between two metal surfaces. Heavily loaded gear applications can operate in the boundary wear regime, meaning the cation in that they provide a different Extreme Pressure (EP) oil film is squeezed out completely. EP additives put down an aggressive coating that challenge than other lubricant applica- carries the load and protects the metal surfaces in lieu of the lost oil film. These surface-active additives grab onto and disperse contaminants in bulk oil so that tions. In non-gear applications, the mov- Dispersants they do not collect in the gearbox, but instead can be carried to the oil filter for removal. ing surfaces are in sliding motion or roll- They are used more often in automotive gear oil than in industrial gear oil. These are not common, but some gear oils are formulated to mix with water and stay ing motion. Gear teeth, however, expe- Emulsifiers mixed, such as when water contamination is impossible to avoid. rience both rolling and sliding motion Demulsifiers Surface-modifying components are used to promote the separation of water. Surface-tension-reducing polymeric compounds are used to inhibit the formation of foam at the same time. With these interesting Defoamants conditions in mind, the formulator has on the surface of the oil that could result in housekeeping, oxidation and wear issues. Sticky polymers with high molecular weight are added to increase a gear oil’s ability to Tackifiers numerous ingredients available to build climb and cling to gears. a gear lubricant that provides proper pro- These are not common in lower viscosity enclosed gear applications, but are often used Solid Lubricants for lubrication of open gears. EP additives lay down a layer of solids that keep the metal tection. See Table 1 for a list of common surfaces from rubbing. Common examples include molybdenum disulfide and graphite. ingredients used in various combinations Polymeric ingredients are added to modify wax crystals that form in oils at low Pour Point Depressants temperatures. They keep the oil from gelling up, thereby expanding the oil’s operability for gear oil formulas. A formula does not range on the low end. have to contain every one of these addi- A vegetable or animal fatty acid is put into formulations as a friction modifier in formulas Compounding Additives tives, and there are multiple additives for gear applications sensitive to most EP additives.

Reprinted courtesy of Lubrication Engineers, Inc.

[www.geartechnology.com] 64 GEAR TECHNOLOGY | October 2013 sufficient direction to make an educated decision. Instead, the following 10-step process is recommended to anyone who is responsible for purchasing enclosed gear lubricants. 1. Set lubrication goals. As with most things in life, it is very important to have a goal. This is even important when it comes to selecting a gear lubricant for use in a specific piece of equipment. Most maintenance groups have a broad goal of increasing the reliability of the equipment for which they are responsible. In trying to improve reliability, one thing that is often reviewed is “uptime.” The Figure 1 Gear oil categories. higher the percentage of uptime, the more reliable it is considered. Lubrication the existing workload of maintenance requirements are for the equipment. has often been traced to reliability. Also, staff. As a result, time spent on improving Some will publish a specification that lists many maintenance individuals would like equipment reliability through lubrication the physical and performance require- to reduce the amount of time they have has been decreased. ments for the gear lubricants. Some gear to spend performing lubricant-related The gear purchasing process should OEMs even take it a step further by cre- maintenance projects. High-performance start with evaluating the experi- ating their own approval system, includ- lubricants are available that can be used ence, knowledge and services offered ing approvals and the publication of a list to help improve reliability. Lubrication by the individual or company provid- of approved products. It is important to has also been traced to improved energy ing the lubricants. Today, groups like become familiar with these specifications efficiency, an area that has been given the International Council for Machinery or approval lists so as not to void any much attention in recent years. Improved Lubrication and the Society of Lubrication warranties provided by the OEM and to heat removal and friction reduction in a Engineers offer certification programs for maximize the reliability of the equipment. gear application can result in decreased lubrication professionals. It is a good idea Many lubricant purchasers fail to con- energy consumption. to ask your lube provider whether they or sider the compatibility of the lubricant So the question remains, what is the somebody on their support staff has been with the equipment in which it is going goal for selecting a gear lubricant for a certified by one of these organizations. If to be installed. Some OEMs use coat- specific application? Is the one current- all your potential gear lubricant supplier ings or paints to protect the insides of a ly in use not performing as needed? Is can provide is a price list and specifica- gearbox from corrosion. Unfortunately, there a desire to change from one suppli- tion sheet, it should raise an immediate some lubricants can compromise these er to another? Is it a new piece of equip- red flag. The price paid for the lubricant coatings. Another compatibility issue can ment that needs to be filled for the first should include the physical lubricant as be the use of certain elastomeric seals in time? Are there availability issues with well as professional service to go along a gearbox. If the lubricant is incompat- the lubricant currently in use? Does the with it. Ray Thibault, a lubricant consul- ible with these elastomers, the seals could company have an edict to reduce energy tant, trainer and author, provides this great start leaking. If not caught soon enough, consumption? Is there a desire to increase segue from Step 2 to Step 3: these leaks can result in lubricant star- the maintenance intervals? Goals must be “While a product data sheet provides vation. Oil leaks also can result in safety personalized and they must be specific. useful information, the true test of gear issues if the oil collects where it causes a Without a specific goal, there is little rea- oil is how it works in the system. Adhere slip hazard. son to push ahead to steps 2–10. to OEM guidelines and consult your Based upon specific end uses of a gear- 2. Seek professional advice and con- lubricant supplier for further informa- box, there are circumstances in which the sultation. Ideally, a lubricant sales pro- tion.” (Ref. 1) OEM-recommended oil does not provide fessional or consultant is available to 3. Review OEM recommendations, adequate protection. In these cases, it is serve as a value-added member of the including compatibility. The next step is extremely important that the professional team. It used to be that many companies to consider the recommendations of the advisor mentioned in Step 2 is consult- would employ a lubrication engineer or original manufacturer of the gear equip- ed for other recommendations, and that at the very least have a person whose job ment. Ask any potential gear oil suppliers proper testing be conducted to ensure a was focused on equipment lubrication. if they are able to provide evidence that successful change to a new, better-per- Today, most maintenance departments their products are either approved by, or forming product. have been forced to work with fewer peo- meet the requirements of, the OEM. 4. Determine type of load. Figure 1 ple. As a result, a lubrication specialist Often the OEM has deter- illustrates how gear oils are character- on staff is considered a luxury. Instead, mined — through field experience or ized according to their formulation and/ lubrication duties have been added to extensive testing — what the lubricant or usage application. It especially shows

October 2013 | GEAR TECHNOLOGY 65 technical how industrial gear oils are characterized and reliable than before. To meet these ditions, all of which can have significant according to their additive type, specifi- increasing demands, today’s industrial effects on the gearbox. To minimize these cally the wear-related chemistry used. gear oil must contain high-performance effects, you can take precautions such as For example, a gear lubricant may be additive chemistry (Ref. 2).” using air breathers, sight glasses and fil- described as R & O, EP or AW. Certain You must know the construction of the tration devices. The lubricant itself also enclosed gear applications have little gearbox and use this information as part may be required to compensate for some to no load applied. The appropriate oil of the lubricant selection process. This of the challenges caused by the operating in this case might be R & O oil only. As includes the metallurgies, gear geom- conditions. the amount of loading increases, so will etries and the cuts of the gears (rough Extreme temperatures. For an applica- the amount of metal-to-metal contact or smooth). Table 2 illustrates the part tion operating at either extremely high between the gears. For gears operating that gear geometry plays in the lubricant or low temperatures, it may be neces- in the mixed film wear regime, AW oil selection process. sary to choose a synthetic-based lubricant may be needed, while for those operat- The gearbox capacity is a subcategory instead of a mineral-oil-based lubricant. ing in the boundary regime, EP oil may of construction that merits its own dis- For low temperatures, oil should have a be needed. cussion. As noted previously by Cooper, pour point that is 5°C (9°F) below the Sometimes the OEM specifical- many gearboxes are getting smaller. In a startup temperature. Operating tempera- ly describes the type needed either in the small gearbox, less oil is present. As such, tures can also determine the chemistry equipment user’s manual or on a plate it could run hotter, be sheared more by needed in the gear oil. Very aggressive attached directly to the gearbox itself. If the gears and be affected more dramati- EP gear oils might result in heavy deposit not, then it is up to the user to determine cally by contamination. The corollary formation in the gearbox during opera- whether the application subjects the gear- is that in a large box, the oil may circu- tion. Non-EP oil used in an EP oil appli- box to either heavy loads or shock loads late less, run much cooler and last much cation can result in high oil temperatures during operation. In that case, it will longer. Although this sounds like an due to excess frictional heating of the oil. require EP oil that contains active sulfur endorsement for larger gearboxes, they Particulate contamination. In a coal and phosphorous compounds that form a are not suitable — or even possible — with or rock crushing plant, it is inevitable protective chemical layer on the gear sur- some applications. that dust and dirt will be in the air, and faces when the fluid is compressed out of Many lubricant additives activate at it is very difficult to keep the particles the meshed gears. In extreme loading cases, certain temperatures. With that in mind, from finding their way into the gear oil. it might be helpful to use gear lubricant it is possible that a large gear set might Filterable gear oil would allow filtration that contains solid EP additives. However, experience elevated wear because the oil to remove harmful contaminants without it is important to note whether fine filtra- never gets hot enough for the additives removing valuable additives. tion is in use, because it can remove solid to activate. On the other hand, the wrong Water contamination. In water treat- additives and make this specific product additive system employed in a small, hot ment facilities, it is nearly impossible to ineffective. Some OEMs specifically recom- gearbox could result in an aggressive gear keep water out of some gearboxes, mak- mend against the use of solid additives, so it additive prematurely activating, oxidiz- ing it extremely important to choose a is important to know this. ing and leaving behind deposits. The gear lubricant with excellent water sepa- 5. Know gearbox construction and oil capacity of the gearbox can have a ration properties. capacity. A gearbox contains various dramatic effect on the gear oil. As such, 7. Identify viscosity recommendation. components, including — but not limited capacity must be considered as a part of The viscosity of a gear lubricant is a mea- to — the case, gears, bearings, shafts and the selection process. Also, if the goal surement of its ability to flow in an appli- seals. The construction of the gearbox, determined in step 1 was to extend the cation. This is a very important consider- including its geometric configuration, is interval between lubricant drains, the size ation in selecting gear oil. If the oil is too often contingent upon how the gearbox of the gearbox case is very important. thick, it will not flow into the gear contact is required to transmit power within the The more lubricant there is in the gear zones. If the oil is too thin, it will be com- given application. As described by Tim case, the more additive reserves there are pressed out of the contact zones or fling Cooper of Lubrizol: to extend the life of the lubricant. off the gears while they are in motion. In “Today’s gearboxes often are smaller 6. Minimize effects of operating envi- either case, lubricant starvation will occur, and made from new materials; they are ronment. A gearbox could be operating which can result in premature wear-relat- getting pushed to produce more power in an environment that is hot, cold, dusty, ed failures. The primary means of gear and at the same time be more durable wet or various combinations of these con- lubricant selection, with regard to viscos-

Table 2 Effect of gear type on lubricant chemistry selection Gear Geometry Type Lubricant Chemistry Spur Helical Worm Bevel Hypoid Light loads & slow speeds R & O inhibited Normal loads Normal loads only Normal loads Not recommended Satisfactory for use in most Specified for most EP gear lube Heavy or shock loading Heavy or shock loading applications Heavy or shock loading applications Compounded Not normally used Not normally used Preferred by most OEMs Not normally used Lightly loaded applications Heavy or shock loading and/ Heavy or shock loading and/ Heavy or shock loading and/ Heavy or shock loading and/ Heavy or shock loading and/ Synthetic or extreme temps or extreme temps or extreme temps or extreme temps or extreme temps

[www.geartechnology.com] 66 GEAR TECHNOLOGY | October 2013 ity, is to use the OEM requirement. If an Table 3 AGMA viscosity grades for gear oils ISO Grade Kinematic Viscosity at 40°C Kinematic Viscosity at OEM recommendation is not available, AGMA Number Equivalent min / max cSt 100°C min / max cSt there are two other methods to obtain 0, 0S 32 28.8 / 35.2 - / - viscosity recommendations. The first is 1, 15 46 41.4 / 50.6 - / - 2EP, 25 68 61.2 / 74.8 - / - to use the viscosity ranges recommend- 3EP, 3S 100 90 / 110 - / - ed by the American Gear Manufacturer’s 4EP, 4S 150 135 / 165 - / ‑ Association, per its 9005-E02 standard 5EP, 5S 220 198 / 242 6EP, 6S 320 288 / 352 (Ref. 3), illustrated in Table 3. 7 Comp, 7EP, 7S 460 141 / 506 - / ‑ The second method is attributed to 8 Comp, 8EP, 8S 680 612 / 748 - / ‑ renowned gear expert Robert Errichello 8A Comp, 8A EP 1000 900 / 1100 - / ‑ (Ref. 4), and is based upon a calcula- 9EP, 9S 1500 1350 / 1650 - / ‑ 10EP, 10S - 2880 / 3520 - / ‑ tion method that employs the following 11EP, 11S - 1440 / 5060 - / ‑ equation: 12EP, 12S 6120 / 7480 - / ‑ (1) 13EP, 13S 190 / 220 V40 = 7000 / √V1 14R 428.5 / 857.0 where: 15R - 857.0 / 1714.0 V is the viscosity at 40°C, in cSt; 40 per-second (8,000 feet per minute)… it has experience in these cases. If not, V1 = pitchline velocity of the lowest speed gear in the gearbox in and worm gears that operate at or below request testing or continue searching for feet-per-minute = 0.262 × speed 2,400 rpm worm speed or 10 meters-per- another supplier. (pinion rpm) × pinion diameter second (2,000 feet-per-minute) sliding 10. Evaluate price. Evaluating the price (inches) velocity (Ref. 6).” is the last step in this process for a reason. If there is no oil cooler on the indus- Anything above these gear speeds is Unfortunately, many gear oil purchasers trial gear drive, it is best to determine the considered a high-speed gear, and it is evaluate price first, and sometimes it is maximum expected ambient temperature best to consult the OEM recommenda- the only number they evaluate. This can during operation and: tions for lubricant recommendations. be a costly mistake. According to Mike a. Increase one ISO viscosity grade if the Figure 2 is a simple schematic that sum- Johnson, lubrication consultant, trainer ambient temperature exceeds 35°C marizes how load, speed and viscosity and author: (95°F). come together during the lubricant selec- “Performance lubricants are often not b. Increase two ISO viscosity grades if tion process (Ref. 7). considered for use because of price objec- the ambient temperature exceeds 50°C 9. Ensure fluid durability for extended tions. Maintenance costs range from 5–15 (122°F). drains. Today, people are realizing that percent of a plant’s cost of manufacturing, If there is an oil cooler, the maximum there is a hidden cost to using inexpensive, depending upon the industry. Lubricant ambient temperature is less important lower performance lubricants. The less purchases represent only 1–3 percent of because the oil’s temperature can be con- time a lubricant lasts during service, the maintenance expenses. Yet, the portion of trolled. Therefore, the oil’s temperature more maintenance it takes to change the the budget that can be directly impacted should determine the viscosity. lubricant. In addition, the more frequently by lubricant expenditures can represent c. Increase one ISO viscosity grade if the the lubricant is changed, the more waste about 35 percent (20 percent from parts oil temperature exceeds 65°C (150°F). lubricant there is to be disposed. While replacement, plus 15 percent from lube d. Increase two ISO viscosity grades if the there are plenty of companies specializing program routine and overtime repair oil temperature exceeds 85°C (185°F). in waste oil disposal, they do charge for labor). The cost-to-cost leverage fac- If the oil temperature exceeds 90°C their services. With these hidden costs in (194°F), use a cooler such as a fan or a mind, many users are looking to extend heat exchanger (Ref. 5). their drain intervals. 8. Consider gear speed. Viscosity often Gear oil durability requires that a prop- is related proportionally to the speed at er synergy exists between the base fluids which the gearbox is operating. The gen- and additives chosen for the gear prod- eral belief is that high-speed applications uct. The user must consider the gearbox require low-viscosity lubricants, and low- application to know what type of stress- speed applications require high-viscosity es it will put on the lubricant. Improper lubricants. AGMA provided a general selection will accelerate the demise of the guideline in its 9005–94 specification, lubricant’s physical and chemical proper- which serves as a good rule of thumb. ties. For example, as mentioned in Step 6, When referring to its viscosity grades filtration tools can overcome some of the shown in Table 3, AGMA stated: issues caused by the operating environ- “These guidelines are directly appli- ment. However, filters also might remove cable to… gears that operate at or below some of the additives, such as tackifi- 3,600 revolutions per minute, or a pitch- ers and defoamants. Consult the manu- line velocity of not more than 40 meters- facturer of the gear lubricant to verify if Figure 2 Effect of speed and load on lubricant selection.

October 2013 | GEAR TECHNOLOGY 67 technical tor for lubricant savings opportunity vs. ences between the claims made. Without running this test, it is even worse. Imagine lubricant expense is an astounding 35:1. knowledge, the tendency might be to go a sample that has a 50 lb Timken result. Investment in either process or product with the product with the most numbers If the same lab runs this test, at least one improvements can produce returns at and OEM claims on the data sheet. While test in 20 will deviate by as much as 15 lb. several hundred percent investment with this shows that the supplier was willing Within the precision of this test, the same just a little effort (Fig. 3).” (Ref. 8) to put a sizeable investment into prod- operator could produce a 35 lb Timken While consideration of price is a valid uct development testing, it still doesn’t result or a 65 lb Timken result, and sta- part of the lubricant selection process, it necessarily prove that one product is bet- tistically these would be the same result. should always be the last step. ter than the other for the application. Be Now, seeing that the reproducibility is 75 By the time steps 1–9 have been com- wary of the lubricant sales person who percent, two different labs could produce a pleted, it is likely that the most appro- just points out one specific data point and 12.5 lb result or 87.5 lb result —and these priate lubricant for the gear application emphasizes this for the sale. There are would be considered statistically the same has become apparent. Yet, if there are other factors that affect the significance result for the average of this imaginary 50 still several products that appear to be of those numbers, such as applicability to lb sample. equivalent, then price should play into the application, test precision and units Next, it is a good idea to pay close the selection process. The highest-priced portrayed. Let’s take a look at just a few. attention to the units reported on a prod- lubricant is not necessarily the best for a Many companies will show the Timken uct data sheet. Once again using the ficti- given application. For example, if a gear- test: ASTM D2782 (Ref. 9). What is not tious 50 lb Timken result, a lab in the U.S. box has leaking problems, it is not likely widely known outside of the laboratory might report that data as 50 lb, while a that an expensive synthetic lubricant will is the precision of this test. Most ASTM lab in Europe might present it in metric provide value. On the flip side, this does test methods include a repeatability and units as 22.6 Kg. Both of these are cor- not mean you should purchase the least reproducibility statement. Repeatability is rect, but the U.S. lab number looks much expensive gear oil and ignore the leak- a measure of error between multiple test higher. One might mistake the U.S. result ing gearbox. In a case such as this, it is runs, on the same sample, by the same as a better result when they are actually a maintenance issue and not a lubricant operator running the same instrument, the exact same number. As a sideline to issue. As described by Johnson, leaving while reproducibility is the error between this, there are various standards groups a problem like this unresolved can cost multiple test runs conducted on the same active throughout the world. They might the company much more in the long run sample by different operators on different publish very similar methods, yet there than initiating good maintenance practic- instruments. can be subtle differences. One cannot es and choosing high-performance lubri- For the Timken test, the repeatability is just assume that results published using cation products. 30 percent of the mean on one of 20 sam- the same instrument are comparable, Important numbers. Assuming that ples and the reproducibility is 75 percent because the various methods used can steps 1–10 have been considered, and of the mean on one of 20 samples. This cause differences in results. For example, that the final decision comes down to a means that the error from the same lab an ASTM method might produce differ- comparison of data sheets, the question on 20 runs will likely produce at least one ent results than an ISO method on the still remains: What numbers should one run with up to 30 percent error. The rest same instrument. consider important? A review of various of the runs may be somewhat better than There are two common corrosion gear lubricant supplier data sheets will that, but expect the possibility of at least tests used within the lubricant industry: show that there can be dramatic differ- 30 percent error. When different labs are ASTM D665 (Ref. 10) and ASTM D130 (Ref. 11). Both have nuances, depending upon the application. The D665 has an A and B version of the test method. The A version uses deionized water for the testing, while the B version uses standard saltwater. Traditionally, the saltwater version is more severe, so when considering results one should ensure that the same test conditions were employed. The D130 test employs two different test temperatures. This can make a big difference depending upon the EP package used in the gear oil’s formulation. The same result published on two competitive data sheets might not mean the same thing if the temperature is not published. The gear lubricant features that should be evaluated when comparing data sheets depend upon the application. See Table Figure 3 Typical maintenance budget divisions.

[www.geartechnology.com] 68 GEAR TECHNOLOGY | October 2013 Table 4 Important information to look for on product data sheets Application Lubricant Feature Common Tests Optimal Results Check for any approval that is All OEM Approvals required. Viscosity, ASTM D445 varies by grade All Viscosity Viscosity-Brookfield, ASTM D2983 varies by grade Extreme temps (extremely low startup: <-26°C (-15°F) or continued exposure to extremely Synthetic NA NA high: >82°C (180°F)) Oxidation @121°C, ASTM D2893B <6 max Lightly loaded or high-temp operation R & O Oxidation Rig Test, viscosity increase, L60-1 <100% Rust Test, ASTM D665B pass Light-to-medium loading Anti-Wear (AW) Four-Ball Wear, ASTM D4172 <0.50 mm Four-Ball EP Weld Point, ASTM D2783 250 Kg Four-Ball EP LWI, ASTM D2783 >60 Medium-to-heavy loading Extreme Pressure (EP) FZG Scuffing, DIN 51354 >12 FVA 54 Micropitfing Load Stage >10 Timken OK Load, ASTM D2782 >60 lb min Foaming Characteristics, ASTM D892 0/0/0 Release of air for lubrication or housekeeping Anti-Foaming issues Flender Foam Test <10% increase Emulsion Characteristics @ 82°C, ASTM D1401 40-40-0 / 10 Water removal when necessary Water Separability Demulsibility Characteristics EP, ASTM D2711B Max 2% H2O in oil, 80 ml free H20, 1 ml of emulsion Rust Test, ASTM D665B pass Rust or yellow metal protection Anti-Corrosive Copper Corrosion, ASTM D130 1a or 1b

8. Johnson, M., “High-Performance Lubricants: 4 for a list of common lubricant features that many end users look to their lubri- Cost vs. Performance,” Tribology and cross-referenced with application condi- cant suppliers for assistance. This is a Lubrication Technology, Society of Tribologists and Lubrication Engineers, Park Ridge, IL, May tions and optimal test results indicating a good plan, but it can sometimes result 2010. lubricant’s suitability for that application. in a mere comparison of price or data 9. ASTM International, “D2782 Standard While the lubricant industry is consid- sheet numbers; in other words — a num- Test Method for Measurement of Extreme- ered a relatively mature industry, there bers game. Instead, try using this 10-step Pressure Properties of Lubricating Fluids,” Conshohocken, PA, 2011. are still areas of active research. The lead- process for lubricant selection to make 10. ASTM International, “D665 Standard Test ing edge for lubricant manufacturers is the process easier and more systematic, Method for Rust-Preventing Characteristics of to formulate products that can be used resulting in improved equipment reliabil- Inhibited Mineral Oil in the Presence of Water,” in the challenging wind turbine gearbox ity. Remember: Be careful when playing Conshohocken, PA, 2011. 11. ASTM International, “D130 Standard Test applications. the numbers game. Most players end up Method for Corrosiveness to Copper from Over the years, wind turbine OEMs losing. Petroleum Products by Copper Strip Test,” have found that their gear sets are noto- Conshohocken, PA, 2011. rious for micropitting, also sometimes References 12. Errichello, R., “Selecting and Applying 1. Thibault, R., “Certification Matters: Part Lubricants to Avoid Micropitting of Gear called fatigue scoring, flecking, frost- Teeth.” Machinery Lubrication, Noria ing, glazing, gray staining, microspalling, III Gearbox Principles and Lubrication.” Lubrication Management and Technology, Corporation, November 2002. peeling or superficial spalling. (Ref. 12) Applied Technology Publications, Barrington, For more information: The FVA 54 test evaluates this phe- IL, July/August 2011. Lubrication Engineers, Inc. nomenon. This test, which is specific to 2. Cooper, T., “Selecting the Right Industrial Gear 300 Bailey Avenue base fluid, viscosity and additive chem- Oil,” Machinery Lubrication, Noria Corporation, Fort Worth, TX Tulsa, OK, November 2008. Phone: (800) 537-7683 istry, is not easy to pass. This is why 3. American Gear Manufacturers Association, www.le-inc.com some wind turbine OEMs have come to American National Standard Industrial Gear respect the data from this test and have Lubrication ANSI/AGMA 9005-E02, American now incorporated it into their specifica- Gear Manufacturers Association, Alexandria, GA, 2002. tions. Several OEMs also require a pass- 4. Errichello, R., “Selecting and Applying ing result for their general industrial gear Lubricants to Avoid Micropitting of Gear John Sander is vice specifications. Teeth.” Machinery Lubrication, Noria Corporation, November 2002. president of technology at 5. Ludwig, L. G., “Lubrication Selection for Lubrication Engineers, Inc. Conclusion Enclosed Gear Drives,” Machinery Lubrication, He has been responsible for a variety of lubricant quality, Several resources are available to help Noria Corporation, Tulsa, OK, November 2008. formulation and testing 6. American Gear Manufacturers Association, the end user select the right gear lubri- activities since he began American National Standard Industrial cant. Some have focused only on speed, his career at LE in 1989. Gear Lubrication ANSI/AGMA 9005- D94, He is an STLE-certified lubricating specialist temperature and load, while others have American Gear Manufacturers Association, and has authored or co-authored more than Alexandria, GA, 1994. added operating environment to the 20 technical and marketing papers and one 7. Lansdown, A. R., Lubrication and Lubricant mix. Still others have added lubricant book chapter. John holds a BS in chemistry and equipment compatibility. All of these Selection: A Practical Guide, Mechanical from Wichita State University and an MS in Engineering Publications, London, 1996. tend to confuse the end user. The result is environmental science from Friends University.

October 2013 | GEAR TECHNOLOGY 69 industry news

Engineering has to offer the industrial marketplace. Randall Gear Technology Publications would like to thank the 50+ attendees who joined HOSTS TECHNICAL DINNER DURING GEAR us for the breakfast seminar. EXPO Randall Publications LLC Publisher and Editor-in-Chief Holroyd Precision Michael Goldstein and the editing team at Gear Technology INVESTS IN LOCAL WORKFORCE hosted a technical dinner at Lorenzo’s Ristorante (Indianapolis), an authentic Italian restaurant a few blocks from Gear Expo When the latest cohort of craft apprentices joins Rochdale, 2013. The dinner included Gear Technology technical edi- U.K.-based Holroyd Precision Limited in September 2013, the tors Robert Errichello (also Geartech president and long- individuals concerned will be continuing a tradition that goes back for almost as long as the 150-plus years that Holroyd has been in the region. “As a company, we are committed to investing in the local workforce,” comments Don Whittle, human resource director. “Indeed, as part of our strategy to maintain the exacting engineering standards that we have become renowned for, every year we look to take on a number of young people; developing their skills through a strong, engineering- based modern apprenticeship program that typically takes up to four years to complete. This is in addition to offering sum- mer placement opportunities to promising engineering degree students.” Very real career opportunities “Perhaps most importantly,” Whittle continues, “when inter- time AGMA training instructor), AGMA and industry veter- viewing for each year’s apprentices, we look very carefully at ans Octave Labath, Chuck Shultz and Robert Smith, as well where future skills gaps may exist in our business. This not only as many key international gear authors and educators: Alex ensures solid succession planning by developing the core skills Kapelevich (AK Gears), Dr. Ulrich Kissling (KISSsoft), Frank essential for the future of Holroyd, but also gives each appren- Uherek, (Rexnord), Dr. Karsten Stahl (FZG), Dr. Michael Otto tice a very real career opportunity to work towards.” (FZG), Dr. Carlo Gorla (Politecnico di Milano), Jannik Henser Apprentices joining Holroyd only a few years ago would (WZL), Dr. Carlos Wink (Eaton) and Jane Muller (Geartech). have completed their first year of training at the company’s The evening provided an excellent opportunity to discuss the onsite training school. However, today’s apprentices spend past, present and future of the gear industry as well as share twelve months with the teaching partner to Holroyd, Rochdale dinner with old and new friends. Gear Technology thanks every- Training Association. Having worked with Rochdale Training one for joining us, and we look forward to hosting our next Association for many years, Whittle decided to move Holroyd’s industry event in Detroit. first year apprenticeship learning program off-site to the training provider in 2006. “We decided that it made good sense to GEAR AND GEAR DRIVE MARKETING pool our resources,” he says. “As a result, Holroyd apprentices Power Transmission Engineering sponsored a free breakfast continue to receive the highest standards of initial training, seminar on Wednesday September 18th during Gear Expo 2013. Rochdale Training Association benefits from the government Dave Friedman, associate publisher and advertising sales man- funding that our apprentices attract, while other apprentices ager, discussed how to build brand identity, print vs. online are now able to see and experience the Holroyd way of doing advertising and how to best use the tools Power Transmission things.” Developing key skills from day one During year one, Holroyd apprentices learn a range of key engineering skills at Rochdale Training. This is in addition to attending college for one day each week to study towards the BTEC Ordinary National Certificate. With their first year completed, they then return to Holroyd’s headquarters for on-the- job training. Ultimately working towards the NVQ Level 3, they continue with day release, progressing to the BTEC Higher National Certificate award.

[www.geartechnology.com] 70 GEAR TECHNOLOGY | October 2013 Providing first-class progression “Industry-recognized qualifications and a career with plenty of opportunities for progression, however, aren’t necessarily where the story ends,” adds Whittle. “Whenever we feel that an apprentice has the necessary ability and aptitude, we’ll continue to support them through degree-level study – and beyond – if that’s a route they’re happy to pursue. We really do aim to provide our employees with the best opportunities available.” Long and successful careers It’s a testament to the quality of Holroyd’s selection process and training that the majority of those awarded an apprenticeship with the company not only stay the course, but typically go on to enjoy long and successful careers with the machine tools and precision components specialist.

GEAR CUTTING SOLUTIONS

Former apprentice, Philip Hart, 32, is a perfect example of Holroyd’s commitment to staff development. It was while Hart was working through his NVQ Level 3 in 1998 that it was decided to “fast track” him onto a university course instead. He went on to secure an honors degree in engineering at Salford University. Now a research and development engineer with Holroyd, Hart has recently achieved full membership of the Institute of Mechanical Engineers (IMechE) – quite possibly the highest accolade to his technical expertise so far. Another example of Holroyd’s commitment to employee development is Production Foreman, Steve Greenwood. After completing his apprenticeship in 1988, he gained experience across several areas of the business, including time working on multi-axis rotor grinding machines and a specialist supercharg- er production cell, before being promoted to the role of production foreman in the Precision Components Division. Currently responsible for a team of 30 staff, Greenwood heads a department with an annual turnover of £6.5 million. He says: “The apprenticeship program at Holroyd is the best you can get. It provides first-rate training, incredible levels of support and encourages a real work ethos.” Perhaps the best person to ask about the opportunities provided by Holroyd, however, is current apprentice, Josh Mills. “I’m thoroughly enjoying what I’m doing and I’m getting paid for it,” says Mills, 20, who began his engineering apprenticeship in 2011 after previously working in a car body shop. “I’m

October 2013 | GEAR TECHNOLOGY 71 industry news learning cutting-edge skills that will put me in good stead for In 1989, Eaton acquired the South Bend plant, which is part the future.” of the company’s Vehicle Group business, and employs more Commenting on her organization’s relationship with Holroyd than 110 people. The facility contributes nearly $200 million to Precision Limited, Rochdale Training Association’s Chief the local economy through taxes, wages and supplier impact. Executive, Jill Nagy, adds: In addition, Eaton South Bend and its employees donated “We have worked with Holroyd for over 25 years and $41,000 in 2012 to local community organizations such as the immensely value the partnership we have developed. During United Way of St. Joseph County, La Casa de Amistad Hispanic this time we have helped recruit, develop and train their Community Center and the St. Margaret’s House center for apprentices, many of whom are from the local community. women and children. “Only recently, Holroyd recruited a young person from one of our employability courses. That person not only completed an apprenticeship, but also progressed into higher education. Inductoheat Holroyd provides outstanding opportunities for local residents PROMOTES TARPINIAN TO PROCESS and young people. HR Director, Don Whittle, was also a board METALLURGIST/LABORATORY member of Rochdale Training for many years. As a result, we SUPERVISOR greatly benefited from Holroyd’s advice and guidance, which enabled us to deliver our Apprenticeship Program according to Inductoheat, Inc. is pleased employers’ needs.” to announce the promo- tion of Sean Tarpinian to the new position of process met- Eaton Corp. allurgist/laboratory supervi- BRINGS FORGING OPERATION IN-HOUSE sor. Tarpinian is a graduate of Schoolcraft College, where he Diversified industrial manufacturer Eaton has announced that earned his associate degree its South Bend, Indiana, facility has added a $1.9 million cross- in metallurgy and welding wedge-rolling machine for use in the production of transmis- technology. He most recently sion shafts for heavy-duty trucks. The new machine improves earned a Bachelor of Science manufacturing efficiency by completing a forging process in in Applied Technologies from South Bend with the cross-wedge-rolling system. It replaces a Eastern Michigan University. He is a native Michigander and hammering press operation that previously was outsourced. In has been employed at Inductoheat for two years as a process a traditional hammering press, brute force is used to forge a metallurgist. Tarpinian will supervise the lab personnel and hot piece of steel into the size and shape required by customers. allocate laboratory equipment as required to meet customer With Eaton’s new cross-wedge-rolling machine, steel is heated expectations. This position reports directly to the lab manager. “We are pleased to have Sean in this new role. He brings a wealth of technical, organizational and leadership skills that will continue to improve customer satisfaction,” said Robert Madeira, vice president of heat treating at Inductoheat Inc. Arrow to 2,200 degrees Fahrenheit and rolled – rather than pressed – Gear to form the transmission shafts. ANNOUNCES NEW Built in Belarus, Eaton’s cross-wedge-rolling machine is one CHIEF FINANCIAL of fewer than 10 such systems in the world – and one of only OFFICER a few in the United States. The South Bend plant currently is completing tests of the new machine, which is expected to be Arrow Gear is pleased to fully operational by mid-September. announce the appointment “This is a unique process that will significantly improve our of Andrew Mazzarella as the manufacturing efficiency,” said David Larkins, South Bend company’s new chief finan- plant manager. “We’re very excited to have it here in South cial officer (CFO). Mazzarella B e n d .” joined Arrow Gear in The South Bend plant supplies gear forgings to three Eaton mid-August. He has an extensive background in executive facilities – in Kings Mountain, North Carolina; Shenandoah, level finance for the manufacturing sector. A graduate of the Iowa; and San Luis Potosi, Mexico – which assemble them into University of Illinois in accounting, Mazzarella began his career transmissions for leading global truck manufacturers. South working for a Fortune 200 company in the automotive replace- Bend also supplies precision gear forgings for use in off-road ment parts industry; eventually achieving the position of CFO. and watercraft recreational vehicles. After moving on to CFO positions at several middle‐market

[www.geartechnology.com] 72 GEAR TECHNOLOGY | October 2013 companies, he later became part of an ownership team that operated a manufacturing company which supplied products to the automotive industry. Here he performed the dual role of CFO and vice president of manufacturing; heading up the company’s main manufacturing facility in Carson City, Nevada. CAREER Mazzarella’s diverse experience in the financial requirements of OPPORTUNITY manufacturing is a valued addition to the Arrow Gear executive team. Since 1918 Fabco Automotive Corporation has formed a reputation based upon innovative engineering, sophisticated manufacturing and responsive customer service. Today, we are a UL Certified TS16949 tier Oerlikon Graziano 1 transportation industry supplier that designs and builds a broad range of Steer Drive Axles, Transfer DISCUSSES MEASUREMENT OF FRICTION Cases, Split Shaft Power Take Offs, Specialty Gearboxes COEFFICIENT and other industry leading products and services. We are located in Livermore, California, with operations in High-performance transmission specialist Oerlikon Graziano Livonia, Michigan and Steyr, Austria. shared its extensive knowledge and innovative research tech- We are seeking an energetic and experienced person niques at the World Tribology Congress 2013, in Turin, from to become our Account Manager. This position has September 8-13, stand 56. The event, organized by the Italian a product focus of selling power transmission com- Tribology Association (AIT), occurs every four years and proponents (gearboxes, transmissions and powertrain vides a unique opportunity for discussion of recent develop- drives) to specialty markets such as oil and gas, mining, industrial, marine and specialty vehicle. Extensive ex- ments in tribology and to strengthen the link between research perience is required in sales management and techni- organizations and industry. cal sales support for such products and industries. This “Creating low friction surfaces is a crucial factor in Oerlikon can be a home-office based position with up to 75% Graziano’s development of market-leading transmission sys- travel required. tems, and we intend to share our methods for measurement Please go to our Career Opportunities page at: of the friction coefficient involved in cylindrical gear teeth www.fabcoautomotive.com/careers/index.htm for meshing,” says Oerlikon Graziano Chairman and Managing more details about this career opportunity. Director, Paolo Ramadori. “The effects of gear mesh on transmission efficiency have been estimated with an analytical approach that requires a suitable corrective coefficient calibration: using prototype development, intensive testing and sta- tistical approach — DOE methodology — we are able to deliver a more accurate, proven efficiency model to predict the power losses of transmission systems.” Vincenzo Solimine, Oerlikon Graziano virtual validation engineer and Davide Crivello, Oerlikon Graziano testing engineer, delivered a speech on “Measurement of friction coefficient Accudrive http://www.accudrv.com/index.html involved in cylindrical gear teeth meshing,” at the Congress, [PRECISION GEAR GRINDING] which offered diverse scientific sessions on specific tribology-related topics, a broad exhi- • Spur / Helical up to 59" O.D. – 26" Face bition and various collat- • Accurate quotes – Competitive prices – Fast turn-around tel.773-376 4906 fax.773-376 4946 eral events. It is seen as a • Emergency “breakdown” support crucial knowledge shar- • Support system for OEM parts ing tool that continues • Full complement of testing to promote collaborative equipment for complete opportunities for the and comprehensive ongoing development charting. Calibrated and of technologies. certified on a regular Eco-tribology schedule. and sustain- Trusted by OEM, MRO and ability were Gear Job Shop customers for the primary nearly two decades. focus in this Your project is as important to year’s Congress, us as it is to you. and Oerlikon (773) 376-4906 Graziano’s study of www.Accudrv.com friction, wear and [email protected] lubrication in cylindrical

October 2013 | GEAR TECHNOLOGY 73

1 of 2 9/24/2013 11:25 AM industry news gear teeth meshing has been crucial to its development of gearing, saw cutting of test specimens, tractor/trailer fleet and full boxes and drive systems for EVs and HEVs. Due to efficiency compliance with ISO 9001 certification standards. Workpieces requirements and NVH expectations, this emerging market is to 50 tons are routinely processed, using existing and new crane the most demanding in terms of maximizing the operation of equipment recently installed. driveline components. “Oerlikon Graziano’s calculation code for the efficiency model is all-encompassing and considers both load dependent Dana and load-independent contributions to power losses,” explains EXPANDS GEAR MANUFACTURING Solimine. The activity is focused on the experimental evalua- CAPABILITIES IN THAILAND tion of power losses due to cylindrical gears meshing to obtain a mathematical expression of the friction coefficient. In par- Dana Holding Corporation recently announced it will con- ticular, the parameters under investigation are oil viscosity, the struct a state-of-the-art gear manufacturing operation in most important gear geometry sizes and working conditions.” Rayong, Thailand, to support growing customer demand for Spicer axles in the region. The new Dana facility, scheduled to open next year, will have the capacity to deliver 600,000 Complete Heat gear sets to the region. “Dana is committed to delivering dif- ferentiated innovations for growth markets such as Thailand,” Treating said Mark Wallace, president of Dana Light Vehicle Driveline ACQUIRES WISCONSIN STEEL Technologies. “By expanding our gear development and manu- INDUSTRIES, INC. facturing capabilities in the region, Dana will deliver programs more efficiently, and be equipped to handle projected market Complete Heat Treating, LLC announced the completion of its growth.” For more than two decades, Dana has supported major acquisition of all assets and equipment of the former Wisconsin automakers in Thailand and the region with the production of Steel Industries, Inc. Complete co-owners Jake and TJ Dolhun axles and drive shafts. Major customers include Ford, Mazda, made the announcement. The combined companies boast 75 Nissan, Suzuki, and Tata. Dana currently employees 650 people years of service to the metalworking industry, with substantial at three facilities in the country. Approximately 125 new jobs heat treating and related capabilities. The purchase of Wisconsin will be created to support the expansion. Steel was made by Complete in 2011, with the relocation of all equipment and key personnel having now concluded. Gleason ACQUIRES SAIKUNI MACHINERY

Gleason Corporation announced that it has acquired Saikuni Machinery Co., Ltd., located in Niigata City, Japan. Saikuni is a manufacturer of gear cutting tool sharpening equipment, cutting tool inspection equipment, rack milling machines and other metal cutting and finishing equipment. Saikuni has manufactured certain Gleason products, including Gleason’s BPG Blade Profile Grinding Machine, for sale both in Japan and abroad, and Gleason has worked with Saikuni in selling certain of its products as well. John J. Perrotti, president and CEO of Gleason Corporation, said “Given Gleason’s strategic partnership with Saikuni since 1997, the significance of the Japanese market and our large customer base within Japan, the acquisition strengthens our ability to provide our customers in Japan and the broader region with All equipment from both companies has been consolidat- effective local solutions and support.” ed at the 65,000 square foot Complete facility in Milwaukee, Gleason has a long-standing presence in the Japanese mar- where the highlight is a gas-fired car bottom furnace with a ket through its Gleason Asia Co., Ltd. subsidiary, with sales 53' × 22' × 14' workspace, powered by 40,000,000 BTUs with a and service operations located in Tokyo, Nagoya and Osaka. 1,000,000-pound load capacity and operating temperatures to Gleason will operate the Saikuni business with the current 2,150°F max. management team and approximately 25 employees under the The equipment and services now offered include five car bot- name Gleason-Saikuni Co., Ltd. tom furnaces, five box furnaces, heavy-duty polymer and water quench tanks, stress relieving, sand blasting, prime and finish painting, annealing, normalizing, BHN inspection, straighten-

[www.geartechnology.com] 74 GEAR TECHNOLOGY | October 2013

calendar

October 28–31—Power Transmission and Control November 12–15—Manufacturing Days. Davis, 2013. Shanghai New International Expo Centre, Shanghai, California. DMG/Mori Seiki’s four-day, complimentary event China. Organized by Deutsche Messe, PTC Asia is the continent’s centers around the company’s new highly-automated factory, leading trade fair for electrical and mechanical power transmis- Mori Seiki Manufacturing, and its neighboring research and sion, fluid power, compressed air technology, machine parts, development hub, Digital Technology Laboratory (DTL). Similar bearings, linear motion systems, internal combustion engines in format to DMG/Mori Seiki’s annual Innovation Days event and gas turbines. Sponsors include Bosch Rexroth, Emerson, held in the spring, Manufacturing Days offers machine demon- DMG, Parker, Siemens, EMAG, SKF, Lenze, Tsubaki, ABB, NSK, strations, industry seminars, tours of both the U.S. factory and SEW Eurodrive, Gates and others. An important part of PTC DTL facilities, and California-style wine and dine events. “Our ASIA is the gathering of companies from industries including customers and partners can expect the same caliber of informa- gears, chain transmission, belt transmission, couplings, brakes, tion and hospitality at Manufacturing Days as they’ve experi- electrical power transmission, fasteners, springs and powder enced at Innovation Days,” says Mark Mohr, president of DMG/ metallurgy. It is held in combination with CEMAT Asia 2013, the Mori Seiki USA. “However, Manufacturing Days is unique in that international exhibition for material handling, automation tech- it’s focused more on the latest applications in manufacturing.” nology, transport systems and logistics. For more information, Seminars include presentations from industry and DMG/Mori visit www.ptc-asia.com/EN/. Seiki experts. Topics include the latest in aerospace, automotive and medical machining, sustainability in manufacturing, and October 29–31—South-Tec 2013. TD Convention software and automation implementation. For more informa- Center, Greenville, South Carolina. South-Tec draws manufactur- tion, visit www.mdays2013.com. ing suppliers, distributors and equipment builders from across North America and around the world. With hundreds of exhibi- November 15–21—ASME 2013. San Diego, tors, attendees will find all the products and services needed to California. The annual ASME International Mechanical streamline their various manufacturing processes. Automotive, Engineering Congress and Exposition is a premier global con- advanced materials, energy, aerospace, biosciences plus many ference that focuses on today’s technical challenges, research others are all represented. Over 34 percent of the jobs in the updates and breakthrough innovations that are shaping the Greenville region are tied to manufacturing, drawing a skilled future of engineering. The congress convenes engineers, sci- workforce that invigorates the area with new ideas and a strong entists and technologists of all disciplines for the purposes of entrepreneurial spirit. Panel discussions include workforce exploring solutions to global challenges and for the advance- development, supply chain optimization and a brief manufac- ment of engineering excellence worldwide. The congress will turing overview from the Department of Defense. The Additive feature a technical program that promises to be the most exten- Manufacturing/3-D Printing Resource Center will offer new tech- sive and diverse in the history of the exhibition. In line with the nologies and designs that can help lower production expenses. national strategic initiatives, ASME and the organizers of IMECE For more information, visit www.southteconline.com. have chosen advanced manufacturing as the overall theme for 2013. Technical presentations include aerospace technology, November 6–8—AWEA Wind Energy Fall energy, heat transfer and thermal engineering, systems/design, Symposium. Colorado Springs, Colorado. The administra- advanced manufacturing, education and more. For more infor- tion’s recent commitment to renewable energy initiatives has mation, visit www.asmeconference.org. arrived as the wind energy industry is emerging from a record year in new capacity additions and is moving to design a robust November 18–21—Fabtech 2013. McCormick Place, strategic direction for 2014 and beyond. With that, the AWEA Chicago. North America’s largest metal forming, fabricating, Wind Energy Fall Symposium returns to offer a unique plat- welding and finishing event boasts more than 35,000 attendees form. In 2012 the AWEA Wind Energy Fall Symposium hosted and 1,500 exhibiting companies. Keynote presentations include hundreds of key decision makers, including over 20 CEOs, 50 “Navigating the Fiscal Reality,” and “Accelerating Performance vice presidents, and 55 directors. Now is the time to join fel- through Flawless Execution.” Panel discussions include dis- low executives from across the industry for a stimulating and cussions of the state of the industry, solutions for a qualified thought-provoking discussion on analyzing market challenges, workforce pipeline, a professional welders’ competition and new examining potential solutions, and steering the industry towards product presentations. Pavilions include finishing, stamping, a new phase of growth in America’s successful form of renewable tube and pipe, forming, and fabrication and welding. Attendees energy. For more information, visit www.awea.org. can meet with suppliers, see the latest products/technologies and find the tools to improve productivity and increase profits. November 12–15—AmCon 2013. Suburban For more information, visit www.fabtechexpo.com. Collection Showplace. Novi, Michigan. AmCon is a contract manufacturing expo for all job shops and contract manufacturers that provides custom metal, plastic, rubber or electronic parts and related manufacturing services to OEMs. Attendees include top level purchasing, engineering and production managers who are directly involved in buying custom contract manufacturing services. Representatives from companies of all sizes attend from a range of industries, often with blueprints in hand. The AmCon shows occur regionally throughout the year. Highlights this year include the Power of Persuasion video presentation, new technology seminars and new contract manufacturing services. For more information, visit www.amconshows.com.

[www.geartechnology.com] 76 GEAR TECHNOLOGY | October 2013 12th International Plus: Transmission Expo CTI Symposium Automotive Transmissions, HEV and EV Drives

2-5 December 2013, Berlin Germany 8-11 December 2014, Berlin

Experts in the Plenum

Dr Carsten Breitfeld | BMW AG Dr Herbert Demel Dr Ulrich Eichhorn | German Association of the Automotive Industry (VDA) Dr Robert Fischer | AVL List GmbH Dr Carsten Breitfeld Dr Herbert Demel Dr Ulrich Eichhorn Dr Robert Fischer Jean-Marc Gales Jean-Marc Gales | CLEPA Jörg Grotendorst | Siemens AG Takashi Hata | Jatco Ltd. Bernd Heid | McKinsey & Company, Inc. Mihir Kotecha | GETRAG Corporate Group Jörg Grotendorst Takashi Hata Bernd Heid Mihir Kotecha Thomas Kroher Thomas Kroher | ADAC Motorwelt Max Nakagawa | Denso International Europe Arnold Paluch | Adam Opel AG Coen Rooijmans | Bosch Transmission Technology B.V. Prof. Dr Dirk Uwe Sauer | RWTH Aachen Ulrich Schwarz | Denso International Europe Max Nakagawa Arnold Paluch Coen Rooijmans Prof. Dr Dirk Uwe Sauer Ulrich Schwarz

 Extensive OEM reports Panel discussion  Special sessions 2013: “CO2 Challenge – How to master it?” CVT, Commercial Vehicles, Functional Safety  Delegates from over 20 countries Simultaneous Translation German English  1,700 participants in USA, China & Europe in 2012 English Conference Documentation!  Most international* industry meeting in Europe (* over 40% participants from non-German speaking countries)

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P2300327_Anz_203_273_3mm_Anschnitt_PTE.indd 1 06.09.2013 11:11:55 ad index

3M Abrasives — page 15 Gleason Corp. — pages 40-41 Mitutoyo — page 13 www.3M.com/cubitron2/GearGrinding www.gleason.com www.mitutoyo.com/getgold Accu-Drive — page 73 Grupos Diferenciales — page 11 Moog Inc. — pages 34, 79 www.accudrv.com www.gruposdiferenciales.es moog.jobs All Metals & Forge Group, LLC — page 16 Hans-Jürgen Geiger Maschinen-Vertrieb — page 38 Motion, Drive and Automation North America — page 75 www.steelforge.com www.geiger-germany.com www.motiondriveautomation.com B&R Machine & Gear Corp. — Inside Back Cover Index Technologies — page 79 Norton/Saint-Gobain — page 31 www.brgear.com www.gallenco.com www.nortonindustrial.com/vitrium3 The Broach Masters & Universal Gear — page 27 Ipsen International — page 39 Overton Chicago Gear — page 19 www.broachmasters.com www.ipsenusa.com www.oc-gear.com Circle Gear — page 79 Kapp Technologies — page 3 Presrite Corp. — page 20 www.circlegear.com www.kapp-usa.com www.presrite.com CTI Symposium — page 77 Klingelnberg — Outside Back Cover Process Equipment — page 37 www.getriebe-symposium.de/gt www.klingelnberg.com www.gearinspection.com DMG/Mori Seiki — page 43 Koepfer America — page 79 Proto Manufacturing — page 17 www.dmgmoriseikiusa.com www.koepferamerica.com www.protoxrd.com DTR Corp. — page 23 Liebherr — page 5 Reishauer — page 49 www.dragon.co.kr www.liebherr.com www.reishauer.com EMAG LLC — page 35 Luren Precision Co. Ltd. — page 21 Richardson Manufacturing — page 4 www.emag.com www.lurenchicago.com www.rmc-BIGCNC.com Fabco Automotive — page 73 Machine Tool Builders Inc. — page 4 Schnyder S.A. — page 71 www.fabcoautomotive.com/careers/index.htm www.machinetoolbuilders.com www.hanikcorp.com Forest City Gear — page 7 McInnes Rolled Rings — page 14 Star SU LLC — pages IFC–1, 79 www.forestcitygear.com www.mcinnesrolledrings.com www.star-su.com The Gear Machinery Exchange — page 78, 79 Midwest Gear & Tool Inc. — page 71 Stresstech Group — page 53 www.gearmachineryexchange.com [email protected] www.stresstechgroup.com The Gear Works—Seattle, Inc. — page 79 Mitsubishi Heavy Industries — page 8 Yager Gear Enterprise Ltd. — page 79 www.thegearworks.com www.mitsubishigearcenter.com www.yagergear.com German Machine Tools of America (GMTA) — page 63 Mitsubishi Materials — page 47 www.gmtamerica.com www.mmus.com

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[www.geartechnology.com] 78 GEAR TECHNOLOGY | October 2013 classified

Spiral Bevel Gears

for Electric and Pneumatic Tools, Machine Tools, Agricultural Machinery and Automobiles CareersCareers geared geared to succeed.to succeed. Global opportunities available. GLOBALGlobal GEAR opportunities ENGINEERING available. OPPORTUNITIES AVAILABLE Moog’s motion control technology and products are found around the world Moog’sfrom helicopters motion controlto fighter technology planes and deep and sea products drills to syringeare found pumps. around We the world We’refromfoster helicopters an looking environment to fighterwhere for ourtalented planes11,000 engineersand deepengineers andsea technologists drills to withsyringe feel pumps. We empowered and inspired to achieve remarkable things. The work we do matters, atfoster least an environment seven years where ourof 11,000 experience engineers andin technologists feel as does every single person who works with us. gearempowered manufacturing and inspired to achieve to remarkable join our things. business The work we do matters, We’re looking for talented engineers with at least seven years of experience as does every single person who works with us. iniCareersn gearBaguio manufacturing City, geared to join Philippines, our business to succeed. in Bagui oTorrance, City, Philippines, We’reTorra nlookingce, Califo forrnia talented and Wolve engineersrhampton, U winitthed at Ki nleastgdom .seven If you are years of experience CaliforniainGlobalterested opportunities in joini andng our team Wolverhampton, available. in the Philippines, but are not United a resident there, in gear manufacturing to join our business in Baguio City, Philippines, Kingdom.you will receive housing If you benefits are and interested travel allowance. in joining ToMoog’srrance motion, Calif ocontrolrnia a technologynd Wolve randha mproductspton, U areni tfounded K iaroundngdom the. I fworld you are Tofrom apply, helicopters please send to fighteryour resume planes to [email protected] deep sea drills orto visitsyringe moog.jobs pumps. We ISO 9001:2008 ourinterested team in joiniin ngthe our teamPhilippines, in the Philippines, but but are are notnot a resid ent there, foster an environment where our 11,000 engineers and technologists feel ayou YOUempoweredresident will CAN receive DO and THIS inspiredhousingthere, to benefitsachieve you remarkable willand travel receive things. allowance. The work housing we do matters, as does every single person who works with us. benefitsTo apply, please and send travel your resume allowance. to [email protected] or visit moog.jobs Yager Gear Enterprise Co., Ltd. We’re looking for talented engineers with at least seven years of experience ADD: No. 57, Shigu Ln., Guozhong Rd., Dali Dist., ToYOUin gearapply, CAN manufacturing DO please THIS to join send our business your in Ba gresumeuio City, Philip ptoines , Torrance, California and Wolverhampton, United Kingdom. If you are Taichung City 412, Taiwan [email protected] in joining our team in theor Philippines, visit moog.jobsbut are not a resident there, Tel: +886-4-24076223 EXT. 30 you will receive housing benefits and travel allowance.

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October 2013 | GEAR TECHNOLOGY 79 addendum The Ever-EvolvingApple Parer

Mike Viney’s curiosity about the evolving designs undoubtedly catalyzed of apple parers began after reading the article, by a free market system,” “There’s a Fascination in Apple Parers” by Marion Viney added. Levy, which appeared in the second edition of And the history of these simple Linda Campbell’s 300 Years of Kitchen Collectibles. machine designs is quite intriguing “I also have an early memory of seeing Levy on a PBS news to anyone with a passing interest in program that highlighted early apple parer designs he had col- gears. “A turntable parer known as F.W lected and categorized,” Viney said. “My wife and I bought and Hudson’s Improved Apple Parer with a sold antiques during college and this experience sparked my patent date of Dec. 2, 1862 uses epicy- interest in collecting.” clic gears to rotate the apple around a Viney, intrigued with the human ingenuity stationary blade,” Viney said. “The S.S. involved in apple parers, decided Hersey with patent dates of June 18, 1861 and to create an online muse- Aug. 30, 1864 has a gear mechanism that allows the paring arm um with photos, histor- to switch between two bevel gears rotating in opposite direc- ic facts and videos tions. Thus, apples can be pared in two directions. The Bergner of these ingenious lathe apple parer with a patent date of Jan. 9, 1872, utilizes a devices. rack and pinion gear to move the paring arm over the rotating apple (George Bergner was a gunsmith who served as a Union soldier in the Civil War).” Viney receives many inquiries from his website, particularly from collectors seeking the estimated value of certain apple parers. It also attracts the interest of websites, magazines and pub- lishers seeking apple parer photographs. With so much information on the website dedicated to gears, it came as a bit of a shock to hear that his current science cur-

“During the 18th and 19th centuries, apples were a critical winter staple in the United States. The apple was also a major U.S. export. During the fall season communities gathered in social get-togethers called apple bees to prepare large quantities of apples for winter storage. Preparing enough apples was a monumental task. Farmers created homemade apple paring devices made of wood and sometimes iron to make the job easier. Some of these early designs employed gears made of wood.“ Viney continued, “As America underwent industrialization during the 19th century, the use of iron to produce manufac- riculum doesn’t include a section on gearing mechanisms. tured interchangeable parts acted as a catalyst for the “During my entire career, I have not helped students explore proliferation of apple parer designs.” gears,” Viney said. “My current curriculum does include simple In J. Lambert’s 1991 article, “Some Rare machines, but I have to add information about gears.” Apple Parers,” he notes that more than We won’t hold it against him, since Viney has put together a 100 apple parer patents were website that celebrates science, engineering and includes plenty granted from 1850 to 1890. of gears. Viney, a secondary science “It is my personal belief that those of us in industrialized teacher for the past 27 nations live in a world of prepared immediacy. Everything from years, has collected much fine fitting clothes to food to technology is served to us on of this information for the demand,” Viney said. “How do companies know what sizes to general public at his web- make for clothing, what processes were involved in making my site, appleparermuseum. cheeseburger, how does my car engine work? For many techno- com. “Apple paring was a logical devices, gears are a part of this mystery.” singular problem solved in so many different ways and

[www.geartechnology.com] 80 GEAR TECHNOLOGY | October 2013 BIG GEARS IN-HOUSE STEEL MATERIAL WAREHOUSE STRAIGHT BEVEL GEARS: 80"PD SPIRAL BEVEL GEARS: 66"PD

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TOLL FREE: 800·238·0651 [email protected] · www.brgear.com MACHINE AND GEAR CORPORATION HEADING THE LEAGUE: THE NEW WINNING TEAM BY KLINGELNBERG

KLINGELNBERG OERLIKON HÖFLER MEASURING TECHNOLOGY BEVEL GEAR TECHNOLOGY CYLINDRICAL GEAR TECHNOLOGY

Heading the league requires real key players, that live the team MEASURING CENTER P 40 spirit. That’s what all departments of Klingelnberg do every day. ¾ Enhanced measuring technology: As a result, from today three great strikers raise the bar in gear Even more precise measuring results due to groundbreaking improvements manufacturing. All our disciplines – bevel gear technology, cylindrical gear technology and measuring technology – are prepared CUTTING MACHINE C 30 to score in a long run. ¾ New unique operating concept: Simplifying the manufacturing process With each of our brand new innovations, gear manufacturers due to an easy-to-use touchscreen display all over the world will have a walk-over in their markets. GRINDING MACHINE VIPER 500 ¾ Highly versatile: Play up eld: KLINGELNBERG America, Inc. Retooling from proﬁ le grinding to www.klingelnberg.com p. +1 734 470 6278 generating grinding within short time (VIPER 500 W) www.ho er.com e. [email protected]

MEASURING TECHNOLOGY BEVEL GEAR TECHNOLOGY CYLINDRICAL GEAR TECHNOLOGY SUBJECT TO CHANGES.

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