2018/2019

solutionsgear manufacturing technology magazine

Bright Future Smart. In sight with digital services employing AR technology. The Evolution of At the Speed of Light Chamfer Cutting Innovations in Hard Power Skiving, non-contact laser inspection, and Closed Loop manufacturing. Customer Success Metalcastello meets surging demand with Power Skiving. Welcome to Gleason

Dear Valued Customers:

You’ve heard it called Industry 4.0 or perhaps the Smart Factory – the convergence of new digital technologies that are fast re-shaping the way we make things. Like those that came before it, this latest industrial revolution is creating considerable upheaval, as well as enormous opportunity for new products that work intelligently together to reduce John J. Perrotti downtime, improve quality and deliver a host of other benefits. President and Chief Executive Officer We call that Smart.

It’s an exciting time at Gleason. With the industry’s approach that optimizes the production process by most comprehensive array of solutions we’re helping networking Gleason Power Skiving machines directly with our customers benefit from smart new technologies in Gleason GMS® metrology equipment. Measurements every gear manufacturing category. We’re leveraging and the resulting corrective actions are fast, accurate and breakthroughs in digital, Augmented Reality, laser, automated. software, designs and innovative processes to meet long- Our Gleason 4.0 solutions have four families: gUptime, standing – or brand new – gear design, production and gProcess, gProduction and gTools. We are developing inspection challenges. the digital world for gearing around these families. The As our Cover Story suggests, we’re leaving no stone goal: zero planned downtime, connectivity from design to unturned. With the addition of a new Chamfer Hobbing production and inspection – and most of all, extraordinary process, we now have expanded our array of integrated, value for our customers. automated and productive chamfering solutions to reduce Exciting developments are taking shape in gear, gearbox cost and improve quality. and drivetrain design as well. A new interface connecting We have truly revolutionary advancements with our GMSL our KISSsoft and GEMS software empowers designers multi-sensor Inspection System, which uses non-contact with new product optimization tools. We also continue with laser scanning to acquire massive amounts of data at solutions to better link design and production. rapid speed compared to tactile probing, opening new …And much more. We’re excited about what the future frontiers in gear analysis. With the new GRSL, we’ve holds. We hope you partner with Gleason when taking the employed the same non-contact laser scanning technology next step down this smart new technology path. for in-line inspection.

Hard Power Skiving has become an economical option for fine finishing, and includes a Closed Loop systems

2 Welcome to Gleason Features 2018/2019

04 Cover Story: The Evolution of Chamfer Cutting

08 Bright Future In Sight With Digital Services 04 10 Power Skiving as a Hard Finishing Alternative

12 In-Process Gear Inspection at Light Speeds 08 14 New Technology Center in Switzerland

16 Precision Segmented Collets Improve Workholding Life 10 18 Pentac®Mono for Bevel and Hypoid Gear Sets

21 Dressing Tools for Grinding and Honing Applications 12

22 Powerful Gear Design

24 Spheric® Power Honing With the New 150SPH 14

26 Metalcastello/Italy: Adding Power Skiving to Meet Surging Demand

29 IT S.A./Switzerland Improves Machine Performance with 22 Gleason Global Services

30 KHK/Japan Sets the Standard in Stock Gears 24

26 © 2018 Gleason Corporation. All Rights Reserved. SOLUTIONS is published regularly throughout the year, and distributed worldwide. Please address correspondence to: Christian Albrecht, Editor, SOLUTIONS. Gleason Corporation. 1000 University Ave., P.O. Box 22970, Rochester, NY 14692-2970 U.S.A., 585-473-1000 • Fax 585-461-4348 • www.gleason.com • e-mail: [email protected]

3 Cover Story

The Evolution of Chamfer Cutting New Genesis® 160HCD Hobbing and Chamfering Machine adds Chamfer Hobbing to integrated chamfering and deburring solutions.

utomotive gear manufacturers potential for sharp, brittle edges after Chamfer Solutions for Every A in particular recognize that heat treat, as well as to avoid material Application premature transmission failure, plus conditions in the tooth flank prior to At Gleason, we’re working to offer less-than-optimal fuel efficiency, or the hard finishing operations. these manufacturers chamfering and unacceptable noise can result from Chamfering and deburring are deburring solutions that are just as easy application of transmission gears particularly critical in advance of the to apply as the primary soft and hard operating with anything less than honing process, where excessive processes. With our latest Genesis® a flawless tooth flank. For these stock and hardened burrs can greatly series of hobbing and chamfering manufacturers, generating a chamfer diminish honing tool life and, as a machines, we give users the ability to to precise customer specification for result, significantly increase cost per apply the optimum chamfering process size, shape and angle is of critical piece. for their particular application – up to importance in order to minimize the and including truck-size gears.

4 Cover Story Cover Story

The new Chamfer Hobbing process offers an extremely effi cient solution to create the desired chamfer without secondary burrs.

Chamfer rolling, available on the Chamfering is performed using a those commonly produced in the Genesis 210HiC Hobbing Machine Gleason Chamfer Hob, with diameters chamfer rolling process are also easily and horizontal P90CD, is ideal for similar to a gear hob, made with the achievable. planetary pinion applications requiring latest high-speed steel materials like In the Chamfer Hob design process, particularly fast cycle times (10 seconds G50 and featuring AlCroNite®Pro Gleason software is used to identify or less chip-to-chip) or for shafts with coating for exceptional tool life in dry and avoid all potential collisions of the little or no clearance below the root cutting conditions. Gleason Chamfer tools with the counter flank and with diameter. The formation of a secondary Hobbing employs one Chamfer Hob interfering contours above and below burr requires removal by an additional for each tooth flank, with a tooth profile the actual gearing. operation downstream in advance of a which is specifically designed for the subsequent honing operation. particular chamfer form to be realized. Finally, the Gleason Chamfer Hobbing process offers tool shifting which, as As an alternative, Gleason now offers a This design delivers greater flexibility – compared to competitive processes, new process called Chamfer Hobbing. It comma or parallel-chamfer forms are delivers increased tool life and minimal delivers, in parallel to hobbing, long tool possible as well as chamfers along change times resulting in lower cost- life cutting dry, and does not generate the tooth edge only, or including per-piece. a secondary burr requiring removal the root area. Chamfer angles like downstream.

Chamfer Hobbing for Lower Cost Per Workpiece The new-design Genesis 160HCD combines the proven Genesis vertical hobbing platform with an integrated chamfering/deburring station to perform the Chamfer Hobbing process in parallel to hobbing, and thus achieving cycle times that satisfy the requirements for automotive MT, DCT, and electrical spur gear transmissions. A high speed 2-position gantry loads the workpiece for hobbing, transfers the workpiece to the chamfering station and then delivers the finished workpiece to the parts conveyor.

5 Cover Story

Contour Milling: Mastering Chamfers on Larger Gears

Chamfer Contour Milling offers producers of larger, ‘truck-size’ gears a fl exible, easy and economical process for their increasingly important chamfer/deburr operations.

hile chamfering gets increased generally a star-shaped body with 2-4 the chamfer size and angle depends W focus with automotive-size standard, replaceable indexable carbide on machine movements and not on gears, effective solutions for larger, inserts – contour mills the chamfer with the tool design, the process is quite ‘truck-size’ gears are becoming nearly the desired characteristics. universal. It can, with only a few set as important – and more readily of indexable carbide inserts, cover The Chamfer Contour Milling process available. parts ranging from module 2.5 mm is similar to hobbing in that it is to the maximum machine capacity of The new continuous ‘fly cutting’ continuously indexing and creates a module 8 mm. The process enables process offers significant advantages cutter path that envelopes the tooth just a relatively few different standard for improving chamfering flexibility as geometry from the outside of the part insert blade sets to accommodate a well as reducing machine and tooling in. All six axes in the chamfer unit are wide range of gear sizes, geometries costs as compared to chamfering on a used during generation of the tool path, and chamfer requirements. Due to the dedicated, stand-alone machine. The and the tool seeks to use the straight size of the cutter some clearance below continuous fly cutting process, called side of the indexable blades to optimize the root diameter is necessary to avoid Chamfer Contour Milling, generates a the process. The result is a faceted collision. This requested clearance chamfer along the gear edge contour by chamfer finish, similar to the finish after depends on chamfer angle, root synchronizing fly cutter and workpiece a hobbing process. Since each edge chamfer requirements and tool diameter. rotation such that the fly cutter – of the tooth is done separately and

6 Cover Story Cover Story

Therefore best results with this chamfer While available for wet cutting, the contour milling process can be expected 400HCD is also optimized for dry with disc type parts or shaft type parts hobbing and chamfering. A machine with some distance between the root bed with steep angles and large diameter of the gear and the shaft itself. openings directs hot chips away from machine components. Additionally, hob head and workpiece spindle Genesis 400HCD Hobbing and speeds can accommodate the latest Chamfer Contour Milling Machine tool materials like G50 or even G90 ® While fly cutter chamfering has long with AlCroNite Pro coatings for high been successfully employed on performance cutting. bevel gear cutting machines, it has Designing the machine for dry hobbing just been adapted for the first time also enables the chamfer process to as a viable chamfering process for run dry without limits. Chamfer Contour cylindrical gears on Gleason’s new Milling is a process where fl exibility, Genesis 400HCD Hobbing Machine, low tool cost and high tool life match designed for workpieces up to 400 mm perfectly with dry cutting. Fly cutter with indexable carbide inserts for outside diameter and module 8 mm. economical chamfering. The optional Chamfer Contour Milling station, positioned at 90 degrees to the In Summary main hobbing work area, allows parallel hobbing and chamfering processes to It's fortunate that, today, manufacturers application – from small pinions produced increase productivity. A four-station ring now have a variety of integrated and with the shortest possible cycle times, loader transfers workpieces between automated chamfer/deburr options through automotive-type gears and the machine’s central worktable and the available, whether the well-proven shafts, up to truck-size gears and job chamfering/deburring station, which is chamfer rolling process, or these newest shop applications. These are complete equipped with the aforementioned fly Chamfer Hobbing and Chamfer Contour solutions as well, including machine, cutter. The new software interface allows Milling processes. Better yet, Gleason tooling and application expertise. an easy and fast learning experience for hobbing machines are available with smooth set up and operation. the right chamfer process for every

Gottfried Klein Director of Product Management Hobbing, Chamfering and Shaving Gleason Corporation

Chamfer Contour Milling in parallel to gear hobbing on the 400HCD does not add cycle time.

7 Digital Service Digital Service

Digital Service: Bright Future In Sight

Gleason digital service technologies solve service problems on the fl y – or even before they occur. End result? Uptime like you’ve never seen.

ne of your machines is down, and Reality to project documents onto the Gleason on to develop two new ‘digital’ Othe clock is ticking. You’re losing glasses and highlighting or labeling service technologies that will make a precious production time and putting certain components in the technician’s quantum leap in service speed and a tight customer delivery date at risk. field of view. Your machine’s up and efficiency: Your Gleason service technician arrives, running again in a fraction of the time it but it could take hours to diagnose the used to take. problem, communicate with support Gleason Connect+ staff at the Gleason factory, and then Gleason Connect+ is based on the implement a remedy. The Future of Service Has Arrived familiar Gleason remote service concept. Or not. Gear manufacturers have high This service option was installed across expectations for their advanced new the board as long ago as the 1990s, Fortunately, your Gleason service production machines. They’re capable using MS Windows. The new feature technician is equipped with a pair of of delivering performance far in excess with Gleason Connect+ is the service Gleason Smart Glasses. The glasses of what was possible just a few years referred to as “Augmented Reality”. are equipped with a bi-directional before. Gleason's customers expect The core of this innovation is formed communications capability that enables these machines to be up and running by Smart Glasses with a viewing field the service technician to deliver live productively around the clock – onto which information can be projected. imagery and voice communications to and there’s little tolerance for any Projection options range from the the support staff at the factory. Now, extended period of downtime, whether highlighting of individual components to they’re already working together to for unexpected service or routine the transmission of complex suggested quickly identify the problem. The support maintenance. The recognition of this solutions. It puts office-based Gleason staff then guides the technician through new service paradigm has spurred service staff in a position either to help the service process, using Augmented

8 Digital Service Digital Service

Gleason Fingerprint user interface. Clear graphical display allows for rapid identifi cation of faults.

the customer directly or to support the Augmented Reality has enabled comparison of the machine’s current Gleason customer service engineer Gleason to create a win-win-situation: status and the ideal/normal status on on site with information and additional noticeably shorter machine downtimes the user interface of Gleason machines. documentation. In collaboration with for the customer and a Service Fingerprint information can then result customers or the engineer, a problem can Organization which can work much in faster, more detailed diagnostics and thus be detected more quickly, reducing more effectively. more proactive service actions. system downtime to a minimum. This new diagnosis tool, unique to Gleason, is the starting point for Gleason's vision for the future: to move away from the conventional reactive servicing model toward status-based and, eventually, anticipatory/predictive maintenance. The eventual goal for this development is intended to be the Gleason Fingerprint™ “smart machine”, where the machine Similar to a human’s fingerprint, is capable of completely automated machines have a specific mechanical and continuous self-diagnosis. Direct fingerprint too. It’s unique to the transmission of all the necessary data machine, and can show the machine’s for servicing/repair then takes place true condition. Gleason Fingerprint is automatically and without service based on the well-known Kilometer Zero intervention at the ideal time – before a Test. It can be used to retrieve a direct fault can happen.

‘Digital’ isn’t just for new machines. Gleason Connect® is available for older machines, with installation of Robert Peyr the Gleason Connect® box, which Product Manager digitally connects your machine to Global Services Gleason Global Services for remote analysis and troubleshooting.

9 Power Skiving

New Frontiers for Power Skiving

Power Skiving is the new competitive alternative for hard fi nishing, with the potential for major savings.

hat began a few years ago as Effective Machining of Small Internal outstanding choice for machining W a promising, but specialized, and External Gears both shafts (Figure 1) and internal process alternative for cylindrical gears gears. Furthermore, the 100PS can be Internal and external gears with small with challenging interference contours equipped with an integrated chamfering/ overrun space can be produced more is now exceeding performance and deburring station for external gears. economically than shaping using the application expectations. There are now The chamfering process is interpolated 100PS, the smallest machine in the Gleason Power Skiving solutions for before the final cut and helps achieve Gleason Power Skiving family. In soft cutting and hard finishing of internal finished machining quality afterwards. the case of external gears with small and external gears and for machining For internal gears, the 100PS has a overrun space, Power Skiving may shafts, worms and special profiles such patented deburring unit which can be even outperform hobbing, since small as cycloidal gears, as well as for gears programmed via 2 NC axes. As a special hob diameters actually impede the as large as module 9 mm and diameters feature, the machine provides the option efficiency of the hobbing process, while up to 800 mm. for skiving worms (Figure 2). highly productive Power Skiving cutters Getting here hasn’t been without its with relatively large diameters can challenges. Power Skiving places instead be used. Medium and Large-Sized Workpieces considerable demands on the overall The horizontal arrangement of the With Integrated Deburring system of machine/clamping device/tool/ workpiece axis and equipment with process. The best possible result can For medium and large-sized workpieces a tailstock make the 100PS an only be achieved if these elements are up to 800 mm in diameter and module 9, working in harmony with one another and the system as a whole has the necessary stiffness. Gleason has worked hard to put the complete system in place: process simulation, production machines and metrology equipment, workholding, tools and support services – all working in concert. Fig. 1 Fig. 2

10 Power Skiving

there is a whole range of Gleason Power Machine Power Skived Part Skiving machines, from the 300PS to the 600PS, which can be expanded to a diameter up to 800 mm. The machine concepts with extreme stiffness are perfectly complemented by modular workholding equipment in various sizes. The precision and reliability of the overall system results in shorter cycle times, as well as Closing the Loop... outstanding gear quality and surface finish. Not only can cycle times be Feedback of reduced by a factor of 2 to 5 (depending Measured Results on the application) but, when compared to gear shaping, tool cost per workpiece is significantly reduced as well.

Hard Power Skiving: Attractive Alternative Gear Inspection The demand for quieter gear boxes and higher torque increasingly require finishing of hardened gears. Now, for Inspection Sheet the first time, Hard Power Skiving brings economical hard finishing solutions to the small to medium-sized internal gears market. Tooth space position is detected systems, including solid carbide or PM Closing the Loop on Quality with the stock dividing sensors – similar tools, as well as indexable carbide-insert Finally, the Gleason Closed Loop to those on grinding machines (Figure cutting blades, are incorporated in these method optimizes the production 3). The combination of the extremely stiff Power Skiving solutions. process by networking Gleason machines with direct drives, simulation Power Skiving machines directly with software, process expertise and modern Gleason GMS® metrology equipment. carbide tools combine to achieve Simulation Software Measurements and the resulting quality and surface finish levels that are Most importantly, Gleason Power Skiving corrective actions are fast, accurate perfectly adequate for the majority of technology and simulation software (Fig. and automated. finishing applications. 4), enables the end user to simulate the entire skiving process in advance Despite significant and sustained to determine the most effective process progress in recent years, the potential Power Skiving for Bevel Gear Cutting strategy and tool design. The simulation of Power Skiving is far from exhausted. Machines software analyzes the impact of various It will be exciting to see where Gleason It is also possible to install Power tool geometries and process parameters goes from here. Skiving onto the current generation of on chip formation, gear-cutting quality Gleason bevel gear cutting machines and the collision situation, as well as with an expansion package. Various tool effects on cycle time.

Udo Stolz Vice President Worldwide Sales and Marketing Gleason Corporation

Fig. 3 Fig. 4

11 Non-Contact Laser Inspection

In-Process Gear Inspection at Light Speeds

New GRSL technology adds value to high volume transmission gear inspection by combining revolutionary non-contact laser inspection with tried-and-true composite roll testing.

leason Metrology Systems is in most high volume gear production G racing to keep pace with the where 100% inspection is required. This inspection challenges that now exist new product follows the strategy of the for today’s gear manufacturers and, recently introduced multi-purpose GMSL ultimately, to add value with new non-contact inspection system from technologies that improve accuracies, Gleason: the industry’s most powerful cycle times, capabilities and ease of use. multi-sensor instrument for gear inspection and process development. Where the GMSL was developed to GRSL: Bringing Non-Contact to High exceed the requirements of today’s most Volume stringent gear processing research, development and reverse engineering The most recent example of where all needs, the GRSL brings high accuracy, of these ‘added value’ user benefits high speed, non-contact measurement have converged in a single technology: of gears in-process to the high volume GRSL combines the latest the new Gleason GRSL Gear Rolling production environment, where non-contact gear analytical System with non-contact laser inspection. measurement innovation with the performance expectations have never GRSL combines the latest non-contact double fl ank roll test gear inspection been higher. gear analytical measurement innovation process, including nick detection, to deliver with the tried-and-true double flank roll The new, powerful GRSL product unprecedented in-process inspection speed and fl exibility for cylindrical gears up to 250 test gear inspection process used today stays true to the strategy Gleason's mm in diameter.

12 Non-Contact Laser Inspection

Non-contact (laser) index and profi le inspection can be performed on all the gear teeth in a matter of just 10 to 15 seconds, as compared to several minutes when done conventionally. Develop New Gears partner customers continue to ask for. the involute and index measurements, Faster with GMSL It adds value by adding measuring with common charting as seen on the capability with multiple sensors on a GMS line of analytical machines in use GRSL joins GMSL®, the industry’s first common platform to reduce cost of throughout the gear industry. non-contact multi-sensor inspection ownership, the number of operators system with both cylindrical gear Consider the possibilities of full, high required and the footprint. In addition, and bevel gear measuring capability. speed involute and index measurement it adds throughput by measuring both GMSL is a true gear design and in process, inline. Add to that the ability the composite, functional error and development tool that combines to network this data in a closed loop the individual part characteristics of the data acquisition speeds of configuration directly to the machine both involute and index simultaneously non-contact laser scanning with the tool using Gleason Connect® to during the same revolution of the gear complete gear inspection capabilities communicate results that can assist during the test cycle. inherent in Gleason’s standard line of in determining necessary changes to GMS gear inspection products. the machine tool, the cutting tool, part setup, etc. All of this is now available, Single Platform, Exciting Possibilities fully integrated with the traditional double flank roll, composite testing still This patent pending, dual purpose thus delivering significant throughput called out on most part prints today in inspection system provides additional value. The GRSL also offers the high volume gear production. value by offering the versatile GRSL flexibility of operating the analytical platform in three different configurations and composite, double flank tests for use as a stand-alone manual gauge, independent of one another if desired. a semi-automatic gauge or even as Faster Cycle Times, Greater This can offer advantages such as a fully automated gauge where high Throughput extending the life of the master gear if, for volume throughput is the priority. Tests The possibilities are exciting to think example, it is determined that not all parts for full analytical results of both involute about and the capabilities continue require double flank composite testing. and index are performed on all teeth to grow. Measurements of analytical for most external, cylindrical gears characteristics are typically taken on up to 250 mm diameter in a matter a dedicated, stand-alone analytical of seconds along with the composite machine in a lab or on the shop floor, double flank roll test, with both tests not inline. This typically takes several taking place simultaneously. minutes for a sampling of teeth for With the new GRSL, the power of high involute measurement and all teeth speed involute and index measurements for index. The GRSL offers analytical Douglas Beerck Vice President and also comes with the ability to integrate measurement of all teeth in a matter of General Manager with Gleason Metrology’s GAMA gear seconds, with many tests completed Gleason Metrology analysis and charting output. This means in 10 to 15 seconds, and provides Systems options for AGMA, DIN, ISO as well as the double flank composite test data OEM specific analysis are available for simultaneously, including nick detection,

13 New Facilities

Gleason-Pfauter Studen Leaps Forward

Gleason-Pfauter Studen's new Technology Center keeps pace with growing global demand and exciting strategies for future growth.

fter one year of planning and Gleason will produce horizontal and needs of a modern machine builder A preparation followed by a year vertical hobbing machines for gears with has been a huge leap forward, of construction, the Gleason-Pfauter diameters up to 250 mm, including the according to Gleason-Pfauter Studen Studen operations have relocated to existing product portfolio, the Genesis General Manager Rudolf Moser. “New an advanced new Technology and series and future machine developments technologies, including Power Skiving, Manufacturing Center located just as well as automation solutions. are driving great interest and business a short distance from the previous opportunities from our customer base,” Moving into a work environment that building in Studen, Switzerland. Here, says Mr. Moser. “Our success is a has been tailored to suit the exact credit to our employees. Through their efforts our business continues to grow each year. Our new factory will create an even better environment to further develop new products and technologies and continue producing the highest quality machines.” The new building’s footprint expands office space by 30% and machine assembly capacity by almost 60% compared to the previous premises.

14 New Facilities

The assembly area has grown in height About the New Gleason-Pfauter Studen to fit an optimized storage of pallets and create the possibility to directly load Technology and Manufacturing Center machines from assembly floor to heavy trucks inside the building. Even with Location: Customer Benefits: the larger footprint, Gleason-Pfauter ▪ Studen, Switzerland ▪ Standardized, highly efficient continues to optimize material flow and assembly methodologies. work processes. Special attention has Resources: ▪ Robust quality systems to drive been paid to the carbon footprint of the ▪ Hobbing, Profile Grinding and continuous improvement. new facility, utilizing energy-efficient Power Skiving machines. construction materials, integrating ▪ Optimized capacity utilization to ▪ Automation solutions. thermal insulation and installing an air- help meet and exceed customer based heating system. Energy savings ▪ Full customer service and expectations for delivery. are expected to be significant, with training support. 100% of the plant’s energy needs met from renewable hydropower.

In the LEED at Gleason Works (India)

leason is proud to announce Gthat, just a year after the Grand Opening of the ultra-modern new Gleason Works (India) factory in Bangalore, the facility has been awarded the prestigious LEED (Leadership in Energy and Environmental Design) Platinum Certification. LEED is the global 'standard' for recognizing the level of sustainability, efficiency and cost- savings achieved by "green" buildings. A Platinum rating is the highest of four LEED certification levels, and a measure of seven key criteria that Bangalore has excelled at, including: 1. Site: 4. Materials and Resources: 7. Regional Priority: Construction pollution prevention Track and monitor waste during Purchasing local Hardscape and softscape efficiencies construction “The building was constructed with Water harvesting Recycled content a target of LEED Silver or Gold certification, but with the addition of a 2. Water Efficiency: 5. Indoor Environmental Quality: rooftop solar (photovoltaics) system to Low VOC paints and flooring Water conservation and treatment over meet a significant part of the facility’s 40% Fresh air – 30% extra energy needs we were able to achieve 3. Energy and Atmosphere: 6. Innovation in Design: the highly sought-after Platinum level,” High performance glass, HVAC systems, Solar (Photovoltaics) says Tom Sawyer, Gleason Cutting Tools Facility Manager and Project LED lighting Water use reduction – exemplary Leader of the construction project. “It’s performance truly a testament to Gleason’s global commitment to sustainability.”

15 New Workholding Solutions

The New Blue: Improving Workholding Life

Gleason’s new Segmented Collets deliver exceptionally reliable, accurate and ‘universal’ bore clamping for a very wide range of cylindrical (and some bevel) gear production applications.

ear manufacturers today must so a single collet can accommodate a Gturn on a dime to meet fast- range of bore diameters, thus helping changing customer demand and to reduce both equipment cost and marketplace conditions with faster the non-productive time needed for production of smaller lot sizes. More changing over less flexible workholding. frequent part changeover has fostered These segmented collets are typically the development of workholding composed of an assembly of high- systems with quick-change, often strength steel segments bonded tool-less designs to take increasingly together with rubber utilizing an valuable non-productive time out of injection molding process. This steel/ the process. This new gear production rubber assembly delivers both a wider paradigm has also exposed the range of expansion than steel alone inherent weaknesses of conventional and, additionally, vibration dampening. I.D. clamping devices that lack flexibility Typically, the collet is expanded and/or reliability – and created an (chucked) or contracted (de-chucked) opportunity to greatly improve overall by an expander that’s actuated by a clamping performance.

Segmented Collets Made More Reliable Workholding systems using segmented collets that expand to center and clamp in the gear bore bearing diameter are among the best solutions for today’s small-batch, diverse-part production environments. Their expansion range inherently offers users greater flexibility,

16 New Workholding Solutions

drawbar connected to the production common sizes for automotive gear machine. As the expander pulls down it manufacturers and many others. Each causes the collet to expand and produce configuration delivers a particularly a particularly rigid radial face clamping/ wide expansion range of up to .76 pull back effect on the workpiece. mm so that fewer sizes are needed to accommodate a wider range of bore But the composite metal/rubber clamping applications – cylindrical, as construction that gives a segmented well as some bevel gears. The outside collet its wide expansion range also diameter of the collet blanks can also be exposes an Achilles heel: reliability. Over easily and quickly ground to a specific time, after thousands of chuck/de-chuck customer size. It’s the closest thing yet cycles, excessive wear and runout often to a ‘universal’ segmented collet design. become evident. These conditions can be further exacerbated by what’s known Even more compelling is the new as ‘over-chuck’, or when chucking is product’s exceptional performance. initiated without a gear blank in place. In order to minimize or eliminate Excessive runout can result from just altogether the potential for excessive one or two instances, not to mention wear, fatigue and runout, Gleason causing the collet to break. started development with a clean sheet, and employing both FEA and the most In response, Gleason’s Tooling Products rigorous lifecycle testing using test Group has developed a completely new fixturing to cycle prototypes through a segmented collet that combines highly simulated chucking/de-chucking cycle desirable flexibility with exceptional Segmented collets give workholding maximum over one million times – or many times accuracy and reliability. Only eight wear life; with sizes and an expansion range what could be expected during the different configurations of the new covering the bore clamping requirements of average life expectancy of the product. Gleason single-angle Segmented Collet the most common cylindrical – and some In fact, over the course of a million bevel – gear types and sizes. are needed to cover bore diameters cycles or more, these new Segmented ranging from 20 to 100 mm – the most Collets showed no evidence of excessive wear or fatigue – with runout never exceeding 5 microns. The process helped validate the Today, Gleason is rolling out Segmented new design and, most importantly, Collets in conjunction with many of its proved that the proprietary new existing workholding systems, including injection molding process that Gleason the latest quick-change models, developed with its supplier would and for use on all types of Gleason eliminate the potential for the rubber and non-Gleason gear production elements that are injected between the machines. Customers will have ready steel segments from ‘dis-bonding’ with access to these products quickly and the steel segments and causing the on-demand from strategic Gleason collet to fail. Additionally, the proprietary locations worldwide, where they can rubber ‘recipe’ developed for the rubber be easily ground to specific customer elements exceeded expectations and requirements and delivered in a matter the criteria set for characteristics like of just a few weeks. elongation, hardness, sensitivity to changes in the environment, stability, and even its distinctive blue color.

Tim Zenoski Director, Global Gleason quick change workholding solutions Product Management, Workholding for both cylindrical and bevel gear bores now feature a new segmented collet that greatly The Gleason Works improves clamping reliability, fl exibility and accuracy.

17 Pentac®Mono

In a Class by Itself

Bevel and hypoid gearsets which are hard fi nished by grinding are fi rst semi-fi nished with the single indexing face milling process, requiring greater effi ciency and cost effectiveness. Enter the Pentac®Mono-RT.

hen the full profile cutter blade each blade acts as an inside as well as between inside and outside cutting W system (center in Figure 1) was an outside blade promised a duplication edge because they are part of one introduced, the manufacturer hoped of cutting efficiency. blade. The unfavorable chip formation this was the solution for highest chip requires high cutting forces leading The practical experiences with full removal effectiveness compared to the to severe part heat up and high profile blades revealed several inside-blade, outside-blade system (far temperature drop between first and disadvantages which had not been left in Figure 1). The idea of using the last cut slot (red temperature labeling anticipated. It began with cutter head same blades in all the cutter head slots in Figure 2). Also the phenomenon of building, which can only achieve appeared tempting and the fact that chip packing between two consecutive an averaging of the radial errors

Fig. 1: Three different systems for chip removal.

Vcut Vcut Clearance Vcut Gap Chip Wedge Angle Connected Chip Wedge Cutting Side Neutral Chip Neutral Angle Front Front Clearance Face Face Side L-Chip Equal Wedge Full Profi le Chip Equal Wedge Angle 1st Mono-Blade Angles (Outside) Outside Blade 1st Full Profi le Blade Clearance Wedge Chip Connected Chip Gap Wedge Angle Chip Angle Clearance Side Neutral Neutral Cutting Front Front Rolled Up Side Face Face Side Chip Partial Profi le Rolled Up Equal Wedge Chip (Generating) Equal Wedge 2nd Mono-Blade Side Chip Angle Angles (Inside) Inside Blade 2nd Full Profi le Blade

18 Pentac®Mono

Full Profile Blade System Inside-Blade/Outside-Blade System

43°C/32°C 110°F/90°F

54°C/41°C 35°C/29°C 130°F/105°F 95°F/84°F

68°C/49°C 29°C/25°C 155°F/120°F 85°F/77°F

85°C/57°C 24°C/21°C 185°F/135°F 75°F/70°F

105°C/65°C 18°C/18°C 220°F/150°F 65°F/65°F

Fig. 2: Compare the part temperatures generated by the full profile blade cutter head versus the inside-blade/outside-blade Pentac®Mono-RT system. The full blade system results in chip formation requiring high cutting forces and causing severe high part temperatures that impact part quality and cutter tool life. By contrast, the Pentac®Mono produces far less process heat. blades appeared more frequently than milling cutter system was developed either an inside or and outside blade. experienced with the traditional inside- with the Pentac®Mono-RT. Just like the Building and truing of Pentac®Mono blade, outside-blade cutter system. full profile system, the Pentac®Mono cutter heads is done fully automatically requires only one type of identical with the Gleason 500CB Cutter Build blades for all cutter head slots (shown and Truing Machine. Via network, the The Mono Blade Breakthrough far right in Figure 1). The clearance actual cutter summary, as well as all gap which is achieved by stepped slot cutter head specific data, is transmitted A technologically sound solution for an bottom radii alternates from one slot to to the 500CB. Because of the radial advanced and highly productive face the next and makes the identical blades blade positioning principle in the

19 Pentac®Mono

Figure 3: Automatic building and truing of Pentac®Mono with 500CB. Figure 4: Phoenix 280CX after cutting with 7.5" Pentac®Mono-RT cutter head.

Pentac®Mono cutter head, a perfect Hardac cutter heads were radially Ultimately, all the Pentac®Mono-RT radial truing can be achieved during the truable and provided a large range of advantages result in an increase of part automatic cutter build operation. radii to be covered with one specific quality, improved blade summary and cutter size by utilizing parallel spacers cutter logistics and a reduction of the Although the Pentac®Mono blades all between slot bottom and blade. In tool cost per part by about 50%. have a zero degree side rake angle, order to achieve similar flexibility, new the cutting edges act sharp due to an Pentac®Mono cutter heads also feature increased top rake angle. The chips parallel spacer elements with a prismatic roll up very compact and exit the space profile which allow covering a range of between two consecutive blades before up to 10 mm radius change. the same blade enters a slot again. The cutting forces of Pentac®Mono are Pentac®Mono cutter heads use the same lower than the forces of the full profile blade summary for inside and outside system. Lower cutting forces and less blades, are radially truable and cause Dr. Hermann J. chip deformation work result in an up to lower process heat than cutters with full Stadtfeld 40°C reduced temperature step between profile blades. Lower cutting forces and Vice President first and last cut slot. In connection with the elimination of chip packing results in Bevel Gear Technology the low cutting edge runout of radially a smooth cutting process which makes Research & Development trued Pentac®Mono cutters, the cutting Pentac®Mono the ideal cutter system for process runs very smooth and delivers face milling. At the end of a tool life, the Gleason Corporation high surface finish and improved blades in outside slots are only worn on spacing. A view of a Pentac®Mono 7.5 the outside cutting edges and the blades inch cutter head in the work chamber of in inside slots are only worn on the a Phoenix® 280C after cutting a ring gear inside cutting edges. In most cases of Uwe Gaiser is shown in Figure 4. pinion and gear cutting it will be possible Dipl.-Ing (FH) to “switch” the blades from outside to Director Product Pentac®Mono is, for the future of inside slots and vice versa in order to Management stick blade cutter heads, a major step run a second tool life without re-grinding Bevel Gear Solutions forward, comparable to the Hardac® and re-coating of blades. Gleason Corporation cutter system breakthrough for side relief arc ground blades back in 1960.

20 Diamond Dressing Tools

New Dressing Tools Work Harder

Productive new dressing tools that last longer and produce better quality are vital to hard fi nishing processes such as honing and continuous generating grinding.

n hard gear finishing operations Geared Up for Honing For prototypes, universal dressers can manufacturers naturally tend to focus produce any kind of profile modification I Gleason Diamond Dressing Gears most on machines and cutting tools. required. For smaller lot sizes, flexible can be designed for conventional and When parts are produced as required, dressers with a certain pressure Spheric® Honing, including the required grinding wheels and honing tools get angle and module range are used. profile modifications as well as specific much of the credit. But just as critical Workpiece-specific Diamond Dressing bias/twist. Usually they have a bigger are the dressing tools that put the Discs usually include a tip radius number of teeth than the workpiece to correct profile onto the cutting tool. The dresser for fillet blending or even full improve tool life, a module range from rapid development in cutting materials form root grinding. Most importantly, all 0.8 to 6 mm, and are designed for the and bonding systems has led to a new of these dressers can be used as part type of gear honing machine requested. generation of advanced tools – all of of the highly desirable twist controlled Diamond type as well as grit size, bond which need to be dressed quickly and grinding process. type (usually electroplated Nickel),bond with the highest quality. properties and thickness together with Ultimately, hard finishing processes can Gleason Hurth Tooling has long a very precise finishing process of the benefit greatly from the use of Gleason been a leading producer of Diamond plated diamonds define the quality that dressers that combine the highest Dressing Gears for honing and will be achieved as well as the life time quality, superior performance and Diamond Dressing Discs for continuous of the dresser. maximum tool life in perfect fashion. generating and profile grinding. Today, Gleason is successfully fitting the highly desirable properties of these dressers Perfect Fit for Threaded Wheel to the needs of the latest honing and Grinding grinding tools. While Diamond Dressing Gears are Dr. Klaus Lösch typically designed for one specific Senior Engineer workpiece, the Diamond Dressing Development Discs used in threaded wheel grinding Gleason Hurth have a higher variety of applications. Tooling GmbH

21 Design Software

▪ System-level evaluations ▪ Highly efficient data processing ▪ Model complete gear units and drivetrains + The Power of 2

n line with the motto "Two software elements. The software guarantees the gearbox on one another. System solutions – one goal", an interface you can perform quick and accurate reliability, load spectrum calculation, Ihas recently been created which strength calculations. It also provides efficiency and thermal balance exchanges gear design data between reports containing detailed information evaluation, modal analysis are now KISSsoft KISSsys® and Gleason about safety factors and service life available. And all that with consideration GEMS®. This innovation combines the values. Interfaces to all the standard of all possible misalignments calculated strengths of both systems to create CAD programs complete the features of in KISSsoft, coming from shaft a highly optimized overall system to this product. deflections, planet carrier deformations, meet gearbox/drivetrain requirements bearing stiffnesses, thermal effects, and KISSsys is KISSsoft‘s system add-on for strength, noise and efficiency. A others. that enables you to model complete further advantage is the combination gear units and drivetrains. KISSsoft of gearbox/drivetrain design with the calculates the service life and strength gear design – by taking into account all GEMS: Optimized Gear Design and of the different machine elements, manufacturing and production aspects. Analysis and transfers the results to KISSsys, Here's an overview of both systems, where they are displayed in clear With GEMS, Gleason has introduced and how they work together. overviews. To achieve this, KISSsys the next-generation design and brings together kinematic analysis, 3D manufacturing system for bevel gears. graphics, and user-defined tables and It is a powerful new software platform KISSsoft KISSsys: System Design dialogs. that provides highly desirable gear and Simulation design and analysis capabilities, KISSsys allows the users to perform KISSsoft works on the basis of seamlessly connects with all your system level evaluations in one run, international calculation standards to existing Gleason design software – and while considering the interdependent provide extensive optimization options helps optimize the complete bevel gear effects of every single components of for the entire sizing process of machine manufacturing process.

22 Design Software Design Software

▪ Optimized gear design and analysis ▪ Open design, seamless connectivity ▪ User interface and data + processing innovations

The new KISSsoft/GEMS design interface gives users two powerful software tools that now work together to improve gear, gearbox and drivetrain system performance.

The GEMS architecture is very clear Two Software Solutions, One Goal This process allows the user to and flexible, because – based on the evaluate and optimize in a more GEMS and KISSsys programs are now process sequence – all the necessary accurate way any type of bevel or linked by a direct interface to exchange work steps are clearly arranged in hypoid gearset with a closed loop gear and system design data between different "apps". In turn, these apps between the simulation and the the two software packages. help you design and analyze gears. manufacturing processes. They also create manufacturing data From a gearbox model in KISSsys, for tooling, milling and grinding data, GEMS supplies the values for the and 3D coordinates for the closed-loop geometry data of a selected bevel gear manufacturing process. In addition, this pair, which is imported and directly enables prompt implementation "time- set in the corresponding KISSsoft to-market" of new functionalities. calculation. Thanks to the automatic communication between the bevel set GEMS is the world’s first software and shaft modules in KISSsys, KISSsoft for gear design that can be operated determines the EPG misalignments of entirely via its touch screen. It is also the gears, taking shaft bending values fully compatible to keyboard and mouse into account. operation which allows spontaneous changing between an initial touch All the important results such as interaction to the keyboard for example transmission error, meshing stiffness, to enter numerical data during a tooth root stresses, or even contact pressure Markus Bolze Juerg Langhart contact optimization. The GEMS on the flanks of the pinion and the Manager Bevel Gear Technical Sales software is also developed to be utilized wheel can finally be displayed in Theory and Software KISSsoft AG on a tablet or a hybrid laptop to create a KISSsys after transferring back the The Gleason Works better User Experience (UX). result data from GEMS.

23 Hard Finishing With Power Honing Gets Even Better The new-design Gleason 150SPH Spheric® Power Honing Machine takes a proven concept to new levels to meet the hard fi nishing challenges of increasingly complex gears with highly desirable low-noise characteristics.

n the early 1990s, Gleason did a great due to the nature of the process mean deal of pioneering work to develop that there is also no risk of workpieces Ihoning into an independent Power being subjected to thermal damage like As with other processes, productivity Honing process. In fact, today’s machines grinding burn. High residual compressive can be increased mainly by means of facilitate removal rates which are in no stresses to prevent micro-pitting and help higher cutting speeds which go along way inferior to those of grinding. extend the long service life of the gears. with higher rpm of the honing ring. A ring-shaped honing head is typically Power Honing has thus become a full- These benefits accommodate used in gear honing, with large bearings fledged hard finishing method on par new developments in gear design, and motors being essential prerequisites with gear grinding – with even some key in particular. Higher and higher for this head design, limiting its advantages over the grinding process. performance levels and significantly maximum speed. With a tool spindle more stringent requirements with regard For example, the particular kinematics speed of 3,000 rpm Gleason has been to noise characteristics are making gears of the 150SPH allow a narrow used today increasingly complex. cross-axis angle to be implemented between the tool (honing ring) and the workpiece, making it possible to Power Honing Gets Faster machine workpieces with interfering contours. This is not possible using At the same time, productivity is expected machining processes which require to increase. This can essentially be tool overrun travel. Another key benefit achieved by two measures: minimizing is the much-validated fact that honed non-productive time and reducing primary components will feature favorable noise machining time. Both objectives were characteristics due to the typical surface the focus as Gleason sought to improve structure of their tooth flanks. The very on the already very successful 150SPH low cutting speeds prevailing in honing Spheric® Power Honing Machine.

24 The new simplifi ed automation concept serves both disc-type parts and shafts. One linear loading axis transports parts from the conveyor directly to the workpiece spindle. Roll checking of workpieces is executed in between part pickup station and loading onto the workpiece spindle. The diamond master dressing gear and dressing roll are both stored and brought into action with the same grippers that also transfer the workpieces.

the benchmark in gear honing for years, time. The double-flank roll test to check dressing tools are always stored safely achieving very short honing times with initial machining quality, for example, has outside the work chamber and can be a classic honing ring design. The newly been eliminated from the manufacturing conveniently maintained and changed. developed high-speed honing head path and integrated into the loading The entire automation system of the allows speed increases of over 60% step instead. Workpieces are no longer new 150SPH is accommodated behind resulting in a tool spindle speed of 5,000 checked on the work spindle before the the machine, thus reducing the required rpm and, consequently, increases in honing process is started – they are floor space for the machine and its productivity of up to 30%. now validated in parallel with the actual automation by about 40% compared to machining time. This saves several The significant increase in speed is its predecessor. seconds on every workpiece and – in achieved by a specific tool head design the event of a faulty part – considerably The new SPH relies on the Spheric which arranges bearings and motor more, as the workpiece in question never Honing kinematics which have been no longer circularly around the honing makes it to the honing process. tried and tested over decades. This ring, but in the axial direction behind the technology, developed and patented by tool. The new design allows a reduction The entire automation process has Gleason, uses three interpolating linear of bearing diameters and an increase been significantly simplified, with a axes to permit the flexible design of of honing speeds. As a consequence remarkably positive impact on tooling- tooth flank modifications in the process. the cup-type head does not feature up time. Workpieces are removed As with grinding, Spheric Honing allows tailstock support to clamp workpieces, straight from the conveyor belt using crowning and lead angle modifications to which makes the concept ideally suited a double gripper and moved in a be influenced by the process alone. for workpieces which do not require linear motion directly towards the work tailstock clamping – disk-type workpieces spindle. The work spindle takes the for example. The classic ring-shaped role of a pick-up spindle, removes the honing head is available as an option part from the gripper and takes the to machine shaft-type workpieces and shortest route to the honing head. The parts requiring tailstock support. roll checking unit is located on the route between the conveyor belt and the transfer position to the work spindle, Dr. Antoine Türich including a SPC/NiO drawer. Optimized Automation, Minimal Non- Director Product Productive Time The dressing tools (diamond dressing Management In addition to the newly-developed high- gear and diamond roller) are located Hard Finishing speed honing head, both the automation outside the work area and can be Solutions concept and the auxiliary functions loaded onto the work spindle by the Gleason Corporation have been thoroughly redesigned and existing gripper system. The loading optimized to minimize non-productive system ensures that high-precision

25 Customer Success

Adding Power Skiving to Meet Surging Demand

Italian gear manufacturer Metalcastello’s investment in new Gleason Power Skiving technology comes just in time, as global demand surges for high- precision transmission gears used in heavy construction equipment and vehicles for agriculture.

hat a difference a few years Perfect Timing for Power Skiving simultaneously improving quality from can make. The global heavy DIN 9 to DIN 7. For Metalcastello S.p.a., the Bologna, Wconstruction equipment and agriculture Italy manufacturer whose heavy-duty “There was nothing wrong with the vehicle markets are flourishing transmission gears and shafts are used traditional shaping process or the again, fueled by new investment in in earth-moving machines, tractors, and Gleason shaping machines that the infrastructure, energy and mining, industrial vehicles operating on every company was using to produce these and the demands of the fast growing continent, the timing couldn’t be better. gears previously,” explains Gleason emerging countries and their The company’s recent investment in Sales (Italy) Sales Manager Giulio populations. In just a three month period three new Gleason 600PS Power Skiving Santantonio. “Unless of course you want ending in June, for example, heavy Machines has given Metalcastello to machine at speeds four to five times construction equipment manufacturer capacity to spare for the production of faster. When we demonstrated that the Caterpillar saw worldwide sales rise 25% critically important internal ring gears, Gleason Power Skiving process for this year over year, including a 37% increase some as large as 650 mm in diameter, application could achieve remarkable in the Asia Pacific region and 29% in used in the planetary gear systems gains in productivity and quality, Latin America. of a customer’s transmissions – while Metalcastello saw the potential.”

26 Customer Success Customer Success

Seeing is believing, and Metalcastello shaping. Additionally, it was determined demonstrated at Gleason months earlier managers came away firm believers that a cutter made with G70 high speed with an installation of three Gleason in the Gleason Power Skiving process steel and using an advanced AlCroNite® 600PS Power Skiving Machines. “While after Gleason conducted trial machining Pro (AlCrN) coating produced the best the Gleason shaping machines used at its facility in Ludwigsburg, Germany. results vs. a G50 cutter. Some 50 parts previously are still producing parts, There, a Gleason 600PS was used to were completed (3,675 m/tooth) with the Metalcastello now relies on the PS machine almost 100 3.5 module, 350 tool before the end of its useful life and machines to do most if not all of the mm diameter 78-tooth ring gears made the need for re-sharpening/re-coating. gears for these important planetary gear of hard 40CrMo4 material – actual systems for transmissions,” explains Today, Metalcastello is reaping the customer parts that were being produced Gleason’s Mr. Santantonio. “Cycle time productivity and quality benefits on Metalcastello’s existing Gleason gear shaping machines. Additionally, the deburring required on the ring gear’s lower face – a separate operation Planetary gear systems with typically done off-line – was instead ring gears as large as 650 mm performed during the trial machining in diameter are a Metalcastello specialty. Gleason Power Skiving by the same cutter used for Power has greatly increased capacity Skiving and thus requiring no additional for the production of these workpiece changeover time. For this important components, and offer operation, Gleason grinds the backside the potential for an economical of the cutter with the required contour of fi ne fi nishing capability with Hard the workpiece to eliminate the burr. Power Skiving. Ultimately, the 100-part demonstration produced some impressive results: the 5.20 minute cycle time for complete machining was some four to five times faster than shaping, and profile, lead and pitch quality were measured at a highly desirable DIN 7, two classes better than what was being achieved by

Three Gleason 600PS Power Skiving Machines have proven to be four to fi ve times faster than their shaping machine predecessors, and improved quality by two DIN classes.

27 Customer Success Service Programs

improvements were as demonstrated which allows for the reading of important extremely rigid platforms and, with the – and quality levels have been even data from an RFID chip found in the addition of stock dividing sensor and the a class or two better than what was Gleason Power Skiving cutters. use of carbide cutting tools designed for achieved in Ludwigsburg.” the task, can deliver quality and surface finish levels to meet many fine finishing Non-productive time is reduced as well Finishing with Hard Power Skiving requirements. with automated workpiece load/unload. The Gleason automation consists of While in the past the quality “Metalcastello is an example of how a 2-station ring loader and 12-station requirements for most, if not all, of local Gleason sales support, combined revolving magazine. Both are easily these ring gears did not call for a hard with the Power Skiving process experts adaptable to handle potentially hundreds finishing operation after heat treat, in Ludwigsburg, can partner with of different part numbers with minimal Metalcastello is now beginning to use innovative companies like Metalcastello changeover. these PS machines to perform Hard to successfully achieve the enormous Power Skiving – an economical hard productivity and quality benefits of this The Gleason PS solution at finishing alternative to finish grinding. exciting technology,” concludes Signore Metalcastello also includes the Gleason “These machines can be easily adapted Santantonio. “The timing, as they say, 160CPS Cutter Positioning System, to perform Hard Power Skiving, so was perfect.” which helps optimize the setting of the Metalcastello can begin realizing fine Power Skiving cutters, and also can be For more information on Gleason Power finishing benefits without additional used to analyze cutter wear through an Skiving, please refer to the article investment in grinding machines,” says integrated microscope and PC. It also starting on page 10 of this issue of Mr. Santantonio. “They are inherently comes equipped with an RFID reader, Solutions magazine.

Metalcastello is an example of how local Gleason sales support, combined with the Power Skiving process experts in Ludwigsburg, can partner with innovative companies like Metalcastello to successfully achieve the enormous productivity and quality benefits of this exciting technology. “ – Giulio Santantonio / Gleason Sales (Italy) Sales Manager

About Metalcastello ” Headquartered in Castel di Casio, Italy near Bologna, Metalcastello S.p.a. is a world leader in the production of gears for mechanical transmissions found in earth-moving equipment, farm tractors, industrial vehicles and naval applications. The company was founded in 1952 and is today part of CIE Automotive Ltd. For more information, visit: www.metalcastello.com.

28 Customer Success Service Programs

Service Improves Machine Performance at IT S.A. International Transmissions S.A. invests in Gleason Service Programs to keep even its older machines up and running productively – and predictively.

invests in Gleason Service models and ‘vintages’ of machines exist. money. We changed that way of IT Programs for a diverse range of At International Transmissions, the thinking and say today: We do not have Gleason machines, including shaving combination of our internal maintenance time for machine failures and waste machines dating back to the 1990s resources with Gleason service skills of performance! It paid to make this as well as several of Gleason’s latest and capabilities has really been the change. ES Shaping Machines and Threaded best of both service worlds. Most Wheel Grinding (TWG) machines. manufacturers are not flexible and only Q: What other Gleason Service In this interview, IT S.A. General offer the standard solutions. We do not Programs are you using? Manager Roberto Baronchelli tells need standard solutions – we need A: We also use the Gleason Connect Gleason Global Services Product solutions that fit in our needs. Remote Service. This is a very fast and Manager Robert Peyr that machine easy system to address machine failures output measured in uptime, quality and Q: Could you see that Gleason if they occur. Even if the part is not in our profitability have never been higher. Service Programs significantly stock, Gleason can temporarily modify improve machine performance? the machine to run on limited conditions A: We could see it for sure. The until the part arrives the next day. Q: Mr. Baronchelli, why did you start unexpected machine failures are gone using Gleason Service Programs? and the cost per machine is lower per Q: Last question. What would you A: One of our strategies is the consistent year because now we invest mostly in say that Gleason Service is doing quality and availability of the machines. small wear parts which protect against differently from the others? larger future damages. Also, the We understand that machines need A: Gleason Service has a very good required high quality after machining preventive maintenance like your car. reaction time, this includes older is provided consistently! We see our machines. Relative to older machines, largest benefits here. Q: Why go with the machine other companies disappoint by saying: manufacturer? Often, the end user Too old, we cannot support you Q: Was there concern in the will try to do all the maintenance with anymore, sorry. This is unacceptable. beginning? their own personnel. Gleason always finds a solution. This A: We saw that Gleason’s flexible ‘made A: Yes. In the beginning we believed is another reason why we choose to fit’ approach to service would be that we had no time for preventive Gleaso,. and have quite a high number perfect for this facility, where so many maintenance and could save the of machines from you.

For more information, please contact: International Transmissions S.A. Via Lische 4 6855 Stabio, Switzerland TEL: +41-91-6416030 internationaltransmissions.ch

Gleason’s Robert Peyr (left) and IT’s Roberto Baronchelli (right).

29 Customer Profi le

KHK Sets the Standard in Stock Gears

Japan’s leading manufacturer of stock gears relies on a diverse array of Gleason technology to meet the production challenges of 180 product lines and 17,300 different types of stock gears.

rom ticket gates to trains…robots CNC Phoenix® 200G and 275G Bevel to rack and pinions. If it uses a Gear Grinding Machines, advanced Fbevel or cylindrical gear there’s a good 300TWG Threaded Wheel Grinding chance that Kohara Gear Industry Co., Machines, Gleason-Saikuni Rack Milling Ltd., Kawaguchi, Japan makes one for Machines and the latest GMS inspection it. The company known as KHK has, technology. Here’s a summary of how for its entire 80 year history, specialized the company is benefiting: in ‘stock’. In fact, KHK was one of More quality and productivity in bevel the first in the industry to introduce gear manufacturing: Bevel gears that the very concept of “stock gears.” were once ground mechanically often Today, the “KHK Stock Gears” catalog suffered from a lack of quality, says Mr. is considered a definitive source for Kohara, and the time required to set up standard gears used by gear design and the equipment also made the problems application engineers around the world. worse. “At the time, operators used Yet, ‘standard’ shouldn’t be confused The KHK Gleason Partnership the techniques that they had learned with ‘simple.’ Quality and complexity over time, and it was so difficult to The long partnership between KHK for all types of gears have risen sharply train others with those techniques and and Gleason dates back to the 1950s. in recent years, making KHK’s task all methods. Yet setup time was almost By 1967, all KHK bevel stock gears the more challenging. How have they completely eliminated the moment we were completely manufactured using done it? “We could not have produced Gleason machinery. Today, KHK such an extensive range of gears operates a comprehensive array of without Gleason machinery,” says KHK Gleason machines, from manual No. Managing Director Kenji Kohara. “It 104 Straight Bevel Gear Generators to would have been very difficult.”

30 Customer Profi le Customer Profi le

KHK relies on Gleason-Saikuni Rack Manufacturing technologies, both milling and grinding, to improve production of high-precision racks for important rack and pinion business.

began using the Phoenix machines, of two or three older machines. Cost Power Grinding Machine for the efficient, and production work became so much reductions, greater throughput and, high-precision grinding of rack flanks. faster. We could also grind gears to a most importantly, “Production of gears Gleason-Saikuni also provides KHK with much higher level of quality, and it also with quality two classes better than the a complete solution that includes milling boosted productivity – Phoenix was truly previous standards,” recalls Mr. Kohara. cutters and grinding and dressing tools. revolutionary.” KHK also takes much of The 300TWG installation even enabled Service, support and peace of mind: the trial and error out of their on-going KHK to launch a new product line called “The comprehensive level of aftermarket new bevel gear development efforts High Quality Ground Gears, made to an support provided that Gleason provides through use of Gleason’s Engineering even higher accuracy standard. was an important reason why KHK and Manufacturing System (GEMS) Rack manufacturing expertise: Racks decided to use Gleason machinery,” and its CAGE™ gear design software for rack and pinions are one of KHK’s concludes Mr. Kohara. “Plenty of highly to calculate machine corrections most essential product lines, accounting skilled and experienced field service and make summary changes. The for nearly 25% of sales. The renowned engineers as well as a quick response system is networked with KHK’s reliability and strong reputation of when problems arise are vital for users Gleason 350GMS Gear Inspection KHK rack products stem from the of imported equipment. They come to System, which provides fast, complete use of Gleason-Saikuni rack milling help straight away. Their level of service inspection data feedback for all types of machines, according to Mr. Kohara. means peace-of-mind.” gears up to 350 mm in diameter. These machines include earlier versions For more information about KHK, visit: More throughput, quality two of what are now called the 2000RM khkgears.net. classes higher, with Threaded Wheel High Performance Rack Power Milling Grinding: A single Gleason 300TWG Machine, for racks up to module 12 mm now does the hard finish grinding work and 2,300 mm in length, and 2000RGP

Phoenix® grinding machines deliver signifi cant 300TWG delivers exceptional fi ne fi nish KHK uses the latest 350GMS Analytical Gear improvements in throughput as well as simple grinding speed and quality. Inspection system for complete inspection of setup and operation. all types of gears.

31 The New gleason.com

From Click to Scroll – For an Industry On the Go

Wherever you are, whatever device you’re using, the new Download brochures and additional technical information gleason.com gives you fast and easy access to valuable with your MyGleason Account and register for the information on all the latest Gleason gear manufacturing eSolutions newsletter and Solutions Magazine. and service technologies. It’s all there in a highly responsive, user-friendly design that Quickly scroll through content rather than tedious clicking… works equally well on smart phone, tablet or desktop, and accessible anywhere in the world in the major languages of Use the new MyWorkpiece feature to find products ideally that region. suited for the production of your particular workpieces… Get instant access today to all the latest news, including events worldwide showcasing Gleason gear technology, at: gleason.com/en/facts-and-news/events

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© Gleason Corporation Gleason, Genesis, GAMA, GEMS, KISSsoft, Phoenix, All other trademarks are the property of their 1000 University Ave, Rochester, NY GMS, GMSL, AlCroNite, KISSsys, Spheric, Pentac, respective owners. All rights reserved. Hardac and Gleason Connect are trademarks of Gleason registered in the U.S. and other countries.